Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
Toledo 1999 , León ➤
02J 5-speed manual gearbox
Gearbox ID
EBD EBF EBJ EBM EBS EGR EGS EGV EGW
FBK
Edition 02.2003
Service
Service Department. Technical Information
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Toledo 1999 , León ➤
02J 5-speed manual gearbox
Repair Group
00 - Technical data
30 - Clutch
34 - Controls, Housing
35 - Gears, Shafts
39 - Final drive, Differential
Technical information should always be available to the foremen and mechanics, because their careful
and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In
addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course,
be observed.
Service
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2010 Seat S.A S01B02J8820
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1 Identification of the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.1 Identification of the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.2 Code letters, group numbers, ratios, filling quantities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
2 Diagram of the drive force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2.1 Diagram of the drive force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3 Calculation of the gear ratio "i" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1 Calculation of the gear ratio "i" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
4.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
1 Clutch action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
1.1 Clutch action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
1.2 Clutch action: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
1.3 Pedal gear: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
1.4 Neutral overpass spring: remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
1.5 Clutch pedal: remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
2 Hydraulic system: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
2.1 Hydraulic system: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
2.2 Clutch pump: remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
2.3 Clutch system: bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3 Clutch unit: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
3.1 Clutch unit: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
4 Clutch: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
4.1 Clutch: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
34 - Controls, Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
1 Gear drive mechanism up to 04.99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
1.1 Gear drive mechanism up to 04.99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
1.2 Gear drive mechanism: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
1.3 Gear lever dust sleeves and knob: separate and install . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
1.4 Gear lever and protective cover: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . .40
1.5 Cables and drive mechanisms: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
1.6 Gear drive mechanism: separate and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
1.7 Gear drive mechanism: adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
2 Gear drive mechanism from 05.99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
2.1 Gear drive mechanism from 05.99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
2.2 Gear drive mechanism: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
2.3 Gear lever dust sleeves and knob: separate and install . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
2.4 Gear lever and protective cover: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . .62
2.5 Cables and drive mechanisms: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
2.6 Gear drive mechanism: separate and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
2.7 Gear drive mechanism: adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
3 Gearbox: separate and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
3.1 Gearbox: separate and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
4 Oil level: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
4.1 Oil level: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
5 Gearbox: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
5.1 Gearbox: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
5.2 Gearbox casing cover, 5th gear: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . .100
5.3 Gearbox casing, gear drive up to 04.99: removing and installing . . . . . . . . . . . . . . . . . . . .103
Toledo 1999 , León ➤
02J 5-speed manual gearbox - Edition 02.2003
Contents i
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
5.4 Gearbox casing, gear drive from 05.99: removing and installing . . . . . . . . . . . . . . . . . . . . . .105
5.5 Input shaft, lay shaft, differential and gearbox forks: removing and installing . . . . . . . . . . . .107
5.6 Gear change: dismantling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
6 Gearbox housing and clutch housing removing and installing . . . . . . . . . . . . . . . . . . . . . . . .127
6.1 Gearbox housing and clutch housing removing and installing . . . . . . . . . . . . . . . . . . . . . . . .127
6.2 Gear selector shaft up to 04.99: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
6.3 Gear selector shaft from 05.99: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
7 Gear box forks: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146
7.1 Gear box forks: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146
35 - Gears, Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
1 Input shaft: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
1.1 Input shaft: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
2 Input shaft: adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165
2.1 Input shaft: adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165
3 Layshaft: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170
3.1 Layshaft: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170
4 Lay shaft: adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195
4.1 Lay shaft: adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195
5 Reverse gear shaft: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198
5.1 Reverse gear shaft: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198
39 - Final drive, Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .203
1 Seals for flanged shafts: replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .203
1.1 Seals for flanged shafts: replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .203
1.2 Left flanged shaft seal: replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .204
1.3 Right flanged shaft seal: replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .206
2 Differential: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .208
2.1 Differential: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .208
2.2 Differential crown: replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .218
3 Differential: adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .221
3.1 Differential: adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .221
4 Adjustment chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
4.1 Adjustment chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Toledo 1999 , León ➤
02J 5-speed manual gearbox - Edition 02.2003
ii Contents
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
00 - Technical data
1 - Identification of the gearbox
1.1 - Identification of the gearbox
Location on the gearbox
-> The 5-speed 02J manual gearbox is assembled in the Toledo and León 1999 ä, in combination with the 4
and 5 cylinder engines.
Code letters and date of manufacture arrow -1-, type of gearbox arrow-2-.
