SM 24

Service
Workshop Manual
Polo 2014 ➤
up! 2017 ➤
5-speed manual gearboxes
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
30 - Clutch
34 - Controls, housing
35 - Gears, shafts
39 - Final drive - differential
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Technical information should always be available to the foremen and mechanics, because their
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careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
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All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2018 Volkswagen AG, Wolfsburg D4B8040D507

Polo 2014 ➤ , up! 2017 ➤
5-speed manual gearboxes 02T and 0DF - Edition 11.2018
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
AG. Volkswagen
1 Safety information . . . . . . . lk. s.w.a.ge.n. . . . . . . . . . . A. G. d. o.e.s n. . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.1 Safety measures wheneworking db
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2 Identification . . . .uth. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ee. o.r . . . . . . . . . . . . . . . . . .
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2.1 Gearbox identification
ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . c. . . . . . . . . . . . . . . . . .
. 2
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3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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3.1 Allocation gearbox - engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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3.2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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3.3 Calculation of gear ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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4 Overview - power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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5 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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5.1 Overview of fitting locations - electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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6.1 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1 Clutch operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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1.1 Overview of fitting locations – clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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1.2 Assembly overview - pedal cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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1.3 Assembly overview - clutch hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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1.4 Assembly overview - clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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1.5 Removing and installing bearing bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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1.6 Removing and installing clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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1.7 Removing and installing over-centre spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.8 Removing and installing extension spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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1.9 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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1.10 Removing and installing clutch master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
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1.11 Removing and installing clutch slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

1.12 Removing and installing lines for clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.13 Bleeding clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1.14 Removing and installing clutch pedal switch F36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.15 Checking clutch master cylinder and clutch slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . 49
1.16 Removing and installing clutch position sender G476 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.17 Repairing clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.1 Assembly overview - clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.2 Removing and installing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1 Selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1.1 Installation position - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1.2 Assembly overview - gear knob and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1.3 Assembly overview - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
1.4 Removing and installing gear knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
1.5 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.6 Repairing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1.7 Adjusting selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
1.8 Checking selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
2 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2.1 Differentiating between gearboxes, Polo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2.2 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2.3 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Contents i
Polo 2014 ➤ , up! 2017 ➤
2.4 Specified torques for gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

3 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
3.1 Assembly overview - assembly mountings, up! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
3.2 Assembly overview - assembly mountings, Polo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
4 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . .ks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
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5 Gear oil . . . . . . . . . . . . . . . . . . . . .o.lk.sw. a.g. . . . . . . . . . . . . . .d.oe. s.n.ot. . . . . . . . . . . . . . . . . . . . 115
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5.1 Checking gear oil level . . . . .se. d.b.y . . . . . . . . . . . . . . . . . . . . . . . . . .u.ar.an. . . . . . . . . . . . . . . . 115
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5.2 Draining and filling gear oil uth.o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .e.e o.r . . . . . . . . . . . . . 116
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6 Securing to engine and gearbox ss support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
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6.1 Securing to engine and gearbox support, gearboxes for up! . . . . . . . . . . . . . . . . . . . . . . . . 119
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6.2 Securing to engine and gearbox support, gearboxes for Polo . . . . . . . . . . . . . . . . . . . . . . 121
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7 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
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7.1 Schematic overview - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
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7.2 Assembly overview - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
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7.3 Assembly overview - cover for gearbox housing and 5th gear . . . . . . . . . . . . . . . . . . . . . . 127
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7.4 Assembly overview - clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
7.5 Assembly overview - shafts, differential, selector mechanism . . . . . . . . . . . . . . . . . . . . . . 130
7.6 Assembly overview - selector unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
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7.7 Assembly overview - selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
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7.8 Removing and installing selector unit with gearbox installed . . . . . . . . . . . . . . . . . . . . . . . . 135
7.9 Repairing selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
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7.10 Repairing selector unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

7.11 Renewing selector shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
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7.12 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
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8 Gearbox housing, clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
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8.1 Assembly overview - gearbox housing and clutch housing . . . . . . . . . . . . . . . . . . . . . . . . 159
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8.2 Repairing clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

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35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
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1 Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
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1.1 Assembly overview - input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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165
1.2 Dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
1.3 Renewing input shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
2 Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
2.1 Assembly overview - output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
2.2 Dismantling and assembling output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

1 Oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
1.1 Overview of fitting locations - seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
1.2 Renewing left seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
1.3 Renewing right oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
2 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
2.1 Assembly overview - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
2.2 Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
2.3 Adjusting differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
ii Contents
Polo 2014 ➤ , up! 2017 ➤
00 – Technical data
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1 Safety information
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(VRL012445; Edition 11.2018)
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⇒ “1.1 Safety measures when working on vehicles with a start/
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stop system”, page 1
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1.1 Safety measures when working on ve‐
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Risk of injury due to automatic start of engine on vehicles with
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♦ Deactivate the start/stop system when working on vehicle.
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Switch off ignition.

♦ Switch on the ignition briefly only if required.
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1. Safety information 1
Polo 2014 ➤ , up! 2017 ➤
2 Identification
⇒ “2.1 Gearbox identification”, page 2
2.1 Gearbox identification

Manual gearbox 02T and manual gearbox 0DF
Code letters and production date -arrow 1- manual gearbox 02T
and manual gearbox 0DF
Only manual gearbox 02T -arrow 2- ⇒ previous illustration
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Continuation for all ir se tee
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Codes and production date of gearbox ss
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Example: PNZ 22 01 4 pt
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Additional data provide information about the production facility.

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The gearbox code is also included on the vehicle data stickers.

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2 Rep. gr.00 - Technical data

Polo 2014 ➤ , up! 2017 ➤
3 Technical data
⇒ “3.1 Allocation gearbox - engine”, page 3 .
⇒ “3.2 Capacities”, page 4 .
⇒ “3.3 Calculation of gear ratios”, page 4 .
3.1 Allocation gearbox - engine

⇒ “3.1.1 Allocation gearbox - engine, Polo, manual gearbox 02T”,
page 3
⇒ “3.1.2 Allocation gearbox - engine, Polo, manual gearbox 0DF”,
page 3
⇒ “3.1.3 Allocation gearbox - engine, up!”, page 3
3.1.1 Allocation gearbox - engine, Polo, manual gearbox 02T

Manual gearbox 5-speed, 02T
Codes aPNZ
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Allocation Engine
ss a 1.2 l - 66 kW 1.2 l - 66 kW c 1.6 l - 66 kW
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Ratio Final drive 65 : 16 = 3.625 65 : 16 = 3.625 59 : 15 = 3.933

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Drive shaft flange diameter 100 mm 100 mm 100 mm
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♦ Individual gear ratios
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♦ Clutch allocation
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3.1.2 Allocation gearbox - engine, Polo, manual gearbox 0DF

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Manual gearbox 5-speed, 0DF

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Codes QGL QTS

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Allocation Engine 1.0 l - 70 kW 1.0 l - 70 kW

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Ratio Final drive 58 : 16 = 3.625 58 : 16 = 3.625

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♦ Gear oil
3.1.3 Allocation gearbox - engine, up!

Codes QWH, TTB
Manufac‐ from 05.16
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3. Technical data 3
Polo 2014 ➤ , up! 2017 ➤

Codes QWH, TTB
Allocation Engine 1.0 l - 66 kW petrol engine
Glean following data from ⇒ Electronic parts catalogue (ETKA) :
♦ Gear oil
3.2 Capacities
Capacity of manual 2.1 l
gearbox
3.3 Calculation of gear ratios

Example:
5th gear Final drive
Drive gear ZG1 = 46 ZA1 = 24
Driven gear ZG2 = 33 ZA2 = 70
i = ZG2 : ZG1 1)
iG = Gear ratio = ZG2: ZG1= 33 : 46 = 0.717
iA = Final drive ratio = ZA2 : ZA1 = 70 : 24 = 2.917
itotal = overall ratio = iG x iA = 0.717 x 2.917 = 2.091
1) Z1 = No. of teeth on driving gear, Z2 = No. of teeth on driven gear
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Rep. gr.00 - Technical data
Polo 2014 ➤ , up! 2017 ➤
4 Overview - power transmission

Designation:
-Arrows- point in direction of travel.
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Ratio
-Arrows- point in direction of travel.
4. Overview - power transmission 5

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5-speed manual gearboxes 02Tth and 0DF - Edition 11.2018
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I - 1st gear
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R - Reverse gear
A - Final drive
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Polo 2014 ➤ , up! 2017 ➤
5 Electrical components
⇒ “5.1 Overview of fitting locations - electrical components”, page
7
5.1 Overview of fitting locations - electrical

components
⇒ “5.1.1 Overview of fitting locations – electrical components,
manual gearbox, up!”, page 7
manual gearbox, Polo”, page 8
clutch mechanism, up!”, page 8
clutch mechanism, Polo”, page 9
5.1.1 Overview of fitting locations – electrical components, manual gearbox, up!
1 - Gearbox neutral position

sender - G701-
❑ Location: beneath se‐
lector unit
❑ Removing and installing
⇒ page 130
2 - Reversing light switch - F4-
❑ Installation location: on
selector unit next to an‐
gled rod for securing se‐ AG. Volkswagen AG d
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5. Electrical components 7
Polo 2014 ➤ , up! 2017 ➤
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5.1.2 Overview of fitting locations – electrical components, manual gearbox, Polo ed
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⇒ page 130
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2 - Gearbox neutral position
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sender - G701-
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❑ Fitting location: in area
of selector unit beneath
angled rod for securing
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selector shaft
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⇒ page 130
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5.1.3 Overview of fitting locations – electrical

components, clutch mechanism, up!
Clutch position sender - G476-
Location: in passenger compartment on clutch master cylinder.
Held in position by retainer -arrow A- and -arrow B-
Removing and installing clutch position sender - G476-
⇒ page 49 .
Clutch pedal switch - F36- (item -2-)

Location: in passenger compartment on mounting bracket for
clutch pedal
Connector -1- is connected; plunger -3- makes contact with clutch
pedal -4-.
Removing and installing clutch pedal switch - F36- ⇒ page 48

Polo 2014 ➤ , up! 2017 ➤
5.1.4 Overview of fitting locations – electrical

components, clutch mechanism, Polo
Clutch position sender - G476- (-arrow A- and -arrow B-)
Fitting location:
In engine compartment beneath supply hose -1- on clutch cylinder
-2- above line -3-.
Removing and installing clutch position sender - G476-
⇒ page 49 .
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5. Electrical components 9
Polo 2014 ➤ , up! 2017 ➤
6 Repair instructions
⇒ “6.1 General repair instructions”, page 10 agen
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A number of general notes on the individual repair procedures,
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For a complete list of special tools used in this workshop manual,
see ⇒ Electronic parts catalogue (ETKA) .
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Gearbox
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♦ When installing the manual gearbox, ensure that the dowel

sleeves between the engine and gearbox are correctly seated.
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♦ When installing mounting brackets or waxed components,

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clean the contact surfaces. Contact surfaces must be free of
com
tion in
wax and grease.
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♦ Allocate bolts and other components using the ⇒ Electronic
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parts catalogue (ETKA) .

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♦ After repairing the gearbox, fill with gear oil.

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After removing gaskets and seals, always inspect contact surfa‐
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ces of housing and shaft for burrs resulting from removal or for
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other signs of damage.

♦ Thoroughly clean joint surfaces and apply sealant .
♦ Allocation ⇒ Electronic parts catalogue (ETKA)
♦ Before installing radial oil seals, half-fill space between sealing
lips with sealing grease -arrow-.
♦ Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
♦ The open side of the oil seals faces toward the side with fluid
filling.
♦ Lightly oil O-rings before installing; this prevents the rings be‐
ing crushed when inserted.
Sealant
♦ Thoroughly clean housing joint surfaces before applying seal‐
ant .
♦ Apply sealant uniformly and not too thickly.
♦ Breather holes must remain free of sealant .

Polo 2014 ➤ , up! 2017 ➤
Locking devices
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♦ Do not overstretch
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♦ Retaining rings must locate properly in grooves.
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♦ Renew spring pins. Installation position: slot must be in line
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with direction of force.
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♦ Loosen and tighten securing bolts and nuts for covers and
hole
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housings alternately and diagonally.
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♦ Do not cant especially delicate parts, such as clutch pressure
plates. Loosen and tighten bolts and nuts alternately and in
stages.
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♦ Specified torques given are for unoiled nuts, bolts and screws.
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♦ Renew self-locking bolts and nuts after each removal. nform

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♦ Ensure with threaded connections that contact surfaces as

well as nuts and bolts are rewaxed only after assembly, if nec‐
m
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♦ Use a thread chaser to clear residual locking fluid from all

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threaded holes into which self-locking bolts are to be screwed.

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Otherwise there is a danger of bolts shearing when subse‐

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♦ Check pitch of thread, to ensure correct thread chaser is used C py
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Bearings cted agen
Prote AG.
♦ Lubricate all bearings with gear oil before installing.

♦ Install new tapered roller bearings as supplied and do not lu‐
bricate additionally.
♦ Install needle bearings with lettered side (thicker metal) to‐
wards fitting tool.
♦ Tapered roller bearings fitted to one shaft must be renewed as
a set. Use same make of bearings.
♦ Heat inner races to about 100 °C with the inductive heater -
VAS 6414- before installing.
♦ Do not interchange outer or inner races of bearings of the
same size. The bearings are matched in pairs.
6. Repair instructions 11
Polo 2014 ➤ , up! 2017 ➤
Shims
♦ Measure shims at several points with a micrometer. The var‐
ious tolerances make it possible to achieve the exact shim
thickness required.
♦ Check for burrs and damage.
♦ Install only flawless shims.
Synchro-rings
♦ Do not interchange them. When reusing synchro-rings, always

fit to the same synchromeshed gear.
♦ Check for wear and renew if necessary.
♦ Check grooves -arrow 1- of synchro-ring -A- and inner ring for
flat spots (worn grooves).
♦ If synchro-rings are coated, coating must not be damaged.
♦ If an intermediate ring -B- is installed, check the outer friction
surface -arrow 2- and inner friction surface -arrow 3- of this
intermediate ring for »scoring«, »signs of abnormal wear« and
»blue discolouration (due to overheating)«.
♦ Check the cone of the synchromeshed gear for »scoring« and
»signs of abnormal wear«.
G. Volkswagen
♦ Moisten synchromesh mechanism wawith
gen Agear oil before instal‐
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inductive heater - VAS 6414- .

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Clutch operation
Disconnect battery earth strap ⇒ Electrical system; Rep. gr. 27 ;
Battery; Disconnecting and connecting battery .
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When reconnecting battery, refer to ⇒ Electrical system; Rep. gr.

l purpos
27 ; Battery; Disconnecting and connecting battery .

Clutch
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♦ Ensure that the pressure plate does not cant: loosen and tight‐
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en bolts alternately and diagonally and in several gradual

ion
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♦ In order to reduce the smell of a burned clutch, the clutch

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housing as well as the stopping face of the flywheel must be

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Prote AG.

Polo 2014 ➤ , up! 2017 ➤
30 – Clutch
1 Clutch operation
⇒ “1.1 Overview of fitting locations – clutch mechanism”,
page 13
⇒ “1.2 Assembly overview - pedal cluster”, page 16
⇒ “1.3 Assembly overview - clutch hydraulics”,
olks
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⇒ “1.4 Assembly overview - clutch release
ris
ed mechanism”, ran
tee
page 24 utho
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⇒ “1.5 Removing and installing bearing bush”, page 25
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⇒ “1.15 Checking clutch master cylinder and clutch slave cylin‐
d
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ility
⇒ “1.16 Removing and installing clutch position sender G476 ”,
ot
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page 49
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spec
⇒ “1.7 Removing and installing over-centre spring”, page 28
es, in part or in w
t to the co
⇒ “1.8 Removing and installing extension spring”, page 30
⇒ “1.6 Removing and installing clutch pedal”, page 26
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⇒ “1.9 Removing and installing mounting bracket”, page 31
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⇒ “1.10 Removing and installing clutch master cylinder”,

page 38
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⇒ “1.11 Removing and installing clutch slave cylinder”,

page 40
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tion in
⇒ “1.12 Removing and installing lines for clutch mechanism”,
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page 44
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⇒ “1.13 Bleeding clutch mechanism”, page 47

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⇒ “1.17 Repairing clutch release mechanism”, page 51

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⇒ “1.1.1 Overview of fitting locations – clutch mechanism, up!”,

page 13
⇒ “1.1.2 Overview of fitting locations – clutch mechanism, Polo”,
page 15
1.1.1 Overview of fitting locations – clutch mechanism, up!
1. Clutch operation 13
Polo 2014 ➤ , up! 2017 ➤
I- AG. Volkswagen AG d
agen oes
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⇒ “1.2.1 Assembly overview – by
Vol not
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pedal cluster, up!”, page 16 rised
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II - ss a ra
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⇒ “1.3.1 Assembly overview –
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clutch hydraulics, up!”,
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page 20 itte
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14 Rep. gr.30 - Clutch

AG. Volkswagen AG d
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Polo 2014 ➤ , up! 2017 gu ➤
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5-speed manual horgearboxes
is
02T and 0DF - Edition 11.2018 eo
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1.1.2 Overview of fitting locations – clutch mechanism, Polo
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pedal cluster, Polo”,
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page 18
spec
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t to the co
clutch hydraulics, Polo, LHD
vehicles”, page 22
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III -
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clutch hydraulics, Polo, RHD
vehicles”, page 23
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Polo 2014 ➤ , up! 2017 ➤
1.2 Assembly overview - pedal cluster

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⇒ “1.2.1 Assembly overviewVo–lkspedal cluster, up!”, page 16
oes
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⇒ “1.2.2 Assembly overview
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1.2.1 Assembly overview – pedal cluster, up!
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1 - Bulkhead
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❑ With support for mount‐
wit
ing bracket and clutch
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master cylinder.
hole
spec
2 - Seal
es, in part or in w
t to the co
❑ Self-adhesive
❑ Renew after removing
mounting bracket or
rrectness of i
clutch master cylinder
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❑ Stick to clutch master

cylinder.
nform
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3 - Supply hose
m
at
❑ ⇒ page 20
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4 - Support
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❑ fit into mounting bracket do

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⇒ page 30 Installing
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for
extension spring
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❑ No specific installation C py
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5 - Clutch position sender -
G476-
❑ Installed depending on
version.
❑ Can be checked using
⇒ Vehicle diagnostic
tester in Guided Fault
Finding mode
❑ Allocation ⇒ Electronic
parts catalogue (ETKA)
⇒ page 49
6 - Spring
❑ Hooked into mounting bracket and into clutch pedal
❑ Removing and installing ⇒ page 30
7 - Bush
❑ Qty. 2
❑ Chamfer -arrow- faces clutch master cylinder.
❑ Press in flush.
8 - Bolt
❑ 13 Nm
9 - Mounting bracket with clutch pedal
10 - Bolt
❑ LHD vehicles
❑ For crash bar on steering column

Polo 2014 ➤ , up! 2017 ➤
❑ 20 Nm
11 - Hexagon nut
❑ LHD vehicles
12 - Crash bar
❑ LHD vehicles
❑ Attached to steering column
❑ Allocate components using ⇒ Electronic parts catalogue (ETKA)
13 - Crash bar
❑ RHD vehicles
❑ Attached to steering column
14 - Bolt
❑ RHD vehicles
AG. Volkswagen AG d
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❑ 20 Nm ed by ara
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15 - Clutch pedal switch
au - F36-
th or
ac
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❑ Installed depending on version.
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nl
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16 - Pivot pin
wit
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❑ For plunger/clutch master cylinder
hole
spec
❑ Renew after removal
es, in part or in w
t to the co
17 - Cap
18 - Buffer stop
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❑ For clutch pedal

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19 - Hexagon nut
❑ Qty. 3
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❑ Self-locking
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❑ 25 Nm
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20 - Bearing bush
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21 - Clutch master cylinder t. Cop py
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22 - Clip cted agen
Prote AG.
❑ To remove pipe/hose line, pull out clip to stop
❑ Can be pressed in as far as stop before fitting line
Polo 2014 ➤ , up! 2017 ➤
1.2.2 Assembly overview – pedal cluster, Polo
1 - Clutch pedal
⇒ page 26
❑ Do not grease
2 - Bearing bush agen
AG. Volkswagen AG d
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❑ Removing and installing d by Vo gu
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⇒ page 25 orise nte
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❑ Do not grease s au ra
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3 - Clutch master cylinder
nl
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⇒ page 38
ab
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4 - Clip
wit
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❑ To remove pipe/hose
hole
spec
line, pull out clip to stop
es, in part or in w
❑ Can be pressed in as far
t to the co
as stop before fitting line
5 - Seal
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❑ Self-adhesive
l purpos
❑ Renew after removing

the clutch master cylin‐
der.
nform
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❑ Glue onto clutch master

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cylinder
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6 - Clutch position sender -
his
ate
G476-
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❑ Can be checked using
for
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⇒ Vehicle diagnostic
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tester in Guided Fault C py
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Finding mode
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❑ Allocation ⇒ Electronic Prote
cted AG.
agen
⇒ page 49
7 - Pivot pin
❑ Do not grease
8 - Bulkhead
❑ With studs for securing mounting bracket and master cylinder
9 - Bush
❑ For upper mounting hole in mounting bracket
❑ Bushes for lower mounting holes in mounting bracket are located in master cylinder
10 - Hexagon nut
❑ For securing mounting bracket and clutch master cylinder to plenum chamber bulkhead
❑ Qty. 3
❑ Self-locking
❑ 25 Nm
11 - Crash bar
❑ Secured to module carrier

Polo 2014 ➤ , up! 2017 ➤
❑ Allocate according to ⇒ Electronic parts catalogue (ETKA)
12 - Hexagon nut
❑ For crash bar on module carrier
❑ 20 Nm
13 - Mounting bracket agen
AG. Volkswagen AG d
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❑ Removing and installing ⇒ page 31 thori
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❑ Using drift - VW 207- drive bushes for the studs
ss a
used to fasten the mounting bracket onto the bulkhead,
c
into the holes in the mounting bracket
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14 - Buffer stop
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15 - Over-centre spring or extension spring
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❑ Grease support on mounting bracket
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hole
❑ For grease allocation, refer to ⇒ Electronic parts catalogue (ETKA) .
spec
es, in part or in w
❑ Installed depending on version.
t to the co
❑ Different versions exist; for correct version refer to ⇒ Electronic parts catalogue (ETKA)
❑ Removing and installing over-centre spring ⇒ page 28
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❑ Removal and installation of extension spring are identical to removal and installation of over-centre spring
⇒ page 28
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16 - Bearing bush
nform
ercia
❑ Do not grease
m
17 - Pivot pin
at
om
ion
❑ For plunger/clutch master cylinder
c
in t
or
his
e

at
do
priv
c
❑ Do not grease
um
for
en
ng
t.
18 - Cap
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Polo 2014 ➤ , up! 2017 ➤
1.3 Assembly overview - clutch hydraulics

⇒ “1.3.1 Assembly overview – clutch hydraulics, up!”, page 20
⇒ “1.3.2 Assembly overview – clutch hydraulics, Polo, LHD vehi‐
cles”, page 22
⇒ “1.3.3 Assembly overview – clutch hydraulics,
agen
AG. VolkswaPolo,
gen AGRHD vehi‐
does
cles”, page 23 V olksw not
g y ua
db ran
se
1.3.1 Assembly
ut
ho
ri
overview – clutch hydraulics, up!
tee
or
a ac
ss
ce
e
nl
1 - Brake fluid reservoir
pt
du
an
itte
y li
2 - Supply hose
erm
ab
ility
ot p
3 - Seal
wit
, is n
h re
❑ If damaged, renew to‐
hole
gether with supply hose
spec
es, in part or in w
❑ The seals must be loca‐
t to the co
ted in supply hose
rrectness of i
l purpos
⇒ page 38
5 - Clip
nform
ercia
m
at
om
io
n
c
in t
r

o
his
ate
do
riv
6 - Mounting bracket with

p
cum
or
clutch pedal
f
en
ng
t.
yi Co
7 - Pivot pin ht. Cop py
rig
❑ For plunger/clutch mas‐ rig ht
py by
Vo
ter cylinder
co lksw
by
cted agen
Prote AG.
8 - Hexagon nut
❑ ⇒ page 16
9 - Seal / O-ring
❑ Renew if damaged
❑ Pull onto line connection
❑ Insert with brake fluid
❑ Seals/O-rings are adap‐
ted to material of line
connection ⇒ page 42
10 - Pipe line
❑ Installed on left-hand drive vehicles as an alternative to pipe/hose line.
❑ Different lengths for LHD and RHD vehicles.
❑ Allocation ⇒ Electronic parts catalogue (ETKA)
11 - Pipe/hose line
12 - Bracket
❑ Only LHD.
❑ Secured to body
❑ For brake lines, pipe line and pipe/hose line.
❑ Identifying differences between brackets for pipe line and pipe/hose line ⇒ page 21 .

AG. Volkswagen AG d
agen
olksw Polo
oes
not 2014 ➤ , up! 2017 ➤
yV gu
5-speed
ised b manual gearboxes 02T and 0DF
ara - Edition 11.2018
nte
or eo
h
ut ra
13 - Brake lines ss a c
ce
le
❑ Various number
un
pt
an
d
itte
y li
erm
ab
14 - Bracket
ility
ot p
wit
is n
❑ Only RHD.
h re
ole,
❑ Secured to body
spec
15 - Dust cap urposes, in part or in wh
t to the co
16 - Bleeder valve
❑ Bleeding clutch mechanism ⇒ page 47
rrectne
❑ Specified torque ⇒ page 47
ss
17 - Hexagon bolt
o
cial p
f i
❑ ⇒ page 24
nform
mer
18 - Clip
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
c
19 - Clutch slave cylinder
um
r
fo
en
ng

t.
yi Co
op py
❑ Removing and installing ⇒ page 40 t. C rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
LHD, identifying differences between brackets for pipe line and
pipe/hose line
Dimension “a” mm Line configuration
approx. 6 Pipe line
approx. 8 Pipe/hose line
AG. Volkswagen AG d
agen oes
olksw not
Polo 2014 ➤ , up! 2017d➤ by
V gu
ara
e nte
horis
02T and 0DF - Edition 11.2018 eo
aut ra
ss c
1.3.2 Assembly overview – clutch hydraulics, Polo, LHD vehicles
ce
le
un
pt
an
d
itte
y li
erm
ab
1 - Hexagon bolt
ility
ot p
wit
❑ Specified torque
is n
h re
⇒ page 24
ole,
spec
2 - Bleeder valve
t to the co
❑ Bleeding clutch mecha‐
nism ⇒ page 47
rrectne
⇒ page 47
s
3 - Dust cap
s o
cial p
f
4 - Supply hose
inform
mer
5 - Brake fluid reservoir
atio
om
n
6 - Seals
c
i
or
n thi
e
❑ Must be fitted in supply

t
sd
va
hose
i
o
pr
cum
r
fo
en
ng
t.
yi
Co
Cop py
t. rig
gh
ht
pyri by
Vo
o
by c lksw
❑ Removing and installing Prote
cted agen
⇒ page 38
AG.
8 - Clip
9 - Seal / O-ring
ted to configuration of
line connection
⇒ page 44
10 - Pipe/hose line
❑ Actual number of windings may vary from that shown in illustration
11 - Bracket
❑ Secured to body
❑ For pipe/hose line
12 - Seal / O-ring
❑ Seals/O-rings are adapted to configuration of line connection ⇒ page 44
13 - Clip

Polo 2014 ➤ , up! 2017 ➤
1.3.3 Assembly overview – clutch hydraulics, Polo, RHD vehicles
1 - Hexagon bolt
⇒ page 24
⇒ page 40
3 - Gearbox
4 - Seal / O-ring
ted to configuration of
line connection
⇒ page 44
5 - Brake fluid reservoir agen
AG. Volkswagen AG d
oes
olksw not
6 - Seals d by V gu
ara
ise nte
❑ Must be fitted in supply uthor eo
hose ss a ra
c
ce
le
un
pt

an
d
itte
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rm
ab
7 - Supply hose
pe
ility
ot
wit

, is n
h re

hole
spec
⇒ page 38
es, in part or in w
t to the co
9 - Clip
rrectness of i

l purpos

10 - Bracket
nform
ercia
❑ Secured to body
m
❑ For brake lines and pipe/hose assembly

com
tion in
r
te o
11 - Brake lines
thi
s
iva
do
12 - Bracket
r
rp
cum
fo
❑ Secured to body
en
ng
t.
yi Co
op
❑ For pipe/hose line C py
t. rig
gh ht
yri
13 - Pipe/hose line
p by
co Vo
by lksw
cted
agen
Prote AG.
Polo 2014 ➤ , up! 2017 ➤
14 - Seal / O-ring
❑ Seals/O-rings are adapted to configuration of line connection ⇒ page 44
15 - Clip
❑ To remove pipe/hose line, pull out clip to stop olkswage es n
ot g
yV
❑ Can be pressed in as far as stop before fitting
se
d line
b ua
ran
ri tee
ho
16 - Bleeder valve au
t or
ac
ss
❑ Bleeding clutch mechanism ⇒ page 47
ce
e
nl
pt
du
an
itte
y li
erm
ab
17 - Dust cap
ility
ot p
wit
, is n
h re
hole
1.4 Assembly overview - clutch release mechanism
spec
es, in part or in w
t to the co
1 - Release bearing
❑ Remove and install to‐
rrectness of i
gether with clutch re‐
l purpos
lease lever and guide

sleeve ⇒ page 51
❑ Do not wash out bear‐
nf
ercia
o
ing; wipe only
rm
m
atio
m
❑ Renew noisy bearings

o
n in
or c
2 - Bolt
thi
te
sd
iva
o
r
rp
cu
o
m
❑ 5 Nm +90°
f
en
ng
t.
yi Co
op
3 - Clutch release lever C py
t. rig
gh ht
yri
❑ Remove and install to‐ p by
co Vo
by lksw
cted agen
Prote
lease bearing and guide
AG.
sleeve ⇒ page 51 .
❑ Remove old grease
❑ Grease contact surface
of ball-head pin with
grease for clutch plate
splines .
❑ Allocate grease using ⇒
Electronic parts cata‐
logue (ETKA) .
4 - Retaining spring
❑ Secure to clutch release
lever
5 - Guide bush
❑ Remove and install to‐
lease bearing and clutch
release lever
⇒ page 51
6 - Ball-head pin
❑ Remove old grease
❑ Grease contact surface of ball-head pin with grease for clutch plate splines .

