2003 SEAT Ibiza 3 Doors Download Service & Repair Manual

Workshop Manual Córdoba 2003 ➤ Ibiza 2002 ➤ 02R, 5-speed Edition 03.2009 Service Service Department. Technical Information

List of Workshop Manual Repair GroupsList of Workshop Manual Repair GroupsList of Workshop Manual Repair Groups Repair Group 00 - Technical data 30 - Clutch 34 - Controls, housing 35 - Gears, shafts 39 - Final drive - differential Service

Contents 00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.1 Code letters, assembly allocation, ratios, capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.2 Filling amounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2 Overview of the drive force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2.1 Calculation of the gear ratio “i” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 3 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1 Clutch mechanism: repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1.1 Clutch actuation mechanism - assembly survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1.2 Pedal mechanism, clutch pump - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 1.3 Removing and installing clutch pedal switch F36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 1.4 Over-centre spring: removing and fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 1.5 Remove and install bearing bracket and master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 18 1.6 Clutch pedal: removing and fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 1.7 Clutch hydraulic system: assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 2 Clutch release assembly, clutch slave cylinder: repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 2.1 Clutch release assembly, slave cylinder - Installation overview . . . . . . . . . . . . . . . . . . . . . . 29 2.2 Clutch slave cylinder: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 2.3 Clutch system: bleeding of air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 3 Clutch: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 3.1 Clutch: assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 3.2 Clutch: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 1 Gear mechanism: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 1.1 Shifting: installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 1.2 Gear stick handle with cover - Installation overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 1.3 Removing / fitting the gear lever knob and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 1.4 Gear lever cover: removing the knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 1.5 Gear selection mechanism:installation overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 1.6 Gear selection mechanism: removing and fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 1.7 Gear drive mechanism: adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 1.8 Selector lever control cable - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 1.9 Remove and install metal or plastic transfer lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 2 Gearbox : removing and fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 2.1 Gearbox : removing and fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 2.2 Transporting and securing gearbox to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 3 Gearbox oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 3.1 Check and refill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 3.2 replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 4 Gearbox: disassembly and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 4.1 Transmission: component survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 4.2 Gearbox: assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 4.3 Cover for gearbox casing and 5th gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 4.4 Transmission housing and shifting: assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 4.5 Input shaft, output shaft, differential and shift fork on transmission - assembly survey . . . . 71 4.6 Input shaft, output shaft, differential and shift fork on transmission: removing and fitting . . 71 5 Gearbox casing and clutch housing: repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 5.1 Gearbox housing and clutch housing - Installation overview . . . . . . . . . . . . . . . . . . . . . . . . 82 5.2 Gearbox casing and clutch housing: repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Córdoba 2003 ➤ , Ibiza 2002 ➤ 02R, 5-speed - Edition 03.2009 Contents i

6 Gear selection mechanism (gearbox side) removing and fitting . . . . . . . . . . . . . . . . . . . . 87 6.1 Gear selection mechanism:installation overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 6.2 Seal gear selection mechanism - replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 7 Gearbox prongs: disassembly and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 7.1 Selector forks - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 7.2 Gear prongs: Repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 1 Disassembly and assembly of the input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 1.1 Input shaft - Installation overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 1.2 Disassembly and assembly of the input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 1.3 Input shaft: adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 2 Secondary shaft: disassembly and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 2.1 Output shaft: Installation overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 2.2 Secondary shaft: disassembly and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 2.3 Secondary shaft: adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 3 Reverse gear shaft: disassembly and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 3.1 Reverse gear shaft - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 3.2 Reverse gear shaft: disassembly and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 4 5th gear: Disassembling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 4.1 5. Road speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 4.2 5ª Remove and install gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 1 Seals for flanged shafts: replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 1.1 Seal for flanged shaft, left hand side: changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 1.2 Right flanged shaft seal: replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 2 Differential: assembly and disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 2.1 Differential: Assembly survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 2.2 Differential: assembly and disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 2.3 Differential: Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 3 Adjustment chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 4 Equivalence table according to applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 4.1 Graphic information on SEAT equivalent tools and equipment . . . . . . . . . . . . . . . . . . . . . . 146 Córdoba 2003 ➤ , Ibiza 2002 ➤ 02R, 5-speed - Edition 03.2009 ii Contents