Toledo 1999 , León ➤
02J 5-speed manual gearbox - Edition 02.2003
1.1 - Identification of the gearbox 1
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
Type of gearbox
-> 02J 5-speed manual gearbox arrow -2-.
Code letters and date of manufacture of gearbox
Example: CZM 15 10 7
I I I l
I I I l
Engine code Day Month Year (1997) of
manufacture
Any additional data refers to the manufacturing process.
Note:
The gearbox code letters are also on the customer vehicle service schedule.
1.2 - Code letters, group numbers, ratios, filling quantities
Manual gearbox 5-speed 02J
Engine code EBD EBF EBJ
Correspondence Type Toledo 1999 ä, León Toledo 1999 ä, León Toledo 1999 ä, León
Engine 1,8 ltr. -92 kW 1,9 ltr. - TDI 81 kW 1,9 ltr. - TDI 66 kW
Gear ratio:
Z2 : Z1
Final drive 72 : 17 = 4,235 61 : 18 = 3,389 61 : 18 = 3,389
1st gear 33 : 10 = 3,300 34 : 09 = 3,778 34 : 09 = 3,778
2nd gear 35 : 18 = 1,944 33 : 16 = 2,063 36 : 17 = 2,118
3rd gear 34 : 26 =1,308 31 : 23 = 1,348 34 : 25 = 1,360
4th gear 35 : 34 = 1,029 29 : 30 = 0,967 34 : 35 = 0,971
5th gear 36 : 43 = 0,837 30 : 39 = 0,769 34 : 45 = 0,756
6th gear - - -
Reverse 17 : 10 x 36 : 20 = 3,060 18 : 09 x 36 : 20 = 3,600 18 : 09 x 36 : 20 = 3,600
Speedometer 13 : 22 = 0,591 13 : 22 = 0,591 13 : 22 = 0,591
Engine code EBD EBF EBJ
Filling quan‐
tity
2,0 litres
Specification Oil for pinions API GL4 SAE 75W90
(Synthetic, high performance)1)
Toledo 1999 , León ➤
02J 5-speed manual gearbox - Edition 02.2003
2 00 - Technical data
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
Engine code EBD EBF EBJ
Clutch action hydraulic hydraulic hydraulic
Clutch plate
ø
215 mm 225 mm 225 mm
Drive shaft
flange ø
100 mm 100 mm 100 mm
ltotal in top
gear
3,545 2,606 2,562
1) Do not mix different types of gear oil, observations=> page 11 .
Manual
gearbox
5-speed 02J
Engine
code
EBM EBS EGR
Corre‐
spond‐
ence
Type Toledo
1999 ä,
León
Toledo
1999 ä,
León
Toledo
1999 ä,
León
Engine 1,8 ltr. -92
kW
2,3 ltr. -
VR5 110
kW
1,9 ltr. -
TDI 66
kW
Gear ra‐
tio:
Z2 : Z1
Final drive 72 : 17 =
4,235
71 : 18 =
3,944
61 : 18 =
3,389
1st gear 33 : 10 =
3,300
33 : 10 =
3,300
34 : 09 =
3,778
2nd gear 35 : 18 =
1,944
35 : 18 =
1,944
36 : 17 =
2,118
3rd gear 34 : 26
=1,308
34 : 26
=1,308
34 : 25 =
1,360
4th gear 35 : 34 =
1,029
35 : 34 =
1,029
34 : 35 =
0,971
5th gear 36 : 43 =
0,837
36 : 43 =
0,837
34 : 45 =
0,756
6th gear - - -
Reverse 17 : 10 x
36 : 20 =
3,060
17 : 10 x
36 : 20 =
3,060
18 : 09 x
36 : 20 =
3,600
Speedom‐
eter
13 : 22 =
0,591
13 : 22 =
0,591
13 : 22 =
0,591
Engine code EBM EBS EGR
Filling quan‐
tity
2,0 litres
Specification Oil for pinions API GL4
SAE 75W90 (Synthetic,
high performance)1)
Oil API GL4
SAE 75W
(Hypoid)1)
Clutch action hydraulic hydraulic hydraulic
Clutch plate
ø
215 mm 225 mm 225 mm
Drive shaft
flange ø
100 mm 108 mm -
TRIPOD
100 mm
ltotal in top
gear
3,545 3,301 2,562
1) Do not mix different types of gear oil, observations => page 11 .
