(TM) Volkswagen Manual de Taller Volkswagen Polo Up 2018 en Ingles

Service
Workshop Manual
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Service Department. Technical Information

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00 - Technical data
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30 - Clutch
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34 - Controls, housing
35 - Gears, shafts
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39 - Final drive - differential
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2018 Volkswagen AG, Wolfsburg D3E8043DC69

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
5-speed manual gearbox 0CF - Edition 06.2018
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety measures when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 1
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1 Allocation gearbox - engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.3 Calculation of gear ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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1.4 Assembly overview - clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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1.5 Removing and installing bearing bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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

1.7 Removing and installing over-centre spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.8 Removing and installing extension spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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1.9 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

1.10 Removing and installing clutch master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
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1.11 Removing and installing clutch slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

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1.12 Removing and installing lines for clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

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1.13 Bleeding clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

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1.14 Removing and installing clutch pedal switch F36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

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1.15 Checking clutch master cylinder and clutch slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . 48

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1.16 Removing and installing clutch position sender G476 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

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1.17 Repairing clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

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2 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.1 Assembly overview - clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
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2.2 Removing and installing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
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34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1 Selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1.1 Installation position - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1.2 Overview - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
1.3 Assembly overview - gear knob and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1.4 Assembly overview - Gear lever and selector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
1.5 Assembly overview - Selector cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
1.6 Removing and installing gear knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.7 Emblem identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1.8 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1.9 Repairing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
1.10 Adjusting selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
1.11 Checking selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
1.12 Dismantling and assembling selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Contents i
Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
1.13 Removing and installing selector cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

1.14 Renewing selector shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
2 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
2.1 Specified torques for gearbox w.ag. e.n.A.G.. V. o.lk.s.w.ag. e.n.A.G.d.oe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
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2.3 Installing gearbox .or.is.e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .a.nt.ee. . . . . . . . . . . . . . . . . . . . . 101
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3 Assembly mountings au . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ac. . . . . . . . . . . . . . . . . . . 110
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3.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
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4 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

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5 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
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5.1 Schematic overview - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
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5.2 Assembly overview - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
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5.3 Assembly overview - clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
5.4 Assembly overview - selector unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
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5.5 Assembly overview - shafts, differential, selector mechanism . . . . . . . . . . . . . . . . . . . . . . 119
5.6 Removing and installing selector unit with gearbox installed . . . . . . . . . . . . . . . . . . . . . . . . 119
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5.7 Renewing selector shaft sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
5.8 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
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6 Gearbox housing, clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
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6.1 Assembly overview - gearbox housing and clutch housing . . . . . . . . . . . . . . . . . . . . . . . . 131
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7 Securing to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
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8 Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
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8.1 Checking gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
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8.2 Draining and filling gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

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35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

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1 Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.1 Assembly overview - input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
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1.2 Dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
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1.3 Adjusting input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

1.4 Renewing input shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
2 Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
2.1 Assembly overview - output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
2.2 Dismantling and assembling output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
2.3 Adjusting output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
3 Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
3.1 Removing and installing reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

1 Oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
1.1 Overview of fitting locations - seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
1.2 Renewing left seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
1.3 Renewing right oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
2 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
2.1 Assembly overview - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
2.2 Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
2.3 Adjusting differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
3 Adjustment overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
ii Contents
Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
00 – Technical data
AG. Volkswagen AG d
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1 Safety information
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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.
Switch off ignition.
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♦ Switch on the ignition briefly only if required.
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1. Safety information 1
Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
2 Identification
⇒ “2.1 Gearbox identification”, page 2
2.1 Gearbox identification

Code letters and production date -arrow 1- manual gearbox
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Manual gearbox 0CF -arrow 2-.
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Example: NNE 15 12 1
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Codes Day Month Year (2011)

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Additional data provide information about the production facility.

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2 Rep. gr.00 - Technical data

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3.1 General repair instructions
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To ensure flawless and successful gearbox repairs, the greatest
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♦ When installing the manual gearbox, ensure that the dowel
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sleeves between the engine and gearbox are correctly seated.
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♦ When installing mounting brackets or waxed components,
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♦ Allocate bolts and other components using the ⇒ Electronic . Cop py
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♦ If the gearbox is repaired, fill with gear oil.
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Gaskets and seals
After removing gaskets and seals, always inspect contact surfa‐
ces of housing and shaft for burrs resulting from removal or for
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.
♦ Allocation ⇒ Electronic parts catalogue (ETKA) .
♦ Breather holes must remain free of sealant .
3. Repair instructions 3
olkswagen AG
en AG. V
Polo 2014 ➤ , up! k2012
swa ➤ , up! 2017 ➤ does no
g
Vol t
5-speed manual
ed
by gearbox 0CF - Edition 06.2018guara
ris nte
utho eo
Locking devices
ss
a ra
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
rrectne
♦ Renew retaining rings.
ss o
cial p
f
♦ Do not overstretch retaining rings.
inform
mer
♦ Retaining rings must locate properly in grooves.
atio
om
n
♦ Renew spring pins. Installation position: slot must be in line
c
i
or
n
with direction of force.
thi
te
sd
iva
o
r
Nuts and bolts

p
cum
r
fo
en
ng
♦ Loosen and tighten securing bolts and nuts for covers and
t.
yi Co
op
housings alternately and diagonally. C py
t. rig
gh ht
yri by
♦ Do not cant especially delicate parts, such as clutch pressure cop Vo
by lksw
plates. Loosen and tighten bolts and nuts alternately and in cted agen
Prote AG.
stages.
♦ Specified torques given are for unoiled nuts, bolts and screws.
♦ Renew self-locking bolts and nuts after each removal.
♦ Ensure with threaded connections that contact surfaces as
well as nuts and bolts are rewaxed only after assembly, if nec‐
essary.
♦ Use a thread chaser to clear residual locking fluid from all
threaded holes into which self-locking bolts are to be screwed.
Otherwise there is a danger of bolts shearing when subse‐
quently being removed.
♦ Check pitch of thread, to ensure correct thread chaser is used
to clean threads and to ensure the threads are not damaged.
Bearings
♦ 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.

Polo 2014 ➤ , up! 2012 ➤ , 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 agen
AG. Volkswagen AG d
oes
olksw not
♦ Do not interchange them. When reusing d by V synchro-rings, always gu
ara
fit to the same synchromeshed gear.
orise nte
eo
h
aut ra
♦ Check for wear and renew ifs necessary.
s c
ce
le
un
♦ Check grooves -arrow 1- of synchro-ring -A- and inner ring for
pt
an
d
itte
flat spots (worn grooves).
y li
erm
ab
♦ If synchro-rings are coated, coating must not be damaged.
ility
ot p
wit
is n
♦ If an intermediate ring -B- is installed, check the outer friction
h re
ole,
surface -arrow 2- and inner friction surface -arrow 3- of this
spec
intermediate ring for »scoring«, »signs of abnormal wear« and

»blue discolouration (due to overheating)«.
t to the co
♦ Check the cone of the synchromeshed gear for »scoring« and
»signs of abnormal wear«.
rrectne
♦ Moisten synchromesh mechanism with gear oil before instal‐
ling.
ss o
cial p
f
Gears and synchro-hubs
inform
mer
♦ Before installing, clean and heat with the inductive heater -

VAS 6414- to maximum 100°C. atio
om
n
c
i
or
♦ Observe installation position

thi
te
sd
va
Synchromeshed gears
i
o
pr
cum
r
fo
en
ng
♦ After assembly, check synchromeshed gears for slight play, or

t.
yi Co
for freedom of movement. Cop py
ht. rig
rig ht
Clutch operation py by
co Vo
by lksw
cted agen
Disconnect battery earth strap ⇒ Electrical system; Rep. gr. 27 ; Prote AG.
Battery; Disconnecting and connecting battery .
When reconnecting battery, refer to ⇒ Electrical system; Rep. gr.
27 ; Battery; Disconnecting and connecting battery .
Clutch
♦ Ensure that the pressure plate does not cant: loosen and tight‐
en bolts alternately and diagonally and in several gradual
stages.
♦ In order to reduce the smell of a burned clutch, the clutch
housing as well as the stopping face of the flywheel must be
thoroughly cleaned with a cloth.
3. Repair instructions 5
Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
4 Technical data
⇒ “4.1 Allocation gearbox - engine”, page 6 .
⇒ “4.2 Capacities”, page 8 . lkswage es n
o ot g
byV ua
d
⇒ “4.3 Calculation of gear ratios”, page 8 . o
ir se
ran
tee
th or
u
4.1 Allocation gearbox - engine
a ac
ss
ce
e
nl
pt
du
⇒ “4.1.1 Allocation gearbox - engine, up!”, page 6 .
an
itte
y li
erm
ab
⇒ “4.1.2 Allocation gearbox - engine, Polo”, page 7 .
ility
4.1.1 Allocation gearbox - engine, up! ot p
wit
, is n
h re
hole
spec
Manual gearbox 5-speed, 0CF
es, in part or in w
t to the co
Codes NTK NTL NTM
Manufactured from 08.11 08.11 08.11
to 10.13 10.13 10.13
rrectness of i
Allocation Engine 1.0 l - 44 KW 1.0 l - 55 KW 1.0 l - 44 KW
l purpos
Ratio Final drive 74 : 19 = 3.895 75 : 18 = 4.1666 74 : 19 = 3.895

Z2 : Z1
nf
ercia
or
Glean following data from ⇒ Electronic parts catalogue (ETKA) :
m
m
atio
om
♦ Individual gear ratios
n in
or c
thi
e
♦ Gear oil
t
sd
iva
o
r
rp
cu
♦ Clutch allocation
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
cop Vo
by lksw
cted agen
Codes NTN Prote
NZC NZD
AG.

to 10.13 10.13 10.13
Z2 : Z1
♦ Gear oil

Codes NZE NZF QCF
to 10.13 10.13
1.0 l - 55 KW
Z2 : Z1
♦ Gear oil

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤

Codes QCG QCH QCJ
to
1.0 l - 55 KW
Z2 : Z1
♦ Gear oil

Codes RNY, UCZ RNZ, UDA
Manufactured from 05.16 05.16
to AG. Volkswagen AG d
agen o s
Allocation Engine 1.0
Volklsw
- 44 KW 1.0 l - e44
noKW
t gu
d by1.0 l - 55 KW 1.0 l - 55 KW ara
ise nte
or
Ratio Final drive aut
h 74 : 19 = 3.895 74 : 19 = 3.895 e or a
Z2 : Z1 ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
♦ Gear oil
wit
is n
h re
ole,
♦ Clutch allocation spec

t to the co
4.1.2 Allocation gearbox - engine, Polo

rrectne

s
Codes QAB QAC QAD

s o
cial p

inform
to
mer
atio

om
n
c

or
n thi
e
Z2 : Z1
t
sd
iva
o
pr
cum
r

fo
en
ng
t.
yi Co
♦ Individual gear ratios Cop py
t. rig
gh ht
yri
♦ Gear oil p by
o Vo
by c lksw
cted agen
♦ Clutch allocation Prote AG.

Codes QAE
Manufactured from 01.14
to
4. Technical data 7
Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤

Codes QAE
Allocation Engine 1.0 l - 55 KW
Ratio Final drive 77 : 16 = 4.813
Z2 : Z1
♦ Gear oil
AG. Volkswagen AG d
agen
4.2 Capacities
oes
olksw not
byV gu
ara
ed
ris nte
Capacity of manual ugearbox
tho (gear‐ e o 1.3
ra
l
box completely dismantled)
ss a c
ce
le
Capacity of manual gearbox (if oil 1.1 l

un
pt
leaked during work on assembled
an
d
itte
y li
gearbox, drive shaft oil seals were
erm
ab
renewed or if gearbox was removed
ility
ot p
and reinstalled)
wit
is n
h re
ole,
spec
t to the co
4.3 Calculation of gear ratios
Example:
rrectne
5th gear Final drive

s
Drive gear ZG1 = 46 ZA1 = 24

s o
cial p
f i
Driven gear ZG2 = 33 ZA2 = 70

nform
mer
atio
i = ZG2 : ZG1 1)
om
n
c
i
or
iG = Gear ratio = ZG2: ZG1= 33 : 46 = 0.717

thi
te
sd
iva
o
r
iA = Final drive ratio = ZA2 : ZA1 = 70 : 24 = 2.917

p
cum
r
fo
en
ng
t.
itotal = overall ratio = iG x iA = 0.717 x 2.917 = 2.091
yi Co
Cop py
ht. rig
1) Z1 = No. of teeth on driving gear, Z2 = No. of teeth on driven gear rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
5 Overview - power transmission

Designation:
-Arrows- point in direction of travel.
1 - Engine
AG. Volkswagen AG d
2 - Clutch ksw
agen oes
not
Vol
by gu
3 - Manual gearbox ised ara
nte
or eo
h
4 - Input shaft s aut ra
c
s
5 - Output shaft
ce
le
un
pt
an
d
itte
6 - Differential
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
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
o
by c lksw
cted agen
Prote AG.
Ratio
-Arrows- point in direction of travel.
5. Overview - power transmission 9