Polo 2014 ➤ , up! 2017 ➤
❑ Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
❑ 20 Nm
7 - Input shaft seal
❑ Renew after removal ⇒ page 176
8 - Gearbox lkswage es n
o ot g
byV ua
d
9 - Hexagon bolt o
ir se
ran
tee
th or
❑ 20 Nm au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
1.5 Removing and installing bearing bush , is n
h re
hole
spec
Removing
es, in part or in w
t to the co
Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and reconnecting battery .
rrectness of i
– Remove over-centre spring/extension spring ⇒ page 28 .
l purpos
– Compress catches -arrows- and take out pin -1- towards right
side.
nf
ercia
– Pull clutch pedal into passenger compartment as far as stop.
orm
m
atio
– Remove over-centre spring/extension spring.
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Turn plunger of clutch master cylinder so that recesses -1- or

marking -2- become visible.
Ensure that recesses -1- and marking -2- point in same direction.
– Remove bearing bush -A- from recesses -1-.
Installing
– Turn plunger of clutch master cylinder so that recesses -1- or
marking -2- become visible.
Ensure that recesses -1- and marking -2- point in same direction.
– Fit and swivel bearing bush -A- into recesses -1-.
– Install over-centre spring/extension spring ⇒ page 28 , and
connect plunger/clutch master cylinder to clutch pedal.
– Use new pivot pin.
– Connect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and connecting battery .
Polo 2014 ➤ , up! 2017 ➤
1.6 Removing and installing
Vol
ksw clutch pedal
age es n
ot g
y ua
db ran
⇒ “1.6.1 Removing and installingorclutch
ise pedal, up!”, page 26 tee
h
ut or
⇒ “1.6.2 Removing and installing
ss
a
clutch pedal, Polo, LHD vehi‐ ac
cles”, page 26
ce
e
nl
pt
du
an
⇒ “1.6.3 Removing and installing clutch pedal, Polo, RHD vehi‐
itte
y li
erm
cles”, page 27
ab
ility
ot p
1.6.1 Removing and installing clutch pedal,
wit
, is n
h re
up!
hole
spec
es, in part or in w
The clutch pedal is removed and installed together with the
t to the co
mounting bracket ⇒ page 31 .
The clutch pedal stays fitted to the mounting bracket.
rrectness of i
l purpos
Polo, LHD vehicles
nf
ercia
Removing
orm
m
atio
– Move driver seat as far back as possible.
om
n in
or c
– Move steering wheel to uppermost position using the entire
thi
te
range of adjustment of the steering column.
sd
iva
o
r
rp
cu
– Remove over-centre spring/extension spring ⇒ page 28 .
o
m
f
en
ng
t.
yi Co
– If installed in area of mounting bracket: remove onboard sup‐ t. Cop py
ply control unit - J519- ⇒ Electrical system; Rep. gr. 97 ;
rig
gh ht
yri by
Control units; Removing and installing onboard supply control cop Vo
by lksw
unit - J519- . cted agen
Prote AG.
Remove pivot pin the for the clutch pedal as follows:

– Break off both locking devices -A- using a screwdriver -1-.
-1- 10 mm hexagon bit

• Turn bearing shaft for clutch pedal to left -arrow- as far as stop.
– Move clutch pedal slightly so that the pivot pin can be pulled
out.

Polo 2014 ➤ , up! 2017 ➤
Installing
Install in reverse order of removal, observing the following:
-1- = 10 mm hexagon bit
• Renew pivot pin after removing.
– Depress clutch pedal slightly and push new pivot pin through
to stop.
– Turn pivot pin to right to stop, -direction of arrow-.
• Locking devices -A- must audibly engage.
– Install over-centre spring/extension spring ⇒ page 28 .
– If removed beforehand: install onboard supply control unit -
J519- ⇒ Electrical system; Rep. gr. 97 ; Control units; Re‐
moving and installing onboard supply control unit - J519- .

Polo, RHD vehicles
Removing AG. Volkswagen AG d
agen oes
olksw not
y V gu
– Remove mounting d b bracket ⇒ page 31 . ara
rise nte
ho eo
– Compress
aut fasteners -arrows-, and pull pivot pin -1- for plunger/
ra
c
clutch
s master cylinder off towards right (shown in illustration
s
ce
e
with mounting bracket installed).

nl
pt
du
an
itte
y li
– Pull clutch pedal as far as stop.

erm
ab
ility
ot p
– Remove over-centre spring/extension spring.

wit
, is n
h re
Remove pivot pin the for the clutch pedal as follows:

hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Break off both locking devices -A- using a screwdriver -1-.

nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Polo 2014 ➤ , up! 2017 ➤

• Turn bearing shaft for clutch pedal to left -arrow- as far as stop.
AG. Volkswagen n AG do
wage es
– Move clutch pedal slightly so olks
y V that the pivot pin can be pulled
not
gu
out. ris
edb ara
nt ee
tho or
s au ac
s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
Installing
t to the co
rrectne
• Renew pivot pin after removing.
ss
– Push new pivot pin through to stop.
o
cial p
f in
– Turn pivot pin to right to stop, -direction of arrow-.
form
mer
atio
• Locking devices -A- must audibly engage.
om
n
c
i
– Install over-centre spring/extension spring ⇒ page 28 .
or
n thi
te
sd
a
– Install mounting bracket ⇒ page 31 .

iv
o
pr
cum
r
fo
en
ng
t.
1.7 Removing and installing over-centre
yi Co
Cop py
.
spring
ht rig
rig ht
py by
co Vo
by lksw
Removing
cted agen
Prote AG.
– Move driver seat as far back as possible.

– Move steering wheel to uppermost position using the entire
range of adjustment of the steering column.
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
– Compress catches -arrows- and pull out pivot pin -1- for plung‐
er/clutch master cylinder towards right side.
– Pull clutch pedal into passenger compartment as far as stop.
– Remove over-centre spring.
Installing

Polo 2014 ➤ , up! 2017 ➤
• Receptacle -arrow- for mounting pin of clutch pedal must be

vertical.
– Insert over-centre spring from side and from below, adjacent
to plunger of master cylinder and adjacent to clutch pedal, into
support -A- in mounting bracket.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
– Now positions over-centre spring on mounting lug of clutch
s c
pedal -arrow-.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Note
nform
mercia
at
♦ The over-centre spring must be located directly in the mount‐

om
io
ing -arrow 1- in the bearing bracket to be fitted correctly on the

n
c
in t
or
clutch pedal -arrow 2- (⇒ see also previous illustration).

his
ate
do
riv
♦ Otherwise, it will not be possible to install the pivot pin -1- for
p
cum
or
the plunger/clutch master cylinder (⇒ next illustration).

f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Press clutch pedal in operating position, and push new pivot

pin -1- for plunger/clutch master cylinder through to stop.
• Make sure that fasteners -arrows- of pivot pin -1- engage.
Polo 2014 ➤ , up! 2017 ➤
1.8 Removing and installing extension

spring
⇒ “1.8.1 Removing and installing extension spring, up!”,
page 30
⇒ “1.8.2 Removing and installing extension spring, Polo”,
page 31
1.8.1 Removing and installing extension

spring, up!
Special tools and workshop equipment required
♦ Hook - 3438- AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Removing
rrectness of i
– Remove mounting bracket ⇒ page 31 .
l purpos
– Carefully clamp mounting bracket in a vice -A-.

• The mounting bracket -arrow 1- is secured in the vice by the
nform
ercia
edge in the front area.

m
a
com
ti
• The edge ensures that the mounting bracket is not pulled out
on in
of the vice when removing the extension spring.
r
te o
thi
s
iva
– Pull extension spring firmly out of support and remove. do

r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
Installing
rig ht
py by
co Vo
by lksw
– Remove mounting bracket ⇒ page 31 .
cted agen
Prote AG.
– Carefully clamp mounting bracket in a vice -A-.

• The mounting bracket -arrow 1- is secured in the vice by the
edge in the front area.
• The edge ensures that the mounting bracket is not pulled out
of the vice when installing the extension spring.
• Install new support -B- for extension spring.
• Slightly grease following areas for extension spring:
• Mounting -B-
• Mounting on clutch pedal -arrow 2-
• Grease ⇒ Electronic parts catalogue (ETKA)
– Attach extension spring to support on clutch pedal.
-Arrow 2-.
– Attach extension spring to support -B- on mounting bracket.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
orise Polo 2014 ➤ , up! 2017 ➤ntee
h
5-speed manual
aut
gearboxes 02T and 0DF - Edition 11.2018 or ac
ss
ce
le
un
1.8.2 Removing and installing extension
pt
an
d
itte
y li
spring, Polo
rm
ab
pe
ility
ot
Removal and installation of extension spring are identical to re‐
wit
, is n
moval and installation of over-centre spring ⇒ page 28
h re
hole
spec
1.9 Removing and installing mounting
es, in part or in w
t to the co
bracket
⇒ “1.9.1 Removing and installing mounting bracket, up!”,
rrectness of i
page 31
l purpos
⇒ “1.9.2 Removing and installing mounting bracket, Polo”,
page 34
nform
ercia
1.9.1 Removing and installing mounting bracket, up!
m
a
com
tion in
r
Special tools and workshop te o
thi
equipment required
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Hose clamp - 3094-

♦ Torque wrench - V.A.G 1331-
♦ Not required, spring-type clip pliers - VAS 5024 A-
Polo 2014 ➤ , up! 2017 ➤
Sealing tool - T10249-

Removing
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery
– Clamp off supply hose to clutch master cylinder using hose

clamp - 3094- .
Caution
Risk of leaking brake fluid.

♦ During the following work, ensure that no brake fluid lands
on longitudinal member or gearbox. If this does happen,
clean the affected areas thoroughly.
♦ Lay a lint-free cloth under clutch master cylinder.
♦ When performing work in the footwell, put cloths on the
carpet to protect it from possible brake fluid spills.
– Disconnect supply hose -1- from clutch master cylinder.

– In addition to clamping off, it can also be sealed with sealing
tool - T10249/1- (⇒ illustration above).
– Pull out clip for pipe/hose assemblye-1-
n AGas
. Vofar
lkswas
agestop
n AG dand re‐
move pipe/hose assembly ⇒ page olks 42 .
wag oes
not
V gu
by ara
– Remove driver side footwell
oris
ed cover ⇒ General body repairs, nte
interior; Rep. gr. 68au;t Compartments/covers; Removing and
h eo
ra
installing dash panel
ss end trim on driver side . c
ce
le
un
pt
Vehicles with clutch pedal switch - F36- .

an
d
itte
y li
– Remove clutch pedal switch - F36- ⇒ page 48 .

rm
ab
pe
ility
ot
wit
, is n
LHD vehicles
h re
hole
spec
– Remove crash bar by unscrewing bolt -1-.

es, in part or in w
t to the co
Note nut -2-.

rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Polo 2014 ➤ , up! 2017 ➤
. Volkswagen AG
swa02T and
gen AG 0DF - Edition
does11.2018
k not
Vol gu
d by ara
RHD vehicles ris
e nte
utho eo
ra
– Remove crash bar by unscrewing bolt -1-. ss
a c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Vehicles with clutch pedal sender - G476- :
l purpos
– Unclip clutch position sender - G476- from clutch master cyl‐
inder -arrow A- and remove from fitting location -arrow B-.
nform
ercia
– Remove clutch position sender - G476- with electrical con‐

m
nector connected.
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
Continuation for all
cted agen
Prote AG.
– Unscrew securing nuts.

– Remove mounting bracket with clutch master cylinder.
Installing
Install in the reverse order of removal, observing the following.
Note
♦ Renew self-locking nut.

♦ Renew seal for clutch master cylinder after removing mounting
bracket or clutch master cylinder ⇒ Item 2 (page 16) .
– Tighten securing nuts for mounting bracket.
Polo 2014 ➤ , up! 2017 ➤
LHD vehicles
– Install crash bar; tighten bolt -1-.
Note nut -2-.
RHD vehicles
– Install crash bar; tighten bolt -1-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
Vehicles with clutch pedal sender - G476- :

e
nl
pt
du
an
itte
– Fit clutch position sender - G476- on clutch master cylinder

y li
erm
ab
into fitting location -arrow B- and clip it in -arrow A-.

ility
ot p
wit
– Test clutch position sender - G476- by tugging on it.

, is n
h re
hole
Vehicles with clutch pedal switch - F36- .

spec
es, in part or in w
– Install clutch pedal switch - F36- ⇒ page 48 .

t to the co

rrectness of i
– Install driver side footwell cover ⇒ General body repairs, in‐

terior; Rep. gr. 68 ; Compartments/covers; Removing and
l purpos
installing dash panel end trim on driver side .

nform
ercia
– After removing hose clamp - 3094- , supply hose -1- must be

returned to its original position and shape.
m
at
om
io
– Press pipe -3- all the way in at master cylinder connection, and
n
c
in t
r
press securing clip -2- in all the way.

o
his
ate
do
riv
– Test line by tugging on it.

p
cum
for
– Bleed clutch mechanism ⇒ page 47 .

en
ng
t.
yi Co
op py
Specified torques t. C rig
gh ht
pyri by
♦ For securing mounting bracket to plenum chamber bulkhead
co Vo
by lksw
cted agen
⇒ page 16 Prote AG.
♦ Crash bar to steering column ⇒ page 16
1.9.2 Removing and installing mounting

bracket, Polo

Polo 2014 ➤ , up! 2017 ➤
♦ Hose clamps to 25 mm - 3094-
♦ Sealing tool - T10249-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
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un
pt
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ility
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Removing wit
is n
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ole,
spec

t to the co
LHD vehicles
– Unclip engine control unit from bracket on plenum chamber
bulkhead without disconnecting electrical connector, and lay
rrectne
it to one side ⇒ Rep. gr. 24 ; Engine control unit .

ss o
cial p
f inform
mer
atio
om
n
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i
or
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te
sd
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pr
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fo
en
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
Polo 2014 ➤ , up! 2017 ➤
RHD vehicles
In some vehicles, master cylinder is located behind a line for air
conditioning system -arrow-.
An insulation mat is installed in conjunction with some engines.

Appearance may be different from that illustrated.
– Remove heat insulation mat. Note itemag-1 toG.4-.
en A Volkswagen AG
doe
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Continuation for all ed by ara
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o
– Remove clutch position sender
auth - G476- (without disconnecting eo
ra
connector) from masterss cylinder ⇒ page 49 . c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
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hole
spec
– Using hose clamp - 3094- , clamp off supply hose -2- to clutch
es, in part or in w
master cylinder.
Note t to the co
rrectness of i
l purpos
♦ Clamping off the supply hose with the hose clamp - 3094- will
cause a permanent deformation.
nform
ercia
♦ However, this does not damage the supply hose.

m
♦ After removing the hose clamp - 3094- , the supply hose must
com
tio
be returned to its original shape.

n in
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Caution
fo
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t.
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op
C py
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♦ During the following work, ensure that no brake fluid lands cop Vo
by lksw
cted agen
Prote AG.

Polo 2014 ➤ , up! 2017 ➤
– In addition, for disconnecting, supply hose can be sealed with

sealing tool - T10249/1- .
– Pull off supply hose -2- (⇒ previous illustration).
– Pull clip for pipe/hose assembly -1- all way out (⇒ previous
illustration) and pull off pipe/hose assembly ⇒ page 44 .
– Seal openings.
– Unscrew nut -2-, detach crash bar -1-, and push to one side.
– Remove following components if installed in area of mounting
bracket:
Onboard supply control unit - J519- (do not disconnect connector)
⇒ Electrical system; Rep. gr. 97 ; Control units; Removing and
installing onboard supply control unit - J519-
Footwell vent on driver side ⇒ Heating, air conditioning; Rep. gr.
87 ; Air duct; Assembly overview – air duct and air distribution in
passenger compartment
– Unscrew nuts -1- and -2-. AG. Volkswagen AG d

agen oes
ksw
– Remove mounting bracket -3-. by Vol not
gu
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Installing thor eo
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Install in reverse order of removal, observing the following: s
ce
le
un
pt
– Renew self-locking nuts and seal for clutch master cylinder
an
d
itte
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after removing.
erm
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ility
ot p
wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
– Fit crash bar -1-, and tighten nut -2-.

atio
om
– If removed beforehand, reinstall following components:

n
c
i
or
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e
Onboard supply control unit - J519- ⇒ Electrical system; Rep. gr.

t
sd
iva
97 ; Control units; Removing and installing onboard supply control

pr
cum
r
fo
unit - J519-
en
ng
t.
yi Co
op
Footwell vent on driver side ⇒ Heating, air conditioning; Rep. gr. C py
t. rig
87 ; Air duct; Assembly overview – air duct and air distribution in
gh ht
yri by
passenger compartment
cop Vo
by lksw
cted agen
Prote AG.
– Insert clutch position sender - G476- into master cylinder with
electrical connector connected. Push it in as far as stop
⇒ page 49 .
AG. Volkswagen AG d
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olksw not
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Polo 2014
ut
ho ➤ , up! 2017 ➤ eo
ra
a
5-speed
ss manual gearboxes 02T and 0DF - Edition 11.2018 c
ce
le
un
pt
– Connect pipe/hose line -1- to connection ⇒ page 44 .
an
d
itte
y li
erm
ab
– Connect supply hose -2- at clutch master cylinder.
ility
ot p
wit
• After removing the hose clamp - 3094- , the supply hose must
is n
h re
ole,
spec
LHD vehicles
t to the co
– Clip engine control unit with connector connected into bracket
on plenum chamber bulkhead ⇒ Rep. gr. 24 ; Engine control
unit .
rrectness o
cial p
f inform
RHD vehicles
mer
atio
m
– If fitted, fold heat insulation mat in the sequence -1, 2, 3-

o
n
c
around lines.
i
or
n thi
te
sd
a
– Secure heat insulation mat with lock washer -4-.

iv
o
pr
cum
r
fo
en
ng
t.
yi Co
op
– Bleed clutch mechanism ⇒ page 47 . C py
ht. rig
rig ht
– Install and/or connect battery ⇒ Electrical system; Rep. gr.
py by
co Vo
by lksw
27 ; Battery; Disconnecting and connecting battery . Prote
cted AG.
agen
Specified torques
♦ For securing mounting bracket to plenum chamber bulkhead
⇒ page 16
♦ Crash bar to module carrier ⇒ page 16
1.10 Removing and installing clutch master

cylinder
⇒ “1.10.1 Removing and installing clutch master cylinder, up!”,
page 38
⇒ “1.10.2 Removing and installing clutch master cylinder, Polo”,
page 39
1.10.1 Removing and installing clutch master

cylinder, up!
Removing
Remove mounting bracket with clutch master cylinder
⇒ page 31 .

Polo 2014 ➤ , up! 2017 ➤
The figure shows installed mounting bracket with clutch master

cylinder.
– Pull pivot pin -A- for plunger/clutch master cylinder in direction
of -arrow 1- out of clutch pedal.
– Unscrew securing bolts -arrows 2- and remove clutch master
cylinder from mounting bracket.
– Remove clutch master cylinder from mounting bracket.
Installing
Install in the reverse order of removal, observing
agen
AG. Vthe following.
olkswagen AG
do w es n
olks ot g
• Renew seal for clutch masteredcylinder
by
V
⇒ Item 2 (page 16) . ua
ran
ris tee
• Renew pivot pin -A- after
au
thremoving.
o
or
ac
ss
• Pivot pin -A- must audibly engage in clutch pedal.
ce
le
un
pt
an
d
– Ensure proper engagement by carefully pulling pivot pin.

itte
y li
erm
ab
– Install clutch master cylinder to mounting bracket using se‐
ility
ot p
curing bolts -arrows 2-.
wit
is n
h re
Specified torque ⇒ page 16 .
ole,
spec
Install mounting bracket with clutch master cylinder ⇒ page 31 .
t to the co
Specified torques
♦ Clutch master cylinder to mounting bracket ⇒ page 16
rrectne
1.10.2 Removing and installing clutch master
ss o
cylinder, Polo
cial p
f inform
mer
atio
m
Note
o
n
c
i
or
n thi
te
sd
a
♦ Before replacing the clutch master cylinder due a suspected

iv
o
r
defect, use Guided Fault Finding ⇒ Vehicle diagnostic

p
cum
r
fo
tester.
en
ng
t.
yi Co
op py
♦ When performing work in the footwell, put cloths on the floor t. C rig
gh ht
covering to protect it from possible brake fluid spills. yri
p by
co Vo
by lksw
cted agen
Prote AG.
Removing
– Remove mounting bracket with clutch master cylinder
⇒ page 31 .
– Compress fasteners -1- on pivot pin for plunger/clutch master
cylinder -arrows- (shown in illustration with mounting bracket
installed).
Polo 2014 ➤ , up! 2017 ➤
– Pull pivot pin for plunger/clutch master cylinder in direction of

-arrow A- out of clutch pedal.
Clutch master cylinder is engaged in mounting bracket by means
of catches -arrows B-.
– Release locking tabs -arrows B- from clutch master cylinder,
and forcefully pull clutch master cylinder out of mounting
bracket.
Illustration shows only 2 of 4 locking tabs -arrows B-.wagen AG. Volkswagen AG doe
olks s no
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Installing edb ara
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Install in the reverse order of removal, tho
observing the following. eo
au ra
c
ss
• Renew pivot pin -arrow A- after removing.
ce
e
nl
pt
du
an
• Pivot pin -arrow A- must audibly engage in clutch pedal.
itte
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erm
ab
– Ensure proper engagement by carefully pulling pivot pin.
ility
ot p
wit
, is n
– Engage clutch master cylinder in mounting bracket
h re
-arrows B-.
hole
spec
es, in part or in w
– Ensure proper engagement by carefully pulling clutch master
t to the co
cylinder.
– Install mounting bracket ⇒ page 31 .
rrectness of i
1.11 Removing and installing clutch slave
l purpos
cylinder
nf
ercia
o
⇒ “1.11.1 Removing and installing clutch slave cylinder, up!”,
rm
m
page 40
atio
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n in
c
⇒ “1.11.2 Removing and installing clutch slave cylinder, Polo”,

or
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e
page 42
t
sd
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cu
1.11.1 Removing and installing clutch slave
o
m
f
en
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t.
cylinder, up!
yi Co
Cop py
ht. rig
rig ht
Special tools and workshop equipment required py by
co Vo
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cted
agen
Prote AG.

Polo 2014 ➤ , up! 2017 ➤
Removing
Note
♦ Before replacing the clutch slave cylinder due a suspected

defect, you must first use Guided Fault Finding ⇒ Vehicle
diagnostic tester.
. Volkswagen AG
gen AG d
♦ Make sure you Vdo
olksnot depress the clutch pedal
wa oes
not if the clutch
slave cylinder se
d bis removed from the gearbox with the
y gu
arapipe/hose
assembly thorstill
i attached. Otherwise the piston will bentpressed
ee
out ofs the clutch slave cylinder and thus destroyed.
u or
a ac
s
ce
e
nl
pt
– If air filter prevents access to clutch slave cylinder, it must be

du
an
itte
removed ⇒ Rep. gr. 24 ; Air filter; Removing and installing air

y li
erm
ab
filter housing .
ility
ot p
wit

, is n
h re

hole
spec
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter;

es, in part or in w
t to the co
Assembly overview - starter .

– Lay a lint-free cloth under clutch slave cylinder.
rrectness of i
– Release clip -A- with a screwdriver and disconnect pipe/hose

line -B- from connection.
l purpos
– Pull pipe/hose line -B- out of clutch slave cylinder and seal
openings.
nf
ercia
orm
– Remove bolts -arrows- and remove clutch slave cylinder.

m
atio
om
n in
or c
thi
te
sd
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ng
t.
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Cop py
. rig
Installing
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
– Insert clutch slave cylinder and tighten bolts -arrows-.
– Connect pipe/hose assembly -B- and secure with clip -A-.
Polo 2014 ➤ , up! 2017 ➤
Disconnecting and connecting lines for clutch hydraulics

Disconnecting
– Release clip -3- with a screwdriver and disconnect pipe/hose
line -1- from connection -4-.
Connecting AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
e
Note horis nte
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aut ra
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♦ It is also possible to install an O-ring instead of the seal -2-
s
ce
le
⇒ page 42 .
un
pt
an
d
itte
y li
♦ Renew seal -2- if damaged.
rm
ab
pe
ility
ot
wit
– Press pipe/hose line -1- into connection -4- until clip -3- en‐
, is n
h re
gages audibly.
hole
spec
– Test pipe/hose line by tugging on it.
es, in part or in w
t to the co
Seals and O-rings for pipe and hose lines
rrectness of i
Item Material of line connection
l purpos
1 Line connection with circumferential groove

-arrow 1-
nform
ercia
2 Line connection with shoulder -arrow 2-

m
a
com
ti
3 Line connection with shoulder -arrow 2- and cir‐
on in
cumferential groove -arrow 3-
r
te o
thi
s
iva
do
• For line connection having circumferential groove -arrow 1-
r
rp
cum
and -arrow 3-, a seal or O-ring must be set there.
fo
en
ng
t.
yi Co
– Bolt clutch slave cylinder to gearbox -arrows-. t. Cop py
rig
gh ht
– Insert pipe/hose assembly -B- into clutch slave cylinder as far yri
p by
o Vo
by c
as stop.
lksw
cted agen
Prote AG.
– Press in clip -A- to stop.
– Test line by tugging on it.
– Install starter ⇒ Electrical system; Rep. gr. 27 ; Starter; As‐
sembly overview - starter .
– Install battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Re‐
moving and installing battery .
– If air filter has been removed, it must be reinstalled now ⇒
Rep. gr. 24 ; Air filter; Removing and installing air filter hous‐
ing .
Specified torques
♦ Clutch slave cylinder to gearbox ⇒ page 24
1.11.2 Removing and installing clutch slave

cylinder, Polo

Polo 2014 ➤ , up! 2017 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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ho eo
aut ra
ss c
ce
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un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Removing
nform
mercia
a
com
tio
Note
n in
r
te o
thi
s
iva
♦ Before replacing the clutch slave cylinder due a suspected

do
r
rp
defect, you must first use Guided Fault Finding ⇒ Vehicle

cum
fo
diagnostic tester.
en
ng
t.
yi Co
op py
♦ Make sure you do not depress the clutch pedal if the clutch
. C rig
ht ht
rig
slave cylinder is removed from the gearbox with the pipe/hose py by
o Vo
assembly still attached. Otherwise the piston will be pressed
by c lksw
cted agen
out of the clutch slave cylinder and thus destroyed.
Prote AG.

– Lay a lint-free cloth under clutch slave cylinder.
– Release clip -A- with a screwdriver and disconnect pipe/hose
line -B- from connection.
– Pull pipe/hose line -B- out of clutch slave cylinder and seal
openings.
– Remove bolts -arrows- and remove clutch slave cylinder.
Caution
Risk of contamination due to brake fluid spill.

