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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 Lupo

Original Volkswagen repair manual


16,62 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

6.035 KB

200 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 Lupo 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
    24
  • 2 Servicing clutch release mechanism
    25
  • 2.1 Servicing clutch release mechanism
    25
  • 3 Servicing clutch
    28
  • 3.1 Servicing clutch
    28
  • Controls, Housing
    33
  • 1 Servicing gear selector mechanism
    33
  • 1.1 Servicing gear selector mechanism
    33
  • 1.2 Installation position of gear selector mechanism
    33
  • 1.3 Removing and installing selector lever knob and gaiter
    36
  • 1.4 Servicing gear stick and gear stick housing
    38
  • 1.5 Assembly overview - removing and installing selector cables
    42
  • 1.6 Removing and installing gear selector mechanism
    45
  • 1.7 Adjusting gear selector mechanism
    47
  • 2 Removing and installing gearbox
    51
  • 2.1 Removing and installing gearbox
    51
  • 3 Checking gear oil
    65
  • 3.1 Checking gear oil
    65
  • 4 Dismantling and assembling gearbox
    66
  • 4.1 Dismantling and assembling gearbox
    66
  • 4.2 Overview
    66
  • 4.3 Assembly overview
    68
  • 4.4 Removing and installing cover for gearbox housing and 5th gear
    69
  • 4.5 Removing and installing gearbox housing and selector mechanism
    72
  • 4.6 Removing and installing input shaft, output shaft (pinion shaft), differential and selector forks
    74
  • 4.7 Assembly sequence
    77
  • 5 Servicing gearbox housing and clutch housing
    95
  • 5.1 Servicing gearbox housing and clutch housing
    95
  • 6 Dismantling and assembling gearbox selector mechanism
    105
  • 6.1 Dismantling and assembling gearbox selector mechanism
    105
  • 7 Dismantling and assembling selector forks
    111
  • 7.1 Dismantling and assembling selector forks
    111
  • Gears, Shafts
    118
  • 1 Dismantling and assembling input shaft
    118
  • 1.1 Dismantling and assembling input shaft
    118
  • 2 Adjusting input shaft
    131
  • 2.1 Adjusting input shaft
    131
  • 2.2 Table of adjustment shims
    133
  • 2.3 Performing measurement check
    135
  • 3 Dismantling and assembling output shaft
    136
  • 3.1 Dismantling and assembling output shaft
    136
  • 4 Adjusting output shaft
    166
  • 4.1 Adjusting output shaft
    166
  • 5 Dismantling and assembling reverse shaft
    169
  • 5.1 Dismantling and assembling reverse shaft
    169
  • Final drive, Differential rear
    174
  • 1 Renewing oil seals for flanged shafts
    174
  • 1.1 Renewing oil seals for flanged shafts
    174
  • 1.2 Renewing oil seal for left flanged shaft
    174
  • 1.3 Renewing oil seal for right flanged shaft
    177
  • 2 Dismantling and assembling differential
    180
  • 2.1 Dismantling and assembling differential
    180
  • 3 Adjustment overview
    193
  • 3.1 Adjustment overview
    193
  • 4 Adjusting differential
    194
  • 4.1 Adjusting differential
    194
Manufacturer's designation 5-speed manual gearbox 02J
Manufacturer Volkswagen
Suitable for Lupo (1998 - 2006)
Suitable car types 6X
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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