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
I - 1st gear
II - 2nd gear
AG. Volkswagen AG d
III - 3rd gear agen oes
olksw not
y V gu
b ara
IV - 4th gear rise
d
nte
tho eo
V - 5th gear ss au ra
c
ce
le
R - Reverse gear
un
pt
an
d
itte
y li
A - Final drive
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! 2012 ➤ , up! 2017 ➤
6 Electrical components
⇒ “6.1 Overview of fitting locations - electrical components”, page
11
6.1 Overview of fitting locations - electrical

components
⇒ “6.1.1 Overview of fitting locations – electrical components,
manual gearbox”, page 11
clutch mechanism, up!”, page 11
clutch mechanism, Polo”, page 12
6.1.1 Overview of fitting locations – electrical components, manual gearbox
1 - Gearbox neutral position

sender - G701-
❑ Location: beneath se‐
lector unit
❑ Removing and installing
⇒ page 119
2 - Reversing light switch - F4-
❑ Location: on selector
unit
⇒ page 118
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
6.1.2 Overview of fitting locations – electrical

components, clutch mechanism, up!
l purpos
Clutch position sender - G476-

nform
ercia
Location: in passenger compartment on clutch master cylinder.

m
at
om
io
Held in position by retainer -arrow A- and -arrow B-

n
c
in t
or
his
e
Removing and installing clutch position sender - G476-

at
do
riv
⇒ page 48 .
p
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
6. Electrical components 11
Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
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 47
6.1.3 Overview of fittingagen

locations –Aelectrical
AG. Volkswagen G do
es n
ksw
components,
d by Vol
clutch mechanism, Polo
ot g
ua
r
e an
ris tee
Clutch position sender
ut - G476- (-arrow A- and -arrow B-)
ho or
a ac
ss
Fitting location:
ce
e
nl
pt
du
In engine compartment beneath supply hose -1- on clutch cylinder
an
itte
y li
-2- above line -3-.
erm
ab
ility
ot p
Removing and installing clutch position sender - G476-
wit
, is n
⇒ page 49 .
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Polo 2014 ➤ , up! 2012 ➤ , 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”, page 20
⇒ “1.4 Assembly overview - clutch release mechanism”,
page 24
⇒ “1.5 Removing and installing bearing bush”, page 25
⇒ “1.6 Removing and installing clutch pedal”, page 26
⇒ “1.7 Removing and installing over-centre spring”, page 28
⇒ “1.8 Removing and installing extension spring”, page 30
⇒ “1.9 Removing and installing mounting bracket”, page 31
⇒ “1.10 Removing and installing clutch master cylinder”,
page 39
⇒ “1.11 Removing and installing clutch slave cylinder”,
page 41
⇒ “1.12 Removing and installing lines for clutch mechanism”,
page 43
⇒ “1.13 Bleeding clutch mechanism”, page 46
⇒ “1.14 Removing and installing clutch pedal switch F36 ”,
page 47
⇒ “1.15 Checking clutch master cylinder and clutch slave cylin‐
der”, page 48
⇒ “1.16 Removing and installing clutch position sender G476 ”, AG. Volkswagen AG d
page 48 agen oes
olksw not
V gu
by ara
⇒ “1.17 Repairing clutch release mechanism”, page 51 rise d
nte
ho eo
ut
1.1 Overview of fitting locations – clutch
a ra
ss c
ce
mechanism
e
nl
pt
du
an
itte
y li
⇒ “1.1.1 Overview of fitting locations – clutch mechanism, up!”,
erm
ab
page 13
ility
ot p
wit
, is n
⇒ “1.1.2 Overview of fitting locations – clutch mechanism, Polo”,

h re
page 15
hole
spec
es, in part or in w
1.1.1 Overview of fitting locations – clutch mechanism, up!

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
13
by c lksw
cted
1. Clutch operation
agen
Prote AG.
Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
I-
⇒ “1.2.1 Assembly overview –
pedal cluster, up!”, page 16
II -
⇒ “1.3 Assembly overview -
clutch hydraulics”, page 20
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
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
ht. rig
rig ht
py by
14
co Vo
by lksw
cted
Rep. gr.30 - Clutch
agen
Prote AG.
Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
1.1.2 Overview of fitting locations – clutch mechanism, Polo
I-
pedal cluster, Polo”,
page 18
II -
clutch hydraulics, Polo, LHD
vehicles”, page 22
III -
clutch hydraulics, Polo, RHD
vehicles”, page 23
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.
1. Clutch operation 15
Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
1.2 Assembly overview - pedal cluster

⇒ “1.2.1 Assembly overview – pedal cluster, up!”, page 16
⇒ “1.2.2 Assembly overview – pedal cluster, Polo”, page 18
1.2.1 Assembly overview – pedal cluster, up!
1 - Bulkhead
❑ With support for mount‐
ing bracket and clutch
master cylinder.
2 - Seal
AG. Volkswagen AG d
❑ Self-adhesive agen oes
olksw not
y V gu
❑ Renew after removing ise
d b ara
nte
mounting bracket or uthor eo
clutch master cylinder ss a ra
c
❑ Stick to clutch master
ce
e
nl
pt
du
cylinder.
an
itte
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erm
ab
3 - Supply hose
ility
ot p
❑ Renewing ⇒ page 20
wit
, is n
h re
4 - Support
hole
spec
❑ fit into mounting bracket
es, in part or in w
t to the co
⇒ page 31 Installing
extension spring
❑ No specific installation
rrectness of i
position needs to be ad‐
hered to.
l purpos
5 - Clutch position sender -

G476-
nf
ercia
or
❑ Installed depending on m
m
atio
version.
om
n in
c
❑ Can be checked using

or
thi
e
⇒ Vehicle diagnostic
t
sd
iva
tester in Guided Fault

o
r
rp
cu
o
Finding mode
m
f
en
ng
t.
yi Co
❑ Allocation ⇒ Electronic Cop py
parts catalogue (ETKA)
t. rig
gh ht
pyri by
co Vo
by lksw
cted
⇒ page 48
agen
Prote AG.
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
16 Rep. gr.30 - Clutch

Polo 2014 ➤ , up! 2012 ➤ , 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
❑ Allocate components using ⇒ Electronic parts catalogue (ETKA)
14 - Bolt
❑ RHD vehicles
❑ 20 Nm
15 - Clutch pedal switch - F36-
❑ Installed depending on version. lkswage es n
o ot g
yV ua
❑ Allocate components using ⇒ Electronicir se
dparts catalogue (ETKA)
b ran
o tee
❑ Removing and installing ⇒ page 47auth or
a
ss c
16 - Bearing mounting
ce
e
nl
pt
du
❑ For plunger/clutch master cylinder
an
itte
y li
erm
❑ Renew after removal
ab
ility
ot p
17 - Cap
wit
, is n
h re
18 - Buffer stop
hole
spec
❑ For clutch pedal
es, in part or in w
t to the co
19 - Hexagon nut
❑ Qty. 3
rrectness of i
❑ Self-locking
l purpos

❑ 25 Nm
nf
ercia
20 - Bearing bush
rm
m
atio

om
n in
or c
21 - Clutch master cylinder

thi
te
sd
a

iv
o
r
rp
cu
o
22 - Clip
f
en
ng
t.
yi Co
❑ To remove pipe/hose line, pull out clip to stop Cop py
t. rig
gh
❑ Can be pressed in as far as stop before fitting line
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
1.2.2 Assembly overview – pedal cluster, Polo
1 - Clutch pedal
⇒ page 26
❑ Do not grease
2 - Bearing bush
⇒ page 26
❑ Do not grease
⇒ page 40
4 - Clip
❑ To remove pipe/hose
line, pull out clip to stop
❑ Can be pressed in as far
as stop before fitting line
5 - Seal
❑ Self-adhesive
❑ Renew after removing
mounting bracket or
clutch master cylinder
❑ Glue onto clutch master
cylinder
6 - Clutch position sender -
G476-
❑ Can be checked using
⇒ Vehicle diagnostic
tester in Guided Fault
Finding mode . Volkswagen AG
gen AG does
swa
❑ Allocation ⇒ Electronic by Volk not
gu
parts catalogue (ETKA) rised ara
nte
o eo
aut
h
ra
⇒ page 49 ss c
ce
le
un
pt
7 - Pivot pin
an
d
itte
y li

rm
ab
pe
ility
❑ Do not grease
ot
wit
, is n
h re
8 - Bulkhead
hole
spec
❑ With studs for securing mounting bracket and master cylinder

es, in part or in w
t to the co
9 - Bush
❑ For upper mounting hole in mounting bracket
rrectness of i
❑ Bushes for lower mounting holes in mounting bracket are located in master cylinder
l purpos
10 - Hexagon nut
❑ For securing mounting bracket and clutch master cylinder to plenum chamber bulkhead
nform
ercia
❑ Qty. 3
❑ Self-locking
m
a
com
tio

n in
r
te o
thi
❑ 25 Nm
s
iva
do
r
rp
11 - Crash bar
um
fo
en
g
❑ Secured to module carrier

n
t.
yi Co
Cop py
t. rig
gh ht
yri by
18
op Vo
by c lksw
Rep. gr.30 - Clutch Prote
cted AG.
agen
AG. Volkswagen AG d
agen oes Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
olksw not
yV gu
ed b 5-speed aramanual gearbox 0CF - Edition 06.2018
nte
ris
tho eo
❑ Allocate according
s au to ⇒ Electronic parts catalogue (ETKA) r ac
s
ce
e
12 - Hexagon nut
nl
pt
du
an
❑ For crash bar on module carrier itte
y li
erm
ab
ility
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❑ 20 Nm
wit
, is n
h re
hole
13 - Mounting bracket
spec
es, in part or in w
❑ For clutch pedal
t to the co
❑ Using drift - VW 207- drive bushes for the studs used to fasten the mounting bracket onto the bulkhead,
rrectness of i
into the holes in the mounting bracket
l purpos
14 - Buffer stop
15 - Over-centre spring or extension spring
nf
ercia
❑ Grease support on mounting bracket
orm
m
❑ For grease allocation, refer to ⇒ Electronic parts catalogue (ETKA) .
atio
om
n in
❑ Installed depending on version.
or c
thi
e
❑ Different versions exist; for correct version refer to ⇒ Electronic parts catalogue (ETKA)
t
sd
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❑ Removing and installing over-centre spring ⇒ page 28
o
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❑ Removal and installation of extension spring are identical to removal and installation of over-centre spring
t.
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⇒ page 28 C py
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16 - Bearing bush
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❑ Do not grease
agen
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❑ For plunger/clutch master cylinder
❑ Do not grease
18 - Cap
Polo 2014 ➤ , up! 2012 ➤ , 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, Polo, RHD vehi‐
cles”, page 23 . Volkswagen AG
gen AG d a oes
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1.3.1 Assembly overview – clutch hydraulics, up!
not
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1 - Brake fluid reservoir ss c
ce
e
nl
pt
2 - Supply hose
du
an
itte
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erm
3 - Seal
ab
ility
ot p
❑ If damaged, renew to‐
wit
, is n
gether with supply hose
h re
hole
❑ The seals must be loca‐
spec
ted in supply hose
es, in part or in w
t to the co
rrectness of i
⇒ page 39
l purpos
5 - Clip
nf
ercia
orm
m
atio
m

o
n in
or c
6 - Mounting bracket with
thi
te
sd
a
clutch pedal
iv
o
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cu
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❑ For plunger/clutch mas‐ Cop py
ter cylinder
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8 - Hexagon nut
by c lksw
cted agen
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❑ ⇒ 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 43
❑ Allocation ⇒ Electronic
10 - Pipe
❑ 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 .

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
13 - Brake lines
❑ Various number
. Volkswagen AG
❑ Allocation ⇒ Electronic parts catalogue (ETKA) kswagen AG does
n ol ot g
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14 - Bracket sedb ran
ri tee
❑ Only RHD. ho
aut or
ac
ss
❑ Secured to body
ce
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nl
pt
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15 - Dust cap
an
itte
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ab
16 - Bleeder valve
ility
ot p
❑ Bleeding clutch mechanism ⇒ page 46
wit
, is n
h re
❑ Specified torque ⇒ page 46
hole
spec
17 - Hexagon bolt
es, in part or in w
t to the co
❑ ⇒ page 24
18 - Clip
rrectness of i
❑ To remove pipe/hose line, pull out clip to stop
l purpos

19 - Clutch slave cylinder
nform
ercia

m
at
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ion
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or
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ate
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LHD, identifying differences between brackets for pipe line and

p
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or
pipe/hose line
f
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t.
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op
Dimension “a” mm Line configuration
C py
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approx. 6 Pipe cop Vo
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approx. 8 Pipe/hose line
Prote AG.
Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
1.3.2 Assembly overview – clutch hydraulics, Polo, LHD vehicles
1 - Hexagon bolt
❑ Specified torque
⇒ page 24
2 - Bleeder valve
⇒ page 46
❑ Bleeding clutch mecha‐
nism ⇒ page 46
3 - Dust cap
4 - Supply hose
5 - Brake fluid reservoir
6 - Seals
❑ Must be fitted in supply
hose AG. Volkswagen AG d
agen oes
❑ If damaged, renew to‐ olksw not
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gether with supply hose rised ara
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7 - Clutch master cylinder aut ra
ss c
ce
e
nl
pt
⇒ page 40
du
an
itte
y li
erm
8 - Clip
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
9 - Seal / O-ring
rrectness of i
l purpos

nform
ercia
ted to configuration of
line connection
m
at
⇒ page 43
om
ion
c

in t
or
his
ate
10 - Pipe/hose line
do
priv
cum
or
❑ Actual number of windings may vary from that shown in illustration

f
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Cop py
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❑ Removing and installing ⇒ page 43 opyri
gh by
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11 - Bracket Prote
cted AG.
agen
❑ For pipe/hose line

12 - Seal / O-ring
❑ Seals/O-rings are adapted to configuration of line connection ⇒ page 43
13 - Clip

