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  • Examplepage for repair manual 5-speed manual gearbox 02R Volkswagen R GmbH
  • Examplepage for repair manual 2 5-speed manual gearbox 02R Volkswagen R GmbH
  • Examplepage for repair manual 3 5-speed manual gearbox 02R Volkswagen R GmbH

5-speed manual gearbox 02R Volkswagen R GmbH

For Polo / Polo Sedan

Original Volkswagen repair manual


14,29 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

4.646 KB

168 Sites

Detailed technical data

Immediately readable

This repair manual contains: Fault finding, power transmission, Repairing clutch mechanism, Removing and installing gearbox, Input shaft, Adjustment overview and Differential. Show more
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Repair manual Polo / Polo Sedan 5-speed manual gearbox 02R Volkswagen R GmbH PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 Identification of gearbox
    1
  • 1.1 Location on gearbox
    1
  • 1.2 Identification code, assembly allocation and capacities
    1
  • 2 Overview - power transmission
    3
  • 3 Calculating overall gear ratio “i”
    5
  • 4 General repair instructions
    6
  • 4.1 Gearbox
    6
  • 4.2 Gaskets and seals
    6
  • 4.3 Sealant
    6
  • 4.4 Locking devices
    7
  • 4.5 Nuts and bolts
    7
  • 4.6 Mountings
    7
  • 4.7 Shims
    7
  • 4.8 Synchro-rings
    8
  • 4.9 Gear wheels
    8
  • 4.10 Synchromeshed gears
    8
  • 4.11 Clutch
    8
  • Clutch
    9
  • 1 Fault finding, power transmission
    9
  • 2 Repairing clutch mechanism
    10
  • 2.1 Overview - clutch actuation
    10
  • 2.2 Assembly overview - pedal cluster
    11
  • 2.3 Distinguishing between clutch pedal switches F36
    12
  • 2.4 Removing and installing clutch pedal switch F36 with rectangular housing
    12
  • 2.5 Removing and installing clutch pedal switch F36 with round housing
    13
  • 2.6 Removing and installing over-centre spring
    13
  • 2.7 Removing and installing mounting bracket for clutch pedal
    15
  • 2.8 Removing and installing clutch pedal
    18
  • 2.9 Assembly overview - hydraulics - LHD
    19
  • 2.10 Assembly overview - hydraulics - RHD
    22
  • 2.11 Removing and installing master cylinder
    24
  • 2.12 Removing and installing slave cylinder
    26
  • 2.13 Bleeding clutch mechanism
    28
  • 3 Repairing clutch release mechanism
    30
  • 4 Repairing clutch
    32
  • Controls, housing
    35
  • 1 Fault finding, power transmission
    35
  • 2 Repairing selector mechanism
    36
  • 2.1 Installation position of selector mechanism
    36
  • 2.2 Overview of selector mechanism
    37
  • 2.3 Assembly overview - gear knob and cover
    38
  • 2.5 Repairing gear lever and selector housing (through 05. 06)
    40
  • 2.6 Repairing gear lever and selector housing (from 06.06)
    42
  • 2.7 Assembly overview - removing and installing selector cables
    44
  • 2.8 Removing and installing selector mechanism
    48
  • 2.9 Adjusting selector mechanism
    52
  • 3 Removing and installing gearbox
    56
  • 3.1 Removing gearbox
    57
  • 3.2 Transporting gearbox
    62
  • 3.3 Install gearbox
    62
  • 4 Checking gear oil
    68
  • 5 Dismantling and assembling gearbox
    69
  • 5.1 Overview - gearbox
    69
  • 5.2 Assembly overview
    69
  • 5.7 Assembly sequence - Dismantling and assembling gearbox completely
    81
  • 6 Repairing gearbox housing and clutch housing
    94
  • 9 Dismantling and assembling selector forks
    106
  • Gears, shafts
    111
  • 1 Input shaft
    111
  • 1.1 Dismantling and assembling input shaft
    111
  • 1.2 Modification in springs for 5th gear synchronisation from gearbox date 05111
    118
  • 1.3 Adjusting input shaft
    118
  • 2 Output shaft
    123
  • 2.1 Dismantling and assembling output shaft
    123
  • 2.2 Adjusting output shaft
    136
  • 3 Reverse shaft
    140
  • 3.1 Dismantling and assembling reverse shaft
    140
  • Final drive - differential
    144
  • 1 Renewing flange shaft oil seals with gearbox installed
    144
  • 1.1 Renewing oil seal for left flange shaft
    144
  • 1.2 Distinguishing seals for right flange shaft
    146
  • 1.3 Renewing seal (two-part seal and sleeve for right flange shaft)
    146
  • 2 Adjustment overview
    153
  • 3 Differential
    154
  • 3.1 Dismantling and assembling differential
    154
  • 3.2 Adjusting differential
    162
Manufacturer's designation 5-speed manual gearbox 02R Volkswagen R GmbH
Manufacturer Volkswagen
Suitable for Polo / Polo Sedan (2002 - 2007)
Suitable car types 9N
Transmission designations 02R
Transmission types GVZ, HVU, HWY, EWR, GGV, GGU, HGY, HGX, HGW, HET, EWT, EMD, HZP, JEP, EET, EWS, FNY, MDN, MZM, KFK, MAL, MAR, MAT, MNY, MUW, MUX, MZK, MZL, MZN, MZR, MZS, HZN, JCZ, JDA, JDB, JDC, JDD, JDE, JXY, JYF
Engine code BBU
Category Reparaturanleitung

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