2003-2008 SEAT Ibiza Service & Repair Manual
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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
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Lifetime Access
Fast Download Speeds
Offline Viewing
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Full Search Facility
Print one or all pages of your manual
$33.99
2003-2008 SEAT Ibiza (6L) OEM Service & Repair Manual
Engines covered:
- 1.2L I3
- 1.4L I4
- 1.6L I4
- 1.8L I4 20v Turbo
- 2.0L I4
- 1.4L I3 TDI (diesel)
- 1.9L I4 TDI (diesel)
The 2003-2008 SEAT Ibiza (6L) OEM Service & Repair Manual cuts through diagnostic confusion with precise technical information for every engine variant in the lineup. From the economical three-cylinder options to the tire-spinning 1.8L 20v Turbo and long-legged TDI diesels, this factory documentation delivers exact specifications developed specifically for these Volkswagen Group platforms.
This manual transforms complex systems into manageable service procedures with exploded component views, removal sequences, and critical reassembly steps. You'll discover precise fuel pressure specifications, suspension alignment values, timing belt procedures, and component clearances organized by vehicle system—from drivetrain to climate control, brakes to body components.
Whether you're decoding that intermittent ABS fault, performing the critical 60,000-mile service, or rebuilding a gearbox, this manual eliminates the parts-swapping guesswork. Get your repairs right the first time with the exact procedures these precision-engineered machines require.
Printable: Yes
Language: English
Compatibility: Pretty much any electronic device, incl. PC & Mac computers, Android and Apple smartphones & tablet, etc.
Requirements: Adobe Reader (free)