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤

1.3.3 Assembly overview – clutch hydraulics, Polo, RHD vehicles
1 - Hexagon bolt
⇒ page 24
⇒ page 41
3 - Gearbox
4 - Seal / O-ring
ted to configuration of
line connection
⇒ page 43
5 - Brake fluid reservoir lkswage es n
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6 - Seals ir se
d ran
tee
ho
❑ Must be fitted in supply aut or
ac
hose ss
ce
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un
pt
❑ If damaged, renew to‐
an
d
itte
gether with supply hose
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rm
ab
pe
ility
7 - Supply hose
ot
wit
, is n

h re
hole
spec
es, in part or in w
⇒ page 40 t to the co
9 - Clip
rrectness of i

l purpos

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

n in
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11 - Brake lines
s
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12 - Bracket
um
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t.
❑ For pipe/hose line
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Cop py
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13 - Pipe/hose line
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pyri by
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c by lksw
cted agen
Prote AG.
14 - Seal / O-ring
Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
❑ Seals/O-rings are adapted to configuration of line connection ⇒ page 43
15 - Clip
16 - Bleeder valve
❑ Bleeding clutch mechanism ⇒ page 46
❑ Specified torque ⇒ page 22
17 - Dust cap
1.4 Assembly overview - clutch release mechanism
1 - Release bearing
❑ To remove and install,
remove gearbox
❑ Remove and install to‐ wage
es n
gether with clutch re‐ yV
olks ot g
ua
lease lever and guide ised b ran
sleeve ⇒ page 51 to uth or tee
or
⇒ page 52 ss
a ac
❑ Do not wash out bear‐ ce

e
nl
pt
du
ing; wipe only an

itte
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❑ Renew noisy bearings
erm
ab
ility
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2 - Bolt
wit
, is n
h re

hole
spec
❑ 5 Nm and turn 90° fur‐

es, in part or in w
ther
t to the co
3 - Clutch release lever

rrectness of i
remove gearbox
l purpos
❑ Remove and install to‐

gether with clutch re‐
lease bearing and guide
nform
ercia
sleeve ⇒ page 51 .
m
at
❑ Remove old grease

om
ion
c
in t
❑ Grease contact surface

or
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e
of ball-head pin with

at
do
riv
grease for clutch plate

p
cum
or
splines .
f
en
ng
t.
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❑ Allocate grease using ⇒
Co
Cop py
Electronic parts cata‐
t. rig
gh ht
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logue (ETKA) . p by
co Vo
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cted agen
4 - Retaining spring Prote AG.

remove gearbox
❑ Secure to clutch release
lever
5 - Guide bush
❑ To remove and install, remove gearbox
❑ Remove and install together with release bearing and clutch release lever ⇒ page 51 to ⇒ page 51

lkswage es n
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tee Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
o
auth 5-speed
or
ac manual gearbox 0CF - Edition 06.2018
ss
ce
le
6 - Ball-head pin
un
pt
an
d
itte
❑ To remove and install, remove gearbox
y li
erm
ab
❑ Remove old grease
ility
ot p
wit
❑ Grease contact surface of ball-head pin with grease for clutch plate splines .
is n
h re
ole,
❑ Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
spec
❑ 20 Nm
t to the co
7 - Input shaft seal
❑ Renew after removal ⇒ page 149
rrectne
8 - Gearbox
s
9 - Hexagon bolt
s o
cial p
f
❑ 20 Nm
inform
mer
atio
m

o
n
c
i
or
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1.5 Removing and installing bearing bush
um
r
fo
en
ng
t.
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op
Removing C py
t. rig
gh ht
yri
Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
p by
co Vo
by lksw
Disconnecting and connecting battery .
Prote
cted AG.
agen
Polo
– Remove over-centre spring/extension spring ⇒ page 28 .
– Compress catches -arrows- and take out pin -1- towards right
side.
– Pull clutch pedal into passenger compartment as far as stop.
up!
– Compress fasteners on pivot pin for plunger of master cylinder
on clutch pedal. Pull off pin towards left.
– Observe extension spring ⇒ page 16 .
If necessary, remove clutch pedal switch - F36- to do so
⇒ page 47 .
Continuation for all

– 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-.
Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
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-.
Polo
– Install over-centre spring/extension spring ⇒ page 28 .
– Connect plunger/clutch master cylinder to clutch pedal.
– Use new pivot pin.
up!
– Observe extension spring ⇒ page 16 .
– Install clutch pedal switch - F36- if necessary ⇒ page 47 .
– Connect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
1.6 Removing and installing clutch pedal

⇒ “1.6.1 Removing and installing clutch pedal, up!”, page 26
⇒ “1.6.2 Removing and installing clutch pedal, Polo, LHD vehi‐
cles”, page 26
⇒ “1.6.3 Removing and installing clutch pedal, Polo, RHD vehi‐
cles”, page 27
1.6.1 Removing and installing Gclutch pedal,

A . Volkswagen AG d
up! Vol
kswagen oes
not
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db ran
The clutch pedal is removedorand
ise installed together with the tee
mounting bracket ⇒ pagea31
u .
th or
ac
ss
The clutch pedal stays fitted to the mounting bracket.
ce
le
un
pt
an
d
1.6.2 Removing and installing clutch pedal,

itte
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rm
ab
Polo, LHD vehicles

pe
ility
ot
wit
, is n
Removing
h re
hole
spec
– Move driver seat as far back as possible.

es, in part or in w
t to the co
– Move steering wheel to uppermost position using the entire

range of adjustment of the steering column.
rrectness of i
– Remove over-centre spring/extension spring ⇒ page 28 .

l purpos
– If installed in area of mounting bracket: remove onboard sup‐

ply control unit - J519- (do not disconnect connector) ⇒
Electrical system; Rep. gr. 97 ; Control units; Removing and
nform
ercia
installing onboard supply control unit - J519- .

m
a
com
tion in
r
te o
thi
s
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rp
cum
fo
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! 2012 ➤ , up! 2017 ➤
Removing bearing shaft for eclutch

n AG. Vopedal:
lkswagen AG
ag does
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Vol
– Break off both locking devices -A- using a screwdriver
ot g -1-.
by ua
ed ran
ris tee
tho or
au 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
-1- = 10 mm hexagon bit
rrectness of i
• Turn bearing shaft for clutch pedal to left -arrow- as far as stop.
l purpos
– Move clutch pedal slightly so that the pivot pin can be pulled
out.
nf
ercia
orm
m
atio
om
n in
or c
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f
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t.
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Cop py
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Installing cop Vo
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cted agen
Prote
Install in reverse order of removal, observing the following:
AG.

• 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.
– 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- .
1.6.3 Removing and installing clutch pedal,

Polo, RHD vehicles
Removing
– Remove mounting bracket ⇒ page 35 .
Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
– Compress fasteners -arrows-, and pull pivot pin -1- for plunger/
clutch master cylinder off towards right (shown in illustration
with mounting bracket installed).
– Pull clutch pedal as far as stop.
Volkswa
– Remove over-centre spring/extension
swa
gen AG
.
spring.
gen AG
does
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Remove pivot pin the for
se
d bthe clutch pedal as follows: ara
nte
ri
utho eo
ra
a c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
– Break off both locking devices -A- using a screwdriver -1-.
, 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
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• Turn bearing shaft for clutch pedal to left -arrow- as far as stop.
o
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rp
cu
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m
f
en
ng
– Move clutch pedal slightly so that the pivot pin can be pulled
t.
yi Co
out. Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Installing
• Renew pivot pin after removing.
– Push new pivot pin through to stop.
– Turn pivot pin to right to stop, -direction of arrow-.
• Locking devices -A- must audibly engage.
– Install mounting bracket ⇒ page 35 .
1.7 Removing and installing over-centre

spring
Removing
– Move driver seat as far back as possible.

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
– 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.
– Remove over-centre spring.
Installing
• Receptacle -arrow- for mounting pin of clutch pedal must be

vertical.
– Insert over-centre spring from side and from below, adjacent n AG. Volkswagen AG do
to plunger of master cylinder and adjacent to clutch pedal, intoolkswage es n
ot g
support -A- in mounting bracket. d byV ua
ra e nte
ris
utho eo
ra
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ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
– Now position over-centre spring on mounting lug of clutch
es, in part or in w
pedal -arrow-.
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
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cum
for
en
Note
ng
t.
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Cop py
t. rig
♦ The over-centre spring must be located directly in the mount‐
gh ht
yri by
ing -arrow 1- in the bearing bracket to be fitted correctly on the
cop Vo
by lksw
cted
clutch pedal -arrow 2- (⇒ see also previous illustration).
agen
Prote AG.
♦ Otherwise, it will not be possible to install the pivot pin -1- for
the plunger/clutch master cylinder (⇒ next illustration).
Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
– 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.
– Connect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
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
1.8 Removing and installing extension
ot p
wit
, is n
spring
h re
hole
spec
⇒ “1.8.1 Removing and installing extension spring, up!”,
es, in part or in w
page 30
t to the co
⇒ “1.8.2 Removing and installing extension spring, Polo”,
page 31
rrectness of i
1.8.1 Removing and installing extension
l purpos
spring, up!
nform
ercia
Special tools and workshop equipment required

m
at
♦ Hook - 3438-
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.
Removing
– 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 removing the extension spring.
– Pull extension spring firmly out of support and remove.

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
Installing
– 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.
Volkswa
• Install new support
swa
gen-B-
AG. for extension
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dospring.
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• Slightly by
dgrease following areas for extensionuaspring:
ran
e
ris tee
ho
• Mounting
aut -B- or
ac
ss
• Mounting on clutch pedal -arrow 2-
ce
e
nl
pt
du
an
itte
• Grease ⇒ Electronic parts catalogue (ETKA)
y li
erm
ab
– Attach extension spring to support on clutch pedal.
ility
ot p
-Arrow 2-.
wit
, is n
h re
hole
– Attach extension spring to support -B- on mounting bracket.
spec
es, in part or in w
t to the co
1.8.2 Removing and installing extension
spring, Polo
rrectness of i
Removal and installation of extension spring are identical to re‐
l purpos
moval and installation of over-centre spring ⇒ page 28
1.9 Removing and installing mounting

nform
ercia
bracket
m
at
om
io
⇒ “1.9.1 Removing and installing mounting bracket, up!”,

n
c
in t
or
page 31
his
ate
do
riv
⇒ “1.9.2 Removing and installing mounting bracket, Polo”,

p
cum
or
page 35
f
en
ng
t.
yi Co
op
1.9.1 Removing and installing mounting bracket, up!
C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
Special tools and workshop

equipment required
AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
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an
d
itte
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ab
ility
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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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pr
cum
r
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Hose clamp - 3094-

♦ Torque wrench - V.A.G 1331-
♦ Not required, spring-type clip pliers - VAS 5024 A-
Sealing tool - T10249-
Removing
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery .

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nt
ut
ho Polo 2014ee➤ or , up! 2012 ➤ , up! 2017 ➤
a ac
ss 5-speed manual gearbox 0CF - Edition 06.2018
ce
e
nl
pt
du
– Clamp off supply hose to clutch master cylinder using hose
an
itte
y li
clamp - 3094- .
erm
ab
ility
ot p
wit
Caution , is n
h re
hole
spec
Risk of leaking brake fluid.
es, in part or in w
t to the co
♦ During the following work, ensure that no brake fluid lands
on longitudinal member or gearbox. If this does happen,
clean the affected areas thoroughly.
rrectness of i
♦ Lay a lint-free cloth under clutch master cylinder.
l purpos
♦ When performing work in the footwell, put cloths on the

carpet to protect it from possible brake fluid spills.
nform
mercia
at
om
ion
c
– Disconnect supply hose -1- from clutch master cylinder.
in t
or
his
ate
– In addition to clamping off, it can also be sealed with sealing
do
priv
c
tool - T10249/1- (⇒ illustration above).
um
for
en
ng
t.
yi
– Release securing clip -2- to stop using screwdriver or a pointed
Co
op py
object and disconnect pipe -3- from clutch master cylinder.
. C rig
ht ht
rig by
py Vo
– Remove driver side footwell cover ⇒ General body repairs,
co lksw
by
cted agen
interior; Rep. gr. 68 ; Compartments/covers; Removing and Prote AG.
installing dash panel end trim on driver side .
Vehicles with clutch pedal switch - F36- .
– Remove clutch pedal switch - F36- ⇒ page 47 .
LHD vehicles
– Remove crash bar by unscrewing bolt -1-.
Note nut -2-.
RHD vehicles
– Remove crash bar by unscrewing bolt -1-.
Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
Vehicles with clutch pedal sender - G476- :

– Unclip clutch position sender - G476- from clutch master cyl‐
inder -arrow A- and remove from fitting location -arrow B-.
– Remove clutch position sender - G476- with electrical con‐
nector connected.