♦ Do not operate clutch pedal after pipe/hose line has been
disconnected.
Polo 2014 ➤ , up! 2017 ➤
Installing
– Fit clutch slave cylinder -A- and secure with bolts -arrows-.
– Connect pipe/hose assembly -B-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
Disconnecting and connecting lines for clutch hydraulicsaut
ho eo
ra
ss c
Disconnecting
ce
le
un
pt
an
d
– Release clip -3- with a screwdriver and disconnect pipe/hose
itte
y li
line -1- from connection -4-.
erm
ab
ility
ot p
Connecting
wit
is n
h re
ole,
spec
Note
t to the co
♦ It is also possible to install an O-ring instead of the seal -2-
⇒ page 44 .
rrectne
♦ Renew seal -2- if damaged.
ss o
– Press pipe/hose line -1- into connection -4- until clip -3- en‐
cial p
f i
gages audibly.
nform
mer
– Test pipe/hose line by tugging on it.
atio
om
n
c
i
or
n thi
te
Seals and O-rings for pipe/hose line or pipe line
sd
iva
o
pr
cum
r
fo
Item Material of line connection
en
ng
t.
yi Co
op
1 Line connection with circumferential groove C py
t. rig
-arrow 1-
gh ht
pyri by
Vo
o
by c
2 Line connection with shoulder -arrow 2-
lksw
cted agen
Prote AG.
3 Line connection with shoulder -arrow 2- and cir‐
cumferential groove -arrow 3-
• For line connection having circumferential groove -arrow 1-
and -arrow 3-, a seal or O-ring must be set there.
Specified torques
♦ Clutch slave cylinder to gearbox ⇒ page 24
1.12 Removing and installing lines for clutch

mechanism

Polo 2014 ➤ , up! 2017 ➤

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Removing
– Remove complete air filter housing if it prevents access to the
rrectness of i
lines for clutch mechanism ⇒ Rep. gr. 24 ; Air filter; Removing
and installing air filter housing .
l purpos

nform
ercia
Polo, LHD vehicles

m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
RHD vehicles
en
ng
t.
yi Co
op
In some vehicles, master cylinder is located behind a line for air C py
ht. rig
conditioning system -arrow-. rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Remove heat insulation mat. Note item -1 to 4-.
Caution

♦ During the following work, ensure that no brake fluid lands
Polo 2014 ➤ , up! 2017 ➤
– Using hose clamp - 3094- , clamp off supply hose -2- to clutch
master cylinder.
Note
♦ Clamping off the supply hose with the hose clamp - 3094- will
cause a permanent deformation.
♦ However, this does not damage the supply hose.
♦ After removing the hose clamp - 3094- , the supply hose must
– Pull out clip for pipe/hose line -1- as far as stop, and remove
pipe/hose line.
– Seal openings.
– Pull out clip -A- as far as stop and pull off pipe/hose line -B-.
– Seal openings.
Note
-Arrows- can be disregarded.
– Seal off open lines and connections if necessary with clean

plugs from engine bung set - VAS 6122- .
– Move pipe/hose line clear and remove it.
Installing
– Connect pipe/hose assembly -1- to clutch master cylinder andn AG. Volkswagen AG do
clutch slave cylinder. lkswage es n
Vo ot gu
by ara
– Test line by tugging on it. ed nte
oris eo
th
• After removing the hose clamp - 3094- , theau ra
ss supply hose -2- c
must be returned to its original shape.
ce
le
un
pt
an
d
Polo, LHD vehicles

itte
y li
erm
ab

ility
ot p

wit
is n
unit .
h re
ole,
spec
t to the co
RHD vehicles
rrectne
around lines.
s

s o
cial p
f i

nform
mer

atio
om
n
c
– Install battery and battery tray ⇒ Electrical system; Rep. gr.

i
or
n thi
27 ; Battery; Removing and installing battery .

te
sd
iva
o
pr
– Install complete air filter housing ⇒ Rep. gr. 24 ; Air filter;

cum
r
fo
Removing and installing air filter housing .

en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Polo 2014 ➤ , up! 2017 ➤
1.13 Bleeding clutch mechanism

♦ Brake filling and bleeding unit - VAS 5234-
Note
♦ The clutch system must always be bled after performing work

. Volkswage
on the hydraulic clutchlksmechanism.
wage
n AG n AG d
oes
not
o
yV gu
♦ When performing ised the
b following steps, make sure that no
arabrake
nte
fluid escapes ut
hoonto
r
the gearbox. eo
a ra
s c
♦ Prefilling system
s is not necessary!
ce
e
nl
pt
du
♦ Before bleeding, fill brake fluid reservoir with brake fluid up to

an
itte
y li
“max” marking.
erm
ab
ility
ot p
♦ Clutch pedal is at rest position, is not being depressed.

wit
, is n
h re
♦ Brake fluid: Allocation ⇒ Electronic parts catalogue (ETKA) .

hole
spec
es, in part or in w
– Remove complete air filter housing if it prevents access to

t to the co
bleeder valve (-arrow- in illustration below) ⇒ Rep. gr. 24 ; Air

filter; Removing and installing air filter housing .
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Polo 2014 ➤ , up! 2017 ➤
– Move clutch pedal back to its rest position.

– Remove protective cap from bleeder valve -arrow-.
– Connect brake filling and bleeding equipment .
– Connect bleeder hose to pressure hose of fluid collector bottle.
To bleed system, use 670 mm long bleed hose - V.A.G 1238/B3-
if necessary.
– Switch on brake filling and bleeding equipment .
• Working pressure 2.0 bar.
– Open bleeder valve.
– Allow about 100 cm3 of brake fluid to flow out.
– Close bleeder valve.
– Rapidly operate pedal from stop to stop 10 to 15 times.
– Open bleeder valve. n AG. Volkswagen AG do
lkswage es n
Vo ot g
y
– Allow another 50 cm3 of brake d b
ir sefluid to flow out.
ua
ran
o tee
th or
– Close bleeder valve. au ac
ss
ce
e
– Switch off brake filling and bleeding equipment and relieve

nl
pt
du
pressure completely from equipment.
an
itte
y li
erm
ab
– Depress clutch pedal several times after completion of bleed‐
ility
ot p
ing process.
wit
, is n
h re
Specified torque:
hole
spec
es, in part or in w
Component Nm
t to the co
Bleeder valve 4.5
rrectness of i
1.14 Removing and installing clutch pedal

l purpos
switch - F36-
To ensure sufficiently secure seating in mounting bracket for
nf
ercia
clutch pedal, clutch pedal switch - F36- may be installed only

rm
m
once.
atio
om
n in
c
Removing
or
thi
te
sd
a
– Remove driver side footwell cover ⇒ General body repairs,

iv
o
r
rp
cu
interior; Rep. gr. 68 ; Compartments/covers; Removing and

o
m
f
en
ng

t.
yi Co
op py
– Pull connector off clutch pedal switch - F36- .
t. C rig
gh ht
pyri by
Vo
– Turn clutch pedal switch - F36- on mounting bracket 45° in
co lksw
by
cted agen
direction of -arrow- and pull out of support. Prote AG.
Installing
– Grease plunger.
– Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
Clutch pedal switch - F36- is installed from passenger compart‐
ment.
• Clutch pedal must always remain in rest position when clutch
pedal switch - F36- is being installed. During entire installation
procedure, clutch pedal is only allowed to be touched with
plunger head of clutch pedal switch - F36- .

Polo 2014 ➤ , up! 2017 ➤
– Insert clutch pedal switch - F36- into mounting bracket support

and turn 45° in direction of -arrow-.
– Push connector onto clutch pedal switch - F36- .
– Install driver side footwell cover ⇒ General body repairs, in‐
terior; Rep. gr. 68 ; Compartments/covers; Removing and
1.15 Checking clutch master cylinder and

clutch slave cylinder
Carry out Guided Fault Finding using ⇒ Vehicle diagnostic
tester before renewing clutch master cylinder due to suspected
fault.
1.16 Removing and installing clutch position

sender - G476-
⇒ “1.16.1 Removing and installing clutch position sender G476 ,
up!”, page 49
⇒ “1.16.2 Removing and installing clutch position sender G476 ,
Polo”, page 50
1.16.1 Removing and installing clutch position

sender - G476- , up!
Removing
– Unclip clutch position sender - G476- from clutch master cyl‐
inder -arrow A- and remove from fitting location -arrow B-.
– Remove clutch position sender - G476- from masteragcylinder,
en AG. V
olkswagen AG
does
and disconnect connector. olksw not
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Installing
h re
hole
spec
– Fit clutch position sender - G476- on clutch master cylinder

es, in part or in w
into fitting location -arrow B- and clip it in -arrow A-.

t to the co
– Test clutch position sender - G476- by tugging on it.

rrectness of i
– Connect electrical connector.

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Prote
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agen 1. Clutch operation
Polo 2014 ➤ , up! 2017 ➤
1.16.2 Removing and installing clutch position

sender - G476- , Polo
♦ Hook - 3438-
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Removing
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LHD vehicles
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RHD vehicles
on in
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In some vehicles, master cylinder is located behind a line for air

s
iva
conditioning system -arrow-.

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– Remove heat insulation mat. Note item -1 to 4-.

Polo 2014 ➤ , up! 2017 ➤

– Unclip clutch position sender - G476- on master cylinder
-arrow A- and -arrow B-. agen
AG. Volkswagen AG d
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– Remove clutch position sender - G476- from master cylinder,byV gu
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and disconnect connector. horis nte
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Installing
nform
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– Insert clutch position sender - G476- into master cylinder with

m
electrical connector connected. Push it in as far as stop.
a
com
tion in
• Clutch position sender - G476- must clip in -arrow A-.
r
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– To check, pull on clutch position sender - G476- -arrow B-.
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around lines.
LHD vehicles
unit .
1.17 Repairing clutch release mechanism

Polo 2014 ➤ , up! 2017 ➤
Grease for splines

Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
Removing and installing clutch release lever -A- with release
bearing and guide sleeve
• Gearbox has been removed.
– Unscrew bolts -arrows-.
– Pull clutch release lever with release bearing and guide sleeve
off input shaft and ball stud.
Install in reverse order of removal.
– Install gearbox ⇒ page 100
agen .
AG. Volkswagen AG d
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Specified torquesed by V ara
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or
• Guide sleeve
au
th to gearbox ⇒ page 24 eo
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nl
Removing and installing guide sleeve from/to clutch release bear‐

pt
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– Remove clutch release lever together with release bearing

ility
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and guide sleeve ⇒ page 52 .

wit
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– Push guide sleeve -3- upwards out of release bearing -2-.

hole
spec
es, in part or in w
– Turn guide sleeve -3- about 90° in direction of arrow relative

t to the co
to release bearing -2- until locking lugs of guide sleeve align

with grooves -4- of release bearing.
rrectness of i
– Pull guide sleeve out of release bearing in this position.

Install in reverse order of removal.
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– Install clutch release lever together with release bearing and

nf
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guide sleeve ⇒ page 52 .

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an
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5-speedaumanual gearboxes 02T and 0DF - Edition 11.2018
th or
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Removing and installing release bearing
nl
pt
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and guide sleeve ⇒ page 52 .
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– Press together locking lugs -arrows- on back of clutch release
, is n
h re
lever and remove release bearing -A- from clutch release lev‐
hole
spec
er.
es, in part or in w
t to the co
– To install, press release bearing -A- into clutch release lever
until retaining lugs -arrows- engage.
– Grease contact surface for clutch release lever on ball-head
rrectness of i
pin with grease for clutch plate splines .
l purpos
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Polo 2014 ➤ , up! 2017 ➤
2 Clutch
⇒ “2.1 Assembly overview - clutch”, page 54
⇒ “2.2 Removing and installing clutch”, page 55
2.1 Assembly overview - clutch
1 - Flywheel
⇒ Rep. gr. 13 ; Cylinder
block (gearbox end);
Removing and installing
flywheel .
❑ Ensure that centring
pins fit tightly
❑ Keep contact surface for
clutch lining free of
grooves, oil and grease.
2 - Clutch plate
❑ Centring ⇒ page 55
3 - Thrust plate
⇒ page 55
❑ Check ends of dia‐
phragm spring
⇒ page 56
❑ Check spring connec‐
tions and riveted con‐
nections ⇒ page 57 .
4 - Bolt n AG. Volkswagen AG do
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❑ Allocation ⇒ Electronic olks es n
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parts catalogue d (ETKA)
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❑ Loosen aor u tighten alter‐
tho
or
ac
natelysand
s diagonally in
small steps (1 full turn)
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❑ M 6: 13 Nm
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❑ M 7: 20 Nm
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Rep. gr.30 - Clutch cted agen
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Polo 2014 ➤ , up! 2017 ➤
AG. Volkswagen AG d
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2.2 Removing and installing clutch
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Special tools and workshop
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equipment required
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♦ Counter-hold tool - 3067-

♦ Centring pin - 3190 A-
♦ For engines having a crankshaft of smaller diameter or having
needle bearings in the crankshaft - ⇒ page 58 centring man‐
drel - T10086-
♦ Grease for splines
Removing
• Gearbox is removed.
2. Clutch 55
Polo 2014 ➤ , up! 2017 ➤
– Use counter-hold tool - 3067- to loosen bolts.

To prevent the pressure plate from becoming distorted during re‐
moval (causes clutch grab when driving off), always keep to the
following procedure when unbolting the pressure plate:
– Loosen all bolts alternately and diagonally in small steps (1 full
turn).
– Remove pressure plate and clutch plate.
Installing
Note
♦ Select clutch pressure plate and pressureolkplate
swa according to
ge es n
ot g
engine code and ⇒ Electronic parts catalogue
d byV (ETKA) . ua
ran
e
ris tee
♦ Clean splines of drive shaft and,uthif the clutch plate has been
o
or
used, clean the splines of the shub.
s a
Remove corrosion and ap‐ ac
ply a very thin coat of clutch plate spline grease to splines.
ce
e
nl
pt
Then, move the clutch plate back and forth on the drive shaft
du
an
itte
until the hub moves easily on the shaft. Remove excess
y li
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grease.
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♦ Clutch pressure plates are protected against corrosion and
, is n
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greased. With the exception of the friction surface for the
hole
spec
clutch plate, the clutch pressure plate must not be cleaned.
es, in part or in w
Service life of clutch will otherwise be shortened considerably.
t to the co
♦ The friction surface of the clutch pressure plate and the fly‐
wheel must be cleaned (degreased) thoroughly.
rrectness of i
♦ If the clutch has burnt out, thoroughly clean the gearbox in the
area of the clutch as well as parts of the engine facing the
l purpos
gearbox in order to reduce the smell of burnt linings.
nf
ercia
♦ Clutch plate linings must make full contact with flywheel and
friction surface of clutch pressure plate. Only then insert se‐ orm
m
atio
curing bolts.
om
n in
c
♦ Tighten or loosen securing bolts alternately and diagonally in

or
thi
e
small steps (1 full turn) in order not to damage centring holes

t
sd
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of pressure plate and centring pins of flywheel.

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♦ Check whether dowel sleeves for aligning engine and gearbox

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are fitted in cylinder block and install if necessary. C py
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♦ If dowel sleeves are not fitted, difficulties shifting gears, clutch
py by
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problems and possible noises from the gearbox (rattling of Prote
cted AG.
agen
gears which are not engaged) could occur.
• Installation position of clutch plate: lettering

“Getriebeseite” (gearbox end) or spring cage faces pressure
plate.
Check ends of diaphragm spring

• Wear to half the thickness of the diaphragm spring -arrows- is
permitted.

Polo 2014 ➤ , up! 2017 ➤
Check spring connection and riveted fastenings.

– Check spring connection between thrust plate and cover for
cracks and make sure rivet fastenings are seated tightly.
– If pressure plate has damaged springs or loose rivet connec‐
tions -arrows-, it must be renewed.
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Check extension springs and riveted connections
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I - Extension springs OK.
, is n
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hole
• Minor kinks on the outside area -arrows A- have series pro‐
spec
duction status.
es, in part or in w
t to the co
II - Extension springs damaged
• Renew clutch pressure plate if springs are broken or badly
rrectness of i
bent -arrow B-.
l purpos
– Check spring connections -arrows A- for damage, and make

sure that rivet joints -arrows B- are firmly seated.
nform
ercia
• Renew clutch pressure plate if spring connections are broken

or badly bent, or if riveting is loose.
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– Make sure rivet joints -arrows B- on all extension springs
pyri by
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-arrows A- are firmly seated.
by lksw
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Prote AG.
– Tighten all bolts one after another (clockwise) to final torque.
• Renew clutch pressure plate if riveting -arrow B- is loose.
Check metal ring.

– Check that metal ring in clutch pressure plate -arrow- is not
damaged.
• Renew clutch pressure plate if metal ring is broken.
2. Clutch 57
Polo 2014 ➤ , up! 2017 ➤
– To centre clutch plate, use centring mandrel - 3190 A- .
. Volkswagen AG
gen AG
For engines having a crankshaft
Vol
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a does
not or
having an needle bearing
ed -arrow-
by in the crankshaft gu
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Centring clutch disc and removing and installing pressure plate t to the co
for engines having a crankshaft of smaller diameter or having a rrectness of i
needle bearing -arrow- in the crankshaft
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nf
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– Tighten all bolts alternately and diagonally in small steps (1 full

or
turn).
m
m
atio
m
– Install gearbox ⇒ page 100 .

o
n in
or c
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Specified torques
t
sd
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♦ Pressure plate to flywheel ⇒ page 54 .

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Polo 2014 ➤ , up! 2017 ➤
AG. Volkswagen AG d
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agen 5-speed
oes manual gearboxes
not
02T and 0DF - Edition 11.2018
ol
byV gu
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34 – Controls, housing
ho eo
aut ra
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1 Selector mechanism
itte
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ility
⇒ “1.1 Installation position - selector mechanism”, page 59
ot
wit
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⇒ “1.2 Assembly overview - gear knob and cover”, page 61
h re
hole
spec
⇒ “1.3 Assembly overview - selector mechanism”, page 62
es, in part or in w
t to the co
⇒ “1.4 Removing and installing gear knob”, page 65
⇒ “1.5 Removing and installing selector mechanism”, page 67
rrectness of i
⇒ “1.6 Repairing selector mechanism”, page 71
l purpos
⇒ “1.7 Adjusting selector mechanism”, page 74

⇒ “1.8 Checking selector mechanism”, page 78
nform
ercia
1.1 Installation position - selector mecha‐

m
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tion in
nism
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♦ Disconnect battery before working on selector mechanism in
. C rig
ht ht
rig
engine compartment ⇒ Electrical system; Rep. gr. 27 ; Bat‐
py by
co Vo
tery; Disconnecting and connecting battery .
by lksw
cted agen
Prote AG.
♦ Removing and installing selector mechanism ⇒ page 67 .
-Arrow A- indicates the gear selection movement and gear se‐

lector cable.
-Arrow B- indicates the gate selection movement and gear selec‐
tor cable.
1. Selector mechanism 59
Polo 2014 ➤ , up! 2017 ➤
A - Gear selector cable

B - Gate selector cable
C - Heat shield
❑ Remove before remov‐
ing selector mecha‐
nism.
1 - Gearbox selector lever
2 - Relay lever
AG. Volkswagen AG d
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60 Rep. gr.34 - Controls, housing

Polo 2014 ➤ , up! 2017 ➤
1.2 Assembly overview - gear knob and cover
1 - Emblem
❑ Except for GT versions
❑ Can be carefully levered
off gear knob of plastic
or leather
2 - Gear knob
❑ With gaiter
❑ Gear knob and gaiter
cannot be separated
from one another
❑ Always renew together
⇒ page 65
3 - Clip
❑ For securing gear knob
to gear lever
❑ Secure to gear knob us‐
ing hose clip pliers -
V.A.G 1275 A-
4 - Centre console cover
❑ Combined with upper
part of centre console in
one part
❑ Is an individual part in
some equipment ver‐ AG. Volkswagen AG d
sions ⇒ General body agen oes
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repairs, interior; Rep. ed by V gu
ara
gr. 68 ; Centre console; horis nte
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Assembly overview – aut ra
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centre console ss
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5 - Noise insulation
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❑ Not fitted in all vehicles

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❑ Arrow on noise insulation points in direction of travel

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❑ Locking lugs are arranged at varying intervals

h re
ole,
spec
❑ Therefore it can be installed in only one position

t to the co
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cial p
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Prote AG.
Polo 2014 ➤ , up! 2017 ➤
1.3 Assembly overview - selector mecha‐

nism
⇒ “1.3.1 Assembly overview - selector mechanism, up!”,
page 62
⇒ “1.3.2 Assembly overview - selector mechanism, Polo”,
page 64
1.3.1 Assembly overview - selector mechanism, up!
Note
♦ Lubricate bearing positions and sliding surfaces.

1 - Selector shaft with selector

shaft cover
2 - Seal
⇒ page 148
3 - Slide block
4 - Gate relay lever
❑ Greasing ⇒ page 73 .
❑ Fitting position
⇒ page 73
❑ After installing, adjust agen
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⇒ page 74 ise
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❑ Remove and install gate auth eo
ra
relay lever together with ss c
cable end-piece
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⇒ page 71
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5 - Cable end-piece
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❑ For gate selector cable

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to relay lever
h re
hole
❑ After installing, adjust

spec
es, in part or in w
selector mechanism
t to the co
⇒ page 74
❑ Do not interchange; ca‐
ble end-pieces securing
rrectness of i
gate selector cable to

gate relay lever and
l purpos
gear selector cable to

gearbox selector lever
nform
ercia
are different
m
❑ Allocation ⇒ page 73 .
a
com
tio
❑ Removing from gate re‐

n in
r
te o
lay lever ⇒ page 72

thi
s
iva
do
❑ Pressing onto gate relay

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lever ⇒ page 72
fo
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6 - Gearbox selector lever t. Cop py
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❑ Install so that master spline aligns with selector shaft ⇒ page 74
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Prote AG.
❑ Fitting position ⇒ page 73
❑ After installing, adjust selector mechanism ⇒ page 74

Polo 2014 ➤ , up! 2017 ➤
7 - Hexagon nut
8 - Cable end-piece
❑ For gear selector cable to gearbox selector lever
❑ Do not interchange; cable end-pieces securing gate selector cable to gate relay lever and gear selector
cable to gearbox selector lever are different
9 - Securing clip
10 - Gate change cable
❑ Connect to cable end-piece.
11 - Gear change cable
❑ Fitting position ⇒Apage
agen
G. Volk59
swagen AG
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12 - Hexagon d b nut
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❑ utQty.
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❑s M 6: 8 Nm
s
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❑ M 8: 20 Nm
pt
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13 - Seal
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ility
❑ Between selector housing and underbody

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❑ Renew selector housing after removing

h re
hole
❑ Self-adhesive
spec
es, in part or in w
❑ Bond to selector lever housing

t to the co
14 - Selector housing
15 - Securing clip
rrectness of i

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❑ Do not damage cables when removing

nform
ercia
16 - Hexagon bolt
m
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om
io
❑ Qty. 3
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❑ For cable support bracket

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❑ 20 Nm
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17 - Cable support bracket

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18 - Grommet
Prote AG.
❑ Qty. 3
❑ Cable support bracket mounting on gearbox
19 - Spacer
❑ Qty. 3
20 - Clip
Polo 2014 ➤ , up! 2017 ➤
1.3.2 Assembly overview - selector mechanism, Polo
Note


shaft cover
2 - Seal
⇒ page 148
3 - Slide block
⇒ page 73
❑ After installing, adjust
selector mechanism
⇒ page 74
❑ Remove and install gate
relay lever together with
cable end-piece
⇒ page 71
5 - Cable end-piece
AG. Volkswagen AG d
❑ For gate selector cable agen oes
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to relay lever ed by
V gu
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❑ After installing, adjust ut
hor eo
selector mechanism ss a ra
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⇒ page 74
ce
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❑ Do not interchange; ca‐

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ble end-pieces securing

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gate selector cable to

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ility
gate relay lever and

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gear selector cable to

h re
hole
gearbox selector lever

spec
are different
es, in part or in w
t to the co
❑ Removing from gate re‐
lay lever ⇒ page 72
rrectness of i
❑ Pressing onto gate relay

l purpos
lever ⇒ page 72
nform
ercia
m
❑ Install so that master spline aligns with selector shaft ⇒ page 74

com
tion in

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s

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7 - Hexagon nut
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8 - Cable end-piece
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❑ For gear selector cable to gearbox selector lever Prote
cted AG.
agen

Polo 2014 ➤ , up! 2017 ➤
❑ Do not interchange; cable end-pieces securing gate selector cable to gate relay lever and gear selector
cable to gearbox selector lever are different
9 - Securing clip agen
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❑ Renew after removal d by
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10 - Gate change cable ut
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❑ Connect to cable end-piece. ss c
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11 - Gear change cable
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12 - Hexagon nut
es, in part or in w
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❑ Qty. 4
❑ M 6: 8 Nm
❑ M 8: 20 Nm
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13 - Seal
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❑ Between selector housing and underbody

❑ Renew selector housing after removing
nform
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❑ Self-adhesive
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❑ Bond to selector lever housing
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14 - Selector housing
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15 - Securing clip
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❑ Fitting position ⇒ page 74 op Vo
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16 - Hexagon bolt
AG.
❑ Qty. 3
❑ For cable support bracket
❑ 20 Nm
17 - Cable support bracket
18 - Grommet
❑ Qty. 3
❑ Cable support bracket mounting on gearbox
19 - Spacer
❑ Qty. 3
20 - Clip
1.4 Removing and installing gear knob

Polo 2014 ➤ , up! 2017 ➤
♦ Hose clip pliers - V.A.G 1275 A-
♦ Wedges - T10383-
Removing
• Cover centre console in area of gear lever boot with a cloth.
up! AG. Volkswagen AG d
agen oes
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– Using wedge - T10383/1- , carefully lever offbygear
Vo lever gaiter gu
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in rear area from centre console -arrows-.orised
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Polo 2014 ➤ , up! 2017 ➤
– Lift up gear lever boot slightly in rear area.

– Using a flat-bladed screwdriver, carefully push detents -A- in
front area of gear lever boot in direction of -arrow-.
– Remove gear lever boot from centre console.
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Carefully insert lever. On some vehicles it might be helpful to be‐
wit
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gin »at front«.
h re
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– Using wedge - T10383- , carefully lever gear lever gaiter off
es, in part or in w
centre console insert -arrows-.
t to the co
– Alternatively, use removal wedge - 3409- to lever out gear
lever gaiter.
rrectness of i
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– Pull gear lever gaiter upwards off gear knob.

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– Open clamp -arrow- and pull off gear knob together with gear
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– Press gear knob together with gear lever gaiter onto gear lever
agen
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as far as stop.
– Secure gear lever knob to gear lever using clamp -arrow-. Use
hose clip pliers - V.A.G 1275 A- to do this.
up!
Install gear lever boot as follows:
– First, insert gear lever boot to stop in front area of centre con‐
sole.
– Then engage gear lever boot to stop in rear area of centre
console.
1.5 Removing and installing selector mech‐

anism
Polo 2014 ➤ , up! 2017 ➤
Removing
– Remove gear lever gaiter with gear knob and any noise insu‐
lation from frame for centre console ⇒ page 61 .
up! agen
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– Remove centre console insert ⇒ General ed by
V
body repairs, inte‐ gu
ara
rior; Rep. gr. 68 ; Centre console;horis Removing and installing nte
eo
centre console insert . s aut ra
c
s
– Unbolt back of upper part of centre console ⇒ General body
ce
e
nl
pt
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repairs, interior; Rep. gr. 68 ; Centre console; Removing and
an
itte
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installing centre console .
erm
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ility
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– Unbolt lower part of centre console in footwell ⇒ General body
wit
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repairs, interior; Rep. gr. 68 ; Centre console; Removing and
h re
installing centre console .
hole
spec
Polo
es, in part or in w
t to the co
– Remove centre console with securing bracket ⇒ General body
repairs, interior; Rep. gr. 68 ; Centre console; Assembly over‐
view - centre console .
rrectness of i

l purpos
– Unscrew nuts -arrows- for selector housing and, if necessary,

centre console securing bracket. To do this, carefully raise
nf
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lower part of centre console.

rm
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– Lower selector housing.

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– If fitted, remove insulation from selector housing ⇒ General

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body repairs, interior; Rep. gr. 68 ; Centre console; Assembly

iv
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overview – centre console .

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– Remove complete air filter housing if it is located over selector
Co
op py
mechanism ⇒ Rep. gr. 24 ; Air filter; Removing and installing
t. C rig
gh ht
yri
air filter . p by
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by c lksw
cted agen
Prote AG.