00 – Technical data 1 Gearbox identification Location on the gearbox The 02R 5-speed manual gearbox is fitted in the Ibiza 2002 ▸, Córdoba 2003▸ see table ⇒ page 1 . Code letters and date of manufacture -arrow 1-, type of gearbox -arrow 2-. Identification letter allocation ⇒ page 1 . Type of gearbox 02R 5-speed manual gearbox -arrow 2-. Engine code and manufacture date of gearbox Example: EWR 11 09 1 I I I l I I I l Identification letters Day Month Model year 2001 Any additional data is related to the manufacturing process. Note The gearbox identification letters can also be found on the vehicle data sticker. 1.1 Code letters, assembly allocation, ratios, capacities Manual gearbox housing 02R, 5-speed Identification let‐ ters EWT - GGU - JDA JDA EWR - GGV EWR - JCZ JDB - GVZ - HWY JDE JDD JXY Corre‐ spond‐ ence Type Ibiza 2002 ▸, Córdoba 2003▸ Ibiza 2002 ▸, Córdoba 2003▸ Ibiza 2002 ▸, Córdoba 2003▸ Ibiza 2002 ▸, Córdoba 2003▸ Ibiza 2002 ▸ Ibiza 2002 ▸, Córdoba 2003▸ Ibiza 2002 ▸, Córdoba 2003▸ Ibiza 2002 ▸, Córdoba 2003▸ Córdoba 2003 ➤ , Ibiza 2002 ➤ 02R, 5-speed - Edition 03.2009 1. Gearbox identification 1

Manual gearbox housing 02R, 5-speed Identification let‐ ters EWT - GGU - JDA JDA EWR - GGV EWR - JCZ JDB - GVZ - HWY JDE JDD JXY En‐ gine 1.9l - TDI 74 kW without DPF 1.9 l - TDI DPF 74 kW 1.4l - TDI 55 kW without DPF 1.4l - TDI 59 kW without DPF 1.8 l - 20VT 110/132 kw 1.4l - TDI DPF 59 kW 1.4 l - TDI DPF 59kw 1.9 l - TDI 74 Kw without DPF and 1.9 l - TDI DPF 74 Kw Gear ratio: Z 2 : Z 1 Final group 60 : 19 = 3,158 60 : 19 = 3,158 61 : 18 = 3,389 61 : 18 = 3,389 62 : 17 = 3,647 61 : 18 = 3,389 60 : 19 = 3,158 60 : 19 = 3,158 1. Road speed 34 : 09 = 3,778 34 : 09 = 3,778 33 : 10 = 3,300 33 : 10 = 3,300 33 : 10 = 3,300 34 : 09 = 3,778 34 : 09 = 3,778 34 : 09 = 3,778 2. Road speed 33 : 16 = 2, 063 33 : 16 = 2, 063 35 : 18 = 1,944 35 : 18 = 1,944 35 : 18 = 1,944 33 : 16 = 2,063 33 : 16 = 2,063 33 : 16 = 2, 063 3. Road speed 30 : 23 = 1,304 30 : 23 = 1,304 34 : 26 = 1,308 34 : 26 = 1,308 34 : 25 = 1,360 31 : 23 = 1,348 30 : 24 = 1, 25 34 : 26 = 1,308 4. Road speed 28 : 31 = 0,903 28 : 31 = 0,903 34 : 35 = 0,971 34 : 35 = 0,971 30 : 29 = 1,034 29 : 30 = 0,967 27 : 32 = 0,844 33 : 36 = 0,916 5. Road speed 28 : 40 = 0,700 28 : 40 = 0,700 34 : 45 = 0,756 34 : 45 = 0,756 31 : 38 = 0,816 30 : 39 = 0,769 27 : 41 = 0,658 28 : 40 = 0,700 speed in re‐ verse 18:09 X 36:20 = 3,600 18:09 X 36:20 = 3,600 17 : 10 X 36 : 20 = 3.060 17 : 10 X 36 : 20 = 3.060 17 : 10 X 36 : 20 = 3.060 10 X 36 : 18:09 X 36:20 = 3,600 18:09 X 36:20 = 3,600 Speed ome‐ ter 13 : 22 = 0,591 1) 13 : 22 = 0,591 13 : 22 = 0,591 13 : 22 = 0,591 13 : 22 = 0,591 - - - 1) Speedometer only for gearboxes with identification letters EWT. 1.2 Filling amounts Identification letters EWT - GGU - JDA EWR - GGV EWR - JCZ JDB - GVZ - HWY JDE JDD Filling quantity 1.9 litres Specification Gear oil API GL4 SAE 75W -Hypoid- Clutch action hydraulic Clutch plate ∅ 228 mm 216 mm 216 mm 225 mm 8.50 in 216 mm Drive shaft flange ∅ 100 mm - TRIPOD 100 mm - TRIPOD 100 mm - TRIPOD 100 mm - TRIPOD 100 mm - TRIPOD 100 mm - TRIPOD i total in top gear 2,210 2,562 2,562 2,976 2,606 2,077 Córdoba 2003 ➤ , Ibiza 2002 ➤ 02R, 5-speed - Edition 03.2009 2 Rep. Gr.00 - Technical data