– 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. agen

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♦ Renew seal for clutchsmasterd by
cylinder after removing mounting ara
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bracket or clutch master
thor cylinder ⇒ Item 2 (page 16) . eo
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– Tighten securing nuts for mounting bracket.
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LHD vehicles
ility
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– Install crash bar; tighten bolt -1-.

wit
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Note nut -2-.

spec
es, in part or in w
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Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
RHD vehicles
– Install crash bar; tighten bolt -1-.
Vehicles with clutch pedal sender - G476- :

– Fit clutch position sender - G476- on clutch master cylinder
into fitting location -arrow B- and clip it in -arrow A-.
– Test clutch position sender - G476- by tugging on it.
Vehicles with clutch pedal switch - F36- .
– Install clutch pedal switch - F36- ⇒ page 47 .
Continuation for all AG. Volkswagen AG d
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– Install driver side footwell cover ⇒ General bodybyrepairs,
Vol
in‐ gu
ara
terior; Rep. gr. 68 ; Compartments/covers; Removing
rise
d and nte
installing dash panel end trim on driver sideut .
ho eo
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– After removing hose clamp - 3094- , supply hose -1- must be

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returned to its original position and shape.
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– Press pipe -3- all the way in at master cylinder connection, and
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press securing clip -2- in all the way.
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– Test line by tugging on it.
hole
spec
– Bleed clutch mechanism ⇒ page 46 .
es, in part or in w
t to the co
Specified torques
♦ For securing mounting bracket to plenum chamber bulkhead
rrectness of i
⇒ page 16
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♦ Crash bar to steering column ⇒ page 16 nf

ercia
1.9.2 Removing and installing mounting

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bracket, Polo
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♦ Hose clamps to 25 mm - 3094-

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Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
♦ Sealing tool - T10249-
AG. Volkswagen AG d
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Removing
t to the co
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LHD vehicles
l purpos
– Unclip engine control unit from bracket on plenum chamber

bulkhead without disconnecting electrical connector, and lay
nform
ercia
it to one side ⇒ Rep. gr. 24 ; Engine control unit .

m
at
RHD vehicles
om
ion
c
in t
In some vehicles, master cylinder is located behind a line for air

or
his
e
conditioning system -arrow-.

at
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rig ht
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Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
AG . Volkswage
An insulation mat is installed in conjunction
ksw
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n AG d
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s no
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Appearance may be different
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ise
– Remove insulation
ut
ho mat. Note item -1 to 4-.
r tee
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– Remove clutch position sender - G476- (without disconnecting
an
itte
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connector) from master cylinder ⇒ page 49 .
erm
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– Using hose clamp - 3094- , clamp off supply hose -2- to clutch
master cylinder.
rrectness of i
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Note
nform
ercia
♦ Clamping off the supply hose with the hose clamp - 3094- will
m
cause a permanent deformation.
at
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♦ However, this does not damage the supply hose.
in t
or
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ate
♦ After removing the hose clamp - 3094- , the supply hose must
do
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be returned to its original shape.
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Risk of leaking brake fluid. Prote AG.

– 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 43 .
– Seal openings.
Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
– 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 n AG. Volkswagen AG do
lkswage es n
passenger compartment byV
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ua
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un
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– Unscrew nuts -1- and -2-.
an
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– Remove mounting bracket -3- with clutch master cylinder.
pe
ility
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Installing
wit
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hole
spec
es, in part or in w
t to the co
Note
rrectness of i
♦ Renew self-locking nut.
l purpos
♦ Renew seal for clutch master cylinder after removing mounting

bracket or clutch master cylinder ⇒ Item 5 (page 18) .
nform
mercia
a
com
tion in
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te o
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– Fit crash bar -1-, and tighten nut -2-.
Co
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– If removed beforehand, reinstall following components: yri
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cted
Onboard supply control unit - J519- ⇒ Electrical system; Rep. gr.
agen
Prote AG.
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
– Insert clutch position sender - G476- into master cylinder with
electrical connector connected. Push it in as far as stop
⇒ page 49 .
– Connect pipe/hose line -1- to connection ⇒ page 43 .

– Connect supply hose -2- at clutch master cylinder.
• After removing the hose clamp - 3094- , the supply hose must
LHD vehicles
– Clip engine control unit with connector connected into bracket
on plenum chamber bulkhead ⇒ Rep. gr. 24 ; Engine control
unit .

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
RHD vehicles
– If fitted, fold insulation mat in the sequence -1, 2, 3- around
lines.
– Secure insulation mat with lock washer -4-.
– Install and/or connect battery ⇒ Electrical system; Rep. gr.
27 ; Battery; Disconnecting and connecting battery .
Specified torques
♦ For securing mounting bracket to plenum chamber bulkhead
⇒ page 18
♦ Crash bar to module carrier ⇒ page 18
1.10 Removing and installing clutch master

cylinder
⇒ “1.10.1 Removing and installing clutch master cylinder, up!”,
page 39
⇒ “1.10.2 Removing and installing clutch master cylinder, Polo”,
page 40
1.10.1 Removing and installing clutch master

cylinder,agup!
en AG. V
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Special tools and
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♦ Torqueuthwrench
o - V.A.G 1331- eo
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Removing
Remove mounting bracket with clutch master cylinder
nf
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⇒ page 31 .
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Prote AG.
Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
The figure shows installed mounting bracket with clutch master

cylinder.
– Pull pivot pin -A- for plunger/clutch master cylinder
genin
AGdirection
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does
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of -arrow 1- out of clutch pedal. yV
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– Unscrew securing bolts -arrows 2-thand
or
is remove clutch master
e or
cylinder from mounting bracket.s au ac
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– Remove clutch master cylinder from mounting bracket.
nl
pt
du
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Installing
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• Renew seal for clutch master cylinder ⇒ Item 2 (page 16) .
h re
hole
spec
• Renew pivot pin -A- after removing.
es, in part or in w
t to the co
• Pivot pin -A- must audibly engage in clutch pedal.
– Ensure proper engagement by carefully pulling pivot pin.
rrectness of i
– Install clutch master cylinder to mounting bracket using se‐
l purpos
curing bolts -arrows 2-.

Specified torque ⇒ page 16 .
nform
ercia
Install mounting bracket with clutch master cylinder ⇒ page 31 .

m
at
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Specified torques
on
c
in t
or
♦ Clutch master cylinder to mounting bracket ⇒ page 16
his
ate
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1.10.2 Removing and installing clutch master

f
en
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cylinder, Polo Cop py
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Note
Prote AG.
♦ Before replacing the clutch master cylinder due a suspected

defect, use Guided Fault Finding ⇒ Vehicle diagnostic
tester.
♦ When performing work in the footwell, put cloths on the floor
covering to protect it from possible brake fluid spills.
Removing
– Remove mounting bracket with clutch master cylinder
⇒ page 35 .
– Compress fasteners -1- on pivot pin for plunger/clutch master
cylinder -arrows- (shown in illustration with mounting bracket
installed).

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
AG. Volkswagen AG d
agen oes
– Pull pivot pin for plunger/clutch master cylinder
olks in direction of
w not
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-arrow A- out of clutch pedal. se
d b ara
nte
ri
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Clutch master cylinder is engaged in mounting
ut bracket by means ra
sa c
of catches -arrows B-. s
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nl
pt
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– Release locking tabs -arrows B- from clutch master cylinder,
an
itte
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and forcefully pull clutch master cylinder out of mounting
erm
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bracket.
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Illustration shows only 2 of 4 locking tabs -arrows B-.
, is n
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hole
Installing
spec
es, in part or in w
t to the co
• Renew seal for clutch master cylinder ⇒ Item 5 (page 18) .
rrectness of i
• Renew pivot pin -arrow A- after removing.
l purpos
• Pivot pin -arrow A- must audibly engage in clutch pedal.

– Ensure proper engagement by carefully pulling pivot pin.
nform
ercia
– Engage clutch master cylinder in mounting bracket

m
at
-arrows B-.
om
ion
c
in t
– Ensure proper engagement by carefully pulling clutch master
or
his
e
cylinder.
at
do
priv
c
– Install mounting bracket with clutch master cylinder
um
for
en
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⇒ page 35 .
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Cop py
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1.11 Removing and installing clutch slave
rig by
copy Vo
by lksw
cylinder
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Prote AG.

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
Removing
Note
♦ Before replacing the clutch slave cylinder due a suspected

defect, you must first use Guided Fault Finding ⇒ Vehicle
diagnostic tester.
♦ Make sure you do not depress the clutch pedal if the clutch
slave cylinder is removed from the gearbox with the pipe/hose
assembly still attached. Otherwise the piston will be pressed
out of the clutch slave cylinder and thus destroyed.
– If air filter prevents access to clutch slave cylinder, it must be

removed ⇒ Rep. gr. 24 ; Air filter; Removing and installing air
filter housing .
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter;
Assembly overview - starter .
– Remove gear selector cable, gate selector cable and cable
support bracket from gearbox and tie it up ⇒ page 65 .
– 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 gsealAG. Volkswagen AG d
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openings. Vo lksw
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– Remove bolts -arrows- and remove clutchorslave
ise cylinder. nte
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nl
pt
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ility
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Installing
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
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ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
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by lksw
cted agen
Prote AG.

Polo 2014 ➤ , up! 2012 ➤ , 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
Note
♦ It is also possible to install an O-ring instead of the seal -2-

⇒ page 43 .
♦ Renew seal -2- if damaged.
– Press pipe/hose line -1- into connection -4- until clip -3- en‐
gages audibly.
– Test pipe/hose line by tugging on it.
Seals and O-rings for pipe and hose lines

Item Material of line connection
1 Line connection with circumferential groove
-arrow 1-
2 Line connection with shoulder -arrow 2-
3 Line connection with shoulder -arrow 2- and cir‐
cumferential groove -arrow 3- wage
e
olks s no
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• For line connection having circumferentialise
dgroove
b -arrow 1- ara
nte
and -arrow 3-, a seal or O-ring must be
thorset there. eo
u ra
sa c
– Bolt clutch slave cylinder to gearbox
s -arrows-.
ce
e
nl
pt
du
– Insert pipe/hose assembly -B- into clutch slave cylinder as far

an
itte
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as stop.
erm
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ility
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– Press in clip -A- to stop.

wit
, is n
h re
hole
spec

es, in part or in w
t to the co
– Install gear selector cable, gate selector cable and cable sup‐
port bracket ⇒ page 65 .
rrectness of i
– Adjust selector mechanism ⇒ page 76 .

l purpos
– Install starter ⇒ Electrical system; Rep. gr. 27 ; Starter; As‐

sembly overview - starter .
nform
ercia
– Install battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Re‐

moving and installing battery .
m
at
om
io
– If air filter has been removed, it must be reinstalled now ⇒

n
c
in t
or
Rep. gr. 24 ; Air filter; Removing and installing air filter hous‐
his
te
ing .
a
do
priv
cum
or
Specified torques
f
en
ng
t.
yi Co
♦ Clutch slave cylinder to gearbox ⇒ page 24 Cop py
ht. rig
rig ht
py by
o Vo
1.12 Removing and installing lines for clutch
by c lksw
cted agen
Prote AG.
mechanism
Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
AG. Volkswagen AG d
Removing olksw
agen oes
not
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by
– Remove complete air filter housing if it prevents access to the rised ara
nte
lines for clutch mechanism ⇒ Rep. gr. 24 ; Air filter; Removing
ut
ho eo
ra
and installing air filter housing . ss a c
ce
e
nl
pt
du
an
itte
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erm
ab
Polo, LHD vehicles
ility
ot p
wit
, is n
– Unclip engine control unit from bracket on plenum chamber
h re
bulkhead without disconnecting electrical connector, and lay
hole
spec
es, in part or in w
t to the co
RHD vehicles
rrectness of i
l purpos
nf
ercia
orm
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atio
om
n in
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An insulation mat is installed in conjunction with some engines.
Co
op py
Appearance may be different from that illustrated.
t. C rig
gh ht
pyri by
Vo
o
– Remove insulation mat. Note item -1 to 4-. by c lksw
cted agen
Prote AG.
Caution
Risk of leaking brake fluid.


Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
– Using hose clamp - 3094- , clamp off supply hose -2- to clutch
master cylinder. . Volkswage AG n AG d
agen oes
olksw not
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db ara
Note rise nte
tho eo
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♦ Clamping off sthe supply hose with the hose clamp - 3094- will
ce
le
cause a permanent deformation.

un
pt
an
d
itte
y li
♦ However, this does not damage the supply hose.
erm
ab
ility
ot p
♦ After removing the hose clamp - 3094- , the supply hose must
wit
is n
h re
ole,
spec
– Pull out clip for pipe/hose line -1- as far as stop, and remove
t to the co
pipe/hose line.
– Seal openings.
rrectne
– Pull out clip -A- as far as stop and pull off pipe/hose line -B-.
s
– Seal openings.
s o
cial p
f inform
mer
Note
atio
om
n
c
i
or
n
Ignore -arrows-.
thi
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sd
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pr
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– Seal off open lines and connections if necessary with clean
um
r
fo
plugs from engine bung set - VAS 6122- .

en
ng
t.
yi Co
op py
– Move pipe/hose line clear and remove it. t. C rig
gh ht
pyri by
Installing
co Vo
by lksw
cted agen
Prote AG.
– Connect pipe/hose assembly -1- to clutch master cylinder and

clutch slave cylinder.
• After removing the hose clamp - 3094- , the supply hose -2-
must be returned to its original shape.
Polo, LHD vehicles
unit .
Polo, RHD vehicles

lines.
– Install battery tray and battery ⇒ Electrical system; Rep. gr.
– Install complete air filter housing ⇒ Rep. gr. 24 ; Air filter;
Removing and installing air filter housing .
Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
1.13 Bleeding clutch mechanism

♦ Brake filling and bleeding unit - VAS 5234-
AG. Volkswagen AG d
agen oes
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Note
un
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♦ The clutch mechanism must be bled after performing work on
pe
ility
the hydraulic system.
ot
wit
, is n
h re
♦ During the following work, ensure that no brake fluid lands on
hole
longitudinal member or gearbox.
spec
es, in part or in w
♦ Prefilling system is not necessary!
t to the co
♦ Before bleeding, fill brake fluid reservoir up to “max” marking
with brake fluid. rrectness of i
♦ Clutch pedal is at rest position, is not being depressed.

l purpos
♦ Brake fluid: Allocation ⇒ Electronic parts catalogue (ETKA) .

nform
ercia
– Remove complete air filter housing if it prevents access to

m
bleeder valve (-arrow- in illustration below) ⇒ Rep. gr. 24 ; Air

com
tio
filter; Removing and installing air filter housing .

n in
r
te o
thi
Polo
s
iva
do
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rp
cum
– Remove protective cap from bleeder valve -arrow-.