Toledo 1999 , León ➤
02J 5-speed manual gearbox - Edition 02.2003
1.2 - Code letters, group numbers, ratios, filling quantities 3
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
Manual
gearbox
5-speed 02J
Engine code EGS EGV
Correspond‐
ence
Type Toledo
1999 ä,
León
Toledo 1999
ä, León
Engine 1,9 ltr. - TDI
81 kW
1,8 ltr. -92
kW
Gear ratio:
Z2 : Z1
Final drive 61 : 18 =
3,389
72 : 17 =
4,235
1st gear 34 : 09 =
3,778
33 : 10 =
3,300
2nd gear 33 : 16 =
2,063
35 : 18 =
1,944
3rd gear 31 : 23 =
1,348
34 : 26
=1,308
4th gear 29 : 30 =
0,967
35 : 34 =
1,029
5th gear 30 : 39 =
0,769
36 : 43 =
0,837
6th gear - -
Reverse 18 : 09 x
36 : 20 =
3,600
17 : 10 x 36 :
20 = 3,060
Speedome‐
ter
13 : 22 =
0,591
13 : 22 =
0,591
Engine code EGS EGV
Filling quantity 2,0 litres
Specification Oil for pinions API GL4 SAE 75W
(Hypoid)1)
Clutch action hydraulic hydraulic
Clutch plate ø 225 mm 215 mm
Drive shaft flange
ø
108 mm - TRI‐
POD
100 mm
ltotal in top gear 2,606 3,545
1) Do not mix different types of gear oil, observations => page 11 .
Manual
gearbox
5-speed 02J
Engine code EGW FBK
Correspond‐
ence
Type Toledo 1999
ä, León
Toledo 1999
ä, León
Engine 1,8 ltr. -92
kW
2,3 ltr. - VR5
125 kW
Gear ratio:
Z2 : Z1
Final drive 72 : 17 =
4,235
63 : 16 =
3,938
1st gear 33 : 10 =
3,300
33 : 10 =
3,300
2nd gear 35 : 18 =
1,944
35 : 18 =
1,944
3rd gear 34 : 26
=1,308
34 : 25
=1,360
4th gear 35 : 34 =
1,029
30 : 29 =
1,034
Toledo 1999 , León ➤
02J 5-speed manual gearbox - Edition 02.2003
4 00 - Technical data
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
Manual
gearbox
5-speed 02J
5th gear 36 : 43 =
0,837
31 : 38 =
0,815
6th gear - -
Reverse 17 : 10 x 36 :
20 = 3,060
17 : 10 x 36 :
20 = 3,060
Speedome‐
ter
13 : 22 =
0,591
13 : 22 =
0,591
Engine code EGW FBK
Filling quantity 2,0 litres
Specification Oil API GL4 SAE
75W 90 (Synthet‐
ic-High Perform‐
ance)1)
Oil for pinions
API GL4 SAE
75W (Hypoid)1)
Clutch action hydraulic hydraulic
Clutch plate ø 215 mm 225 mm
Drive shaft
flange ø
100 mm 108 mm - TRI‐
POD
ltotal in top gear 3,545 3,209
1) Do not mix different types of gear oil, observations => page 11 .
Toledo 1999 , León ➤
02J 5-speed manual gearbox - Edition 02.2003
1.2 - Code letters, group numbers, ratios, filling quantities 5
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
2 - Diagram of the drive force
2.1 - Diagram of the drive force
Description
1 Engine
2 Clutch
3 Manual gearbox
4 Primary shaft
5 Secondary shaft
6 Differential
The arrows indicate the direction that the vehicle is moving in
Toledo 1999 , León ➤
02J 5-speed manual gearbox - Edition 02.2003
6 00 - Technical data
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2002 SEAT TOLEDO MK2 Service and Repair Manual
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What's Included?
Lifetime Access
Fast Download Speeds
Online & Offline Access
Access PDF Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
Description
Get your hands on the 2002 SEAT TOLEDO MK2 Service and Repair Manual, your go-to resource for fixing vehicle issues. Whether you're a professional mechanic or a DIY enthusiast, these auto repair manuals provide comprehensive instructions and procedures to help you tackle car problems with ease. The manual includes technical data, diagrams, a complete list of car parts, and images, making it suitable for both novice and experienced car mechanics. It covers various sections such as maintenance, engine, control system, mechanical, fuel service specifications, and much more. The manual is available in .PDF format, ensuring compatibility with Windows and Mac operating systems. With this manual, you can save time, stay updated, and enhance your knowledge of car repair. It's a valuable resource that allows you to carry the necessary information with you into the garage or workshop. Take advantage of the detailed instructions, wiring schematics, and specifications to efficiently service and repair your vehicle. Invest in this manual to ensure the durability and performance of your vehicle for years to come.
