2011-2014 SEAT Ibiza Service & Repair Manual
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Workshop Manual
Ibiza 2008 ➤
Ibiza ST 2010 ➤
Toledo 2013 ➤
02R 5-speed manual gearbox
Edition 12.2012
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
2 Overview - power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Calculating overall gear ratio “i” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 Code, engine allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.1 Ibiza 2008 ►, Ibiza ST 2010 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.2 Toledo 2013 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5 Filling quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.1 Ibiza 2008 ►, Ibiza ST 2010 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.2 Toledo 2013 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6.1 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6.2 Gaskets, seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6.3 Sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6.4 Locking devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.5 Bolts, nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.6 Antifriction bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.7 Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.8 Synchromesh rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.9 Gear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.10 Mobile pinions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.11 Coupling unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
7 Safety precautions for vehicles with start/stop system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1 Clutch mechanism: repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.1 Clutch actuation: assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2 Assembly overview - pedal cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3 Removing and installing clutch pedal switch F36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.4 Mounting bracket with clutch master cylinder: Removing and installing . . . . . . . . . . . . . . 16
1.5 Clutch pedal with over-centre spring: Removing and installing, left-hand drive vehicles . . 19
1.6 Clutch pedal: Removing and installing, right-hand drive vehicles . . . . . . . . . . . . . . . . . . . . 22
1.7 Assembly overview - hydraulics (LHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.8 Assembly overview - hydraulics (RHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.9 Removing and installing clutch master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.10 Clutch slave cylinder: Removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.11 Bleeding clutch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2 Clutch release assembly: repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3 Clutch: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1 Gear mechanism: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.1 Gear selection mechanism: installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.2 Gear stick handle with cover - Installation overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.3 Removing and installing the gear stick handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.4 Gear selection mechanism:installation overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.5 Gear selection mechanism cables: removing and fitting; general overview . . . . . . . . . . . . 44
1.6 Gear selection mechanism: Removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1.7 Gear selection mechanism: Adjust convergence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2 Gearbox Removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.1 Removing and installing the gearbox, Ibiza 2008 ►, Ibiza ST 2010 ► . . . . . . . . . . . . . . . . 54
Ibiza 2008 ➤ , Ibiza ST 2010 ➤ , Toledo 2013 ➤
02R 5-speed manual gearbox - Edition 12.2012
Contents i
2.2 Gearbox Removing and installing, Toledo 2013 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4 Gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.1 Check and refill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.2 Renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
5 Gearbox Disassembling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
5.1 Overview - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
5.2 assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
5.3 Assembly overview - removing and installing cover for gearbox housing and 5th gear . . . . 86
5.4 Removing and installing gearbox housing and selector mechanism - Assembly overview
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
5.5 Removing and installing input shaft, output shaft, differential and selector rods - Assembly
overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
5.6 Assembly sequence - removing and installing cover for gearbox housing and 5th gear . . 89
5.7 Assembly sequence - Dismantling and assembling gearbox completely . . . . . . . . . . . . . . 95
6 Gearbox casing and clutch housing: Repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
7 Selector unit (gearbox side) disassembly and assembly (selector shaft can be removed from
the selector cover) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
8 Selector unit (gearbox side) disassembly and assembly (selector shaft cannot be removed
from the selector cover) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
9 Dismantling and assembling selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
1 Input shaft: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
1.1 Input shaft: Disassembling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
1.2 Input shaft: setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
2 Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
2.1 Secondary shaft: Disassembling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
2.2 Secondary shaft: setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
3 Reverse gear shaft: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
3.1 Dismantling and assembling reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
1 Replace seals for flanged shafts with installed equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 157
1.1 Renewing oil seal for left flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
1.2 Distinguishing seals for right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
1.3 Renewing seal (two-part seal and sleeve for right flange shaft) . . . . . . . . . . . . . . . . . . . . . . 159
1.4 Renewing seal and sleeve together (one-piece seal and sleeve for right flange shaft) . . . . 162
2 Adjustment overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
3 Differential assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
3.1 Differential: Disassembling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
3.2 Differential: Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Ibiza 2008 ➤ , Ibiza ST 2010 ➤ , Toledo 2013 ➤
02R 5-speed manual gearbox - Edition 12.2012
ii Contents
00 – Technical data
1 Gearbox identification
(ERL002280; Edition 12.2012)
⇒ “4 Code, engine allocation”, page 5 .