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! 2012 ➤ , up! 2017 ➤
up!
– Raise vehicle.
Clutch slave cylinder -arrow 1- is accessible from beneath vehicle
on left-hand side, in vicinity of gearbox selector lever -arrow 2-.
AG. Volkswagen AG d
agen oes
olksw not
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ara
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ris nte
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aut ra
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nl
pt
du
an
itte
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erm
ab
– Remove protective cap from bleeder valve -arrow-.
ility
ot p
– Connect brake filling and bleeding equipment .
wit
, is n
h re
hole
To bleed system, use 670 mm bleeder hose - V.A.G 1238/B3- if
spec
necessary.
es, in part or in w
t to the co
– To do this, connect the bleeder hose to the collector bottle of
the brake bleeding device.
rrectness of i
– Connect bleeder hose to bleeder valve -arrow- (illustrated in
top view).
l purpos
– Switch on brake filling and bleeding equipment .
nf
ercia
• Working pressure 2.0 bar.
orm
m
atio
– Open bleeder valve.
om
n in
c
– Allow about 100 cm3 of brake fluid to flow out.

or
thi
te
sd
iva
– Close bleeder valve.

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rp
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f
– Rapidly operate pedal from stop to stop 10 to 15 times.

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ng
t.
yi Co
op py
– Open bleeder valve.
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ht ht
rig by
py
– Allow another 50 cm3 of brake fluid to flow out.
co Vo
by lksw
cted agen
Prote AG.
– Close bleeder valve.
– Switch off brake filling and bleeding equipment and relieve
pressure completely from equipment.
– Depress clutch pedal several times after completion of bleed‐
ing process.
Specified torque:
Component Nm
Bleeder valve 4.5
1.14 Removing and installing clutch pedal

switch - F36-
To ensure sufficiently secure seating in mounting bracket for
clutch pedal, clutch pedal switch - F36- may be installed only
once.
Removing
– Remove driver side footwell cover ⇒ General body repairs,
interior; Rep. gr. 68 ; Compartments/covers; Removing and
– Pull connector off clutch pedal switch - F36- .
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
e nte
Polo 2014 ➤ , up! 2012 ➤ , up!horis
2017 ➤ eo
ut
5-speed manual gearbox 0CF
ss a - Edition 06.2018 ra
c
ce
le
un
pt
– Turn clutch pedal switch - F36- on mounting bracket 45° in
an
d
itte
direction of -arrow- and pull out of support.
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rm
ab
pe
ility
Installing
ot
wit
, is n
– Grease plunger.
h re
hole
spec
– Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
es, in part or in w
t to the co
Clutch pedal switch - F36- is installed from passenger compart‐
ment.
rrectness of i
• Clutch pedal must always remain in rest position when clutch
pedal switch - F36- is being installed. During entire installation
l purpos
procedure, clutch pedal is only allowed to be touched with

plunger head of clutch pedal switch - F36- .
nform
ercia
– Insert clutch pedal switch - F36- into mounting bracket support

m
a
and turn 45° in direction of -arrow-.
com
tion in
r
– Push connector onto clutch pedal switch - F36- .

te o
thi
s
iva
do
– Install driver side footwell cover ⇒ General body repairs, in‐
r
rp
cum
terior; Rep. gr. 68 ; Compartments/covers; Removing and
fo
en
g

n
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Cop py
t. rig
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pyri by
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by c lksw
cted agen
Prote AG.
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 48
⇒ “1.16.2 Removing and installing clutch position sender G476 ,
Polo”, page 49
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 master cylinder,
and disconnect connector.

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
Installing
– Fit clutch position sender - G476- on clutch master cylinder
into fitting location -arrow B- and clip it in -arrow A-.
– Test clutch position sender - G476- by tugging on it.
– Connect electrical connector.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
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1.16.2 Removing and installing clutch position
or eo
th
au ra
sender - G476- , Polo
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
♦ Hook - 3438-
ility
ot p
wit
, is n
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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
m
Removing
o
n in
or c
thi
e

t
sd
iva

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cu
o
m
f
LHD vehicles
en
ng
t.
yi Co
op py
– Unclip engine control unit from bracket on plenum chamber t. C rig
gh ht
bulkhead without disconnecting electrical connector, and lay pyri by
Vo
co
by lksw
cted agen
Prote AG.
RHD vehicles
Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
An insulation mat is installed in conjunction with some engines.

Appearance may be different from that illustrated.
– Remove insulation mat. Note item -1 to 4-.

– Unclip clutch position sender - G476- on master cylinder
-arrow A- and -arrow B-.
– Remove clutch position sender - G476- from master cylinder,
and disconnect connector.
lkswage es n
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byV ua
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Installing
ce
e
nl
pt
du
– Insert clutch position sender - G476- into master cylinder with

an
itte
y li
electrical connector connected. Push it in as far as stop.

erm
ab
ility
ot p
• Clutch position sender - G476- must clip in -arrow A-.

wit
, is n
h re
– To check, pull on clutch position sender - G476- -arrow B-.

hole
spec
– Disregard items -1, 2 and 3-.

es, in part or in w
t to the co
rrectness of i
l purpos

lines.
nform
ercia

m
at
om
ion
c
LHD vehicles
in t
or
his
ate

do
riv

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

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
1.17 Repairing clutch release mechanism

Special tools and work‐ AG. Volkswagen AG d
shop equipment re‐ agen oes
olksw not
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quired d by gu
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♦ Torque wrench - auth eo
ra
V.A.G 1331- ss c
ce
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un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
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ole,
spec
t to the co
rrectne
Removing and installing
ss
clutch release lever -A-
o
cial p
f i
with release bearing and
nform
guide sleeve
mer
atio
m
• Gearbox has been re‐

o
n
c
i
moved.
or
n thi
te
sd
a
– Unscrew bolts
iv
o
pr
c
-arrows-.
um
r
fo
en
ng
t.
yi
– Pull clutch release
Co
op py
lever with release
t. C rig
gh ht
yri
bearing and guide p by
co Vo
sleeve off input shaft
by lksw
cted agen
Prote
and ball stud.
AG.
Install in reverse order of

removal.
– Install gearbox
⇒ page 101 .
Specified torques
• Guide sleeve to gear‐
box ⇒ page 24
Removing and installing guide sleeve from/to clutch release bear‐

ing
– Remove clutch release lever together with release bearing
and guide sleeve ⇒ page 51 .
– Push guide sleeve -3- upwards out of release bearing -2-.
– Turn guide sleeve -3- about 90° in direction of arrow relative
to release bearing -2- until locking lugs of guide sleeve align
with grooves -4- of release bearing.
– Pull guide sleeve out of release bearing in this position.
Install in reverse order of removal.
– Install clutch release lever together with release bearing and
guide sleeve ⇒ page 51 .
Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
Removing and installing release bearing

– Press together locking lugs -arrows- on back of clutch release
lever and remove release bearing -A- from clutch release lev‐
er.
– 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
pin with grease for clutch plate splines .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
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aut ra
ss c
ce
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un
pt
an
d
itte
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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
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
o
by c lksw
cted agen
Prote AG.

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
2 Clutch
⇒ “2.1 Assembly overview - clutch”, page 53
⇒ “2.2 Removing and installing clutch”, page 54
2.1 Assembly overview - clutch
1 - Flywheel
⇒ Rep. gr. 13 ; Cylinder
block (gearbox end);
Removing and installing
flywheel .
❑ Ensure that centring
pins fit tightly gen AG
. Volkswagen AG
swa does
❑ Keep contact surface for yV
olk not
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clutch lining free of rised b ara
nte
grooves, oil and grease.utho eo
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sa ac
2 - Clutch plate s
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pt
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ab
❑ Centring ⇒ page 54
ility
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3 - Thrust plate
h re
hole
spec
⇒ page 54
es, in part or in w
t to the co
❑ Check ends of dia‐
phragm spring
⇒ page 56
rrectness of i
❑ Check spring connec‐
l purpos
tions and riveted con‐

nections ⇒ page 56 . nform
ercia
4 - Bolt
m
at
om

on
c
in t
or
❑ Loosen or tighten alter‐

his
ate
nately and diagonally in

do
priv
small steps (1 full turn)

um
for
en
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❑ M 6: 13 Nm
n
t.
yi Co
op py
❑ M 7: 20 Nm
. C rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
2. Clutch 53
Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
2.2 Removing and installing clutch

equipment required
AG. Volkswagen AG d
agen oes
olksw not
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ara
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ris nte
ho eo
aut ra
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ce
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un
pt
an
d
itte
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ab
ility
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wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
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or
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♦ Counter-hold tool - 3067-
Co
Cop py
ht. rig
ht
♦ Centring pin - 3190 A-
rig by
copy Vo
by lksw
cted
agen
Prote AG.
♦ Grease for splines

Removing
• Gearbox is removed.

AG. Volkswagen AG d
agen oes
olksw not
yV gu
ed b Polo 2014 ➤ , up! 2012 ➤ara, nup! 2017 ➤
ris tee
ut
ho 5-speed manual gearbox 0CF - Edition or06.2018
a ac
ss
– Use counter-hold tool - 3067- to loosen bolts.
ce
le
un
pt
an
d
itte
To prevent the pressure plate from becoming distorted during re‐
y li
rm
ab
moval (causes clutch grab when driving off), always keep to the
pe
ility
following procedure when unbolting the pressure plate:
ot
wit
, is n
h re
– Loosen all bolts alternately and diagonally in small steps (1 full
hole
turn).
spec
es, in part or in w
– Remove pressure plate and clutch plate.
t to the co
Installing
rrectness of i
Note
l purpos
♦ Allocate clutch plate and clutch pressure plate according to
nform
ercia
engine code and ⇒ Electronic parts catalogue (ETKA) .

m
a
♦ Clean splines of drive shaft and, if the clutch plate has been
com
tion in
used, clean the splines of the hub. Remove corrosion and ap‐
r
te o
thi
ply a very thin coat of clutch plate spline grease to splines.
s
iva
Then, move the clutch plate back and forth on the drive shaft
do
r
rp
c
until the hub moves easily on the shaft. Remove excess
um
fo
en
grease.
ng
t.
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op py
♦ Clutch pressure plates are protected against corrosion and
. C rig
ht ht
rig
greased. With the exception of the friction surface for the py by
co Vo
clutch plate, the clutch pressure plate must not be cleaned.
by lksw
cted agen
Prote
Service life of clutch will otherwise be shortened considerably.
AG.
♦ The friction surface of the clutch pressure plate and the fly‐
wheel must be cleaned (degreased) thoroughly.
♦ 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
gearbox in order to reduce the smell of burnt linings.
♦ Clutch plate linings must make full contact with flywheel and
friction surface of clutch pressure plate. Only then insert se‐
curing bolts.
♦ Tighten securing bolts in small steps (1 full turn) diagonally in
order not to damage centring holes of pressure plate and cen‐
tring pins of flywheel.
♦ 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.
• Installation position of clutch plate: lettering

“Getriebeseite” (gearbox end) or spring cage faces pressure
plate.
2. Clutch 55
Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
Check ends of diaphragm spring

• Wear to half the thickness of the diaphragm spring -arrows- isagen
AG. Volkswagen AG d
oes
permitted. olksw not
yV gu b ara
ed nte
oris e
th or
au ac
ss
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un
pt
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d
itte
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
Check spring connection and riveted fastenings.
t to the co
– Check spring connection between thrust plate and cover for
cracks and make sure rivet fastenings are seated tightly.
rrectness of i
– If pressure plate has damaged springs or loose rivet connec‐
l purpos
tions -arrows-, it must be renewed.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
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Check extension springs and riveted connections

n
t.
yi Co
Cop py
I - Extension springs OK.
t. rig
gh ht
pyri by
Vo
co
• Minor kinks on the outside area -arrows A- have series pro‐
by lksw
cted agen
duction status.
Prote AG.
II - Extension springs damaged

• Renew clutch pressure plates if springs are broken or badly
bent -arrow B-.
– Check spring connections -arrows A- for damage, and make
sure that rivet joints -arrows B- are firmly seated.
• Renew clutch pressure plate if spring connections are broken
or badly bent, or if riveting is loose.
– Make sure rivet joints -arrows B- on all extension springs

-arrows A- are firmly seated.
– Tighten all bolts one after another (clockwise) to final torque.
• Renew clutch pressure plate if riveting -arrow B- is loose.

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
Check metal ring.