Polo 2014 ➤ , up! 2017 ➤
5-speed manual
en AG. Volkswgearboxes
agen AG 02T and 0DF - Edition 11.2018
ag does
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– Pull cable end-piece off gear selector ed b cable and gate selector
y ara
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cable forward to stop in -directionhoris
of arrow 1- and then lock in eo
-direction of arrow 2-. aut ra
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l purpos
In some equipment versions, the gear selector cable is only ac‐

cessible from beneath vehicle in -direction of arrow-.
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Continuation for all by c lksw
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Prote AG.
– Remove securing clips -arrows- for cables from cable support
bracket.
– Detach heat shield ⇒ General body repairs, exterior; Rep. gr.
66 ; Heat shields; Overview of fitting locations - heat shields .
– Swing down gear lever housing and remove with selector ca‐
bles.
Installing
Install in the reverse order of removal, observing the following.
– Route Bowden cables -1- from selector mechanism -2- to
gearbox as follows:
♦ Cables must be routed parallel to one another as far as cable
support bracket on gearbox.
♦ Bowden cables must be laid in the intended indentation in heat
shield -3-.
olkswagen AG
Polo 2014 ➤ , up! 2017 ➤ wage
n AG. V does
olks not
5-speed manual gearboxes 02T and 0DF - Edition
db
y11.2018
V gu
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Clip -A- holds cables and heat shield in position (if applicable).
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– Insert cables into cable end-pieces.
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Install securing clips -arrows- for cables to cable support bracket.
atio
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– Align selector housing parallel to body.

o
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• Distance to body must be same on both sides.

t
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– Adjust selector mechanism ⇒ page 74 .
um
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ng
t.
– Install centre console and tighten bolts ⇒ General body re‐
yi Co
op py
pairs, interior; Rep. gr. 68 ; Centre console; Removing and t. C rig
gh ht
installing centre console . yri
p by
co Vo
by lksw
cted
– Install centre console insert ⇒ General body repairs, interior;
agen
Prote AG.
Rep. gr. 68 ; Centre console; Removing and installing centre
console insert .
– Install heat shield ⇒ General body repairs, exterior; Rep. gr.
66 ; Heat shields; Overview of fitting locations - heat shields .
– Assemble exhaust system free of tension ⇒ Rep. gr. 26 ;
Exhaust pipes/silencers; Removing and installing front ex‐
haust pipe .
– If removed, install complete air filter housing ⇒ Rep. gr. 24 ;
Air filter, Removing and installing air filter housing .
– Connect battery and follow procedure after connecting battery
⇒ Electrical system; Rep. gr. 27 ; Disconnecting and con‐
necting battery .
Specified torques
Selector housing to body ⇒ page 62 .

Polo 2014 ➤ , up! 2017 ➤
1.6 Repairing selector mechanism

up!
Removing and installing cable support bracket on gearbox
Bolts -arrow A- are accessible from engine compartment.
Bolt -arrow B- is accessible from beneath vehicle.
Polo
Removing and installing cable support bracket on gearbox AG. Volkswagen AG d
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Bolts -arrow- are accessible from engine compartment. ised b ara
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Remove and install gate relay lever together with cable end-piece.
– Pull locking mechanism forward to stop in
-direction of arrow 1-, and then lock it by turning to left in
rrectness of i
-direction of arrow 2-.
l purpos
– Then push gate relay lever forwards (-direction of arrow 3-).
nf
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Prote AG.
Polo 2014 ➤ , up! 2017 ➤
– Pull off clip -arrow 1- and remove gate relay lever together with
cable end-piece.
• Cable end-piece must be located behind catch -arrow 2-.
• It is permissible to remove cable end-piece only after gate re‐
lay lever has been removed ⇒ page 72 .
– Press cable end-piece onto gate relay lever ⇒ page 72 .
– Insert gate relay lever together with cable end-piece as far as
stop. gen AG
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• Ensure proper engagement of clip. tho eo
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• Cable end-piece must be located behind catch -arrow 2-.
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With gate relay lever removed: levering cable end-piece for gate
es, in part or in w
t to the co
selector cable off gate relay lever
– Fit a flat-bladed screwdriver between bush -B- and gate relay
lever -A-.
rrectness of i
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Pressing on cable end-piece

• Gate relay lever is removed.
• Grease support pins for cable end-piece.
• Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
• Cable end-piece may be pressed only onto bush -arrow-.
• Cable end-piece must move freely on gate relay lever.
• The cable end-piece must be located behind catch.
• Ensure proper engagement.

Polo 2014 ➤ , up! 2017 ➤
Allocation of cable end-pieces

The holes in the cable end-pieces have different diameters.
Cable end-piece for Dimension “a”
-1- Gear selector cable to gearbox selector lever 8.5 mm
-2- Gate selector cable to gate relay lever 10 mm
AG. Volkswagen AG d
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Installation position of gearbox selector lever/gate relay ntlever
ee
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1 - Gearbox
ss selector lever ce
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2 - Gate relay lever engages in guide rail of gearbox selector lever
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via shoe -arrow-.

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Gate relay lever: thoroughly grease following areas in particular

l purpos
prior to installation
• Shaft -A- of gate relay lever -arrows-; amount of grease:
nform
ercia
0.2 grams.
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Gearbox selector lever: thoroughly grease following areas in par‐ Prote AG.
ticular prior to installation
• Guide rail -B- of gearbox selector lever into which gate relay
lever engages.
• Support pin for cable end-piece.
• Illustration of gate relay lever and gearbox selector lever may
differ from actual components.
Polo 2014 ➤ , up! 2017 ➤
Install gearbox selector lever

– When fitting the gearbox selector lever, ensure that the gap
-arrow A- is aligned with the master spline -arrow B-.
Installation position of securing clips -1- and -2-.
1.7 Adjusting selector mechanism G. Volkswage

nA n AG d
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⇒ “1.7.1 Adjusting selector mechanism, up!”,
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⇒ “1.7.2 Adjusting selector mechanism,
ho
ris Polo”, page 76 nte
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♦ Pin - T10027A-
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Prerequisites for adjustment

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Rep. gr.34 - Controls, housing
Polo 2014 ➤ , up! 2017 ➤
• Gearbox, clutch and clutch mechanism must be in proper con‐

dition.
• Gearbox must be in neutral.
Selector shaft must be secured in subsequent work step. This
should be done beneath the vehicle.
Open cable end-pieces on gearbox:
– Pull locking mechanisms on gate selector cable and gear se‐
lector cable end-pieces forward to stop -direction of arrow 1-
and then turn to left to lock -direction of arrow 2-.
• It must be possible to push both cables into the locking mech‐
anisms.
kswage es n
Move selector shaft in correct position for adjustment:by Vo l ot g
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The selector shaft is secured beneath the vehicle. tho tee
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– Press down selector shaft on gearbox selector lever in direc‐
s
ce
e
tion of -arrow 1-.

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pt
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– While pressing down selector shaft, turn angled rod -A- in di‐
erm
ab
rection of -arrow 2-, and at the same time press it in until it
ility
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engages in selector shaft.
wit
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es, in part or in w
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Move gear lever in correct position for adjustment:
rrectness of i
– Detach gear lever boot and, if necessary, noise insulation from
l purpos
centre console ⇒ page 65 .

– In neutral position, hold gear lever towards »left«.
nf
ercia
orm
– Push locking pin - T10027 A- through hole -A- into hole -B-.
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– Wrap left seat belt -1- around gear lever so that belt holds lev‐ cop Vo
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Prote AG.
The gear lever is secured by the locking pin - T10027A- (-A-).

In addition, the seat belt presses the gear lever against the stop
for 1st and 2nd gear -direction of arrow-.
This takes all »play out of the selector mechanism«.
Polo 2014 ➤ , up! 2017 ➤
Adjusting the selector mechanism:

– Gate and selector cables -B- must be inserted, free of tension,
into locking elements -A-.
– Now turn locking mechanisms on gear selector cable and gate
selector cable end pieces clockwise to stop
The spring presses the locking mechanism into original position
lkswage es n
Vo ot g
– Now turn angled ed
by rod -A- back to original position inuara
-direction of or arrow-.
is nte
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uth r
• s a procedure, angled rod -A- must be pressed outac of
During sthis
gearbox.
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ility
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t to the co
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– Remove seat belt from selector lever.

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– Pull locking pin out of holes -A- and -B-.

– Install gaiter and, if present, noise insulation ⇒ page 65 .
nf
ercia
– Check selector shaft can move freely.

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– Check selector mechanism ⇒ page 78 .

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1.7.2 Adjusting selector mechanism, Polo
c by lksw
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Prote AG.

♦ Pin - T10027A-
Prerequisites for adjustment

• Moving parts of selector mechanism and elements transferring
force must be in proper condition.
• Selector mechanism must move freely.

Polo 2014 ➤ , up! 2017 ➤
• Gearbox, clutch and clutch mechanism must be in proper con‐

dition.
• Gearbox must be in neutral.
– Remove complete air filter housing if angled rod for securing
selector shaft and securing mechanism for gear selector cable
and gate selector cable are not accessible ⇒ Rep. gr. 24 ; Air
filter; Removing and installing air filter housing .
Open cable end-pieces on gearbox:
– Pull locking mechanisms on gate selector cable and gear se‐
lector cable end-pieces forward to stop -direction of arrow 1-
and then turn to left to lock -direction of arrow 2-.
• It must be possible to push both cables into the locking mech‐
anisms.
AG. Volkswagen AG d
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Move selector shaft in correct position for adjustment:
ce
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pt
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– Press selector shaft down in -direction of arrow 1-.
itte
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erm
ab
– While pressing down selector shaft, turn angled rod -A- in di‐
ility
ot p
rection of -arrow 2-, and at the same time press it in until it
wit
, is n
engages in selector shaft.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
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Move gear lever in correct position for adjustment:

nf
ercia
o
– Detach gear lever boot and, if necessary, noise insulation from
rm
m
centre console ⇒ page 65 .

atio
om
n in
c
– In neutral position, hold gear lever towards »left«.

or
thi
te
sd
a
– Push locking pin - T10027 A- through hole -A- into hole -B-.
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Prote AG.
– Wrap left seat belt -1- around gear lever so that belt holds lev‐
er.
The gear lever is secured by the locking pin - T10027A- (-A-).
In addition, the seat belt presses the gear lever against the stop
for 1st and 2nd gear -direction of arrow-.
This takes all »play out of the selector mechanism«.
Polo 2014 ➤ , up! 2017 ➤
Adjusting the selector mechanism: AG. Volkswagen AG d

agen oes
ksw
– Gate and selector cables -B- must be inserted, freebyofV tension,
ol not
gu
ara
into locking elements -A-. rise
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– Now turn locking mechanisms on gear selector
ss au
cable and gate ra
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selector cable end pieces clockwise to stop
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The spring presses the locking mechanism into original position
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es, in part or in w
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– Now turn angled rod -A- back to original position in
-direction of arrow-.
rrectness of i
• The angled rod -A- must be pressed out of selector housing to
stop and point straight up.
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– Remove seat belt from selector lever. Cop py
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– Pull locking pin out of holes -A- and -B-. p by
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– Install gaiter and, if present, noise insulation ⇒ page 65 . Prote AG.
– Check selector shaft can move freely.

– Check selector mechanism ⇒ page 78 .
– If removed, install complete air filter housing ⇒ Rep. gr. 24 ;
Air filter; Removing and installing air filter housing .
1.8 Checking selector mechanism

• With gearbox in neutral, gear lever must be in gear lever gate
for 3rd and 4th gear.
– Operate clutch.
– Select all gears several times. Pay particular attention to op‐
eration of reverse gear lock.
– If it continues to be difficult to engage a gear after repeated
attempts, repeat adjustment procedure of selector mechanism
⇒ page 74 .

Polo 2014 ➤ , up! 2017 ➤
2 Removing and installing gearbox

⇒ “2.1 Differentiating between gearboxes, Polo”, page 79
⇒ “2.2 Removing gearbox”, page 79
⇒ “2.3 Installing gearbox”, page 100
⇒ “2.4 Specified torques for gearbox”, page 110
2.1 Differentiating between gearboxes, Polo

Manual gearbox With flange shafts ⇒ “7.1.1 Schemat‐
02T ic overview - gear‐
box, manual gear‐ agen
AG. Volkswagen AG d
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box 02T”, olksw not
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page
ised 123 ara
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Manual gearbox Without flange shaft ⇒au“7.1.2
th
Schemat‐ ra
0DF sic overview - gear‐
s c
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box, manual gear‐

nl
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box 0DF”,
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page 125
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2.2 Removing gearbox
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⇒ “2.2.1 Removing gearbox, up!”, page 79
spec
es, in part or in w
⇒ “2.2.2 Removing gearbox, Polo”, page 88
t to the co
2.2.1 Removing gearbox, up!
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2. Removing and installing gearbox 79

AG. Volkswagen AG d
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olksw not
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Polo 2014 ➤ , up! rise2017 ➤
d b ara
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5-speed manual
aut gearboxes 02T and 0DF - Edition 11.2018 e or
ho
ac
ss
ce
le
un
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equipment required
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es, in part or in w
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Prote AG.
♦ Support - 10 - 222 A-
♦ Adapter - 10 - 222 A /31-1-
♦ Adapter - 10 - 222 A /31-2-
♦ Support - 10 - 222 A /31-3-
♦ Adapter - 10 - 222 A /31-5-
♦ Square tube - T40091/1-
♦ Joints - T40091/3-
♦ Gearbox support - 3282-
♦ Support elements for gearbox (determine when setting ad‐
justment plate on gearbox support )
♦ Sealing cap - T10381/1-
♦ Not required adjustment plate - 3282/63-
♦ Not required: adapter - 3282/64-

Polo 2014 ➤ , up! 2017 ➤
♦ Adjustment plate - 3282/69-
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♦ Engine and gearbox jack - V.A.G 1383 A-
♦ Or engine and gearbox jack - VAS 6931-

Polo 2014 ➤ , up! 2017 ➤
♦ Insert tool - T10509-

– If support bracket - 10 - 222 A- does not yet have hole marked
with -arrow-, then hole must subsequently AG. Volkswagen AGsup‐
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– If located above engine lifting eyes, remove engine cover pan‐

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el and air filter ⇒ Rep. gr. 24 ; Air filter; Removing and

installing air filter housing . h re
hole
spec
es, in part or in w
t to the co
27 ; Battery; Removing and installing battery tray .
– Remove securing clip -1- for gear selector cable -2- from gear‐
rrectness of i
box selector lever.

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– Pull gear selector cable off pin.

– Remove relay lever -3- together with cable end-piece
nf
ercia
⇒ page 71 .
rm
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– Remove gearbox selector lever by unscrewing nut -4-.

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Polo 2014 ➤ , up! 2017 ➤
– Remove cable support bracket from gearbox.

– Tie up gear selector cable and gate selector cable.wagen AG. Volkswagen AG does
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– Remove starter ⇒ Electrical system; Rep. egr.
d b 27 ; Starter;
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Assembly overview - starter . tho
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– Remove clutch slave cylinder -arrows-, lay to side and secure.
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Do not disconnect pipes.
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Caution
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Do not operate clutch pedal any more.
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– Remove upper engine/gearbox securing bolts -arrows A- and Prote AG.
-arrows B-.
– Loosen bolts -arrows A- if necessary using insert tool, 18 mm
- T10509- .
– Install support bracket as follows:
Required material:
♦ Adapter - 10 - 222 A /31-1-
♦ Adapter - 10 - 222 A /31-2-
♦ Connector - T40091/3-
♦ Square tube - T40091/1-
♦ Support - 10 - 222 A /31-3-
♦ Adapter - 10 - 222 A /31-5-
Install support bracket as follows:

Polo 2014 ➤ , up! 2017 ➤
Adapter - 10 - 222 A /31-1- and adapter - 10 - 222 A /31-2- are

placed onto suspension strut supports underneath plenum cham‐
ber cover.
Therefore, remove following components:
♦ Wiper arms ⇒ Electrical system; Rep. gr. 92 ; Windscreen
wiper system; Removing and installing wiper arms .
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gen AG does
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gr. 50 ; Bulkhead; Removing and installing plenum chamber db
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– Fit adapter - 10 - 222 A /31-1- and adapter - 10 - 222
ss A /31-2- c
ce
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onto suspension strut supports.
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Angled pieces of adapters -arrow- point towards engine compart‐
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– If fitted, pull bonnet seal off lock carrier.
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– Position support - 10 - 222 A /31-5- above bonnet catch.
es, in part or in w
t to the co
Correct position is between 2 lugs -arrow-.
rrectness of i
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tion in
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– Slide connector - T40091/3- onto support bracket - 10-222 A- .
– Bolt support bracket - 10-222 A- to adapter - 10 - 222 A /31-1-
and to adapter - 10 - 222 A /31-2- .
– Attach square tube - T40091/1- to support bracket - 10-222
A- .
– Fit square tube on support - 10 - 222 A /31-3- and adapter -
10 - 222 A /31-5- .
– Then attach spindle to front engine support eye.
– Take up weight of engine/gearbox assembly on spindle .

Polo 2014 ➤ , up! 2017 ➤
During subsequent work process, drive shafts with joint sections

must be removed.
– Loosen securing nuts -arrow- for drive shafts ⇒ Running gear,
axles, steering; Rep. gr. 40 ; Drive shaft; Removing and in‐
stalling drive shaft .
– If fitted, remove noise insulation ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Noise insulation; Assembly overview -
noise insulation .
– Remove front left wheel housing liner ⇒ General body repairs,
exterior; Rep. gr. 66 ; Wheel housing liner; Assembly overview
- front wheel housing liner .
– Cover pendulum support.

– Drain gearbox oil -arrow- ⇒ page 115 .
– Remove coupling rod -1- from anti-roll bar on both sides ⇒

Running gear, axles, steering; Rep. gr. 40 ; Subframe; As‐
sembly overview – subframe .
– Press anti-roll bar upwards.
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– Remove both drive shafts with joint sections ⇒ Running gear,
rm
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axles, steering; Rep. gr. 40 ; Drive shaft; Removing and in‐

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stalling drive shaft .

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– Install sealing caps in gearbox.

hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
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Cop py
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Prote AG.

Polo 2014 ➤ , up! 2017 ➤
– If fitted, disconnect electrical connectors:

– Pull connector -1- off gearbox neutral position sender - G701- .
– Pull connector -2- off reversing light switch - F4- .
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– Pull connector -1- off oil level and oil temperature sender - s
ce
le
G266- .
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– Detach exhaust system from subframe ⇒ Rep. gr. 26 ; Ex‐
erm
ab
haust pipes/silencers; Assembly overview - silencer .
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Caution
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Risk of damage to decoupling element.
t to the co
♦ Observe ⇒ Rep. gr. 26 ; Emission control; Assembly
overview - emission control .
rrectness o
– Remove pendulum support.
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– If fitted, remove earth wire -arrow-.

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does Polo 2014 ➤ , up! 2017 ➤
swa
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k manual gearboxes no02T
t gua
and 0DF - Edition 11.2018
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– Remove hexagon bolt -arrow-au
tho for left-hand assembly mount‐ or
ac
ing from gearbox mounting.
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– Lower engine/gearbox assembly via spindles of support
l purpos
bracket - 10-222 A- .
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ercia
• Dimension -a- = about 90 mm

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– Remove gearbox bracket -A- -arrows-.
– Remove lower engine/gearbox connecting bolt -1-.
Note
Loosen engine/gearbox connecting bolts -2- and -3-, and leave

them installed just hand-tight.
– Insert gearbox support - 3282- in engine and gearbox jack .

Polo 2014 ➤ , up! 2017 ➤
Gearbox support - 3282- is aligned with adjustment plate -

3282/69- for removal of gearbox.
– Fit adjustment plate - 3282/69- on gearbox support - 3282-
(adjustment plate fits in only one position).
– Screw in support elements -A- as illustrated on adjustment
plate.
– Position engine and gearbox jack under vehicle. Arrow -B- on

adjustment plate points in direction of vehicle travel (⇒ previ‐
ous illustration).
Rods holding the support elements should be flush with gearbox
support - 3282- at bottom.
– Align adjustment plate parallel to gearbox.
– Then screw pin - 3282/29- einto

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– Remove engine/gearbox
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– Unscrew sengine/gearbox
sa connecting bolt above right drive ac
shaft mounting.
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– Carefully push engine forwards (with aid of 2nd mechanic).

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– Carefully press gearbox off dowel sleeves.

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– Lower gearbox in area of 5th gear (-area A-) and in area of

differential (-arrow B-) alternately using spindles of gearbox
rrectne
support - 3282- .
– When lowering gearbox, change position of gearbox using
s
spindles of gearbox support - 3282- (shown here with a differ‐

s o
cial p
ent gearbox).
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Note
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Please make sure that the coolant hose and electrical wiring re‐
t
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Install gearbox ⇒ page 100 . . Cop py
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2.2.2 Removing gearbox, Polo
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Polo 2014 ➤ , up! 2017 ➤

equipment required
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es, in part or in w
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Cop py
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Prote AG.
♦ Support - 10 - 222 A-
♦ Adapter - 10 - 222 A /8-
♦ Shackle - 10 - 222 A /12-
♦ Gearbox support - 3282-
♦ Adjustment plate - 3282/69-
♦ Support elements for gearbox (determine when setting ad‐
justment plate on gearbox support )
♦ Gearbox lifting tackle - 3336- for transporting gearbox

Polo 2014 ➤ , up! 2017 ➤
AG. Volkswagen AG d
agen oes
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d by ara
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es, in part or in w
t to the co
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♦ Engine support - 3300 A- cted agen
Prote AG.
♦ Support plate - T10413-

♦ Engine and gearbox jack - V.A.G 1383 A-
♦ Or engine and gearbox jack - VAS 6931-
♦ Lifting tackle - 2024 A-
♦ Tensioning strap - T10038-
♦ Protective mat - VAS 531 003-

Polo 2014 ➤ , up! 2017 ➤
Manual gearbox 0DF
♦ Sealing cap - T10381/1-

At a later point, support bracket - 10-222 A- will be fitted onto
longitudinal members with adapters - 10 - 222 A /8- .
• To prevent damage to edges of wings, cover bottom area of
both adapters - 10 - 222 A /8- with self-adhesive fabric tape
-arrow- ⇒ Electronic parts catalogue (ETKA chemical sub‐
stances) . wage
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ss
ce
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pe
ility
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– Remove complete air filter housing ⇒ Rep. gr. 24 ; Air filter;
h re
hole
spec
es, in part or in w
– Remove securing clip -1- for gear selector cable from gearbox
t to the co
selector lever -B-.
– Remove gate relay lever -A- together with cable end-piece
rrectness of i
⇒ page 71 .
l purpos
– Remove gearbox selector lever -B- by removing nut

-arrow 2-.
nform
mercia
– Unscrew bolts -arrows-, and tie up cable support bracket with

a
com
ti
cables.
on in
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te o
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s
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do
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Polo 2014 ➤ , up! 2017 ➤
– Unscrew bolts -arrows- and place clutch slave cylinder to one

side. Do not disconnect lines.
Caution
Do not operate clutch pedal any more.
– Then remove upper securing bolt on starter.

– Then, disconnect cables from starter ⇒ Electrical system;
Rep. gr. 27 ; Starter; Removing and installing starter .
AG. Volkswagen A G do gen
es n swa
– Remove upper engine/gearbox
by
Voconnecting
lk bolts. ot g
ua
d ran
ir se
– If there are hose and cable
tho connections in area of engine sup‐ tee
or
port eyes for supportsbracket
au - 10 - 222 A- , remove these now. ac
s
ce
le
– Remove foam pieces or seal from upper edge of left and right
un
pt
wings ⇒ General body repairs, exterior; Rep. gr. 50 ; Wings;
an
d
itte
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Assembly overview – wings .
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Vehicles with 3-cylinder engine
, is n
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hole
– Set up support bracket - 10-222 A- behind bonnet support.
spec
es, in part or in w
Required material:
t to the co
♦ Adapter - 10 - 222 A /8-
rrectness of i
l purpos
• Fit both adapters - 10 - 222 A /8- so that they are located

slightly below plenum chamber cover -arrow-.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Set up support bracket - 10-222 A- behind bonnet support.
Required material:
♦ Adapter - 10 - 222 A /8-
♦ Shackle - 10 - 222 A /12-
– If necessary, use shackle - 10 - 222 A /12- to attach left spindle.
• Fit both adapters - 10 - 222 A /8- so that they are positioned
slightly below plenum chamber cover.

AG. Volkswagen AG d
agen oes
olksw not Polo 2014 ➤ , up! 2017 ➤
byV gu
ara
rised
5-speed manual gearboxes nte 02T and 0DF - Edition 11.2018
ho eo
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Continuation for all ss c
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nl
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– Pay attention to paint on edges -arrows-.
du
an
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– Secure both adapters - 10 - 222 A /8- with tensioning straps - erm
ab
ility
T10038- .
ot p
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• Tensioning straps must be guided past bonnet hinge/body as
h re
hole
close as possible to bolted connection.
spec
es, in part or in w
– Take up weight of engine/gearbox assembly on spindles.
t to the co
rrectness of i
l purpos
nform
mercia
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ion
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Manual gearbox 0DF
um
for
en
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The drive shafts are located directly in the gearbox
Co
Cop py
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During subsequent work process, drive shafts with joint sections rig ht
py by
Vo
must be removed.
co lksw
by
cted agen
Prote AG.
– With vehicle standing on its wheels, loosen front flange bolts
-arrow- 90° at most, or wheel bearing will be damaged ⇒
Running gear, axles, steering; Rep. gr. 40 ; Drive shaft; Re‐
moving and installing drive shaft .
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐
sulation .
– Remove front left wheel housing liner ⇒ General body repairs,
- front wheel housing liner .
– If fitted, disconnect electrical connectors:

1- Reversing light switch - F4-
2- Gearbox neutral position sender - G701-

Polo 2014 ➤ , up! 2017 ➤
– Pull connector -1- off oil level and oil temperature sender -
G266- .
– Remove nut -arrow- and remove retainer for electrical lines.

– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter;
Assembly overview - starter .
– If present, remove coolant hose bracket from engine.
– Remove radiator cowl with radiator fan -arrow- ⇒ Rep. gr.wa19 gen;AG
. Volkswagen AG
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Radiator, radiator fan; Assembly overview - radiatory Vcowl
olks and not
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radiator fan . isedb ara
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nl
pt
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ility
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hole
spec
es, in part or in w
t to the co
– Place protective mat between radiator and engine.

rrectness of i
– Separate exhaust system from engine and tie it up ⇒ Rep. gr.

26 ; Exhaust pipes/silencers; Assembly overview - silencer .
l purpos
Caution
nf
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orm
m
Risk of damage to decoupling element.

atio
om
n in
c
♦ Observe ⇒ Rep. gr. 26 ; Emission control; Assembly

or
thi
overview - emission control .

te
sd
iva
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rp
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f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Polo 2014 ➤ , up! 2017 ➤
– Remove coupling rod -1- from anti-roll bar on both sides ⇒

Running gear, axles, steering; Rep. gr. 40 ; Subframe; As‐
sembly overview – subframe .
– Press anti-roll bar upwards.
Manual gearbox 02T

– Remove drive shafts from flange shafts making sure not to
damage surface protection ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Drive shaft; Removing and installing drive shaft .
– To free more space for working, swing suspension struts out‐
wards, and support them with hooks -2024 A /1- as shown in
illustration.
WARNING AG. Volkswagen AG d

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Risk of accidents due to loose
orise components of engine support. nte
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♦ Secure locking pin ss a
and swivel joint with locating pin c
-arrow- and nut -1-.
ce
le
un
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itte
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erm
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– Tie up drive shafts as high as possible making sure not to

ility
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damage surface protection ⇒ Running gear, axles, steering;

wit
is n
Rep. gr. 40 ; Drive shaft; Removing and installing drive shaft .

h re
ole,
spec
If left drive shaft is not tied up high enough, it will hinder removal
of gearbox at a later point.

t to the co
Manual gearbox 0DF

rrectne
– Drain gearbox oil -arrow- ⇒ page 115 .

ss o
cial p
f inform
mer
atio
om
n
c
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or
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te
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pr
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t.
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Cop py
t. rig
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95
op Vo
by c lksw
Prote
cted AG.
agen 2. Removing and installing gearbox
Polo 2014 ➤ , up! 2017 ➤
– Remove drive shafts with joint sections ⇒ Running gear,

axles, steering; Rep. gr. 40 ; Drive shafts; Removing and in‐
stalling drive shafts .
– Install sealing caps in gearbox.

– If fitted, remove earth wire -arrow-.
AG. Volkswagen AG d
agen oes
– Remove hexagon bolts -arrows- for lefty Vassembly
olks
w
mounting not
gu
from gearbox mounting. ised b ara
nte
r
ho eo
– Tilt engine and gearbox assembly
sa
ut by lowering spindles of sup‐ ra
c
port bracket - 10-222 A- . s
ce
le
un
pt
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d
itte
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Note
erm
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ility
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Remove lines for lambda probe from plenum chamber bulkhead.

is n
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Do not disconnect pipe/hose system.

ole,
spec
t to the co
• Securing bolts -arrows- for gearbox bracket -A- must be ac‐

cessible.
rrectne

ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
d byV gu
ara Polo 2014 ➤ , up! 2017 ➤
e
oris 5-speed manual gearboxes 02T
nte and 0DF - Edition 11.2018
e
th or
au ac
ss
– Remove lower engine/gearbox connecting bolt -1-.
ce
le
un
pt
an
d
itte
y li
rm
ab
Note
pe
ility
ot
wit
, is n
Loosen engine/gearbox connecting bolts -2- and -3-, and leave
h re
them installed just hand-tight.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Secure support plate - T10413- to subframe -arrow-.
nform
ercia
– Secure engine support - 3300 A- to support plate - T10413- .

m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Attach engine support to engine directly next to gearbox.
On some engines, the engine support - 3300 A- can be located
directly next to the sump.

