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  • Examplepage for repair manual 5-Speed manual gearbox 02J
  • Examplepage for repair manual 2 5-Speed manual gearbox 02J
  • Examplepage for repair manual 3 5-Speed manual gearbox 02J

5-Speed manual gearbox 02J

For Polo

Original Volkswagen repair manual


16,77 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

6.078 KB

202 Sites

Detailed technical data

Immediately readable

This repair manual contains: Servicing clutch control, Removing and installing gearbox and Adjusting input shaft. Show more
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Repair manual Polo 5-Speed manual gearbox 02J PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 Gearbox identification
    1
  • 1.1 Gearbox identification
    1
  • 1.2 Code letters, gearbox allocation, ratios, capacities
    2
  • 2 Transmission layout
    3
  • 2.1 Transmission layout
    3
  • 3 Calculating overall ratio "i"
    5
  • 3.1 Calculating overall ratio "i"
    5
  • 4 General repair instructions
    5
  • 4.1 General repair instructions
    5
  • Clutch
    8
  • 1 Servicing clutch control
    8
  • 1.1 Servicing clutch control
    8
  • 1.2 Assembly overview - Pedal cluster
    9
  • 1.3 Removing and installing clutch pedal
    13
  • 1.4 Removing and installing over-centre spring
    16
  • 1.5 Assembly overview - Hydraulic system
    18
  • 1.6 Removing and installing master cylinder
    21
  • 1.7 Bleeding clutch system
    25
  • 2 Servicing clutch release mechanism
    26
  • 2.1 Servicing clutch release mechanism
    26
  • 3 Servicing clutch
    29
  • 3.1 Servicing clutch
    29
  • Controls, Housing
    34
  • 1 Servicing gear selector mechanism
    34
  • 1.1 Servicing gear selector mechanism
    34
  • 1.2 Installation position of gear selector mechanism
    34
  • 1.3 Removing and installing selector lever knob and gaiter
    37
  • 1.4 Servicing gear stick and gear stick housing
    39
  • 1.5 Assembly overview - removing and installing selector cables
    43
  • 1.6 Removing and installing gear selector mechanism
    46
  • 1.7 Adjusting gear selector mechanism
    48
  • 2 Removing and installing gearbox
    52
  • 2.1 Removing and installing gearbox
    52
  • 3 Checking gear oil
    67
  • 3.1 Checking gear oil
    67
  • 4 Dismantling and assembling gearbox
    68
  • 4.1 Dismantling and assembling gearbox
    68
  • 4.2 Overview
    68
  • 4.3 Assembly overview
    70
  • 4.4 Removing and installing cover for gearbox housing and 5th gear
    71
  • 4.5 Removing and installing gearbox housing and selector mechanism
    74
  • 4.6 Removing and installing input shaft, output shaft (pinion shaft), differential and selector forks
    76
  • 4.7 Assembly sequence
    79
  • 5 Servicing gearbox housing and clutch housing
    97
  • 5.1 Servicing gearbox housing and clutch housing
    97
  • 6 Dismantling and assembling gearbox selector mechanism
    107
  • 6.1 Dismantling and assembling gearbox selector mechanism
    107
  • 7 Dismantling and assembling selector forks
    113
  • 7.1 Dismantling and assembling selector forks
    113
  • Gears, Shafts
    120
  • 1 Dismantling and assembling input shaft
    120
  • 1.1 Dismantling and assembling input shaft
    120
  • 2 Adjusting input shaft
    133
  • 2.1 Adjusting input shaft
    133
  • 2.2 Table of adjustment shims
    135
  • 2.3 Performing measurement check
    137
  • 3 Dismantling and assembling output shaft
    138
  • 3.1 Dismantling and assembling output shaft
    138
  • 4 Adjusting output shaft
    168
  • 4.1 Adjusting output shaft
    168
  • 5 Dismantling and assembling reverse shaft
    171
  • 5.1 Dismantling and assembling reverse shaft
    171
  • Final drive, Differential rear
    176
  • 1 Renewing oil seals for flanged shafts
    176
  • 1.1 Renewing oil seals for flanged shafts
    176
  • 1.2 Renewing oil seal for left flanged shaft
    176
  • 1.3 Renewing oil seal for right flanged shaft
    179
  • 2 Dismantling and assembling differential
    182
  • 2.1 Dismantling and assembling differential
    182
  • 3 Adjustment overview
    195
  • 3.1 Adjustment overview
    195
  • 4 Adjusting differential
    196
  • 4.1 Adjusting differential
    196
Manufacturer's designation 5-Speed manual gearbox 02J
Manufacturer Volkswagen
Suitable for Polo (1995 - 2002)
Suitable car types 6N
Transmission designations 02J
Transmission types EWX, GRJ, EWW, CZL, DBZ, DQY, DSF, DSG, DTA, DUE, EGS, EGR, EGF, EGD, EGC, EGB, EFG, EEA, ECW, EMT, EMS, EMR, ELG, EKW, EKV, EKU, EKH, EKG, EBS, EBQ, EBP, EBN, EBM, EBJ, EBF, EBD, EBA, DZQ, DZL, DZK, DZF, DZC, DYP, DYN, EHA, EGZ, EGY, EGX, EGW, EGV, EGU, EGT, DTK, GPK, FQL, FDU, FDS, FCK, FCJ, FCH, FCF, FBY, FBX, FBW, FBV, FBL, FBK, EZK, EZH, EYD, EXE, EXD, EXB, EXA, EWZ, EWY, EWV, EWU, EWQ, EVS, EVR, EVQ, EUW, EUQ, EUH, ESV, ESP, ERS, ENJ, ENH, EHN, EHC, EHB, DCL, CZM, DEA, JDW, JDM, JEG, JDH, LCC, JDJ, JDR, JEJ, GBV, JDQ
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