– Check that metal ring in clutch pressure plate -arrow- is not
damaged.
• Renew clutch pressure plate if metal ring is broken.
Centring clutch plate

– Tighten all bolts alternately and diagonally in small steps (1 full
turn).
– Install gearbox ⇒ page 101 .
Specified torques
♦ Pressure plate to flywheel ⇒ page 53 .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
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
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
o
by c lksw
cted agen
Prote AG.
2. Clutch 57
Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
34 – Controls, housing
1 Selector mechanism
⇒ “1.1 Installation position - selector mechanism”, page 58
⇒ “1.2 Overview - selector mechanism”, page 60
⇒ “1.3 Assembly overview - gear knob and cover”, page 61
⇒ “1.4 Assembly overview - Gear lever and selector housing”,
page 62
⇒ “1.5 Assembly overview - Selector cables”, page 65
⇒ “1.6 Removing and installing gear knob”, page 67 .
⇒ “1.7 Emblem identification”, page 69 .
⇒ “1.8 Removing and installing selector mechanism”,
page 69 .
⇒ “1.9 Repairing selector mechanism”, page 72 AG. Volkswagen AG d
agen oes
ksw
⇒ “1.10 Adjusting selector mechanism”, pageb76 yV .
ol not
gu
ara
d
ise nte
⇒ “1.11 Checking selector mechanism”, thpage
or 78 . eo
au ra
c
⇒ “1.12 Dismantling and assembling sselector mechanism”,
s
ce
e
page 78
nl
pt
du
an
itte
y li
⇒ “1.13 Removing and installing selector cable”, page 82
erm
ab
ility
ot p
⇒ “1.14 Renewing selector shaft seal”, page 83
wit
, is n
h re
1.1 Installation position - selector mecha‐
hole
spec
nism
es, in part or in w
t to the co
Note
rrectness of i
♦ Disconnect battery before working on selector mechanism in
l purpos
engine compartment ⇒ Electrical system; Rep. gr. 27 ; Bat‐

tery; Disconnecting and connecting battery .
nform
ercia
♦ Removing and installing selector mechanism ⇒ page 69 .

m
at
om
ion
c
-Arrow A- indicates the gear selection movement and gear se‐

in t
or
lector cable.
his
ate
do
riv
-Arrow B- indicates the gate selection movement and gear selec‐

p
cum
or
tor cable.
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
58 Rep. gr.34 - Controls, housing

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
I - up! ⇒ 02 14 - gear lever is

“not” pushed down to engage
reverse gear
II - Polo and up! 03 14 ⇒ - gear
lever “is” pushed down to en‐
gage reverse gear
A - Gear selector cable
B - Gate selector cable
C - Heat shield
❑ Remove before remov‐
ing selector mecha‐
nism.
1 - Gearbox selector lever n AG. Volkswagen AG do
lkswage es n
o ot g
2 - Relay lever d byV ua
ran
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ss
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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
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.
1. Selector mechanism 59
Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
1.2 Overview - selector mechanism
I-
gear knob and cover”,
page 61 . AG. Volkswagen AG d
agen oes
ksw
II - by Vol not
gu
ara
⇒ “1.4 Assembly overview - rise
d
nte
Gear lever and selector hous‐ ut ho eo
ra
ing”, page 62 . ss a c
ce
e
nl
III -
pt
du
an
itte
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erm
Selector cables”, page 65 .
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
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cu
o
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.

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
1.3 Assembly overview - gear knob and cover
1 - Emblem
❑ Can be carefully levered
off gear knob of plastic AG. Volkswagen AG d
or leather agen oes
olksw not
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❑ Different versions for ise d b ara
nte
following configura‐uthor eo
tions: ss a ra
c
❑ Gear lever is NOT
ce
le
un
pt
“pushed down” to en‐
an
d
itte
y li
gage reverse gear
rm
ab
pe
ility
❑ Gear lever is “pushed
ot
wit
down” to engage re‐
, is n
h re
verse gear
hole
spec
❑ Distinguishing
es, in part or in w
⇒ page 69
t to the co
❑ Allocation of emblem ⇒
Electronic parts cata‐
rrectness of i
logue (ETKA)
l purpos
2 - Gear knob
❑ With gaiter
nform
ercia
❑ Gear knob and gaiter

cannot be separated
m
a
from one another
com
tion in
❑ Always renew together
r
te o
thi
s
iva
do
r
⇒ page 67
rp
cum
fo
en
g
❑ Different gear knob

n
t.
yi Co
sizes in receptacle for Cop py
t. rig
gear lever on following yri
gh by
ht
configurations:
op Vo
by c lksw
cted agen
❑ Gear lever is NOT Prote AG.
“pushed down” to en‐
gage reverse gear
verse gear
3 - Clip
❑ For securing gear knob to gear lever
❑ Secure to gear knob using hose clip pliers - V.A.G 1275 A-
4 - Centre console, upper part
❑ up!: forms one part with centre console cover
❑ In some equipment versions, centre console cover is an individual part
5 - Noise insulation
❑ Not fitted in all vehicles
❑ Arrow on noise insulation points in direction of travel
❑ Locking lugs are arranged at varying intervals
❑ Therefore it can be installed in only one position
Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
1.4 Assembly overview - Gear lever and se‐

lector housing
olkswagen AG
en AG. V
⇒ “1.4.1 Assembly overview – gear lever and selector
olks
wag housing; does
not
gear lever is NOT pushed down to engage ed
reverse
byV gear”, gu
ara
page 62 horis nte
eo
t
au ra
⇒ “1.4.2 Assembly overview – gearsslever and selector housing; c
gear lever is pushed down to engage reverse gear”, page 64
ce
e
nl
pt
du
an
itte
1.4.1 Assembly overview – gear lever and selector housing; gear lever is NOT
y li
erm
ab
“pushed down” to engage reverse gear
ility
ot p
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
♦ Lubricate bearing positions and sliding surfaces.
rrectness of i
l purpos
1 - Floor panel
nf
ercia
❑ Bend open tabs to re‐
or
move
m
m
atio
m
❑ Fitting ⇒ page 78
o
n in
or c
thi
2 - Seal
te
sd
iva
❑ Renew base plate after
o
r
rp
cu
removing.
o
m
f
en
ng
t.
yi Co
3 - Selector housing Cop py
ht. rig
rig ht
4 - Securing clip py by
co Vo
by lksw
cted
❑ Do not damage cables
agen
Prote AG.
when removing
5 - Bush
6 - Gate change cable
❑ Lever off gate selector
lever
❑ Press onto gate selector
lever inside selector
mechanism
❑ Fitting position
⇒ page 58
7 - Gear change cable
❑ Lever off gear lever
guide
❑ Press onto gear lever
guide inside selector
mechanism
⇒ page 58
8 - Bearing shell
❑ Is damaged during re‐
moval
9 - Dampers

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
10 - Clip
❑ Secures gate selector lever.
❑ Check for damage
11 - Bearing shell
❑ Fitting position ⇒ page 80
❑ Fit onto gear lever.
❑ Gear lever and ball sockets are listed as one replacement part.
12 - Gear lever
❑ Gear lever and ball sockets are listed as one replacement part.
13 - Bearing bush
❑ Fit onto gear lever.
❑ Supports gear lever in gate selector lever.
14 - Hexagon nut
❑ Qty. 4
❑ M 6: 8 Nm
❑ M 8: 20 Nm
15 - Seal
❑ Between selector housing and underbody
❑ Renew selector housing after removing
❑ Self-adhesive
❑ Bond to selector lever housing
16 - Bearing bush
17 - Compression spring
AG. Volkswagen AG d
18 - Gate selector lever ksw
agen oes
not
ol
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ed
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Removing and installing damping -arrow- ss a ra
c
ce
le
– Press lug -A- of spring to right until it is next to damping

un
pt
an
-arrow-.
d
itte
y li
erm
ab
– Move gear lever to right and pull off damping.

ility
ot p
wit
• After installation, damping must contact extensions -A- and

is n
h re
-B-.
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! 2012 ➤ , up! 2017 ➤
1.4.2 Assembly overview – gear lever and selector housing; gear lever is “pushed
down” to engage reverse gear
1 - Selector mechanism
verse gear AG. Volkswagen AG d
agen
❑ Cannot be disassem‐ Volksw
oes
not
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bled d by ara
rise nte
❑ Gear selector cable and utho eo
ra
gate selector cable can‐ ss a c
not be removed
ce
e
nl
pt
du
an
itte
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⇒ page 69
erm
ab
ility
ot p
2 - Seal
wit
, is n
h re
❑ Self-adhesive
hole
spec
❑ Renew after each re‐
es, in part or in w
moval of selector mech‐
t to the co
anism
3 - Hexagon nut
rrectness of i
❑ Qty. 4
l purpos
❑ M 6: 8 Nm
❑ M 8: 20 Nm
nf
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orm
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atio
om
n in
or c
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te
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Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
1.5 Assembly overview - Selector cables
Note
♦ Lubricate bearing positions and sliding surfaces.

1 - Gear change cable

❑ Connect to cable end-
piece
⇒ Item 12 (page 66) .
⇒ page 58
❑ Gear lever is “NOT”
pushed down to engage
reverse gear: gear se‐
lector cable and gate se‐ gen AG
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lector cable can ybe ol swa
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moved from isselector
ed
b ara
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ut
02 14) ss a ra
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❑ Gear lever is pushed ce
e
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pt
du
“down” to engage re‐ an

itte
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verse gear: gear selec‐
erm
ab
tor cable and gate se‐ ility
ot p
lector cable cannot be

wit
, is n
removed from selector

h re
housing (Polo and up!

hole
spec
03 14 ⇒)
es, in part or in w
t to the co
2 - Gate change cable

❑ Connect to cable end-
piece
rrectness of i
⇒ Item 10 (page 66) .

l purpos
⇒ page 58
nform
ercia
❑ Gear lever is “NOT”

pushed down to engage
m
at
om
reverse gear: gear se‐

ion
c
lector cable and gate se‐

in t
or
lector cable can be re‐

his
ate
moved from selector

do
priv
housing (only up! ⇒

um
for
en
g
02 14)
n
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❑ Gear lever is pushed
C py
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“down” to engage reverse gear: gear selector cable and gate selector cable cannot be removed from
rig ht
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selector housing (Polo and up! 03 14 ⇒)
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3 - Bush
4 - Securing clip
❑ Do not damage cables when removing
5 - Selector housing
❑ Gear lever is “NOT” pushed down to engage reverse gear: selector mechanism can be dismantled (only
up! ⇒ 02 14)
❑ Gear lever “IS” pushed down to engage reverse gear: selector mechanism cannot be dismantled (Polo
and up! 03 14 ⇒)
Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
6 - Hexagon bolt
❑ Qty. 3
❑ For cable support bracket
❑ 25 Nm
7 - Spacer
❑ Qty. 3
❑ For cable support bracket
8 - Grommet
❑ Qty. 3
❑ Cable support bracket mounting on gearbox
9 - Cable support bracket
❑ Remove from gearbox ⇒ page 72 .
❑ After installing, adjust selector mechanism ⇒ page 76
10 - Cable end-piece
❑ For gate selector cable to relay lever lkswage es n
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❑ Remove from relay lever ⇒ page 75 d by ua
ran
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❑ Press onto relay lever ⇒ page 75 utho
or
a ac
❑ Allocation ⇒ page 73 . ss
ce
e
nl
pt
du
11 - Securing clip
an
itte
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ility
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12 - Cable end-piece
wit
, is n
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hole
spec
es, in part or in w
t to the co
❑ For gear selector cable to gearbox selector lever
❑ Allocation ⇒ page 73 .
rrectness of i
13 - Hexagon nut
❑ ⇒ Item 6 (page 118)
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14 - Gearbox selector lever
nf
ercia
❑ Can be renewed with the selector mechanism installed

orm
m
❑ Grease before installing ⇒ page 73 .

atio
om

n in
or c
thi
e
❑ Installing ⇒ page 74
t
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15 - Slide block
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❑ Shoe and relay lever are listed as one replacement part.
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16 - Relay lever
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❑ Grease before installing ⇒ page 74 .

❑ Remove and install together with cable end-piece ⇒ page 74
17 - Clip
❑ Secures relay lever.
❑ Check for damage

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t o
au 5-speed manual gearbox 0CF - rEdition
ac 06.2018
ss
ce
le
un
pt
1.6 Removing and installing gear knob
an
d
itte
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erm
ab
ility
ot p
wit
♦ Hose clip pliers - V.A.G 1275 A-
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
e
♦ Wedges - T10383-
t
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Removing
• Cover centre console in area of gear lever boot with a cloth.
up!
– Using wedge - T10383/1- , carefully lever off gear lever gaiter
in rear area from centre console -arrows-.
Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
5-speed manual gearbox 0CF - Edition 06.2018 agen
AG. Volkswagen AG d
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– Lift up gear lever boot slightly in rear area. rised b ara
nte
tho eo
– Using a flat-bladed screwdriver, carefully push detents -A-
s au in ra
c
front area of gear lever boot in direction of -arrow-. s
ce
le
un
pt
– Remove gear lever boot from centre console.
an
d
itte
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erm
ab
ility
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wit
is n
h re
ole,
spec
t to the co
rrectne
Polo
Carefully insert lever. On some vehicles it might be helpful to be‐
ss
gin »at front«.
o
cial p
f inform
– Using wedge - T10383- , carefully lever gear lever gaiter off
mer
centre console insert -arrows-.
atio
om
n
– Alternatively, use removal wedge - 3409- to lever out gear
c
i
or
n thi
lever gaiter.
te
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– Pull gear lever gaiter upwards, inside out over gear knob. cted agen
Prote AG.
– Open clamp -arrow- and pull off gear knob together with gear
lever gaiter.
Installing
– Press gear knob together with gear lever gaiter onto gear lever
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.