– Apply support to engine at the lower bolt hole for engine and
gearbox.
– Place cloth between engine support - 3300 A- and engine.
– Push engine forwards, taking care not to strike against radiator
and observing coolant line to heat exchanger.

Polo 2014 ➤ , up! 2017 ➤

3282/69- for removal of gearbox.
n AG. Volkswagen A
– Fit adjustment plate - 3282/69- olks
waon
ge gearbox support - e3282-
G do
s no
(adjustment plate fits ind bonly one position).
y V t gu
ar
e an
ris tee
– Screw in support uelements
tho -A- as illustrated on adjustment or
plate. ss a ac
ce
le
un
pt
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ility
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t to the co
ous illustration).
rrectness of i
l purpos
nform
mercia
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tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
– Then screw pin - 3282/29- into rear hole on gearbox for se‐
en
ng
t.
curing bolt of pendulum support.
yi Co
Cop py
t. rig
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pyri by
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o
by c lksw
cted agen
Prote AG.
– Remove engine/gearbox connecting bolts.

– Unscrew engine/gearbox connecting bolt -A- above right
flange shaft (⇒ illustration) or above the right drive shaft sup‐
port.
The bolt head -A- may differ from the one shown in the diagram.
– Press gearbox off dowel sleeves.

AG. Volkswagen AG d
agen oes
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by Vol
Polo g2014
ua ➤ , up! 2017 ➤
d ran
5-speed
rise manual gearboxes 02T and 0DF -teEdition 11.2018
ho eo
aut ra
ss c
Manual gearbox 02T
ce
le
un
pt
– Swing gearbox in area of differential upwards until right flange
an
d
itte
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shaft is located in area of upper bolt hole -A- of engine.
rm
ab
pe
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Manual gearbox 0DF
nform
ercia
– Swing gearbox in area of differential upwards until sealing cap

- T10381/1- is near upper engine bolt hole -A- (⇒ previous il‐
m
a
com
t
lustration).
ion in
r
te o
thi
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t.
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pyri by
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Prote AG.

– Turn gearbox down slightly in area of 5th gear (sheet metal
cover) using spindles of gearbox support - 3282- .
– Guide gearbox with differential -arrow- over subframe, and
swing it out.
• Differential must face upwards.
– If necessary, turn gearbox further upwards near differential
using spindles of gearbox support - 3282- .
– Carefully continue swinging gearbox out -arrow-, and lower it.

– When lowering gearbox, change position of gearbox using
spindles of gearbox support - 3282- .
Note

Polo 2014 ➤ , up! 2017 ➤
2.3 Installing gearbox

⇒ “2.3.1 Installing gearbox, up!”, page 100
⇒ “2.3.2 Installing gearbox, Polo”, page 104
2.3.1 Installing gearbox, up!
Note
Refer to procedure “Removing gearbox” for required special tools

⇒ page 79 .
– If the gearbox is to be renewed, the gearbox selector lever and

relay lever must be transferred to the new gearbox.
– All threaded holes into which self-locking AGbolts
. Volksare
wageto
n Abe
agen G do
screwed must be cleaned of residual
Volksw locking fluid carefully with
es n
ot g
a thread tap. ed
by ua
ra
is nte
or eo
– Clean input shaft splinesau and apply thin coat of grease for
th ra
clutch plate splines s.s c
ce
le
un
pt
The clutch plate must slide easily to and fro on the input shaft.
an
d
itte
y li
– If no dowel sleeves for aligning engine and gearbox are fitted
rm
ab
pe
ility
in cylinder block, install if necessary.
ot
wit
, is n
If dowel sleeves are not fitted, difficulties shifting gears, clutch
h re
hole
problems and possible noises from the gearbox (rattling of gears
spec
which are not engaged) could occur.
es, in part or in w
t to the co
3282/69- for installation of gearbox. rrectness of i

l purpos

plate.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
– Place gearbox on engine and gearbox jack . ht. Cop py
rig
rig ht
– Align adjustment plate parallel to gearbox. py by
co Vo
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cted agen
Rods holding the support elements should be flush with gearbox Prote AG.
ous illustration).

Polo 2014 ➤ , up! 2017 ➤
– Tilt gearbox further using spindles of gearbox support - 3282- .
lkswage es n
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byV ua
Gearbox points downwards in ir searea of 5th gear -A- and in area of
d ran
tee
differential -B- (shown here uth with a different gearbox).
o
or
a ac
ss
– Carefully push engine forwards (with aid of 2nd mechanic).
ce
e
nl
pt
du
– Raise gearbox carefully and guide past subframe.
an
itte
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erm
ab
ility
ot p
Note
wit
, is n
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hole
spec
Be careful of all lines when installing gearbox.
es, in part or in w
t to the co
rrectness of i
– Line up gearbox and install.
l purpos
– Screw in engine/gearbox connecting bolt -arrow- in area of

right drive shaft seal ⇒ page 110 .
nf
ercia
– Install lower engine/gearbox securing bolts ⇒ page 110 .

orm
m
atio
m
– After gearbox has been bolted to engine, remove engine and

o
n in
c
gearbox jack from gearbox.

or
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te
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f
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t.
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Cop py
t. rig
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by
– Fit gearbox bracket -A- with new bolts ⇒ page 111 . Prote
cted AG.
agen

Polo 2014 ➤ , up! 2017 ➤
– Align engine and gearbox in installation position.

– Install new bolt -arrow- for left assembly mounting in gearbox
mounting ⇒ page 111 .
– Do not remove engine support bracket - 10 - 222 A- until all
bolts securing the assembly mounting have been tightened to
specified torque.
– If previously removed, fit bonnet seal to lock carrier.
– Install upper engine/gearbox securing bolts -arrows A- and

-arrows B- ⇒ page 110 .
– Bolts -arrows A- can be tightened using insert tool, 18 mm -
T10509- .
– Fit earth strap if necessary.
AG. Volkswagen AG d
agen oes
olksw not
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– Install pendulum support using new bolts ⇒ Rep. gr.ed 10 by ; As‐ gu
ara
sembly mountings; Assembly overview – assembly horis
mount‐ nte
eo
ings . aut ra
ss c
ce
– Install exhaust system ⇒ Rep. gr. 26 ; Emission control; As‐
e
nl
pt
du
sembly overview – emission control .
an
itte
y li
erm
ab
– Fit drive shafts with joint sections ⇒ Running gear, axles,
ility
ot p
steering; Rep. gr. 40 ; Drive shaft; Removing and installing
wit
, is n
drive shaft .
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Install coupling rod -1- to anti-roll bar on both sides ⇒ Running
gear, axles, steering; Rep. gr. 40 ; Subframe; Assembly over‐
l purpos
view – subframe .
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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rp
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f
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Polo 2014 ➤ , up! 2017 ➤
– If applicable, connect electrical connectors as follows:

– Fit connector -1- to gearbox neutral position sender - G701- .
– Fit connector -2- to reversing light switch - F4- .
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
– Connect connector -1- to oil level and oil temperature sender
itte
y li
erm
- G266- .
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
o
– Install clutch slave cylinder -arrows- ⇒ page 24 .
rm
m
atio
m
– Install starter ⇒ Electrical system; Rep. gr. 27 ; Starter; As‐

o
n in
c
sembly overview - starter .

or
thi
te
sd
iva
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rp
cu
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m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Install cable support bracket to gearbox ⇒ page 62 .


Polo 2014 ➤ , up! 2017 ➤
– Install gearbox selector lever and tighten hexagon nut -4- to

specified torque ⇒ page 62 . gen AG
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a does
lksw not
– Install relay lever -3- together withd bcable
yV
o
end-piece gu
ara
⇒ page 71 . orise nte
h eo
ut ra
– Spread a small amount ofsgrease
sa on pin of gearbox selector c
lever.
ce
e
nl
pt
du
an
itte
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erm
ab
– Attach gear selector cable -2- to gearbox selector lever.
ility
ot p
wit
, is n
– Install new clip -1-.
h re
hole
spec
es, in part or in w
t to the co
– Fill with gear oil ⇒ page 115 .
– If fitted, install noise insulation ⇒ General body repairs, exte‐
rior; Rep. gr. 66 ; Noise insulation; Assembly overview - noise
rrectness of i
insulation .
l purpos

nf
ercia
o
rm
m
atio
m
necting battery .
o
n in
or c
thi
e
– Install engine cover and air filter ⇒ Rep. gr. 24 ; Air filter;
t
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi
2.3.2 Installing gearbox, Polo
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted
Note
agen
Prote AG.
For required special tools, refer to procedure “Removing gearbox”

⇒ page 88 .
– All threaded holes into which self-locking bolts are to be

screwed must be carefully cleaned of residual locking fluid us‐
ing a thread chaser.
– Renew self-locking bolts and nuts after each removal.
– Check whether dowel sleeves for aligning engine and gearbox
are fitted in cylinder block and install if necessary.
If dowel sleeves are not fitted, difficulties shifting gears, clutch
problems and possible noises from the gearbox (rattling of gears
which are not engaged) could occur.
– Ensure that intermediate plate is correctly seated on engine.
– Clean input shaft splines and apply thin coat of grease for
clutch plate splines .
The clutch plate must slide easily to and fro on the input shaft.

Polo 2014 ➤ , up! 2017 ➤
– Secure support plate - T10413- to subframe -arrow-.

– Secure engine support - 3300 A- to support plate - T10413- .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
– Attach engine support to engine directly next to gearbox.
es, in part or in w
t to the co
On some engines, the engine support - 3300 A- can be located
directly next to the sump.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
riv
– Apply support to engine at the lower bolt hole for engine and
p
cum
or
gearbox.
f
en
ng
t.
yi Co
op
C py
ht. rig
rig ht
py by
– Place cloth between engine support - 3300 A- and engine. co Vo
by lksw
cted agen
Prote AG.
– Push engine forwards, taking care not to strike against radiator
and observing coolant line to heat exchanger.

3282/69- for installation of gearbox.
plate.

Polo 2014 ➤ , up! 2017 ➤
– Place gearbox on engine and gearbox jack .

ous illustration).
– Tilt gearbox further using spindles of gearbox support - 3282- .
• Differential area faces upwards.
• 5th gear area (sheet metal cover) faces downwards.
– Then carefully raise gearbox.
Note
– Guide gearbox with differential -arrow- over subframe. lkswage es n
o ot g
byV ua
d
– Swivel gearbox towards engine. o
ir se
ran
tee
th or
u
– Lift gearbox in area of 5th gear (sheet metal cover)
ss
a using spin‐ ac
dle of gearbox support - 3282- .
ce
e
nl
pt
du
an
– Move gearbox into installation position using spindles of gear‐
itte
y li
box support - 3282- .
erm
ab
ility
ot p
– Install lower engine/gearbox securing bolts ⇒ page 110 .
wit
, is n
h re
– Remove engine support - 3300 A- and support plate -
hole
spec
T10413- .
es, in part or in w
t to the co
– Screw in engine/gearbox connecting bolt -A- above right

rrectness of i
flange shaft (⇒ illustration) or above the right drive shaft sup‐

port ⇒ page 110 .
l purpos
– After gearbox has been bolted to engine, remove engine and

gearbox jack from gearbox.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Polo 2014 ➤ , up! 2017 ➤
– Fit gearbox bracket -A- with new bolts -arrows-.

– Moisten bonded rubber mounting of left assembly mounting
and upper section of gearbox bracket with assembly lubrica‐
tion oil ⇒ Electronic Parts Catalogue (ETKA) .
– Install new bolts -arrows- for left assembly mounting in gear‐

box mounting.
specified torque.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
– If present,
ss install earth wire -arrow-. c
ce
e
nl
pt
– Install upper engine/gearbox securing bolts.

du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Install pendulum support using new bolts ⇒ Rep. gr. 10 ; As‐

sembly mountings; Assembly overview – assembly mount‐
nf
ercia
ings .
orm
m
atio
– Check adjustment of assembly mountings ⇒ Rep. gr. 10 ;

om
n in
Assembly mountings; Checking adjustment of assembly

or c
mountings .
thi
te
sd
iva
o
r
– Assemble exhaust system ⇒ Rep. gr. 26 ; Exhaust pipes/

rp
cu
o
silencers; Assembly overview - silencer .

f
en
ng
t.
yi Co
op
– Mount drive shafts with joint sections if necessary ⇒ Running C py
t. rig
gear, axles, steering; Rep. gr. 40 ; Drive shafts; Removing and
gh ht
pyri by
installing drive shafts .
o Vo
by c lksw
cted agen
Prote AG.

Polo 2014 ➤ , up! 2017 ➤
– Install coupling rod -1- to anti-roll bar on both sides ⇒ Running

gear, axles, steering; Rep. gr. 40 ; Subframe; Assembly over‐
view – subframe .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
– Connect connector -1- to oil level and oil temperature sender
pe
ility
- G266- .
ot
wit
, is n
h re
– If removed beforehand, fit coolant hose bracket to engine.
hole
spec
– Check for correct installation position of vacuum hose for
es, in part or in w
t to the co
brake system. Fit vacuum hose, if necessary ⇒ Brake system;
Rep. gr. 47 ; Brake servo/brake master cylinder .
rrectness of i
l purpos
nform
mercia
a
com
– Install starter and retainer for electrical wiring -arrow- ⇒ Elec‐
tion in
trical system; Rep. gr. 27 ; Starter; Assembly overview –
r
te o
thi
starter .
s
iva
do
r
– Install clutch slave cylinder ⇒ page 40 .

rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Gearboxes for vehicles with start-stop system: join connector

-arrow- to gearbox neutral position sender - G701- .

AG. Volkswagen AG d
agen oes
Volksw Polo n2014
ot g ➤ , up! 2017 ➤
y ua
5-speed
rised b
manual gearboxes 02T and 0DF - raEdition
nte 11.2018
tho eo
au r ac
– Install cable support bracket on gearbox,
ss and tighten bolts
-arrows- ⇒ page 62 .
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Install gearbox selector lever -B- ⇒ page 62 .
nf
ercia
– Tighten hexagon nut -arrow 2- ⇒ page 131 .
orm
m
– Install gate relay lever -A- together with cable end-piece
atio
m
⇒ page 62 .
o
n in
or c
thi
e
– Spread small amount of grease on pin of gearbox selector

t
sd
iva
lever -B-.
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
op py
– Attach gear selector cable to gearbox selector lever. t. C rig
gh ht
pyri by
– Renew securing clip -arrow 1- after each removal.
co Vo
by lksw
cted agen
Prote AG.
– Install battery tray, battery and battery cover ⇒ Electrical sys‐
tem; Rep. gr. 27 ; Battery; Removing and installing battery .
– Install air filter ⇒ Rep. gr. 24 ; Air filter; Removing and instal‐
ling air filter housing .
– Install foam pieces or seal at upper edge of left and right wings
⇒ General body repairs, exterior; Rep. gr. 50 ; Wings; As‐
sembly overview – wings .
– Check and fill with gear oil as needed ⇒ page 115 .
– Install front left wheel housing liner ⇒ General body repairs,
– front wheel housing liner .
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 66 ; Noise insulation; Assembly overview - noise insula‐
tion .

Polo 2014 ➤ , up! 2017 ➤
2.4 Specified torques for gearbox

⇒ “2.4.1 Specified torques for gearbox, up!”, page 110
⇒ “2.4.2 Specified torques for gearbox, Polo”, page 110
2.4.1 Specified torques for gearbox, up!

Item Bolt Qua Nm
ntity
1 M12 × 60 3 80
• With insert tool
T10509: »65
Nm«.
2 M10 × 55 3 40
3 M12 × 70 3 80
Item -A- for dowel sleeves for centring
2.4.2 Specified torques for gearbox, Polo

Item Bolt Quantity Nm
1 M12 × 60 2 80
2 M12 × 150 2 80
♦ Additionally, start‐
er to gearbox agen
AG. Volkswagen AG d
oes
olksw not
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3 M10 × 55 3 ris40
ed b ara
nte
o eo
4 M12 × 70 2 aut 80
h
ra
ss c
ce
e
Item -A- dowel sleeves for centring

nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Polo 2014 ➤ , up! 2017 ➤
3 Assembly mountings
⇒ “3.1 Assembly overview - assembly mountings, up!”,
page 111
⇒ “3.2 Assembly overview - assembly mountings, Polo”,
page 112
3.1 Assembly overview - assembly mountings, up!
1 - Engine mounting
❑ ⇒ Rep. gr. 10 ; Assem‐
bly mountings; Assem‐
bly overview - assembly
mountings
AG. Volkswagen AG d
2 - Bolt lksw
agen oes
not
o
❑ Pendulum support to byV gu
ara
ed
nte
subframe horis
eo
ut ra
❑ ⇒ Rep. gr. 10 ; Assem‐ ss a c
ce
e
nl
pt
du
an
itte
mountings
y li
erm
ab
ility
3 - Pendulum support
ot p
wit
, is n
h re
hole
spec
es, in part or in w
mountings
t to the co
4 - Bolt
❑ Pendulum support to
rrectness of i
gearbox
l purpos

nf
ercia
o
mountings
rm
m
atio
m
5 - Bolt
o
n in
or c

thi
te
sd
iva
❑ Gearbox bracket to
o
r
rp
cu
gearbox
o
m
f
en
ng
t.
❑ 40 Nm +90°
yi Co
Cop py
ht. rig
6 - Gearbox bracket rig ht
py by
co Vo
by lksw
7 - Gearbox mounting Prote
cted AG.
agen

bly overview - assembly mountings
8 - Bolt
❑ Gearbox mounting to body
❑ ⇒ Rep. gr. 10 ; Assembly mountings; Assembly overview - assembly mountings
9 - Bolt
❑ Gearbox mounting to body
10 - Bolt
❑ Gearbox bracket to gearbox mounting
❑ 60 Nm +180°
3. Assembly mountings 111

Polo 2014 ➤ , up! 2017 ➤
3.2 Assembly overview - assembly mountings, Polo
1 - Bolt
❑ Qty. 2
❑ Renew after removal AG. Volkswagen AG d
agen oes
❑ Gearbox bracket to olksw not
yV gu
gearbox mountinged b ara
nte
ris
❑ 40 Nm +90°au
tho eo
ra
ss c
2 - Bolt
ce
e
nl
pt
du
❑ Gearbox mounting to
an
itte
y li
body
erm
ab
ility
ot p
wit
, is n
h re
hole
mountings
spec
es, in part or in w
t to the co
3 - Gearbox mounting
rrectness of i
mountings
l purpos
4 - Gearbox bracket
nform
ercia
5 - Bolt
m
at
Qty. 2 (different from qty.
om
io
shown in illustration)
n
c
in t
or
⇒ page 113
his
ate
do
riv

p
cum
for
❑ Gearbox bracket to
en
ng
t.
yi Co
gearbox . Cop py
rig
ht
❑ 40 Nm +90° rig ht
py by
co Vo
by lksw
6 - Pendulum support cted agen
Prote AG.
mountings
7 - Bolt
❑ Pendulum support to subframe
8 - Bolt
❑ Pendulum support to gearbox
9 - Engine mounting
10 - Bolt
❑ Qty. 4
❑ Engine mounting to body
11 - Bolt
❑ Engine mounting to engine

lkswage es n
o ot g
byV u
ir se
d Polo 2014 ➤ ,aup! ran 2017 ➤
tee
o
5-speed
auth manual gearboxes 02T and 0DF - Edition 11.2018 or
ac
ss
ce
e
12 - Bolt
nl
pt
du
an
itte
❑ Qty. 2
y li
erm
ab
❑ Engine mounting to engine
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
Gearbox bracket -A- to gearbox
t to the co
– Renew bolts.
rrectness of i
– Tighten bolts by hand.
– Tighten bolt to specified torque ⇒ Item 5 (page 112) . l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
g
Gearbox bracket to gearbox

n
t.
yi Co
Cop py
– Renew bolts.
t. rig
gh ht
pyri by
Vo
o
– Tighten bolts by hand.
c by lksw
cted agen
Prote AG.
– Tighten bolt to specified torque ⇒ Item 1 (page 112) .
Note
Install engine and gearbox mountings without tension ⇒ Rep. gr.

10 ; Assembly mountings; Assembly overview - Assembly mount‐
ings .
3. Assembly mountings 113

Polo 2014 ➤ , up! 2017 ➤
4 Transporting gearbox
♦ Gearbox lifting tackle - 3336-
– Bolt gearbox lifting tackle - 3336- to clutch housing.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
– Adjust support beam on sliding piece using locking pin
ce
e
nl
pt
-arrow-.
du
an
itte
y li
No. of holes visible = 6
erm
ab
ility
ot p
– Lift gearbox using workshop crane and gearbox lifting tackle -
wit
, is n
3336- .
h re
hole
spec
– Set gearbox aside, for example in a transport container.
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
o
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f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Polo 2014 ➤ , up! 2017 ➤
5 Gear oil
⇒ “5.1 Checking gear oil level”, page 115
⇒ “5.2 Draining and filling gear oil”, page 116
5.1 Checking gear oil level

♦ Socket bit - 3357- for oil filler plug with multi-point socket head
bolt
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
Gear oil ⇒ Electronic parts catalogue (ETKA)

fo
en
ng
t.
yi Co
– Remove noise insulation ⇒ General body repairs, exterior; Cop py
Rep. gr. 66 ; Noise insulation .
t. rig
gh ht
pyri by
Vo
o
by c
– To check gear oil, remove oil plug -arrow-.
lksw
cted agen
Prote AG.
Oil level is correct when gearbox is filled to lower edge of filler
hole.
– If necessary, fill with gear oil to lower edge of filler hole.
– Tighten bolt -arrow-.
5. Gear oil 115

Polo 2014 ➤ , up! 2017 ➤
Various versions of oil filler and drain plug

I - Oil filler plug/oil drain plug with multi-point socket head, 25 Nm
II - Oil filler plug/oil drain plug with hexagon socket head,o30
lkswNm
age es n
ot g
V
by ua
– Install noise insulation ⇒ General body repairs,riexterior;
se
d Rep. ran
tee
gr. 66 ; Noise insulation . ut
ho
or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
5.2 Draining and filling gear oil
es, in part or in w
t to the co
♦ Socket bit - 3357- for oil filler plug with multi-point socket head
rrectness of i
bolt
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
co Vo
by lksw
cted agen
Prote AG.
Gear oil ⇒ Electronic parts catalogue (ETKA) .

Use a clean container with a scale and a 3.0-litre capacity to catch
the gear oil when draining.
Drain gear oil -arrow-.- -
– Tighten oil drain plug -arrow- to specified torque.

Polo 2014 ➤ , up! 2017 ➤
Fill with gear oil

– Remove oil plug -arrow- to fill.
– If previous oil is clean, fill it into gearbox.
Oil level is correct when gearbox is filled to lower edge of filler
hole.
• If oil should get on gearbox and other components, remove it
thoroughly.
Specified torques ⇒ page 116
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
5. Gear oil 117

Polo 2014 ➤ , up! 2017 ➤
6 Securing to engine and gearbox sup‐

port
⇒ “6.1 Securing to engine and gearbox support, gearboxes for
up!”, page 119
⇒ “6.2 Securing to engine and gearbox support, gearboxes for
Polo”, page 121
n AG. Volkswagen A
The gearbox is secured with bolts screwed
olks
wage into bolt holes fordoes n
G
ot g
gearbox support. db
y V ua
r e an
ris tee
tho or
au ac
ss
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Polo 2014 ➤ , up! 2017 ➤
6.1 Securing to engine and gearbox sup‐

port, gearboxes for up!
Special tools and work‐
shop equipment re‐
quired
♦ Gearbox support -
3221- (check and ad‐
just as necessary
⇒ page 119 )
♦ Or gearbox support -
3221A- (check and
adjust as necessary
⇒ page 119 )
lkswage es n
o ot g
♦ or gearbox support - d byV ua
ran
3221B- o
ir se tee
th or
u
♦ Support clamp - ss
a ac
VW 313-
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Gearbox support - 3221-

or gearbox support -
nf
ercia
3221A- (check and ad‐

rm
m
just as necessary)
atio
om
n in
c
– If necessary, drill
or
thi
e
11.0 mm diameter
t
sd
iva
holes -arrows-.
o
r
rp
cu
o
m
f
– Then, mark gearbox

en
ng
t.
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support with Cop py
-3221B- .
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
6. Securing to engine and gearbox support 119

Polo 2014 ➤ , up! 2017 ➤
– Secure gearbox to gearbox support - 3221B- -arrows-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Polo 2014 ➤ , up! 2017 ➤
gen AG. 02T
Volkswand
agen0DF
AG d - Edition 11.2018
wa oes
olks not
yV gu
6.2 Securing to engine and gearbox sup‐
b ara
ed nte
ris
ho eo
port, gearboxes for Polo
t
au ra
c
ss
ce
le
Special tools and work‐
un
pt
an
d
shop equipment re‐
itte
y li
quired
rm
ab
pe
ility
♦ Gearbox support -
ot
wit
, is n
3221- (check and ad‐
h re
hole
just as necessary
spec
⇒ page 121 )
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
♦ or gearbox support -
te o
thi
s
3221A-
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ or gearbox support -
3221B-
♦ Support clamp -
VW 313-
Gearbox support - 3221-

(check and adjust as
necessary)
– If necessary, drill a
hole with 11.0 mm in
diameter -arrow-.
– Then, mark gearbox
support - 3221- with
-3221A- .
6. Securing to engine and gearbox support 121

Polo 2014 ➤ , up! 2017 ➤
– Secure gearbox to gearbox support -arrows-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Polo 2014 ➤ , up! 2017 ➤
7 Dismantling and assembling gearbox

⇒ “7.1 Schematic overview - gearbox”, page 123
⇒ “7.2 Assembly overview - gearbox”, page 126
⇒ “7.3 Assembly overview - cover for gearbox housing and 5th
gear”, page 127
⇒ “7.4 Assembly overview - clutch housing”, page 128
⇒ “7.5 Assembly overview - shafts, differential, selector mecha‐
nism”, page 130
⇒ “7.6 Assembly overview - selector unit”, page 131
⇒ “7.7 Assembly overview - selector forks”, page 134
⇒ “7.8 Removing and installing selector unit with gearbox instal‐
led”, page 135
⇒ “7.9 Repairing selector forks”, page 141
⇒ “7.10 Repairing selector unit”, page 145
⇒ “7.11 Renewing selector shaft seal”, page 148
⇒ “7.12 Dismantling and assembling gearbox”, page 149
7.1 Schematic overview - gearbox

lksw
agen
AG. Volkswagen AG d
oes
n o ot g
yV ua
⇒ “7.1.1 Schematic overview - gearbox,ris
emanual
db gearbox 02T”, ran
tee
page 123 ut
ho
or
sa ac
⇒ “7.1.2 Schematic overview - gearbox,
s
manual gearbox 0DF”,
ce
le
page 125
un
pt
an
d
itte
y li
7.1.1 Schematic overview - gearbox, manual gearbox 02T
erm
ab
ility
ot p
wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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cum
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fo
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t.
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Cop py
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Vo
co lksw
by
cted agen
Prote AG.
7. Dismantling and assembling gearbox 123

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
Polo 2014 ➤ori,s up! 2017 ➤
e nte
h eo
5-speed manual
aut gearboxes 02T and 0DF - Edition 11.2018 ra
c
ss
ce
le
1 - 1st gear
un
pt
an
d
itte
y li
2 - 2nd gear
erm
ab
ility
ot p
3 - 3rd gear
wit
is n
h re
4 - 4th gear
ole,
spec
5 - 5th gear
t to the co
6 - Gearbox housing cover
7 - Gearbox housing
rrectne
8 - Reverse gear wheel
ss
9 - Selector mechanism
o
cial p
f i
❑ (Selector forks)
nform
mer
10 - Clutch housing
atio
om
n
11 - Input shaft
c
i
or
n thi
te
sd
12 - Output shaft
iva
o
pr
cum
r
13 - Differential
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Polo 2014 ➤ , up! 2017 ➤
7.1.2 Schematic overview - gearbox, manual gearbox 0DF
1 - 1st gear
2 - 2nd gear
3 - 3rd gear
4 - 4th gear
5 - 5th gear
7 - Gearbox housing
AG. Volkswagen AG d
❑ (Selector forks) ksw
agen oes
not
Vol
y gu
10 - Clutch housing ise
d b ara
nte
or eo
h
11 - Input shaft s aut ra
c
s
12 - Output shaft
ce
e
nl
pt
du
an
itte
13 - Differential
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Polo 2014 ➤ , up! 2017 ➤
7.2 Assembly overview - gearbox
I-
⇒ “7.3 Assembly overview -
cover for gearbox housing and
5th gear”, page 127
II -
clutch housing”, page 128
III -
shafts, differential, selector
mechanism”, page 130
III -
⇒ “7.6 Assembly overview - se‐
lector unit”, page 131
III -
⇒ “7.7 Assembly overview - se‐
lector forks”, page 134
III - wage
es n
⇒ “7.9 Repairing selector y V olks ot g
ua
forks”, page 141 ised b ran
r tee
ho
III - sa
ut or
ac
⇒ “7.10 Repairing selector
s
ce
le
unit”, page 145

un
pt
an
d
itte
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III -
erm
ab
⇒ “7.11 Renewing selector

ility
ot p
shaft seal”, page 148

wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Polo 2014 ➤ , up! 2017 ➤
7.3 Assembly overview - cover for gearbox housing and 5th gear
1 - Gearbox housing
❑ Repairing ⇒ page 159
2 - Gear wheel for 5th gear
⇒ page 149
3 - Retaining ring
❑ Determining thickness
⇒ page 158
4 - Seal
Note
If gearbox housing cover is removed agen