⇒ “5 Filling quantity”, page 7 .
Location on gearbox
Identification letters and date of manufacture -arrow 1-, type of
gearbox -arrow 2-.
Gearbox type
5-speed manual gearbox 02R -arrow 2-.
Engine code and manufacture date of gearbox
Example: EWR 11 09 1
I I I l
I I I l
Engine code Day Month Model year 2001
Additional data depend on manufacture.
Note
The gearbox identification letters can also be found on the vehicle
data sticker.
Ibiza 2008 ➤ , Ibiza ST 2010 ➤ , Toledo 2013 ➤
02R 5-speed manual gearbox - Edition 12.2012
1. Gearbox identification 1
2 Overview - power transmission
Identification
The -arrows- point forwards.
1 - Engine
2 - Coupling unit
3 - Manual gearbox housing
4 - Drive shaft
5 - Secondary shaft/pinion as‐
sembly
6 - Differential assembly
Gear ratios
Note
The -arrows- point forwards.
Ibiza 2008 ➤ , Ibiza ST 2010 ➤ , Toledo 2013 ➤
02R 5-speed manual gearbox - Edition 12.2012
2 Rep. gr.00 - Technical data
I - gear
II - 2. gear
III - 3. gear
IV - 4. gear
V - gear
R - Reverse
A - Final group
T - Speedometer operation
In vehicles without ABS.
Ibiza 2008 ➤ , Ibiza ST 2010 ➤ , Toledo 2013 ➤
02R 5-speed manual gearbox - Edition 12.2012
2. Overview - power transmission 3
3 Calculating overall 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 gear Final group
driving gear (pri‐
mary)
45 (Z
1
= driving gear) 19 (Z
1
= driving gear)
driving gear
(secondary)
34 (Z
2
= driving gear) 60 (Z
2
= driving gear)
i = Z
2
: Z
1
1)
In this way we can find out:
i
G
= Gear ratio of the individual gears = ZG
2
: ZG
1
= 34 : 45 =
0,756
i
A
= Transmission ratio for bevel gear assembly = ZA
2
: ZA
1
=
60 : 19 = 3,158
By multiplying the gear ration, one obtains the highest gear and
the axle drive.
i
total.
= Total reduction ratio = i
G
x i
A
= 0.756 x 3.158 = 2.387
1) Z
1
= No. of teeth on driving gear, Z
2
= No. of teeth on driven gear
Ibiza 2008 ➤ , Ibiza ST 2010 ➤ , Toledo 2013 ➤
02R 5-speed manual gearbox - Edition 12.2012
4 Rep. gr.00 - Technical data
4 Code, engine allocation
⇒ “5 Filling quantity”, page 7 .
⇒ “4.1 Ibiza 2008 ►, Ibiza ST 2010 ►”, page 5
⇒ “4.2 Toledo 2013 ►”, page 5
4.1 Ibiza 2008 ►, Ibiza ST 2010 ►
When spare parts are required for repair work, the codes of the
gearbox must be observed.