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
5-speed
agen AG.manual
Volkswagegearbox
n AG d
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0CF - Edition 06.2018
w es n
olks ot g
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1.7 Emblem identification ho
ris
ed ran
tee
t or
au ac
Selector mechanism: Symbol
ss line on gear knob:
ce
e
nl
pt
1. - Gear lever is “not” push‐ Continuous -arrow-
du
an
itte
ed down to engage reverse
y li
erm
ab
gear
ility
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2. - Gear lever “is” pushed Interrupted -arrow-
wit
, is n
down to engage reverse
h re
hole
gear
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
r
1.8 Removing and installing selector mech‐

o
his
ate
do
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anism
p
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for
en
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Removing
– Remove gear lever gaiter with gear knob and any noise insu‐
lation from frame for centre console ⇒ page 67 .
up!
– Remove centre console insert ⇒ General body repairs, inte‐
rior; Rep. gr. 68 ; Centre console; Removing and installing
centre console insert .
– Unbolt back of upper part of centre console ⇒ General body
repairs, interior; Rep. gr. 68 ; Centre console; Removing and
installing centre console .
– Unbolt lower part of centre console in footwell ⇒ General body
repairs, interior; Rep. gr. 68 ; Centre console; Removing and
Polo
– Remove centre console with securing bracket ⇒ General body
repairs, interior; Rep. gr. 68 ; Centre console; Assembly over‐
view - centre console .
Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤

– Unscrew nuts -arrows- for selector housing and, if necessary,
centre console securing bracket. To do this, carefully raise
lower part of centre console.
– Lower selector housing.
– If fitted, remove insulation from selector housing ⇒ General
body repairs, interior; Rep. gr. 68 ; Centre console; Assembly
overview – centre console .
– Remove complete air filter housing if it is located over selector
mechanism ⇒ Rep. gr. 24 ; Air filter; Removing and installing
air filter .
– Pull cable end-piece off gear selector cable and gate selector
cable forward to stop in -direction of arrow 1- and then lock in
-direction of arrow 2-.
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pe
ility
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wit
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hole
spec
up!
es, in part or in w
t to the co
In some equipment versions, the gear selector cable is only ac‐
cessible from beneath vehicle in -direction of arrow-.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
– Remove securing clips -arrows- for cables from cable support

rp
cum
fo
bracket.
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ng
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op
– Remove heat shield. C py
ht. rig
rig ht
py by
– Swing down gear lever housing and remove with selector ca‐ co Vo
by lksw
bles. cted agen
Prote AG.
Installing

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
– Route Bowden cables -1- from selector mechanism -2- to

gearbox as follows:
♦ Cables must be routed parallel to one
wage
another
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support bracket on gearbox.
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♦ Bowden cables musthbe ise
or laid in the intended indentation in heat tee
shield -3-. s aut or
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s
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un
pt
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d
itte
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rm
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pe
ility
ot
wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
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up!
nform
ercia
Clip -A- holds cables and heat shield in position (if applicable).
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tion in
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Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤

– Insert cables into cable end-pieces.
Install securing clips -arrows- for cables to cable support bracket.
– Align selector housing parallel to body.
• Distance to body must be same on both sides.
– Install centre console and tighten bolts ⇒ General body re‐
pairs, interior; Rep. gr. 68 ; Centre console; Removing and
– Install centre console insert ⇒ General body repairs, interior;
Rep. gr. 68 ; Centre console; Removing and installing centre
console insert .
– Install heat shield.
– 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 .
Selector cable support bracket to gearbox ⇒ page 65
AG. Volkswagen AG d
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1.9 Repairing selector mechanism y V gu
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Remove cable support bracket from gearbox. s aut ra
c
s
Bolts -arrow A- are accessible from engine compartment.
ce
le
un
pt
an
d
itte
Bolt -arrow B- is accessible from beneath vehicle.

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
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
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pyri by
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Prote AG.

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
Removing and installing gear selector cable and relay lever

– Remove securing clip -1- for gear selector cable -2- from gear‐
box selector lever and pull cable end-piece for gear selector
cable off pin.
– Remove cable end-piece for relay lever -3- together with relay
lever ⇒ page 74 .
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 8.5 mm
gearbox selector lever
2. - Gate selector cable to 10 mm
relay lever
The holes in the cable end-pieces have different diameters. AG. Volkswagen AG d
agen oes
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– Spread a small amount of grease on pin of gearbox selector d byV
o gu
ara
lever. orise nte
eo
h
ut ra
Allocate grease using ⇒ Electronic parts catalogue (ETKA)
ss a . c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
– Renew securing clip -1- for gear selector cable -2- each time
spec
es, in part or in w
after removing.
t to the co
– Install relay lever -3- and cable end-piece together.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
riv
Apply grease to gearbox selector lever

p
cum
for
en
g
• Apply grease to guide rail -B- of gearbox selector lever in which

n
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the relay lever engages, being especially careful when doing C py
ht. rig
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py by
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• Allocate grease using ⇒ Electronic parts catalogue (ETKA) . cted agen
Prote AG.
Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
Install gearbox selector lever

– When fitting the gearbox selector lever, ensure that the gapolkswage es n
ot g
-arrow A- is aligned with the master spline -arrow B-. d by V ua
ran
e
ris tee
utho or
a ac
Note ss
ce
le
un
pt
an
d
The picture of the gearbox selector lever may differ from the orig‐
itte
y li
rm
inal part.
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
ercia
Installation position of gearbox selector lever/relay lever

m
a
1- Gearbox selector lever
com
tion in
r
2- Relay lever engages in guide rail of gearbox selector lever

te o
thi
via shoe -arrow-.
s
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fo
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Prote AG.
Greasing the relay lever.

• Grease shaft -A- of relay lever all over with great care
-arrows-: amount of grease: 0.2 g.
• Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
Note
The picture of the relay lever may differ from the original part.
Removing and installing relay lever with cable end-piece

• To remove relay lever, first detach cable end-piece from gate
selector cable.
This will avoid damage to the gate selector cable.
• Relay lever must be removed before removing cable end-
piece ⇒ page 75 .
– Pull locking mechanism forward to stop in
-direction of arrow 1-, and then lock it by turning to left in
– Then push relay lever forwards (-direction of arrow 3-).

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
– Pull off clip -arrow 1- and remove relay lever together with ca‐
ble end-piece.
Cable end-piece must be located behind catch -arrow 2-.
Note
♦ Lubricate bearing positions and sliding surfaces. agen

AG. Volkswagen AG d
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– Press cable end-piece onto relay lever ⇒ page s75
sa . c
ce
e
nl
– Install relay lever together with cable end-piece to stop.
pt
du
an
itte
y li
• Clip -arrow 1- secures relay lever.
erm
ab
ility
ot p
• Ensure proper engagement of clip.
wit
, is n
h re
• Cable end-piece must be located behind catch -arrow 2-.
hole
spec
es, in part or in w
t to the co
Levering cable end-piece for gate selector cable off relay lever
• Relay lever has been removed.
rrectness of i
– Insert a flat-blade screwdriver -A- between bush -B- and relay
l purpos
lever.
nform
mercia
at
om
ion
c
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or
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ate
do
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for
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Press cable end-pieces onto relay lever

• Relay lever has been removed.
• Cable end-piece may be pressed only onto bush -arrow-.
• Cable end-piece must move freely on relay lever.
• It must be located behind catch -arrow 2- ⇒ page 74 .
Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
Installation position of securing clips -1- and -2-.
1.10 Adjusting selector mechanism

agen
AG. Volkswagen AG d
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♦ Pin - T10027 A- byV ua
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pt
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ility
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es, in part or in w
t to the co
rrectness of i
Prerequisites for adjustment

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• Moving parts of selector mechanism and elements transferring

force must be in proper condition.
nf
ercia
• Selector mechanism must move freely.

orm
m
atio
• Gearbox, clutch and clutch mechanism must be in proper con‐

om
n in
dition.
or c
thi
te
• Gearbox must be in neutral.

sd
iva
o
r
rp
cu
– Remove air filter housing if it prevents access to gearbox se‐

o
m
f
en
ng
lector lever and cable end-pieces of gear selector cable and

t.
yi Co
op
gate selector cable ⇒ Rep. gr. 24 ; Air filter; Removing and C py
t. rig
installing air filter housing .
gh ht
pyri by
Vo
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by
– Check neutral position by pushing down gearbox selector lev‐ cted agen
Prote AG.
er in -direction of arrow-.
• Gearbox selector lever returns to initial position on its own.

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u5-speed manual gearbox 0CF - Edition 06.2018
th or
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ss
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Open cable end-pieces on gearbox:
nl
pt
du
an
itte
y li
– Pull cable end-piece off gear selector cable and gate selector
erm
ab
cable forward to stop in -direction of arrow 1- and then lock in
ility
ot p
wit
, is n
h re
• It must be possible to push the cables into the cable end-piece.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
up!
nf
ercia
orm
• It must be possible to push the cables into the cable end-piece.
m
atio
om
Depending on equipment, the gear selector cable may be acces‐
n in
or c
sible only from beneath vehicle in -direction of arrow-.
thi
te
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Move gear lever in correct position for adjustment:

– Remove gaiter and, if necessary, noise insulation from centre
console ⇒ page 67 .
– Move gear lever to neutral position, press it to left and hold in
this position.
– Push locking pin - T10027 A- through hole -A- into hole -B-.
• Gate selector cable and gear selector cable -B- are located
stress-free in cable end-pieces -A-.
– Now turn locking mechanism on gear selector cable and gate
selector cable end pieces as far as stop in
The spring presses the locking mechanism into original position
AG. Volkswagen AG d
agen oes
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Polo 2014u➤ th , up! 2012 ➤ , up! 2017 ➤
o eo
ra
a
5-speeds manual gearbox 0CF - Edition 06.2018
s c
ce
le
un
pt
– Pull locking pin out of holes -A- and -B-.
an
d
itte
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erm
ab
– Install gaiter and, if present, noise insulation ⇒ page 67 .
ility
ot p
wit
– Check selector shaft can move freely.
is n
h re
ole,
– Check selector mechanism ⇒ page 78 .
spec
t to the co
Air filter; Removing and installing air filter housing .
rrectness o
cial p
f inform
1.11 Checking selector mechanism
mer
atio
m
• With gearbox in neutral, gear lever must be in gear lever gate

o
n
c
i
or
n
for 3rd and 4th gear.
thi
te
sd
va
– Operate clutch.
i
o
pr
cum
r
fo
– Select all gears several times.
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ng
t.
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– If gear lever needs to be “pushed down” to engage reverse
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gear, pay particular attention to operation of reverse gear lock.
rig by
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cted
– If the difficulty in engaging a gear persists after repeated at‐
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Prote AG.
tempts, repeat adjustment procedure of selector mechanism
⇒ page 76 .
1.12 Dismantling and assembling selector

mechanism
⇒ “1.12.1 Dismantling and assembling selector mechanism, -
gear lever is NOT pushed down to engage reverse gear”,
page 78
1.12.1 Dismantling and assembling selector

mechanism, - gear lever is NOT “pushed
down” to engage reverse gear

♦ Release tool - T10236-
♦ Press tool - VW 412-
♦ Assembly tool - T10178-
♦ Adapter - 10 - 222 A /25-
♦ 2 = counter support e.g. from -Kukko- , type 16

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
♦ Wedge - T10357-
Dismantling
– Remove selector mechanism ⇒ page 69 .
– Bend open tabs -arrows- of base plate using a screwdriver
(here only tabs on left side of base plate are marked).
– Remove base plate.
– Remove gasket ⇒ Item 15 (page 63) from selector housing.
– Remove gear selector cable and gate selector cable from se‐
lector housing ⇒ page 82 .
– Pull clip -A- out of bearing shaft for gate selector lever.
– Use screwdriver to press down catch -B- of bearing bush for

gate selector lever. Break off catch if necessary.
– Push bearing bush for gate selector lever out of selector hous‐
ing.
AG. Volkswagen AG d
agen oes
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nl
pt
du
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itte
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ab
ility
– Use screwdriver to press catches -arrows- of ball socket to‐

ot p
wit
wards bearing ball of gear lever guide. Break off catches if

, is n
h re
necessary.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
io
– Lever ball socket and gear lever out of selector housing

n
c
in t
r
-arrow A-.
o
his
ate
do
riv
– Then press ball socket off bearing ball of gear lever guide
p
cum
or
-arrow B- and remove gear lever with gate selector lever.

f
en
ng
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Cop py
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Prote AG.
Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
– Clamp gear lever with gate selector lever in a vice with pro‐
tective jaws.
– Push gate selector lever off gear lever in -direction of arrow-.
Caution
The compression spring -A- may snap off the gate selector
lever in an uncontrolled manner.
Assembling
– Fit bearing bush onto gear lever. n AG. Volkswagen AG do
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ed ran
Installation position of bearing bush thoris tee
or
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Slots around bearing bush -arrow- sare
s pointing towards gear lev‐
ce
le
er.
un
pt
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ole,
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t to the co
rrectne
– Install gate selector lever together with compression spring to
gear lever:
ss o
cial p
f
• Ends -A- and -B- must point in same direction.
inform
mer
– Fit end -A- of compression spring into guide from above (in
atio
direction of gear lever).
om
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or
– Carefully pull end -B- of compression spring down and fit into
thi
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guide (in direction of gear lever).

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– Push gate selector lever -arrow- onto gear lever.

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The compression spring A must not snap off the gate selector
agen
Prote AG.
lever in an uncontrolled manner.
– If removed, push ball sockets onto gear lever.
Installation position of ball sockets

Pins -A- are located in holes -B-.

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
– Fit new ball socket -A- onto gear lever.