2 Overview of the drive force Designation The -arrows- indicate direction of movement. 1 - Engine 2 - Clutch 3 - Manual gearbox housing 4 - Input shaft: 5 - Secondary shaft/pinion as‐ sembly 6 - Differential: Gear ratios Note The -arrows- indicate direction of movement. Córdoba 2003 ➤ , Ibiza 2002 ➤ 02R, 5-speed - Edition 03.2009 2. Overview of the drive force 3

I - 1. Road speed II - 2. Road speed III - 3. Road speed IV - 4. Road speed V - 5. Road speed R - speed in reverse A - Final group T - Speedometer operation 2.1 Calculation of the gear ratio “i” The gear ratio between two gears, is obtained by dividing the number of teeth on the driven gear (Z2), by the number of teeth on the driving gear (Z1). Example: Gears 5. Road speed Final group driving gear (primary) 45 (Z 1 = driving gear) 19 (Z 1 = driving gear) Driven gear (secon‐ dary) 34 (Z 2 = driving gear) 60 (Z 2 = driving gear) i = Z 2 : Z 1 2) In this way we can find out: i G = Gear ratio = ZG 2 : ZG 1 = 34 : 45 = 0.756 i A = Transmission ratio for bevel gear assembly = ZA 2 : ZA 1 = 60 : 19 = 3,158 It is obtained by multiplying the gear ratios of the longest gear and the differential. Córdoba 2003 ➤ , Ibiza 2002 ➤ 02R, 5-speed - Edition 03.2009 4 Rep. Gr.00 - Technical data

i total. = overall ratio = i G x i A = 0.756 x 3.158 = 2.387 2) Z 1 = Number of teeth of driver pinion, Z 2 = number of teeth of driven pinion. Córdoba 2003 ➤ , Ibiza 2002 ➤ 02R, 5-speed - Edition 03.2009 2. Overview of the drive force 5

3 General repair instructions For proper repair of the gearbox, it is important to work with the greatest of care and absolute cleanliness, and to use tools that are in perfect condition. Naturally, the customary basic safety rules must be observed during repair work. A series of general instructions for repair work is now listed, and these are mentioned several times throughout the course of the Repair Manual. These instructions are valid for this Repair Man‐ ual, Contact corrosion ♦ The gearbox casing is made of magnesium alloy. ♦ The surfaces of the bolts and other parts which are in direct contact with the gearbox are made of a material which is es‐ pecially suitable for the magnesium casing. ♦ If inappropriate parts are used (bolts, nuts, washers...), corro‐ sion will be produced through contact and the gearbox casing will be damaged. ♦ If you are doubtful as to whether it is possible to re-use certain parts, it is advisable to fit new ones⇒ Current parts catalogue. WARNING ♦ Only use genuine Seat parts! ♦ Damage from contact corrosion is not covered under the warranty! Gearbox: ♦ Thoroughly clean unions and adjacent areas before removing. ♦ Select the correct bolts and other components ⇒ Parts cata‐ logue . ♦ When installing the manual gearbox, ensure that the dowel sleeves are correctly housed between engine and gearbox. ♦ When installing support stands and waxed components, the contact surfaces must be cleaned. The contact surfaces must be free from wax and grease. ♦ After replacing the gearbox, check oil level and top up if nec‐ essary. ♦ Filling amounts and oil type specifications. Córdoba 2003 ➤ , Ibiza 2002 ➤ 02R, 5-speed - Edition 03.2009 6 Rep. Gr.00 - Technical data

2003 SEAT Ibiza 3 Doors Download Service & Repair Manual

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