Manual gearbox hous‐
ing
5-speed 02R
Engine code LBQ JXY JDD KFK, MZL MUX MAL, MNY,
MZK, MZN
Assignment Type Ibiza 2008 ► Ibiza 2008 ► Ibiza 2008 ► Ibiza 2008
►, Ibiza ST
2010►
Ibiza 2008
►, Ibiza ST
2010►
Ibiza 2008
►, Ibiza ST
2010►
Engine 1.9 l - TDI
DPF 77
kW / 1.9 l -
TDI DPF 66
kW
1.9 l - TDI
DPF 77 kW /
1.9 l - TDI
DPF 66 kW
1.4l - TDI
DPF 59 kW
1.6l - TDI
CR 66 kW /
1.6l - TDI
CR 77 kW
1.6l - TDI
CR 77 kW
1.2l - TDI
CR 55 kW
Transmission:
Z
2
: Z
1
Final
group
60 : 19 =
3,158
60 : 19 =
3,158
60 : 19 =
3,158
60 : 19 =
3,158
62 : 17 =
3,647
61 : 18 =
3,388
1. gear 34 : 09 =
3,778
34 : 09 =
3,778
34 : 09 =
3,778
34 : 09 =
3,778
34 : 09 =
3,778
34 : 09 =
3,778
2. gear 36 : 17 =
2,117
33 : 16 =
2,062
33 : 16 =
2,062
36 : 17 =
2,117
36 : 17 =
2,117
36 : 17 =
2,117
3. gear 33 : 26 =
1,269
34 : 26 =
1,307
30 : 24 =
1,250
33 : 26 =
1,269
34 : 25 =
1,36
33 : 26 =
1,269
4. gear 32 : 37 =
0,864
33 : 36 =
0,916
27 : 32 =
0,843
32 : 37 =
0,864
34 : 35 =
0,971
32 : 37 =
0,864
5. gear 30 : 48 =
0,625
28 : 40 =
0,700
27 : 41 =
0,658
31 : 47 =
0,659
33 : 45 =
0,733
31 : 47 =
0,659
Re‐
verse
gear
18:09 X
36:20 =
3,600
18:09 X
36:20 =
3,600
18:09 X
36:20 =
3,600
18:09 X
36:20 =
3,600
18:09 X
36:20 =
3,600
18:09 X
36:20 =
3,600
4.2 Toledo 2013 ►
When spare parts are required for repair work, the codes of the
gearbox must be observed.
Manual gearbox housing 5-speed 02R
Engine code MZL, MZM MZS
Assignment Type Toledo 2013 ►
Engine 1.6l - TDI CR 77 kW 1.6l - TDI CR 77 kW
Transmission:
Z
2
: Z
1
Final group 60 : 19 = 3,158 62 : 17 = 3,647
gear 34 : 09 = 3,778 34 : 09 = 3,778
2. gear 36 : 17 = 2,117 36 : 17 = 2,117
3. gear 33 : 26 = 1,269 34 : 25 = 1,36
4. gear 32 : 37 = 0,864 34 : 35 = 0,971
5. gear 31 : 47 = 0,659 33 : 45 = 0,733
Ibiza 2008 ➤ , Ibiza ST 2010 ➤ , Toledo 2013 ➤
02R 5-speed manual gearbox - Edition 12.2012
4. Code, engine allocation 5
Manual gearbox housing 5-speed 02R
Engine code MZL, MZM MZS
Reverse gear 18:09 X 36:20 = 3,600 18:09 X 36:20 = 3,600
Ibiza 2008 ➤ , Ibiza ST 2010 ➤ , Toledo 2013 ➤
02R 5-speed manual gearbox - Edition 12.2012
6 Rep. gr.00 - Technical data
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Title: 2011-2014 Seat Ibiza OEM Service & Repair Manual
Equip yourself with the essential resource for maintaining and repairing your Seat Ibiza using the 2011-2014 Seat Ibiza OEM Service & Repair Manual. Tailored specifically for Seat Ibiza models produced from 2011 to 2014, this comprehensive manual is designed to provide professional mechanics and DIY enthusiasts with accurate and detailed service repair information.
Inside, you will find a wealth of features including:
- Complete coverage for 2011-2014 Seat Ibiza models
- Comprehensive repair and service instructions
- Accurate and detailed diagrams
- Diagnostics and troubleshooting guides
- Maintenance schedules and procedures
- Electrical system wiring diagrams
- Specifications and technical data
- Easy-to-follow, step-by-step procedures
- An illustrated parts catalog
With this OEM service and repair manual at your disposal, you can confidently tackle various repairs and maintenance tasks, from engine overhaul and transmission troubleshooting to brake system repairs and electrical diagnostics. Optimize your repair process and maintain your Seat Ibiza’s performance with this essential guide.
Purchase the 2011-2014 Seat Ibiza OEM Service & Repair Manual today and unlock the full potential of your vehicle!