AG. Volkswagen AG d
oes
and installed with gearbox installed, y Volksw not
gu
check oil level and top up with gearised b ara
nte
oil ⇒ page 115 . thor eo
au ra
c
ss
6 - Bolt
ce
e
nl
pt
du
an
itte
y li
erm
ab
❑ 5 Nm and turn 90° fur‐
ility
ot p
ther
wit
, is n
h re
7 - Retaining ring
hole
spec
es, in part or in w
t to the co
⇒ page 158
8 - Synchro-hub with locking
rrectness of i
collar and stop ring for 5-speed
gearbox
l purpos
❑ Dismantling and assem‐

bling ⇒ page 165
nf
ercia
orm
9 - Synchro-ring for 5th gear

m
atio
om
10 - Synchromeshed gear, 5th gear

n in
or c
thi
e
11 - Needle bearing
t
sd
iva
o
r
rp
cu
❑ For 5th gear

o
m
f
en
ng
t.
yi
12 - 5th gear selector fork
Co
Cop py
t.
rig
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pyri by
Vo
co
13 - Pivot pin
by lksw
cted agen
Prote AG.
❑ for 5th gear selector fork.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
Polo 2014
ut
ho ➤ , up! 2017 ➤ eo
ra
a
5-speed
ss manual gearboxes 02T and 0DF - Edition 11.2018 c
ce
le
un
pt
7.4 Assembly overview - clutch housing
an
d
itte
y li
rm
ab
pe
⇒ “7.4.1 Assembly overview - clutch housing, manual gearbox
ility
ot
02T”, page 128
wit
, is n
h re
hole
⇒ “7.4.2 Assembly overview - clutch housing, manual gearbox
spec
0DF”, page 129
es, in part or in w
t to the co
7.4.1 Assembly overview - clutch housing, manual gearbox 02T
rrectness of i
1 - Countersunk bolt
l purpos
⇒ page 196
nform
ercia
2 - Flange shaft with compres‐

m
sion spring
a
com
tio
n in
r
te o
⇒ page 149
thi
s
iva
do
❑ Assembling
r
rp
cum
⇒ page 196
fo
en
ng
t.
yi Co
3 - Bolt . Cop py
rig
ht
❑ Renew after removal rig ht
py by
co Vo
by lksw
cted agen
Prote
ther
AG.
4 - Clutch housing
5 - Gearbox housing
6 - Clutch release lever
❑ With guide sleeve and
release bearing
⇒ page 128
7 - Bolt
⇒ page 24

Polo 2014 ➤ , up! 2017 ➤
7.4.2 Assembly overview - clutch housing, manual gearbox 0DF
1 - Bolt
ther
2 - Clutch housing
3 - Gearbox housing
4 - Clutch release lever
❑ With guide sleeve and
release bearing
⇒ page 24
5 - Bolt
⇒ page 24
lkswage es n
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byV ua
d ran
ir se tee
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a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
o
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f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Polo 2014 ➤ , up! 2017 ➤
7.5 Assembly overview - shafts, differential, selector mechanism
1 - Differential
❑ Dismantling and assem‐
bling ⇒ page 196
2 - Gearbox housing
3 - Oil drain plug
❑ Specified torque AG. Volkswagen AG d
⇒ page 116 lksw
agen oes
not
Vo gu
by
4 - Flange shaft with compres‐ rised ara
nte
sion spring ut
ho eo
ra
a
❑ Only manual gearbox ss c
ce
e
02T
nl
pt
du
an
itte
y li
erm
⇒ page 149
ab
ility
ot p
❑ Assembling
wit
, is n
⇒ page 196
h re
hole
spec
es, in part or in w
❑ Only manual gearbox
t to the co
02T
rrectness of i
⇒ page 196
l purpos
6 - Bolt
❑ Qty. 6
nform
ercia
❑ Self-locking
m
at
om
ion
❑ For securing bearing
c
in t
or
support for input and
his
ate
output shafts
do
priv
c
⇒ Item 18 (page 131) .
um
for
en
g
❑ Bearing support (sheet

n
t.
yi Co
op
metal version): 5 Nm C py
t. rig
and turn 90° further
gh ht
pyri by
Vo
o
by c
❑ Bearing support (cast iron version): 8 Nm and turn 90° further
lksw
cted agen
Prote AG.
7 - Hexagon flange nut
❑ For selector mechanism
❑ Self-locking
❑ 23 Nm
8 - O-ring
9 - Pivot pin
10 - Bolt
❑ 5 Nm and turn 90° further
11 - Selector unit
❑ (Selector shaft with selector shaft cover) ⇒ page 131
❑ Removing and installing with gearbox installed ⇒ page 135
12 - Bolt

Polo 2014 ➤ , up! 2017 ➤
13 - Bolt
❑ 6 Nm
14 - Gearbox neutral position sender - G701-
❑ for vehicles with start/stop system
❑ Switch without seal: clean thread of switch if necessary
❑ Switch without seal: install switch with sealant if necessary
❑ For allocation of sealant, refer to ⇒ Electronic parts catalogue (ETKA) .
❑ Switch with encapsulated seal: renew switch
❑ Switch with separate seal: renew seal
❑ Lightly coat lug with MoS2 grease
❑ Polo - with gearbox installed: Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 66 ;
Noise insulation; Assembly overview – noise insulation .
❑ Installation location up! : on selector uniten⇒AG
page
. Volks131
wagen AG
wag does
❑ 20 Nm yV
olks not
gu b ara
ed
16 - Seal ris nte
utho e or
❑ Not fitted in all gearboxes
ss
a ac
ce
e

nl
pt
du
an
itte
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erm
ab
❑ (Selector forks)
ility
ot p
wit
, is n
h re
hole
18 - Input shaft and output shaft with bearing mounting and deep groove ball bearing
spec
es, in part or in w
❑ If bearing support is separated from gearbox housing, the support must always be renewed
t to the co
❑ Pressing bearing support off and on: Dismantling and assembling input shaft ⇒ page 167
❑ Dismantling and assembling input shaft ⇒ page 167
rrectness of i
❑ Dismantling and assembling output shaft ⇒ page 180
l purpos
19 - Reverse gear shaft

nform
ercia
❑ Note installation position ⇒ page 149

m
at
om
io
21 - Bolt
n
c
in t
or

his
ate
do
riv
❑ For securing shaft for reverse gear

p
cum
for
❑ M 6: 5 Nm and turn 90° further

en
ng
t.
yi Co
op
❑ M 8: 25 Nm and turn 45° further C py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
7.6 Assembly overview - selector unit
⇒ “7.6.1 Assembly overview - selector unit, up!”, page 131
⇒ “7.6.2 Assembly overview - selector unit, Polo”, page 133
7.6.1 Assembly overview - selector unit, up!
Note


Polo 2014 ➤ , up! 2017 ➤
1 - Sleeve
❑ For selector shaft
❑ Driving out ⇒ Fig.
⇒ page 147
❑ Driving in ⇒ page 147
mechanism cover and angled
rod
❑ Renew selector shaft to‐
gether with selector
mechanism cover
⇒ page 135
❑ Removing angled rod
⇒ page 147
❑ Driving in angled rod
⇒ page 147
❑ Also refer to
⇒ Item 15 (page 131) .
❑ Switch without seal:
clean thread of switch if
necessary
❑ Switch without seal: in‐
stall switch with sealant
if necessary gen AG
. Volkswagen AG
swa does
❑ For allocation of seal‐ yV
olk not
gu
ant, refer to ⇒ Electronicrised b ara
nte
parts catalogue (ET‐uth o eo
ra
KA) . ss a c
ce
le
❑ Switch with encapsula‐

un
pt
ted seal: renew switch

an
d
itte
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rm
❑ Switch with separate

ab
pe
ility
seal: renew seal

ot
wit
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❑ Lightly coat lug with MoS2 grease

h re
hole
spec
4 - Clip
es, in part or in w
t to the co
5 - Cap
❑ For gearbox breather
rrectness of i
6 - Seal
l purpos

nform
ercia

m

com
tion in
❑ Illustration may differ from original component

r
te o
thi
s
iva
❑ Install so that master spline aligns with selector shaft

do
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❑ Can be renewed with the selector mechanism installed

fo
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Cop py
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9 - Hexagon nut rig ht
py by
co Vo
❑ Self-locking
by lksw
cted agen
Prote AG.
❑ 23 Nm
10 - Cable end-piece
❑ For gear selector cable to gearbox selector lever

Polo 2014 ➤ , up! 2017 ➤
❑ ⇒ page 62
11 - Securing clip
7.6.2 Assembly overview - selector unit, Polo
Note

1 - Sleeve
⇒ page 147
shaft cover
AG. Volkswagen AG d
❑ Renew together agen oes
olksw not
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❑ Removing and installing ised b ara
nte
⇒ page 139 ut
hor eo
a ra
s c
3 - Angled rod s
ce
e
nl
pt
❑ For adjusting selector
du
an
itte
mechanism
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ab
❑ Removing ⇒ page 147
ility
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hole
spec
es, in part or in w
t to the co
⇒ page 73
5 - Clip
rrectness of i
6 - Seal
l purpos

⇒ page 148
nf
ercia
7 - Cap
orm
m
atio
❑ For gearbox breather

om
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c

or
thi
te
sd
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❑ Illustration may differ

iv
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from original compo‐

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op
❑ Install so that master C py
ht. rig
spline aligns with selec‐ rig ht
py by
tor shaft
co Vo
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cted agen
❑ Can be renewed with the selector mechanism installed
Prote AG.

9 - Hexagon nut
❑ Self-locking
❑ 23 Nm

Polo 2014 ➤ , up! 2017 ➤
7.7 Assembly overview - selector forks
Note
It is not necessary to dismantle the selector fork group in order to dismantle and assemble detent segments,
lock washers and angular contact ball bearings.
1 - Selector fork group with se‐

lector plate
2 - Selector segment for 3rd
and 4th gear
❑ Identification
⇒ page 143
❑ After installation, selec‐
tor segment must still ro‐
tate freely
3 - Angular contact ball bearing
❑ Qty. 4
❑ Press inner race into
outer race ⇒ page 145
❑ Installing ⇒ page 145
4 - Clamping washer wage
es n
lks
❑ Renew after removal d byV
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ran
ir se
❑ Removing ⇒ page 144 tho tee
or
u
❑ Installing ⇒ page 144 ss
a ac
ce
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nl
5 - 1st/2nd gear selector seg‐

pt
du
an
ment
itte
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erm
ab
❑ Identification
ility
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⇒ page 143
wit
, is n
h re
❑ After lock washer is in‐

hole
stalled, segment must

spec
still rotate freely

es, in part or in w
t to the co
❑ Selector fork with selec‐

tor segment
⇒ page 144
rrectness of i
6 - 5th gear selector fork with

l purpos
selector segment
❑ Selector segment is per‐
nf
ercia
manently connected to
or
selector fork.
m
m
atio
m
❑ Identification ⇒ page 143

o
n in
or c
thi
7 - Pivot pin
te
sd
iva
❑ for 5th gear selector fork.

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t.
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Cop py
t. rig
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pyri by
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co lksw
by
cted agen
Prote AG.

Polo 2014 ➤ , up! 2017 ➤
7.8 Removing and installing selector unit

with gearbox installed
⇒ “7.8.1 Removing and installing selector unit, up!”, page 135
⇒ “7.8.2 Removing and installing selector unit, Polo”, page 139
AG. Volkswagen AG d
agen oes
7.8.1 Removing and installing selector unit, byV
olksw not
gu
ara
up! ed
ris nte
ho eo
aut ra
Special tools and workshop equipment required ss c
ce
le
un
pt
♦ Torque wrench - VAS 6583-
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
Removing
mer
atio
m
If installed above selector unit:

o
n
c
i
or
n
thi
te
sd
a

iv
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pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
• Gearbox in neutral position -arrows-. rig ht
py by
co Vo
by lksw
• The angled rod for adjusting the selector mechanism must be cted agen
Prote AG.
disengaged
– Remove securing clip -1- for gear selector cable -2- from gear‐
box selector lever.
– Remove relay lever -3- together with cable end-piece
⇒ page 71 .
– Remove gearbox selector lever by unscrewing nut -4-.

Polo 2014 ➤ , up! 2017 ➤
– Disconnect electrical connectors:

– If present: pull off connector -1- from gearbox neutral position
sender - G701- .
– Pull connector -2- off reversing light switch - F4- .
– Remove gearbox neutral position sender - G701- -1-.
– Install support bracket - 10-222 A- ⇒ page 79 .
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
– If fitted, remove earth wire -arrow- (illustration shows different

wit
, is n
gearbox).
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
c
– Remove hexagon bolt -arrow- for left-hand assembly mount‐

or
thi
e
ing from gearbox mounting.

t
sd
iva
o
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rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
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by Vol
gu
ara
Polo 2014 ➤ , up! 2017 ➤
d
orise 5-speed manualnte gearboxes
eo
02T and 0DF - Edition 11.2018
th
au ra
s c
– Lower engine/gearbox assembly via spindles of support
s
ce
bracket - 10-222 A- . e
nl
pt
du
an
itte
y li
• Make sure that drive shafts do not come into contact with sur‐
erm
ab
rounding components.
ility
ot p
wit
, is n
• Dimension -a- = approx. 50 mm
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Remove bolts -arrows-

– The adhesive effect of the sealant means that the selector unit
needs to be pulled off forcibly. Be careful of the air conditioner
lines where necessary.
– Clean all sealing surfaces.
– Cover gearbox.
Installing
• The selector shaft is in the neutral position (shown here with
the selector unit installed).
• Gearbox in neutral position
• All sealing surfaces are cleaned.
• Apply sealant evenly at several points to the sealing surfaces
of the selector unit.

Polo 2014 ➤ , up! 2017 ➤
– Insert selector unit and tighten with new bolts -arrows-

⇒ page 130 .
AG. Volkswagen AG d
agen oes
ksw
– Fit gearbox bracket -A- with new bolts ⇒ page 111 . by Vol not
gu
d ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
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itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Install new bolt -arrow- for left assembly mounting in gearbox
l purpos
mounting ⇒ page 111 .

nform
ercia

specified torque.
m
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
– Install pendulum support using new bolts ⇒ Rep. gr. 10 ; As‐
p by
co Vo
by lksw
sembly mountings; Assembly overview – assembly mount‐ Prote
cted AG.
agen
ings .

Polo 2014 ➤ , up! 2017 ➤
– If fitted, install gearbox neutral position sender - G701- -1-

⇒ page 130 .
– Fit electrical connectors:
– If present: fit connector -1- to gearbox neutral position sender
- G701- .
– Fit connector -2- to reversing light switch - F4- .
– Slightly pull on connector to ensure it is properly engaged.
– Install gearbox selector lever ⇒ page 62 .

– Tighten hexagon nut -4- ⇒ page 131 .
– Install gate relay lever -3- together with cable
AG. Volend-piece
kswagen AG
agen does
⇒ page 71 . Volksw not
y gu
db ara
– Spread a small amount ofrisgrease on pin of gearbox selector
e nte
lever. tho eo
au ra
c
ss
ce
le
un
pt
an
d
– Attach gear selector cable -2- to gearbox selector lever.

itte
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erm
ab
– Renew securing clip -1- after each removal.
ility
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wit
is n
h re
ole,
spec
t to the co
rrectne
necting battery .
– If removed, install engine cover panel and air filter ⇒ Rep. gr.
s
24 ; Air filter; Removing and installing air filter housing .

s o
cial p
f in
Specified torques
form
mer
♦ Selector unit to gearbox ⇒ page 130

atio
om
n
c
i
or
n thi
7.8.2 Removing and installing selector unit,

te
sd
iva
Polo
pr
cum
r
fo
en
ng
t.
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Co
Cop py
t. rig
gh
♦ Torque wrench - VAS 6583-
ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Polo 2014 ➤ , up! 2017 ➤
Removing
If installed above selector unit:
olkswagen AG
en AG. V
• The angled rod for adjusting the selector mechanism
olks
wag must be does
not
disengaged ed
byV gu
ara
ris nte
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aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
– Remove securing clip -1- for gear selector cable from gearbox
selector lever -B-.
rrectness of i
– Remove gate relay lever -A- together with cable end-piece
l purpos
⇒ page 71 .
nform
– Remove gearbox selector lever -B- by removing nut
ercia
-arrow 2-.
m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi
– Disconnect electrical connector:
Co
Cop py
ht. rig
Gearbox neutral position sender - G701- -2- rig ht
py by
co Vo
by lksw
Take no heed of reversing light switch - F4- -1-. cted agen
Prote AG.
– Remove bolts -arrows-

– The adhesive effect of the sealant means that the selector unit
needs to be pulled off forcibly. Be careful of the air conditioner
lines where necessary.
– Clean all sealing surfaces.
– Cover gearbox.

AG. Volkswagen AG d
ksw
agen oes
not
Polo 2014 ➤ , up! 2017 ➤
ol
d byV 5-speed manual gu gearboxes
ara 02T and 0DF - Edition 11.2018
ise nte
or eo
h
Installing s aut ra
c
s
• The selector shaft is in the neutral position (shown here with
ce
le
un
pt
the selector unit installed).
an
d
itte
y li
erm
ab
ility
ot p
wit
• All sealing surfaces are cleaned.
is n
h re
ole,
• Apply sealant evenly at several points to the sealing surfaces
spec
of the selector unit.
t to the co
rrectne
– Insert selector unit and tighten with new bolts -arrows-
ss
⇒ page 130 .
o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Install gearbox selector lever -B- ⇒ page 62 .
– Tighten hexagon nut -arrow 2- to specified torque
⇒ page 131 .
– Install gate relay lever -A- together with cable end-piece
⇒ page 71 .
– Spread small amount of grease on pin of gearbox selector
lever -B-.
– Attach gear selector cable to gearbox selector lever.
– Renew securing clip -arrow 1- after each removal.
– Fit electrical connector:

– If present: fit connector -2- to gearbox neutral position sender
- G701- .
– Slightly pull on connector to ensure it is properly engaged.
– Take no heed of connector -1- for reversing light switch - F4- .
necting battery .
– If removed, install engine cover panel and air filter ⇒ Rep. gr.
24 ; Air filter; Removing and installing air filter housing .
Specified torques
♦ Selector unit to gearbox ⇒ page 130
7.9 Repairing selector forks

Polo 2014 ➤ , up! 2017 ➤

equipment required
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
♦ Thrust plate - VW 402-

ility
ot p
wit
♦ Thrust piece - 3290/1-

, is n
h re
hole
♦ Assembly tool - 3301-

spec
es, in part or in w
♦ Thrust piece - VW 431-

t to the co
♦ Spacer sleeve - VW 472/2-

rrectness of i
♦ Drift - 10-206-
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
orise Polo 2014 n➤
tee , up! 2017 ➤
h
aut
5-speed manual gearboxes 02T and 0DF - Edition
or
ac 11.2018
ss
ce
e
nl
pt
du
an
♦ Release lever -
itte
y li
80-200-
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
♦ Assembly mandrel -
m
at
10-508-
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Tensioning device -
2070-
Identification of selector
segments and selector
fork for 5th gear with se‐
lector segments
Dimension -a-
1- Selector segment
for 1st and 2nd
gears = 10.35 mm
2- Selector segment
for 3rd and 4th
gears = 78.6 mm
3- 5th gear selector
fork with selector
segments =
79.5 mm

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
Polo 2014 ➤ , up! 2017 ➤ aut ra
c
s
5-speed manual gearboxes 02T and 0DF - Edition 11.2018 s
ce
e
nl
pt
du
an
itte
Selector fork for 1st and 2nd gears with selector segments
y li
erm
ab
Dimension -a- = 75 mm
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
or
Removing lock washer
m
m
atio
m
– Clamp selector fork in vice with protective jaw covers -B-.

o
n in
or c
thi
e
– Lever off lock washer -A- in -direction of arrow-.

t
sd
iva
o
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f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Installing lock washer

– Press lock washer into groove of detent segment using socket
and spinner handle.
Note
After lock washer is installed, detent segment must still rotate

freely.
A - Spinner handle with 10 mm socket

B - Protective jaw covers
Removing angular contact ball bearing
Note
When removing and installing angular contact ball bearing, do not

bend selector forks.

Polo 2014 ➤ , up! 2017 ➤
Pressing inner race -A- of angular contact ball bearing into outer
race
Inner race must engage in outer race.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
Pulling angular contact ball bearing into selector
orise fork to stop nte
th eo
u ra
Depression in thrust piece - 3290/1- sfaces
sa ball bearing. c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
7.10 Repairing selector unit
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Polo 2014 ➤ , up! 2017 ➤

equipment required
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Centring pin - 12-551-
♦ Drift - 2026-
♦ Thrust piece - T40008-
♦ Sealant
♦ Tube - T10203-
– Remove selector mechanism ⇒ page 130 .

Polo 2014 ➤ , up! 2017 ➤
Removing angled rod -A- from selector shaft cover

– Remove outer part of angled rod.
– Then carefully pry out angled rod using a screwdriver.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
Drive angled rod -A- into selector shaft cover

un
pt
an
d
itte
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Installation position:
rm
ab
pe
ility
Marking -1- aligns with marking -2- on selector cover.
ot
wit
, is n
h re
– Install selector mechanism ⇒ page 130 .
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
Driving out selector shaft sleeve -A-

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Driving in selector shaft sleeve -A- to stop

Polo 2014 ➤ , up! 2017 ➤
7.11 Renewing selector shaft seal

♦ Removal tool - T20143/1-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
♦ Tube - VW 423- ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
♦ Sealing grease
cial p
f inform

mer
atio
m
– Remove gearbox selector lever and gate relay lever

o
n
c
⇒ page 62 .
i
or
n thi
te
sd
a
– Lever seal out using a screwdriver.

iv
o
pr
cum
r
fo
or
en
ng
t.
yi Co
op
– Lever seal out as shown. C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Polo 2014 ➤ , up! 2017 ➤
– Lightly oil outer circumference of new oil seal.

– Half-fill space between sealing lip and dust lip -arrow- with
sealing grease .
Inserting oil seal -A- onto stop

– Install gearbox selector lever and gate relay lever
⇒ page 62 .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
o eo
7.12 Dismantling and assembling gearbox
h
aut ra
ss c
ce
e
Removing and installing gearbox housing cover, clutch housing,

nl
pt
du
an
selector shaft with selector mechanism cover, input shaft, output

itte
y li
shaft, differential and selector mechanism.

erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Polo 2014 ➤ , up! 2017 ➤
Special tools and workshop wage

es n
equipment required yV
olks ot g
ua
d b ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Support clamp - VW 313-

♦ Press tool - VW 412-
♦ Gearbox support - 3221A-
♦ or gearbox support - 3221- (modifying ⇒ page 119 )
♦ Guide pin - T10079-

Polo 2014 ➤ , up! 2017 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
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f
en
ng
t.
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Cop py
t. rig
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Prote AG.
♦ Not required: tube - VW 418 A-

♦ Thrust plate - 3074-
♦ Thrust block - T10083-
♦ Shim - T10083/1-
♦ Drip tray - V.A.G 1306-

Polo 2014 ➤ , up! 2017 ➤
♦ or drip tray for workshop hoist - VAS 6208-

♦ Sealant
Dismantling gearbox
– Secure gearbox to engine and gearbox support ⇒ page 118 .
– Remove clutch release lever -A- together with release bearing
and guide sleeve -arrows-.
Manual gearbox 02T
– Place drip tray underneath.
– Drain gear oil.
. Volkswagen AG
gen AG does
– Remove right flange shaft securing bolt V-B-.
olks
wa not
y gu
db ara
– Screw 2 bolts into flange and counter
ris hold
e flange shaft using nte
a lever. tho eo
au ra
c
ss
– Remove flange shaft along with spring, thrust washer and ta‐
ce
e
nl
pt
pered ring.
du
an
itte
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erm
ab
ility
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– Remove gearbox housing cover -arrow-.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
– Pull out pivot pin -1- for 5th gear -2- and remove selector fork.
on
c
in t
or
– Remove securing clip -3- for 5th gear synchro-hub.

his
ate
do
riv
– Remove retaining ring -4- for 5th gear wheel.

p
cum
for
en
ng
– Remove 5th gear synchro-hub and 5th gear wheel.

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Polo 2014 ➤ , up! 2017 ➤
– Remove bearing mounting securing bolts -A- from input and

output shafts.
– Unscrew hexagon collared nut -B- for securing reverse gear
selector mechanism.
Manual gearbox 02T
– Unscrew securing bolt for flange shaft -C- by screwing two
bolts into flange and counter-holding flange shaft with a lever.
– Pull out flange shaft -C- with spring.
– Turn gearbox in support bracket so that clutch housing is up‐
wards.
– Remove securing bolts from clutch housing side for securing
clutch housing to gearbox housing.
– Remove clutch housing, if necessary carefully levering up all
around along protruding housing flange and alternating be‐
tween sides, being careful not to damage sealing surfaces.
– Do not cant clutch housing in order to prevent damage to roller
bearings and their bearing
agen
Aseats
G. Volkson
wagthe
en Ainput
G do and output
shafts. Volksw es n
ot g
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db ran
rise tee
– Removeaudifferential
tho -A- from gearbox housing. or
ac
ss
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
– If fitted on gearbox, remove gearbox neutral position sender -

do
priv
G701- -arrow-.
um
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

Polo 2014 ➤ , up! 2017 ➤
– Remove selector shaft with selector cover -A-. Place selector

shaft in neutral. Then remove bolts -arrows- and pull selector
shaft out of gearbox housing.
– Remove pivot pins -B- located on underside of gearbox.
Gearbox for Polo
– Screw out reversing light switch - F4- -C-.
AG. Volkswagen AG d
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Continuation for all utho eo
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s
– Remove bolt -A- for securing reverse gear wheel shaft.
ce
e
nl
pt
du
an
– Remove pivot pins -B- located on bottom of gearbox.
itte
y li
erm
ab
ility
ot p
wit
Note
, is n
h re
hole
spec
Do not remove sealing cover -arrow- when dismantling gearbox.
es, in part or in w
t to the co
rrectness of i
– Press out input shaft, output shaft with bearing mounting, se‐
l purpos
lector mechanism (selector forks) and reverse gear together.
nform
ercia
Note
m
at
om
ion
c
♦ Position gearbox housing so that dowel sleeves in the gearbox in t

or
his
e
will not be damaged.

at
do
priv
♦ When pressing out, get help from second mechanic to ensure

um
for
en
components do not fall out.

ng
t.
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Cop py
t. rig
gh
– Press input shaft and output shaft off bearing mounting with
ht
pyri by
Vo
deep groove ball bearing ⇒ page 171 .
co lksw
by
cted agen
Prote AG.
Assembling gearbox
Note
♦ Press bearing mounting with deep groove ball bearing onto

input shaft and output shaft ⇒ page 175 .
♦ Press needle roller bearing sleeve for synchromeshed gear for
5th gear onto input shaft ⇒ page 175 .

Polo 2014 ➤ , up! 2017 ➤
– Position assembled components, input shaft -2- and output

shaft -1- with bearing mounting for deep groove ball bearing,
in thrust piece - T10085- .
– Insert selector mechanism (selector forks) -4- in the shaft lock‐
ing collars.
– Install reverse gear shaft -3- with reverse gear.
Installation position of reverse gear wheel: smooth side points
downwards, shoulder and »bevelled teeth« point to clutch end.
AG. Volkswagen AG d
agen oes
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d
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pe
ility
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– Screw guide pin - T10079- onto stud (secures reverse gear)
h re
-arrow-.
hole
spec
es, in part or in w
– Insert components together in gearbox housing. To do this,
t to the co
guide guide pin - T10079- through hole for attachment of se‐
lector mechanism in gearbox housing.
rrectness of i
– Remove guide pin - T10079- .
l purpos
Note the following before pressing in:
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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rp
cum
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
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by lksw
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Prote
♦ Selector forks engage correctly in locking collars.
AG.
♦ Check dimension -a- for output shaft teeth.
Note
♦ Due to different spline heights, dimension -a-, output shafts of

individual gearboxes have different lengths.
♦ A shim - T10083/1- (3 mm thick) may have to be fitted on the
input shaft to ensure that the input shaft and the output shaft
are always pressed in evenly.
♦ This is the reason why dimension -a- for output shaft teeth
must be measured.
Dimension -a- = 30.6 mm

Fit washer - T10083/1- onto input shaft ⇒ next figure.

Polo 2014 ➤ , up! 2017 ➤
Place shim - T10083/1- onto input shaft and carefully press in

bearing mounting together with input shaft and output shaft to
stop
AG. Volkswagen AG d
agen oes
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nl
pt
du
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itte
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ab
ility
ot p
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, is n
h re
hole
spec
es, in part or in w
t to the co
Carefully press in bearing mounting together with input shaft and
output shaft to stop.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
– Install bolt -A- for securing reverse gear wheel shaft.

t.
yi Co
Cop py
.
– Install pivot pin -B- in bottom of gearbox.
ht rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
Cap -arrow- is fitted.
– Install pivot pin -B- in top of gearbox.

– To do this, move selector shaft to neutral position.
– Apply sealant evenly to sealing surface of selector mechanism
cover.
– Install selector unit -A-. Then tighten bolts -arrows-.
Gearbox for Polo
– Screw in reversing light switch - F4- -C-.

Polo 2014 ➤ , up! 2017 ➤

– If removed, insert gearbox neutral position sender - G701-
-arrow- and tighten securing bolt to specified torque
⇒ page 130 .
– Using new bolts -A-, tighten bearing mounting for input and
output shafts.
Note
Tighten bolts to specified torque ⇒ Item 6 (page 130) , working

from centre outwards using alternate sequence.
– Tighten hexagon flange nut -B- for securing selector mecha‐

nism (selector forks).
– Install differential -A-.

– Apply sealant evenly to sealing surface.
– Secure clutch housing to gearbox housing.
– Turn gearbox in support bracket so that gearbox housing is
upwards.
AG. Volkswagen AG d
agen oes
olksw not
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hole
spec
es, in part or in w
t to the co
Installation position of gear wheel for 5th gear -1-:

rrectness of i
The high shoulder -arrow- faces gearbox housing cover.

l purpos
– Install gear wheel for 5th gear -1-.

– Install 5th gear synchromeshed gear with needle bearing.
nform
ercia
– Place 5th gear synchro-ring on synchromeshed gear.

m
a
com
tio
– Install 5th gear synchro-hub complete with locking collar and

n in
r
te o
stop ring.
thi
s
iva
do
– Insert 5th gear selector fork -2- and push in pivot pin -1- to stop
r
rp
cum
fo
in direction of -arrow-.
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Polo 2014 ➤ , up! 2017 ➤
Determine new retaining ring -arrow-.

– Determine thickest possible retaining rings which will still fit for
input shaft -3- and output shaft -4- and install them.
Available retaining rings ⇒ Electronic Parts Catalogue (ETKA)
Thickness (mm)
2.00 2.10
2.20
– Install gearbox housing cover. n AG. Volkswagen AG do
lkswage es n
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Manual gearbox 02T d b ua
ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
– Install both flange shafts with springs, thrust washers and ta‐
spec
pered rings.
t to the co
rrectne
Specified torques
ss o
♦ ⇒ “7.5 Assembly overview - shafts, differential, selector mech‐
cial p
f in
anism”, page 130
form
mer
atio
♦ Gearbox housing to clutch housing
om
⇒ “7.4 Assembly overview - clutch housing”, page 128 .
n
c
i
or
n thi
e
♦ Gearbox housing cover

t
sd
va
⇒ “7.3 Assembly overview - cover for gearbox housing and 5th

i
o
pr
cum
r
gear”, page 127 .

fo
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t.
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Manual gearbox 02T Cop py
t. rig
gh ht
yri
♦ Flange shaft to gearbox (countersunk bolt) p by
co Vo
lksw
⇒ “2.1 Assembly overview - differential”, page 196
by
cted agen
Prote AG.

Polo 2014 ➤ , up! 2017 ➤
8 Gearbox housing, clutch housing

⇒ “8.1 Assembly overview - gearbox housing and clutch housing”,
page 159
⇒ “8.2 Repairing clutch housing”, page 163
8.1 Assembly overview - gearbox housing

and clutch housing
⇒ “8.1.1 Assembly overview - gearbox housing and clutch hous‐
ing, manual gearbox 02T”, page 159
⇒ “8.1.2 Assembly overview - gearbox housing and clutch hous‐
ing, manual gearbox 0DF”, page 161
8.1.1 Assembly overview - gearbox housing and clutch housing, manual gearbox
02T
1 - Sleeve
⇒ page 147 agen
AG. Volkswagen AG d
oes
lksw not
❑ Driving in ⇒ page 147 by Vo gu
ara
d
ise nte
2 - Dowel sleeve uthor eo
a ra
s c
3 - Solenoid s
ce
le
un
pt
❑ Held in place by housing
an
d
itte
joint surface
y li
erm
ab
ility
4 - Cap
ot p
wit
is n
❑ Apply sealant before
h re
ole,
bolting on.
spec
t to the co
5 - Retaining ring
rrectne
❑ Insert in groove of cylin‐
drical roller bearing
ss
6 - Retaining ring
o
cial p
f i
❑ Insert in groove of cylin‐

nform
drical roller bearing

mer
atio
m
7 - Cylindrical roller bearing

o
n
c
i
or
❑ For input shaft

thi
te
sd
va
❑ Pulling out and pressing

i
o
pr
in ⇒ page 165
um
r
fo
en
ng
t.
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Co
Cop py
t. rig
❑ For output shaft
gh ht
pyri by
Vo
o
❑ Pulling out and pressing
c by lksw
cted agen
in ⇒ page 178
Prote AG.
9 - Clutch housing
❑ If renewed, adjust differ‐
ential ⇒ page 206
10 - Input shaft seal
11 - Ball-head pin
8. Gearbox housing, clutch housing 159

Polo 2014 ➤ , up! 2017 ➤
12 - Oil seal for right flange shaft

swage es n
13 - Sleeve yV
olk ot g
ua
d b ran
❑ For oil seal. o
ir se tee
th or
❑ Renew after removal ss
au ac
ce
e
nl
pt
du
an
itte
14 - Hydraulic fluid filler plug
y li
erm
ab
ility
ot p
wit
, is n
15 - Shim
h re
hole
❑ For differential
spec
❑ Determining thickness ⇒ page 206 es, in part or in w
t to the co
16 - Tapered roller bearing outer race
rrectness of i
❑ Pressing out of and into clutch housing ⇒ page 196
l purpos
❑ If renewed, adjust differential ⇒ page 206

17 - Bolt
nf
ercia
o
rm
m
atio
m

o
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
❑ Pulling out of and pressing into clutch housing ⇒ page 196
f
en
ng
t.
yi Co
❑ If renewed, adjust differential ⇒ page 206 t. Cop py
rig
gh ht
yri
19 - Dowel sleeve p by
co Vo
by lksw
cted agen
20 - Gearbox housing Prote AG.

21 - Oil drain plug
22 - Oil seal for left flange shaft

Polo 2014 ➤ , up! 2017 ➤
8.1.2 Assembly overview - gearbox housing and clutch housing, manual gearbox
0DF
AG. Volkswagen AG d
1 - Clutch housing agen oes
olksw not
V gu
by
❑ If renewed, adjust differ‐ rised ara
nte
ential ⇒ page 206 ut
ho eo
ra
s a c
2 - Input shaft seal s
ce
e
nl
pt
du
an
itte
⇒ page 176
y li
erm
ab
ility
3 - Ball-head pin ot p
wit
, is n
h re
⇒ page 24
hole
spec
es, in part or in w
4 - Seal for right drive shaft
t to the co
⇒ page 193
rrectness of i
5 - Hydraulic fluid filler plug
l purpos
⇒ page 116
nform
ercia
6 - Seal
m
at
7 - Plug
om
ion
c
in t
8 - Bolt
or
his
ate
do
priv
cum
for
en
g
ther
n
t.
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Cop py
9 - Baffle plate
t. rig
gh ht
pyri by
❑ Installation position:
o Vo
by c lksw
cted
⇒ page 198 .
agen
Prote AG.
10 - Shim
⇒ page 206
11 - Tapered roller bearing out‐
er race
12 - Bolt
14 - Dowel sleeve
15 - Gearbox housing
16 - Oil drain plug

Polo 2014 ➤ , up! 2017 ➤
agen
02T
AG. V and
olkswagen0DF
AG do- Edition 11.2018
w es n
olks ot g
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17 - Left drive shaftrisseal
ed
b ran
tee
ho
❑ Renew after au removal ⇒
t page 189 or
ac
ss
18 - Sleeve
ce
le
un
pt
an
d
itte
y li
rm
ab
❑ Driving out ⇒ Fig. ⇒ page 147
pe
ility
ot
wit
, is n
h re
19 - Solenoid
hole
spec
❑ Held in place by housing joint surface
es, in part or in w
t to the co
20 - Cap
❑ Apply sealant before bolting on.
rrectness of i
l purpos
21 - Retaining ring
❑ Insert in groove of cylindrical roller bearing
nform
ercia

m
a
❑ For output shaft
com
tion in
❑ Pulling out and pressing in ⇒ page 178
r
te o
thi
s
iva
do
23 - Retaining ring
r
rp
cum
fo
❑ Insert in groove of cylindrical roller bearing

en
ng
t.
yi Co
op
24 - Cylindrical roller bearing C py
ht. rig
rig ht
❑ For input shaft py by
co Vo
by lksw
❑ Pulling out and pressing in ⇒ page 165 cted agen
Prote AG.

Polo 2014 ➤ , up! 2017 ➤
8.2 Repairing clutch housing

equipment required
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Thrust piece - 30 - 555-
♦ Thrust piece - 3124-
♦ Spindle from assembly tool - 3066-
♦ Tools shown in illustration but not mentioned in text are not
required.

Polo 2014 ➤ , up! 2017 ➤
♦ Puller - VAS 251 417- , or e.g. puller - Kukko 18/1-
♦ Splitter - VAS 251

409- or e.g. splitter -
Kukko 17/1-
Pulling out sleeve for

seal
– Fit spacer sleeve -
VW 472/2- and press
tool - 30 - 555- onto
differential. AG. Volkswagen AG d
agen oes
ksw
A - Puller - VAS 251 by
Vol not
gu
ara
417- , or e.g. puller - Kuk‐ rised
nte
ko 18/1- ut
ho eo
ra
s a c
s
B - Splitter - VAS 251
ce
le
un
409- or e.g. splitter - Kuk‐

pt
an
d
ko 17/1-
itte
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rm
ab
pe
ility
Pulling in sleeve for seal

ot
wit
, is n
h re
A - Screw spindle from assembly device - 3066- into threaded

hole
spec
piece of differential.
es, in part or in w
t to the co
B - M12 nut with washer

– Pull in sleeve to stop using thrust piece - 3124- by turning nut
-B-.
rrectness of i
l purpos
Note
nform
ercia
With gearbox dismantled, press sleeve in to stop using thrust

m
piece - 3124- .
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
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t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Polo 2014 ➤ , up! 2017 ➤
35 – Gears, shafts
1 Input shaft
⇒ “1.1 Assembly overview - input shaft”, page 165
⇒ “1.2 Dismantling and assembling input shaft”, page 167
⇒ “1.3 Renewing input shaft seal”, page 176
1.1 Assembly overview - input shaft
Note
♦ When installing new gears or new input shaft, refer to ⇒ Electronic parts catalogue (ETKA) and technical
data.
♦ Install all bearings, synchromeshed gears and synchro-rings on input shaft with gear oil.
♦ Do not interchange synchro-rings. When reusing always fit to the original gear.
1 - Retaining ring
⇒ page 174
2 - 5th gear locking collar with
synchro-hub
❑ Removing and installing n AG. Volkswagen AG do
⇒ page 149 lkswage es n
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❑ Dismantling ir se
d ran
tee
⇒ page 175 utho
or
a ac
❑ Assembling 5th gear ss
ce
e
locking collar and syn‐

nl
pt
du
chro-hub ⇒ page 176 an

itte
y li
erm
ab
ility
⇒ page 175
ot p
wit
, is n

h re
hole
spec
❑ Check for wear

es, in part or in w
⇒ page 172
t to the co
4 - Synchromeshed gear, 5th

gear
rrectness of i
5 - Needle bearing
l purpos
❑ For 5th gear

❑ Renew together with
nform
ercia
sleeve
m
at
6 - Sleeve
om
ion
c
❑ For 5th gear needle

in t
or
bearing
his
ate
do
riv
❑ Renew together with

p
cum
or
needle bearing
f
en
ng
t.
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❑ Press off with bearing Cop py
support and deep
t. rig
gh ht
yri
groove ball bearing
p by
co Vo
by lksw
⇒ page 171 Prote
cted AG.
agen
❑ Pressing on ⇒ page 175
1. Input shaft 165

Polo 2014 ➤ , up! 2017 ➤
7 - Gearbox housing
8 - Bearing mounting with deep groove ball bearing
❑ Renew deep groove ball bearing only together with bearing support
❑ Pressing off ⇒ page 171
❑ Pressing on, from ⇒ page 174
9 - Input shaft
10 - Needle bearing
❑ For 3rd gear
11 - Synchromeshed gear for 3rd gear
12 - Synchro-ring for 3rd gear
❑ Check for wear ⇒ page 172
13 - Locking collar with synchro-hub for 3rd and 4th gear
❑ Press off with 3rd gear synchromeshed gear ⇒ page 171
❑ Dismantling ⇒ page 172
❑ Installation position, locking collar and synchro-hub ⇒ page 172
❑ Assembling ⇒ page 172 .
❑ Check for wear ⇒ page 172 lkswage es n
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byV ua
d
15 - Synchromeshed gear for 4th gear o
ir se
ran
tee
th or
u
16 - Sleeve ss
a ac
ce
le
❑ For 4th gear needle bearing

un
pt
an
d
❑ Renew together with needle bearing

itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
17 - Needle bearing
spec
❑ For 4th gear
t to the co
❑ Renew together with sleeve
18 - Thrust washer
rrectne
19 - Cylindrical roller bearing inner race
s
s o
cial p
f
❑ Pulling off is also possible ⇒ page 171
inform

mer
atio
m
20 - Retaining ring
o
n
c
i
or
❑ Renew
thi
te
sd
va
❑ Determining thickness ⇒ page 174

i
o
pr
cum
r
fo

en
ng
t.
yi Co
op
❑ With retaining ring C py
t. rig
gh ht
❑ Removing ⇒ page 170 yri
p by
co Vo
by lksw
❑ Pressing in ⇒ page 171 . cted agen
Prote AG.
❑ Installation position: retaining ring in bearing faces input shaft
22 - Clutch housing
23 - Spring
166 Rep. gr.35 - Gears, shafts

Polo 2014 ➤ , up! 2017 ➤
24 - 3rd and 4th gear locking collar

25 - 3rd and 4th gear synchro-hub
26 - Locking pieces (qty. 3)
27 - Spring
28 - Locking pieces (Qty. 3)
29 - Synchro-hub for 5th gear
30 - Locking collar for 5th gear
31 - Stop ring
❑ Prevents locking pieces from drifting out
❑ Remove ⇒ page 175
1.2 Dismantling and assembling input shaft

equipment required
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
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nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Input shaft 167

Polo 2014 ➤ , up! 2017 ➤

♦ Tube - VW 415 A-
♦ Tube - VW 422-
lkswage es n
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byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
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un
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an
d
itte
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ab
ility
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wit
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h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
m

o
n
c
i
or
♦ Tube - VW 516-
thi
te
sd
iva
♦ Extension - 30 - 23-
pr
cum
r
fo
en
ng
♦ Drift sleeve - 30 - 100-

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
c by lksw
cted agen
Prote AG.

Polo 2014 ➤ , up! 2017 ➤
lkswage es n
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byV ua
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ir se tee
tho
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a ac
ss
ce
e
nl
pt
du
an
itte
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erm
♦ Circlip pliers - VW 161 A-

ab
ility
ot p
♦ Tube - 2010-
wit
, is n
h re
♦ Thrust block - T10083-

hole
spec
es, in part or in w
♦ Washer - T10083/1-
t to the co
♦ Thrust plate - T10084A-

♦ -Feeler gauge-
rrectness of i
♦ Not applicable: -Kukko1-

l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Input shaft 169

. Volkswagen AG
Polo 2014 ➤ , up! 2017 ➤ wage
n AG does
olks not
5-speed manual gearboxes 02T and 0DF
d b- Edition 11.2018
y V gu
ara
e nte
ris
tho eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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r
rp
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f
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Internal puller - VAS 251 611- , or e.g. internal puller - Kukko

21/5-
♦ Counter support - VAS 251 623- , or e.g. counter support -
Kukko 22/2-
♦ Puller - VAS 251 417- , or e.g. puller - Kukko 18/1-
♦ Splitter - VAS 251 409- or e.g. splitter - Kukko 17/1-
Pulling cylindrical roller bearing out of clutch housing
– When pulling out, squeeze together retaining ring -arrow- of
cylindrical roller bearing, using pliers -C-.
A - Counter support - VAS 251 623- , or e.g. counter support -
Kukko 22/2-
B - Internal puller - VAS 251 611- , or e.g. internal puller - Kukko
21/5-

Polo 2014 ➤ , up! 2017 ➤
Pressing cylindrical roller bearing into clutch housing

– Support gearbox housing with tube - VW 415 A- (not visible in
figure) directly below bearing support.
– When pressing in, squeeze together retaining ring -arrow- for
cylindrical roller bearing using pliers -A-.
– Remove pliers before cylindrical roller bearing is in installation
position. Retaining ring must engage in groove of clutch hous‐
ing.
AG. Volkswagen AG d
es n agen o
Pressing off bearing
yV
olks mounting with deep groove
w
ot gball bearing
b ua
ed ra
– Slide locking
ho
ris collar for 1st and 2nd gear towards 2nd
nte gear.
e
t or
au a
– Then
ss slide thrust plate - T10084/A- sideways onto input
c shaft
to stop.
ce
le
un
pt
an
d
itte
– Insert centring pins in thrust piece - T10081- into holes in input
y li
erm
ab
and output shafts.
ility
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wit
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ole,
spec
t to the co
Press off cylindrical roller bearing inner race together with thrust
rrectne
washer, 4th gear synchromeshed gear with needle bearing, lock‐

ing collar and synchro-hub for 3rd and 4th gear and 3rd gear
synchromeshed gear.
ss o
cial p
– First remove retaining ring with snap ring pliers - VW 161 A- .

inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
ht. rig
Inner race for cylindrical roller bearing can also be pulled off to‐
rig ht
py by
o Vo
gether with synchromeshed gear for 4th gear only
by c lksw
cted agen
Prote AG.
– First remove retaining ring with snap ring pliers - VW 161 A- .
– Position splitter -B- behind teeth of synchromeshed gear for
4th gear which engage in the other gear wheel (not dog teeth)
and tension.
A - Puller - VAS 251 417- , or e.g. puller - Kukko 18/1-
B - Splitter - VAS 251 409- or e.g. splitter - Kukko 17/1-
C - Protective jaw covers
1. Input shaft 171

Polo 2014 ➤ , up! 2017 ➤
Dismantling and assembling 3rd and 4th gear locking collar and
synchro-hub
1- Spring
2- Sliding sleeve
3- Synchro-hub
4- Locking piece
– Slide locking collar over synchro-hub.
Deeper notches -arrow A- for locking pieces in synchro-hub and
notches -arrow B- in locking collar must align.
AG. Volkswagen AG d
agen oes
olksw not
Assembling locking collar and synchro-hub for 3rd and 4th gearsed by V gu
ara
ris nte
o
• Locking collar has been pushed over synchro-hub. aut
h eo
ra
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– Insert locking pieces in deeper notches -arrows- and install
ce
e
nl
pt
springs offset 120°. Angled end of spring must locate in hollow
du
an
itte
locking piece.
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erm
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ility
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hole
spec
es, in part or in w
t to the co
Installation position of locking collar with synchro-hub for 3rd and
rrectness of i
4th gears
l purpos
If present, groove on face -arrow- is towards 4th gear.

High collar faces 3rd gear.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
Checking synchro-ring for wear
op Vo
by c lksw
cted agen
Prote AG.
– Press synchro-ring onto cone of synchromeshed gear and
measure gap -a- using feeler gauge.
– Measure gap size -a- at 3 points offset by 120° using feeler
gauge.
– Make a note of average value.
Gap -a- Installation dimen‐ Wear limit
sion
3rd, 4th and 5th 1.1…1.7 mm 0.5 mm
gear

Polo 2014 ➤ , up! 2017 ➤
Pressing on synchro-hub with locking collar for 3rd and 4th gears
If present, groove on face of locking collar faces towards 4th gear.
High collar of synchro-hub faces 3rd gear.
Pressing on sleeve -A- for 4th gear needle bearing

– After pressing on sleeve -A-, fit 4th gear needle bearing, 4th
gear synchro-ring with synchromeshed gear and thrust wash‐
er.
AG. Volkswagen AG d
agen oes
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Pressing on inner race -A- for cylindrical
d by V roller bearing gu
ara
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or eo
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aut ra
ss c
ce
e
nl
pt
du
an
itte
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ab
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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en
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t.
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Cop py
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py by
co Vo
by lksw
cted agen
Prote AG.
1. Input shaft 173

Polo 2014 ➤ , up! 2017 ➤ olkswagen AG
en AG. V
5-speed manual gearboxes 02T and 0DF - Edition 11.2018 Volkswag does
not
by gu
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Determining thickness of retaining ring oris eo
th
au ra
c
– Insert a 2.0 mm thick retaining ring -A- in groove of inputss shaft
ce
le
and press upwards -arrow-.
un
pt
an
d
itte
y li
– Measure distance between inner race -B- and installed retain‐
erm
ab
ing ring-A- using feeler gauge -C-.
ility
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wit
– Remove retaining ring (only used for measuring purposes).
is n
h re
ole,
– Determine retaining ring from table.
spec
t to the co
Note
rrectne
Allocate retaining rings using ⇒ Electronic parts catalogue (ET‐
KA) .
ss o
cial p
f
The following securing clips are available:
inform
mer
Measured value Retaining ring thick‐ Axial play (mm)
atio
m
(mm) ness (mm)

o
n
c
i
or
n
0.05...0.14 2.0 0.05...0.15
thi
te
sd
va
0.15...0.24 2.1 0.05...0.15

i
o
pr
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fo
0.25...0.34 2.2 0.05...0.15
en
ng
t.
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op
0.35...0.44 2.3 0.05...0.15 C py
ht. rig
rig ht
0.45...0.51 2.4 0.05...0.10 py by
co Vo
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Prote
Press bearing mounting with deep groove ball bearing onto input
AG.
shaft and output shaft.
Note
♦ Due to different spline heights, dimension -a-, output shafts of

individual gearboxes have different lengths (shown here with
shafts installed).
♦ To ensure that bearing support is always evenly pressed onto
shafts, it is necessary for shafts always to be inserted evenly
into thrust block - T10083- .
♦ If necessary, insert a shim - T10083/1- (3 mm thick) into
mounting hole for input shaft ⇒ page 174 .
♦ This is the reason why dimension -a- for output shaft teeth
must be measured.
Dimension -a- = 30.6 mm

Insert shim - T10083/1- ⇒ next figure.
Fit shim - T10083/1- .

Polo 2014 ➤ , up! 2017 ➤
Pressing on bearing support

– Heat inner bearing mounting to approx. 100 °C before press‐
ing on.
WARNING
lkswage es n
o ot g
Wear protective gloves. ed by V ua
ran
ir s tee
tho
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a ac
ss
ce
le
un
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an
d
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ab
pe
ility
Pressing on sleeve -A- for 5th gear needle bearing
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tio
Removing stop ring
n in
r
te o
thi
– Using a screwdriver, unclip hooks -A- of check ring from syn‐
s
iva
chro-hub. do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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by
cted agen
Prote AG.
Dismantling and assembling 5th gear locking collar and synchro-

hub
1- Spring
2- Locking piece
3- Synchro-hub installation position: groove on face
-arrow A- and wide shoulder -arrow B- must face 5th gear.
4- Sliding sleeve
5- Stop ring
Deeper notches -arrow C- for locking pieces in synchro-hub and
notches -arrow D- in locking collar must align.
1. Input shaft 175

Polo 2014 ➤ , up! 2017 ➤
Assembling 5th gear locking collar/synchro-hub

• Locking collar has been pushed over synchro-hub.
– Insert locking pieces in deeper notches -arrows- and install
locking piece.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
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aut ra
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ce
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Installing stop ring
un
pt
an
d
itte
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– Press on stop ring using tube - 2010- .
erm
ab
ility
ot p
– Insert stop ring together with tube - 2010- into 5th gear syn‐
wit
is n
chro-hub/locking collar (observe installation position
h re
ole,
⇒ page 175 ).
spec
The hooks -arrow 1- lock in the recess -arrow 2- of the synchro-
t to the co
hub locking pieces.
– Press stop ring downwards until hooks engage.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
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fo
en
ng
1.3 Renewing input shaft seal

t.
yi Co
Cop py
t. rig
gh
ht
pyri by
Vo
o
by c lksw
cted
♦ Removal tool - T20143/1-
agen
Prote AG.

Polo 2014 ➤ , up! 2017 ➤
♦ Sealing grease
– Remove manual gearbox.
and guide sleeve ⇒ page
gen AG
51
. Vo.lkswagen AG
d a oes
lksw not
– Lever out input
db
y V shaft seal.
o gu
ara
e nte
ris
tho eo
au ra
c
Note
ss
ce
e
nl
pt
du
an
Do not damage oil seal running surface on input shaft.

itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
– Half-fill space between sealing lip and dust lip of new seal with
rrectness of i
sealing grease .
l purpos
– Lightly moisten outer circumference of oil seal with gear oil.

nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
Driving in input shaft oil seal flush
op Vo
by c lksw
cted agen
Prote
AG.

– Install manual gearbox.
1. Input shaft 177

Polo 2014 ➤ , up! 2017 ➤
2 Output shaft
⇒ “2.1 Assembly overview - output shaft”, page 178
⇒ “2.2 Dismantling and assembling output shaft”, page 180
2.1 Assembly overview - output shaft agen

AG. Volkswagen AG d
oes
olksw not
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rise nte
Note utho eo
ra
s a c
s
♦ When installing new gears or new input shaft, refer to ⇒ Electronic parts catalogue (ETKA) and technical
ce
e
nl
pt
du
data.
an
itte
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erm
ab
♦ Install all bearings, synchromeshed gears and synchro-rings on output shaft with gear oil.
ility
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♦ Do not interchange synchro-rings. When reusing always fit to the original gear.
wit
, is n
h re
hole
spec
es, in part or in w
1 - Clutch housing
t to the co
rrectness of i
❑ With retaining ring
l purpos

❑ Pressing in
nf
ercia
o
⇒ page 182 .
rm
m
atio
❑ Installation position: re‐
om
n in
taining ring in bearing
or c
faces output shaft
thi
te
sd
iva
o
r
3 - Output shaft
rp
cu
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m
f
en
ng
❑ If an inner race as bear‐

t.
yi Co
ing seat for cylindrical t. Cop py
roller bearing is present,
rig
gh ht
yri by
it cannot be removed cop Vo
by lksw
from output shaft cted agen
Prote AG.
❑ Check bearing seat or
inner race of cylindrical
roller bearing for scoring
and damage
❑ If cylindrical roller bear‐
ing inner race or bearing
seat is damaged or
scored, renew output
shaft and cylindrical roll‐
er bearing together
shoulder faces 3rd gear
⇒ page 182
5 - Retaining ring
6 - Retaining ring
7 - Gear wheel for 3rd gear
❑ Installation position: shoulder faces 4th gear ⇒ page 182
8 - Retaining ring

Polo 2014 ➤ , up! 2017 ➤
9 - Synchromeshed gear, 2nd gear

10 - Needle bearing AG. Volkswagen AG d
agen oes
❑ For 2nd gear Volksw not
gu
d by ara
e
11 - Inner ring for 2nd gear horis nte
eo
ut
❑ Check lugs for scoring ss a ra
c
ce
le
un
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an
d
❑ Checking synchro-ring, outer ring and inner ring together for wear ⇒ page 183
itte
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erm
ab
12 - Outer bearing race for 2nd gear
ility
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wit
is n
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ole,
❑ Renew if scored
spec
t to the co
13 - Synchro-ring for 2nd gear
rrectne
14 - Locking collar with synchro-hub for 1st and 2nd gear
ss o
cial p
❑ After removing retaining ring, press off with 2nd gear synchromeshed gear ⇒ page 182
f inform
❑ Dismantling ⇒ page 183
mer
atio
❑ Assembling locking collar and synchro-hub ⇒ page 183 and ⇒ page 184
om
n
c
i
or
n thi
te
sd
iva
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pr
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r
15 - Retaining ring
fo
en
ng
t.
yi
❑ Pressing out ⇒ page 182
Co
Cop py
t. rig
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pyri by
Vo
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by c lksw
16 - Synchro-ring for 1st gear Prote
cted AG.
agen
❑ Assemble so that notches engage in locking pieces of locking collar.
17 - Outer ring for 1st gear
❑ Check for scoring or signs of abnormal wear
❑ Insert in synchro-ring
18 - Inner ring for 1st gear
❑ Check lugs for scoring
19 - Needle bearing
❑ For 1st gear
20 - Synchromeshed gear, 1st gear
21 - Bearing mounting with deep groove ball bearing
❑ Renew deep groove ball bearing only together with bearing mounting
2. Output shaft 179

Polo 2014 ➤ , up! 2017 ➤

❑ Installation position: shoulder faces gearbox housing cover ⇒ page 157
24 - Retaining ring
❑ Renew after removal olkswage es n
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yV
sed b ⇒ page 158 ua
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ho
25 - Spring au
t or
ac
ss
ce
le
un
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26 - Sliding sleeve
itte
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erm
ab
27 - Synchro-hub
ility
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28 - Locking pieces (qty. 3)
h re
ole,
spec
t to the co
2.2 Dismantling and assembling output shaft
rrectne
equipment required
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.


Polo 2014 ➤ , up! 2017 ➤
♦ Tube - VW 415 A-

21/5-
♦ Counter support -
VAS 251 621- , or e.g.
counter support -
Kukko 22/1-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
or
Pulling cylindrical roller au ac
ss
bearing out of clutch ce
le
housing
un
pt
an
d
itte
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– When pulling out,
erm
ab
squeeze together re‐
ility
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taining ring -arrow- of

wit
is n
cylindrical roller bear‐

h re
ole,
ing, using pliers -C-.

spec
A - Counter support -
t to the co
VAS 251 621- , or e.g.

counter support - Kukko
22/1-
rrectne
B - Internal puller - VAS

251 611- , or e.g. internal
ss o
puller - Kukko 21/5-

cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Output shaft 181

Polo 2014 ➤ , up! 2017 ➤
Pressing cylindrical roller bearing into clutch housing

– Support gearbox housing with tube - VW 415 A- (not visible in
figure) directly below bearing support.
– When pressing in, squeeze together retaining ring -arrow- for
cylindrical roller bearing using pliers -A-.
– Remove pliers before cylindrical roller bearing is in installation
position. Retaining ring must engage in groove of clutch hous‐
ing.
Pressing retaining ring -1- out of groove

A - Protective gloves
WARNING
AG. Volkswagen AG d
agen oes
olksw not
Ensure retaining ring does not spring out uncontrolled. ed byV gu
ara
ris nte
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aut ra
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ce
le
un
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an
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ab
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ility
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wit
Pressing off 1st and 2nd gear locking collar and synchro-hub
, is n
h re
hole
– After removing retaining ring, press off synchromeshed gear
spec
for 2nd gear together with locking collar and synchro-hub.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
Installation position of 3rd gear and 4th gear
r
te o
thi
s
iva
– Install gear wheel for 4th gear -A- on output shaft. do

r
rp
cum
fo
en
ng
t.
yi Co
op py
Collar -arrow 1- faces 3rd gear wheel -B-. . C rig
ht ht
rig by
py
– Install retaining rings -2- and -3-.
co Vo
by lksw
cted agen
Prote AG.
– Install gear wheel for 3rd gear -B- on output shaft.
Collar -arrow 2- faces gear wheel for 4th gear -A-.
– Install retaining ring -1-.

AG. Volkswagen AG d
agen oes
olksw not Polo 2014 ➤ , up! 2017 ➤
byV gu
ara
rised
5-speed manual gearboxes nte 02T and 0DF - Edition 11.2018
ho eo
aut ra
Checking 1st and 2nd gear synchro-ring, outer ring and inner ring ss c
ce
e
together for wear
nl
pt
du
an
itte
– Place synchro-ring, outer ring and inner ring on cone of syn‐
y li
erm
ab
chromeshed gear.
ility
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wit
– »While pressing«, measure gap size -a- at 3 points offset by
, is n
h re
120° using feeler gauge.
hole
spec
– Make a note of average value.
es, in part or in w
t to the co
Gap “a” Installation dimen‐ Wear limit
sion
rrectness of i
1st and 2nd gears 1.1 - 1.8 mm 0.5 mm
l purpos
Note
nf
ercia
orm
m
Always renew inner ring, outer ring and synchro-ring together.
atio
om
n in
or c
thi
te
sd
Installation position of outer ring, inner ring and synchro-ring for
iva
o
r
2nd gear
rp
cu
o
m
f
en
ng
– Place inner ring -A- on 2nd gear synchromeshed gear.

t.
yi Co
Cop py
ht. rig
Angled lugs -arrow 1- face outer ring -B-. opy
rig by
Vo
ht
c lksw
– Fit outer ring -B-.
by
cted agen
Prote AG.
Lugs -arrow 2- engage in notches -arrow 3- of synchromeshed

gear.
– Fit synchro-ring -C-.
Notches -arrow 4- engage in lugs -arrow 1- of inner race -A-.
Dismantling and assembling locking collar and synchro-hub for

1st and 2nd gears
1- Spring
2- Sliding sleeve
3- Synchro-hub
4- Locking piece
After assembly, the groove on the face -arrow A- and the higher
shoulder -arrow B- of synchro-hub face outer splines of the lock‐
ing collar -arrow C-.
Deeper notches -arrow D- for locking pieces in synchro-hub and
notches -arrow E- in locking collar must align.
2. Output shaft 183

Polo 2014 ➤ , up! 2017 ➤
Assembling locking collar with synchro-hub for 1st and 2nd gears
• Locking collar has been pushed over synchro-hub.
– Insert locking pieces in deeper cut-outs -arrows- and install
locking piece.
Pressing on locking collar and synchro-hub for 1st and 2nd gears
Groove in locking collar for selector fork faces 1st gear and teeth
for reverse gear face 2nd gear.
– Turn synchro-ring so that grooves align with locking pieces.
Fitting retaining ring

– Place 1st gear synchro-ring in locking collar/synchro-hub.
n AG. Volkswagen A age G do
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ara
d
5-speed
orise manual gearboxes 02T and 0DF - Edition
nte
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th
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Installation position of 1st gear inner ring -A-
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Higher shoulder -A- faces 2nd gear -B-. Notches in shoulder
form
mer
-arrows- engage in lugs of outer ring ⇒ page 184 .
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2. Output shaft 185

Polo 2014 ➤ , up! 2017 ➤
39 – Final drive - differential

1 Oil seals
⇒ “1.1 Overview of fitting locations - seals”, page 186
⇒ “1.2 Renewing left seal”, page 187
⇒ “1.3 Renewing right oil seal”, page 191
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❑ Manual gearbox 0DF:
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for right flange shaft
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⇒ page 191
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3 - Seal
❑ Manual gearbox 02T:
for left flange shaft
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❑ Manual gearbox 0DF:

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186 Rep. gr.39 - Final drive - differential

Polo 2014 ➤ , up! 2017 ➤
1.2 Renewing left seal

⇒ “1.2.1 Renewing oil seal for left flange shaft, manual gearbox
02T”, page 187
⇒ “1.2.2 Renewing oil seal for left flange shaft, manual gearbox
0DF”, page 189
1.2.1 Renewing oil seal for left flange shaft, manual gearbox 02T

equipment required
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1. Oil seals 187

Polo 2014 ➤ , up! 2017 ➤
Removing
– Remove wheel.
– Turn steering to left lock.
– Unbolt drive shaft from flange shaft ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Drive shaft; Removing wand
geninstalling
AG. Volkswagen AG d
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drive shaft . yV
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– Remove coupling rod -1- from anti-roll
tho
ris bar ⇒ Running gear, e or
axles, steering; Rep. gr. 40 ; Subframe;
au Assembly overview – ac
ss
subframe .
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le
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– Unscrew nuts -arrows- for swivel joint on suspension link ⇒
rrectne
– Swing wheel bearing housing outwards.
ss
– Pull out left drive shaft between subframe and gearbox.
o
cial p
f in
– When doing this, guide drive shaft into wheel housing and se‐
form
mer
cure to suspension strut with wire. Take care not to damage
atio
paint on drive shaft in the process.
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– Place drip tray under gearbox.
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– Pull out flange shaft with compression spring. by c lksw
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– Remove flange shaft oil seal.

Polo 2014 ➤ , up! 2017 ➤
Installing
– Drive in new seal to stop, being careful not to cant seal.
– Half-fill space between sealing lip and dust lip with sealing
grease .
– Insert flange shaft.
– Press flange shaft against gearbox and secure.
– Install drive shaft ⇒ Running gear, axles, steering; Rep. gr.

40 ; Drive shaft; Removing and installing drive shaft .
– Install coupling rod -1- ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Subframe; Assembly overview – subframe .
– Check gear oil level and top up to lower edge of oil filler hole
if necessary ⇒ page 115 .
gr. 66 ; Noise insulation .
– Attach wheel ⇒ Running gear, axles, steering; Rep. gr. 44 ;
Wheels, tyres; Specified torque for wheel bolts .
Specified torques
♦ Flange shaft to gearbox ⇒ page 196
G. Volkswagen
1.2.2 Renewing oil seal for left flange shaft,
olks
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1. Oil seals 189

Polo 2014 ➤ , up! 2017 ➤

equipment required
AG. Volkswagen AG d
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Prote AG.

Polo 2014 ➤ , up! 2017 ➤
Removing
The drive shaft must be removed in a later step.
– With vehicle standing on its wheels, loosen front flange bolt
– Remove wheel.
– Remove drive shaft ⇒ Running gear, axles, steering; Rep. gr.
– Pull out drive shaft seal.
Installing
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– Half-fill space between sealing lip and agdust
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– Install drive shaft ⇒ Running
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ri gear, axles, steering; Rep. gr. e
40 ; Drive shaft; Removing
aut and installing drive shaft . or
ac
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– Attach wheel ⇒ Running gear, axles, steering; Rep. gr. 44 ;

hole
spec
Wheels, tyres; Specified torque for wheel bolts .

es, in part or in w
t to the co
1.3 Renewing right oil seal

rrectness of i
⇒ “1.3.1 Renewing oil seal for right flange shaft, manual gearbox
02T”, page 191
l purpos
⇒ “1.3.2 Renewing oil seal for right flange shaft, manual gearbox
0DF”, page 193
nform
ercia
1.3.1 Renewing oil seal for right flange shaft, manual gearbox 02T
m
at
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c
in t
or
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ate
do
priv
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for
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t.
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Prote AG.
1. Oil seals 191

Polo 2014 ➤ , up! 2017 ➤

equipment required
AG. Volkswagen AG d
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olksw not
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spec
♦ Multi-purpose tool - VW 771- t to the co

rrectne
ss o
cial p
♦ Drift sleeve - 3158-

inform
mer

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Co
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Removing yri
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co Vo
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agen
Prote AG.
– Turn steering to right to full lock.
– Unbolt drive shaft from flange shaft ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Drive shaft; Removing and installing
drive shaft .
– Raise drive shaft as high as possible and secure, taking care
not to damage surfaces.

Polo 2014 ➤ , up! 2017 ➤

– Remove flange shaft securing bolts. Screw 2 bolts into flange
and counter hold flange shaft using a lever.
– Pull out flange shaft with compression spring. If necessary,
unscrew engine/gearbox securing bolt in area of flange shaft.
– Remove flange shaft oil seal.

AG. Volkswagen AG d
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♦ Do not damage sleeve -A-. Otherwise, leaks will occur.
s a c
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♦ Renew sleeve if damaged ⇒ page 164 and ⇒ page 164 .
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Installing
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grease .
l purpos
– Insert flange shaft.

nform
ercia
– Press flange shaft against gearbox and secure.

m
at
om
– If removed, reinstall engine/gearbox connecting bolt in area of

ion
c
flange shaft ⇒ page 110 .

in t
or
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ate
– Install drive shaft to flange shaft ⇒ Running gear, axles, steer‐

do
riv
ing; Rep. gr. 40 ; Drive shaft; Removing and installing drive

p
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for
shaft .
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C py
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Prote AG.
Specified torques
♦ Flange shaft to gearbox ⇒ page 196
1.3.2 Renewing oil seal for right flange shaft, manual gearbox 0DF
1. Oil seals 193

Polo 2014 ➤ , up! 2017 ➤
Special tools and workshop agen

AG. Volkswagen AG d
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Cop py
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co Vo
by lksw
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Prote AG.

♦ Sealing grease

Polo 2014 ➤ , up! 2017 ➤
Removing
The drive shaft must be removed in a later step.
– With vehicle standing on its wheels, loosen front flange bolt
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– Remove noise insulation Vol ⇒ General body repairs, exterior;
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Rep. gr. 66 ; Noise
ed insulation
by . ara
n is tee
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– Place drip tray
au under gearbox.
th or
ac
ss
– Remove drive shaft ⇒ Running gear, axles, steering; Rep. gr.
ce
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nl
pt
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ab
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– Pull out drive shaft seal.
wit
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rrectness of i
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mercia
at
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c
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in t
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– Half-fill space between sealing lip and dust lip with sealing
f
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grease . Cop
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– Install drive shaft ⇒ Running gear, axles, steering; Rep. gr. gh ht
yri by
40 ; Drive shaft; Removing and installing drive shafts . cop Vo
by lksw
cted agen
Prote AG.
1. Oil seals 195

AG. Volkswagen AG d
agen oes
olksw not
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Polo 2014 ➤ , up! 2017 ➤ ho ris nte
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5-speed manual gearboxess au 02T and 0DF - Edition 11.2018 ra
c
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2 Differential
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⇒ “2.1 Assembly overview - differential”, page 196
wit
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⇒ “2.2 Dismantling and assembling differential”, page 199
hole
spec
⇒ “2.3 Adjusting differential”, page 206
es, in part or in w
t to the co
2.1 Assembly overview - differential
⇒ “2.1.1 Assembly overview - differential housing, manual gear‐
rrectness of i
box 02T”, page 196
l purpos
⇒ “2.1.2 Assembly overview - differential housing, manual gear‐

box 0DF”, page 198
nform
ercia
2.1.1 Assembly overview - differential housing, manual gearbox 02T

m
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c
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p
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❑ 25 Nm
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2 - Right flange shaft
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flange shaft
agen
Prote AG.
❑ Installed behind flange

shafts
4 - Thrust washer
shoulder towards spring
5 - Tapered ring
taper towards differen‐
tial cage
6 - Retaining ring
❑ Holds tapered ring,
thrust washer and
spring in position when
flange shaft is removed
7 - Left flange shaft
8 - Oil seal for left flange shaft
⇒ page 187
9 - Tapered roller bearing outer
race
❑ Pressing in
⇒ page 203 .
10 - Tapered roller bearing in‐
ner race
❑ Pulling off ⇒ page 203
11 - Differential cage
❑ With differential bevel gears, one-piece thrust washer, differential pinion pin and final drive gear
❑ Removing differential bevel gears, one-piece thrust washer and differential pinion pin ⇒ page 206
❑ Installing differential bevel gears, one-piece thrust washer and differential pinion pin ⇒ page 206

Polo 2014 ➤ , up! 2017 ➤
12 - Tapered roller bearing inner race

❑ Pressing out ⇒ page 204 .
❑ Pressing in ⇒ page 204 .
14 - Shim
15 - Oil seal for right flange shaft
❑ The seal is located in a sleeve
⇒ “8.1.1 Assembly overview - gearbox housing and clutch housing, manual gearbox 02T”, page 159
❑ Renew seal after each removal ⇒ page 191
❑ Renew sleeve after each removal ⇒ page 163
16 - Clutch housing
❑ ⇒ “8 Gearbox housing, clutch housing”, page 159
AG. Volkswagen AG d
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2. Differential 197
Polo 2014 ➤ , up! 2017 ➤
2.1.2 Assembly overview - differential housing, manual gearbox 0DF
1 - Left drive shaft seal

⇒ page 189
2 - Gearbox housing
❑ ⇒ “8 Gearbox housing,
clutch housing”,
page 159
3 - Baffle plate
❑ Shoulder points away
from housing
race
❑ Removing ⇒ page 203 AG. Volkswagen AG d
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❑ Pressing in ed byV gu
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❑ Pressing on
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⇒ page 204
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6 - Differential
ole,
spec
❑ With final drive gear
t to the co
7 - Tapered roller bearing inner

race
rrectne
❑ Pressing on
⇒ page 205
ss o
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inform
race
mer
❑ Pressing out
atio
m
⇒ page 204 .
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❑ Pressing in ⇒ page 204 .

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10 - Baffle plate co Vo
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Prote AG.
❑ Shoulder points away from housing

11 - Clutch housing
12 - Seal for right drive shaft

Polo 2014 ➤ , up! 2017 ➤
2.2 Dismantling and assembling differential

equipment required
AG. Volkswagen AG d
agen oes
olksw not
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♦ Press tool - VW 408 A-

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♦ Tube - VW 418 A-
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2. Differential 199
Polo 2014 ➤ , up! 2017 ➤
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♦ Tube - 2040-
♦ Thrust piece - 3002-
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Cop py
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Prote AG.

Polo 2014 ➤ , up! 2017 ➤
AG. Volkswagen AG d
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olksw not
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Prote AG.
♦ Counter-hold tool - 3067-

♦ Tube - 3259-
♦ Tube for wheel bearing - 3345-
♦ Tapered roller bearing puller - V.A.G 1582-
♦ Grip tool - V.A.G 1582/4-
♦ Do not apply: tools 1-4

21/7-
2. Differential 201
Polo 2014 ➤ , up! 2017 ➤
♦ Counter support - VAS 251 623- , or e.g. counter support -

Kukko 22/2- AG. Volkswagen AG d
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Cop py
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by c lksw
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Prote AG.
♦ Thrust plate - 30 - 205-

♦ Torque wrench - V.A.G 1331- (5…50 Nm)
♦ Grip tool - V.A.G 1582/3-

Polo 2014 ➤ , up! 2017 ➤
AG. Volkswagen AG d
agen oes
Note Volksw not
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♦ Heat tapered roller bearing inner races to 100 °C before
ut
ho in‐ eo
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ce
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♦ Always renew both tapered roller bearings together as a set.
un
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♦ If tapered roller bearings, differential cage, gearbox housing
erm
ab
or clutch housing is renewed, adjust differential ⇒ page 206 .
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Pulling outer race for tapered roller bearing out of gearbox hous‐
ole,
spec
ing
t to the co
A - Counter support - VAS 251 623- , or e.g. counter support -
Kukko 22/2-
rrectne
21/7-
s
Manual gearbox 0DF
s o
cial p
f inform
Insert new baffle plate
mer
atio
Installation position: shoulder -arrow- faces away from housing
om
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cted agen
Prote AG.
Pressing tapered roller bearing outer race into gearbox housing

– Support gearbox housing with tube - 3259- directly below
bearing support.
Pulling off tapered roller bearing inner races
2. Differential 203
Polo 2014 ➤ , up! 2017 ➤
. Volkswagen AG
a gen AG does
Pressing on tapered roller bearing inner
Vol races
ksw not
gu
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ed nte
oris eo
WARNING au
th ra
ss c
ce
le
Wear protective gloves.
un
pt
an
d
itte
y li
erm
ab
ility
ot p
– Heat inner tapered roller bearing race to approx. 100 °C before
wit
pressing on.
is n
h re
ole,
– Support inner race on opposite side using installing sleeve -
spec
VW 455- .
t to the co
Shoulder of installing sleeve - VW 455- faces towards differential
cage.
rrectne
Pressing tapered roller bearing outer race -A- out of clutch hous‐
ing
ss o
cial p
f
inform
21/7-
mer
atio
– Clamp internal puller securely behind tapered roller bearing
om
n
outer race.
c
i
or
n thi
te
sd
Manual gearbox 0DF
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
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Vo
co lksw
by
cted agen
Insert new baffle plate (shown here in conjunction with gearbox Prote AG.
housing)
-A-
Pressing tapered roller bearing outer race into clutch housing

Manual gearbox 02T
– Support clutch housing with wheel bearing tube - 3345- di‐
rectly below bearing mounting.
Manual gearbox 0DF
– Set clutch housing directly on pressure plate - VW 402-

Polo 2014 ➤ , up! 2017 ➤
Pulling off tapered roller bearing inner race

– Before fitting extractor, position spacer sleeve - VW 472/2- and
thrust piece - 3002- on differential housing.
Pressing on tapered roller bearing inner race
WARNING
Wear protective gloves.
– Heat inner tapered roller bearing race to approx. 100 °C before

pressing on.
Allocation of differential cage for removing and installing spring

pin
The hole in the differential cage was modified for the longer spring
pin.
Bore Length of spring Clamping sleeve
pin (mm)
wage es n
-A- 24.0 (short Removingy Volks Installing ot g
ua
spring pin) ⇒ pagerise205
db ⇒ page 206 ran
tee
ho
-A- and -B- 36.0 (long spring Removing
aut Installing or
ac
pin) ⇒sspage 205 ⇒ page 206
ce
le
un
pt
Through-hole 36.0 (long spring Removing Installing

an
d
itte
pin) ⇒ page 206 ⇒ page 206

y li
erm
ab
ility
ot p
Pressing off differential pinion pin, and shearing off spring pin
wit
is n
h re
ole,
When pressed out, spring pin will be sheared off.

spec
– Remove remainder of spring pin from differential cage.

t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Differential 205
Polo 2014 ➤ , up! 2017 ➤
Removing long spring pin to remove differential pinion pin

– Drive spring pin -A- out of hole -arrow- in differential housing
using a 5 mm diameter drift -B-.
AG. Volkswagen AG d
agen oes
lksw not
Note by Vo gu
ara
d
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If there is no hole -arrow- in the differential cage, shear off the
th
au ra
spring pin ⇒ page 205 . ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
Installing differential bevel gears
h re
hole
spec
– Lubricate one-piece thrust washer with gear oil and install.
es, in part or in w
t to the co
– Install both sun wheels and secure (e.g. with flange shaft).
– Insert both planet pinions offset 180° and pivot into position.
rrectness of i
– Press in differential pinion pin (-arrow A-) to first planet pinion.
l purpos
– Place threaded pieces -arrows B- in sun gears.
nf
ercia
orm
m
atio
om
n in
or c
thi
Installing spring pin for differential pinion pin
te
sd
iva
o
r
rp
cu
– Align hole in differential pinion pin with hole in differential cage.
o
m
f
en
ng
t.
– Using a drift, drive in spring pin -1- until a dimension
yi Co
op py
-a- of 2.5 mm is attained. t. C rig
gh ht
pyri by
• Spring pin -1- must not touch clutch housing.
co Vo
by lksw
cted agen
Prote AG.
2.3 Adjusting differential

Polo 2014 ➤ , up! 2017 ➤

equipment required
AG. Volkswagen AG d
agen oes
olksw not
y V gu
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tho eo
au ra
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le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
♦ End dimension plate - VW 385/17-

is n
h re
ole,
♦ Universal dial gauge holder - VW 387-

spec

t to the co

rrectne

ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Differential 207
Polo 2014 ➤ , up! 2017 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos

nf
ercia
orm
♦ Tube - 30 - 14-
m
atio
om
n in
♦ Tube - 2040-
or c
thi
te
♦ Tube - 3259-
sd
iva
o
r
rp
cu
♦ Tube for wheel bearing - 3345-

o
m
f
en
ng
t.
yi Co
♦ Not applicable: -Kukko1- t. Cop py
rig
gh ht
pyri by
co Vo
by lksw
cted agen
21/7- Prote AG.

Polo 2014 ➤ , up! 2017 ➤
♦ Thrust plate - 30 - 205-

♦ Dial gauge - VAS 6080A-
It is necessary to readjust the differential when the following com‐
ponents are renewed:
♦ Gearbox housing
♦ Clutch housing
♦ Differential cage
or the
AG. Volkswagen AG d
w agen oes
♦ Tapered roller bearing of differential
yV
olks not
gu
b ara
ed
Manual gearbox 0DF horis nte
eo
t
au ra
Insert new baffle plate ss c
ce
le
un
Installation position: shoulder -arrow- faces away from housing pt

an
d
itte
-A- y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne

s
– Pressing tapered roller bearing outer race (gear wheel slide)

s o
cial p
into gearbox housing.

inform
mer
atio
m
Note
o
n
c
i
or
n thi
e
Inner and outer tapered roller bearing races are paired. Do not
t
sd
iva
interchange!
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Differential 209
Polo 2014 ➤ , up! 2017 ➤
– Press tapered roller bearing outer race (opposite gear-wheel

side) without shim into clutch housing; for manual gearbox
0DF, without baffle plate as well.
Manual gearbox 02T
– Support clutch housing with wheel bearing tube - 3345- di‐
rectly below bearing mounting.
Manual gearbox 0DF
– Set clutch housing directly on pressure plate - VW 402-
– Insert differential in gearbox housing.
– Fit clutch housing and tighten the 5 bolts.
– Attach dial gauge and set to “0” with 1 mm preload.

A - 30 mm dial gauge extension
– Set dial gauge to “0” with 1 mm preload for bearing.
– Move differential up and down. Read and note play indicated
on dial gauge (example: 1.50 mm)
Determining thickness of shim
The specified bearing preload is obtained by adding a constant
value for preload (0.35 mm) to the reading obtained.
Example:
. Volkswagen AG
gen AG does
swa
Measured value 1.50 mm yV
olk not
gu
d b ara
+ Preload (constant) o0.35
ris mm
e nte
eo
h
ut
Thickness of shim = ss a 1.85 mm ra
c
ce
le
un
pt
an
– Remove clutch housing and press out tapered roller bearing
d
itte
y li
outer race -A-.
rm
ab
pe
ility
ot
wit
, is n
21/7-
h re
hole
spec
– Allocate shim(s) using ⇒ Electronic parts catalogue (ETKA) .
es, in part or in w
t to the co
The various thicknesses make it possible to achieve the exact
shim thickness required.
If the size of shim required is larger than those listed in the ⇒
rrectness of i
Electronic parts catalogue (ETKA) , insert two shims totalling the

l purpos
correct figure.
Manual gearbox 0DF
nform
ercia
Insert new baffle plate (shown here in conjunction with gearbox

m
a
com
ti
housing)
on in
r
te o
thi

s
iva
-A-
do
r
rp
cum
fo

en
ng
t.
yi Co
op
– Insert correct shim (in example 1.85 mm) and press tapered
C py
ht. rig
roller bearing outer race into clutch housing again. rig ht
py by
co Vo
by lksw
– Bolt clutch housing to gearbox housing.
cted agen
Prote AG.
Specified torques
♦ Gearbox housing to clutch housing ⇒ page 128

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Service

Service Department. Technical Information

All rights reserved.

Copyright © 2018 Volkswagen AG, Wolfsburg D4B8040D507

3.1 Allocation gearbox - engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3.3 Calculation of gear ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.1 Overview of fitting locations – clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.6 Removing and installing clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

1.11 Removing and installing clutch slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

2.4 Specified torques for gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

7 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

7.10 Repairing selector unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

8.2 Repairing clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

hicles with a start/stop system

Switch off ignition.

2.1 Gearbox identification

Only manual gearbox 02T -arrow 2- ⇒ previous illustration

Codes Day Month Year (2014)

Additional data provide information about the production facility.

The gearbox code is also included on the vehicle data stickers.

2 Rep. gr.00 - Technical data

3.1 Allocation gearbox - engine

3.1.1 Allocation gearbox - engine, Polo, manual gearbox 02T

Ratio Final drive 65 : 16 = 3.625 65 : 16 = 3.625 59 : 15 = 3.933

♦ Individual gear ratios

3.1.2 Allocation gearbox - engine, Polo, manual gearbox 0DF

Manual gearbox 5-speed, 0DF

Codes QGL QTS

Manufac‐ from 10.14 11.14

Allocation Engine 1.0 l - 70 kW 1.0 l - 70 kW

Ratio Final drive 58 : 16 = 3.625 58 : 16 = 3.625

3.1.3 Allocation gearbox - engine, up!

Manual gearbox 5-speed, 0DF

3.3 Calculation of gear ratios

4 Overview - power transmission

1 - Engine n AG. Volkswagen AG do

4. Overview - power transmission 5

6 Rep. gr.00 - Technical data

5.1 Overview of fitting locations - electrical

5.1.1 Overview of fitting locations – electrical components, manual gearbox, up!

1 - Gearbox neutral position

❑ Removing and installing

5.1.3 Overview of fitting locations – electrical

Clutch pedal switch - F36- (item -2-)

Removing and installing clutch pedal switch - F36- ⇒ page 48

8 Rep. gr.00 - Technical data

5.1.4 Overview of fitting locations – electrical

A number of general notes on the individual repair procedures,

which can otherwise be found in the relevant sections of the man‐

♦ When installing the manual gearbox, ensure that the dowel

♦ When installing mounting brackets or waxed components,

parts catalogue (ETKA) .

♦ After repairing the gearbox, fill with gear oil.

other signs of damage.

10 Rep. gr.00 - Technical data

with direction of force.