– Grease ball socket -A- and ball sockets of gear lever.
– Rotate ball socket in -direction of arrow-.
• Seat of journal -1- is in recess -2- of ball socket -A-.
• Damping -4- is fitted between ends of spring -3-.
– Push ball socket -A- together with gear lever and gate selector
lever into selector housing. Note correct installation position
⇒ page 81 .
• All 4 retaining lugs must engage.
– Slide in bearing bush -B- for gate selector lever.
AG. Volkswagen AG d
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Installation position of bearing bush d by V o gu
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Catch -B- must engage in recess uin tho selector housing. eo
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– Secure gate selector lever with clip -A-.
s
ce
le
un
– Install gear selector cable and gate selector cable ⇒ page 62 pt

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and ⇒ page 65 . y li
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ility
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Installing base plate to selector housing

rrectness of i
– Fit new seal to base plate.

l purpos
Caution
nform
mercia
Risk of damage to selector housing and floor plate.

com
tion in
r
Only lightly tighten selector housing.

te o
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– Secure base plate by bending down tabs -arrows- around cir‐

en
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t.
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cumference of base plate (here only tabs on left side of base
Co
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plate are marked).
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– Tabs can be bent down using wedge - T10357- .
c by lksw
cted agen
Prote AG.
- A- = counter support e.g. from -Kukko- , type 16
– Bond new gasket ⇒ Item 15 (page 63) to selector housing.
– Install selector mechanism ⇒ page 69 .
Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
1.13 Removing and installing selector cable

⇒ “1.13.1 Removing and installing selector cable, - gear lever is
NOT pushed down to engage reverse gear”, page 82
1.13.1 Removing and installing selector cable,

- gear lever is NOT “pushed down” to
engage reverse gear
♦ Release tool - T10236-
Removing
– Remove selector mechanism ⇒ page 69 .
– Bend open tabs -arrows- of base plate using a screwdriver
(here only tabs on left side of base plate are marked).
– Remove base plate.
– Remove seal.
AG. Volkswagen AG d
agen oes
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pe
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– Push gear selector cable -1- and gate selector cable -4- off
, is n
h re
gear lever and selector lever, e.g. using release tool - T10236-
hole
spec
or a screwdriver.
es, in part or in w
t to the co
– Pull off securing clips -2- and -3-.

– Pull gear selector cable and gate selector cable from selector
housing.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
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do
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cum
fo
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
82
Prote AG.
Rep. gr.34 - Controls, housing
Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
Installing
– Secure gear selector cable and gate selector cable to selector
housing using securing clips -2- and -3-.
– Push gear selector cable -1- onto gear lever and gate selector
cable -4- onto gate change lever in selector housing.
– Secure base plate to selector housing by pressing down tabs

-arrows- ⇒ page 81 .
– Install selector mechanism ⇒ page 69 .
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1.14 Renewing selector shaft seal
d ran
ir se tee
tho
u or
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ss equipment required
ce
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nl
pt
♦ Removal tool - T20143/1-

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itte
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ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
♦ Tube - VW 423-
m
at
om
ion
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or
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ate
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priv
cum
for
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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.
♦ Sealing grease
Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
– Remove air filter housing completely if it is located above se‐

lector mechanism ⇒ Rep. gr. 24 ; Air filter; Removing and
installing air filter housing .
box selector lever.
– Pull gear selector cable off pin.
– Remove relay lever -3- together with cable end-piece
⇒ page 74 .
. Volkswagen AG
wa gen AG does
– Remove gearbox selector lever by unscrewing nutV-4-.
olks not
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by ara
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au ra
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nl
pt
du
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– Lever out seal with oil seal extractor lever - T20143/1- .
ility
ot p
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
om
i
– Half-fill space between sealing lip and dust lip -arrow- with
on
c
in t
sealing grease .
or
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ate
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for
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Cop py
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rig ht
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co Vo
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Prote AG.
– Drive seal in with tube - VW 423- onto stop.

Perform further installation in reverse order, paying attention to
the following:
– Attach gearbox selector lever to gearbox selector shaft
⇒ page 65 .
– Tighten hexagon nut to specified torque
⇒ Item 13 (page 66) .
Air filter; Removing and installing air filter housing .

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
2 Removing and installing gearbox

⇒ “2.1 Specified torques for gearbox”, page 85
⇒ “2.2 Removing gearbox”, page 85
⇒ “2.3 Installing gearbox”, page 101
2.1 Specified torquesefor gearbox

n AG. Volkswagen AG
wag does
olks no
Item Bolt d by V Quantity Nm t guar
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ris tee
1 M12 tho × 60 3 80 or
au • With insert ac
ss
tool
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un
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T10509:
an
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»65 Nm«.
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2 M12 × 70 2 80
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3 M10 × 55 3 40
h re
ole,
spec
4 For starter only 2 ⇒ Electrical
system; Rep.
t to the co
gr. 27 ; Start‐
er; Assembly
overview -
rrectne
starter
s
Item -A- for dowel sleeves for centring
s o
cial p
f inform
2.2 Removing gearbox
mer
atio
m
⇒ “2.2.1 Removing gearbox, up!”, page 85

o
n
c
i
or
n thi
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⇒ “2.2.2 Removing gearbox, Polo”, page 93

t
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2.2.1 Removing gearbox, up!

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2. Removing and installing gearbox 85

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤

equipment required
AG. Volkswagen AG d
agen oes
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d by ara
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or eo
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pt
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hole
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es, in part or in w
t to the co
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♦ Support - 10 - 222 A-
m
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♦ Adapter - 10 - 222 A /31-1-

or
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♦ Adapter - 10 - 222 A /31-2-

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♦ Support - 10 - 222 A /31-3-

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♦ Adapter - 10 - 222 A /31-5- C py
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♦ Square tube - T40091/1-
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♦ Joints - T40091/3-
Prote AG.
♦ Gearbox support - 3282-

♦ Adjustment plate - 3282/63-
♦ Adapter - 3282/64-
♦ Support elements for gearbox (determine when setting ad‐
justment plate on gearbox support )
♦ Sealing cap - T10381/1-

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
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aut ra
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ce
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un
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d
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ab
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spec
t to the co
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f inform
mer
atio
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c
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t
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♦ Engine and gearbox jack - V.A.G 1383 A-

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♦ Or engine and gearbox jack - VAS 6931- t. Cop py
rig
gh ht
♦ Insert tool - T10509- pyri by
Vo
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by c lksw
cted
agen
Prote AG.

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤

– If support bracket - 10 - 222 A- does not yet have hole marked
with -arrow-, then hole must subsequently be drilled into sup‐
port bracket.
• Dimension -a- = 225 mm.
• Hole diam. = 12.5 mm.
– Remove engine cover and air filter ⇒ Rep. gr. 24 ; Air filter;
27 ; Battery; Removing and installing battery tray .
box selector lever.
⇒ page 74 .
– Remove gearbox selector lever by unscrewing nut -4-.
– Remove cable support bracket from gearbox.

AG. Volkswagen AG d
agen oes
Bolt -arrow B- is accessible from beneath vehicle. olksw not
V gu
d by ara
e
– Tie up gear selector cable and gate selector cable.
horis nte
eo
aut ra
– Remove starter ⇒ Electrical system; Rep. gr.s 27 ; Starter;
s c
ce
e
nl
pt
du
an
itte
y li
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
rrectness of i
l purpos
– Remove clutch slave cylinder -arrows-, lay to side and secure.

nform
ercia
Do not disconnect pipes.

m
at
om
io
Caution
n
c
in t
or
his
ate
Do not operate clutch pedal any more.

do
priv
cum
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! 2012 ➤ , up! 2017 ➤
– Remove upper engine/gearbox securing bolts -arrows A- and

-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- n AG. Volkswagen AG do
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♦ Adapter - 10 - 222 A /31-2- byV
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ua
d ran
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♦ Connector - T40091/3- utho tee
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♦ Square tube - T40091/1- ss
ce
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un
pt
♦ Support - 10 - 222 A /31-3-
an
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♦ Adapter - 10 - 222 A /31-5- pe
ility
ot
wit
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Adapter - 10 - 222 A /31-1- and adapter - 10 - 222 A /31-2- are
h re
hole
placed onto suspension strut supports underneath plenum cham‐
spec
ber cover.
es, in part or in w
t to the co
Therefore, remove following components:
♦ Wiper arms ⇒ Electrical system; Rep. gr. 92 ; Windscreen
rrectness of i
wiper system; Removing and installing wiper arms .
l purpos
♦ Plenum chamber cover ⇒ General body repairs, exterior; Rep.

gr. 50 ; Bulkhead; Removing and installing plenum chamber
cover
nform
ercia
– Fit adapter - 10 - 222 A /31-1- and adapter - 10 - 222 A /31-2-

m
a
com
t
onto suspension strut supports.
ion in
r
te o
Angled pieces of adapters -arrow- point towards engine compart‐
thi
s
iva
ment.
do
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rp
cum
fo
en
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– If fitted, pull bonnet seal off lock carrier.

n
t.
yi Co
Cop py
– Position support - 10 - 222 A /31-5- above bonnet catch.
t. rig
gh ht
pyri by
Vo
o
Correct position is between 2 lugs -arrow-.
c by lksw
cted agen
Prote AG.

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
– Slide connector - T40091/3- onto support bracket - 10-222

agen
A-
AG..Volkswagen AG d
o w es n
olks ot g
– Bolt support bracket - 10-222 A- to adapter - 10d b - 222 A /31-1-
yV ua
ran
and to adapter - 10 - 222 A /31-2- . rise tee
ho t or
au ac
– Attach square tube - T40091/1- to support
ss bracket - 10-222
A- .
ce
le
un
pt
an
d
itte
– Fit square tube on support - 10 - 222 A /31-3- and adapter -
y li
rm
ab
10 - 222 A /31-5- .
pe
ility
– Then attach spindle to front engine support eye. ot
wit
, is n
h re
hole
– Take up weight of engine/gearbox assembly on spindle .
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
During subsequent work process, the drive shafts must be re‐

moved.
m
a
com
tion in
– Loosen securing nuts -arrow- for drive shafts ⇒ Running gear,
r
te o
thi
axles, steering; Rep. gr. 40 ; Drive shaft; Removing and in‐
s
iva
stalling drive shaft .
do
r
rp
cum
fo
– Cover pendulum support.
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Drain gearbox oil -arrow- ⇒ page 134 .
– 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.
– Remove drive shafts with joint sections ⇒ Running gear,
axles, steering; Rep. gr. 40 ; Drive shafts; Removing and in‐
stalling drive shafts .

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
– Install sealing caps in gearbox.
– If fitted, separate connectors.

– Pull connector -1- off gearbox neutral position sender - G701- .
– Pull connector -2- off reversing light switch - F4- .
– Pull connector -1- off oil level and oil temperature sender -
G266- .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
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ility
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wit
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hole
spec
es, in part or in w
– Remove pendulum support.
t to the co
– Detach exhaust system ⇒ Rep. gr. 26 ; Emission control;
Assembly overview – emission control .
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! 2012 ➤ , up! 2017 ➤
en AG. V
olkswagen AG
ag does
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Vol gu
– Remove hexagon bolt -arrow- for left-handed
b assembly
y mount‐ ara
nte
ing from gearbox mounting. thoris 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
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hole
spec
es, in part or in w
t to the co
rrectness of i
– Tilt engine/gearbox assembly.
l purpos
• Securing bolts for gearbox bracket -A- must be accessible.

– Remove gearbox bracket -A-.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
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Cop py
t. rig
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pyri by
Vo
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– Unscrew engine/gearbox connecting bolt -arrow- in area of by c lksw
cted agen
right-hand drive shaft seal.
Prote AG.
Gearbox support - 3282- is aligned with adjustment plate -

3282/63- for removal of gearbox.
– Insert gearbox support - 3282- into engine and gearbox jack .
– Align arms of gearbox support according to holes in adjust‐
ment plate .
– Attach support elements -A- to adjustment plate as illustrated.

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d byV
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Polo 2014 ➤ , up!ot2012
gu
ara ➤ , up! 2017 ➤
o
ir se 5-speed manual gearbox 0CF - nEdition
tee 06.2018
uth or
a ac
ss
– Position engine and gearbox jack under vehicle. Arrow -B- on
ce
e
nl
adjustment plate points in direction of vehicle travel.
pt
du
an
itte
y li
– Align adjustment plate parallel to gearbox.
erm
ab
ility
ot p
– Then screw pin - 3282/29- into rear hole on gearbox for se‐
wit
, is n
curing bolt of pendulum support.
h re
hole
spec
– Secure gearbox with adapter - 3282/64- .
es, in part or in w
t to the co
– Remove lower engine/gearbox connecting bolts.
– Carefully press gearbox off dowel sleeves.
rrectness of i
l purpos
– Alternately lower gearbox ends in area of 5th gear (-area A-)

and in area of differential (-arrow B-) using spindles of gearbox
nform
ercia
support - 3282- .
m
at
om
i
– When lowering gearbox, change position of gearbox using
on
c
spindles of gearbox support - 3282- .
in t
or
his
ate
do
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Note
f
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ng
t.
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op py
Observe connecting lines, hoses and radiator when moving en‐ t. C rig
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gine/gearbox assembly. pyri by
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Prote AG.
⇒ “2.3.1 Installing gearbox, up!”, page 101
2.2.2 Removing gearbox, Polo

Polo 2014 ➤ , up! 2012 ➤ , 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
ility
ot p
wit
, is n
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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
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♦ Support - 10 - 222 A-
sd
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♦ Adapter - 10 - 222 A /8- cu

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ng
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♦ Gearbox support - 3282- t. Cop py
rig
gh ht
♦ Adjustment plate - 3282/70- pyri by
Vo
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by c lksw
cted agen
♦ Support elements for gearbox (determine when setting ad‐ Prote AG.
justment plate on gearbox support )
♦ Gearbox lifting tackle - 3336- for transporting gearbox

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
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un
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d
itte
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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
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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cum
fo
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Adapter - 3282/64-
♦ Sealing cap - T10381/1-
♦ Tensioning strap - T10038-
♦ Insert tool - T10509-

Polo 2014 ➤ , up! 2012 ➤ , 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
m
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om
n in
or c
thi
te
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cu
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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.

♦ Engine and gearbox jack - V.A.G 1383 A-
♦ Or engine and gearbox jack - VAS 6931-
– Remove engine cover and air filter ⇒ Rep. gr. 24 ; Air filter;
27 ; Battery; Removing and installing battery tray .

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
box selector lever.
⇒ page 74 .
– Remove cable support bracket from gearbox.

– Tie up gear selector cable and gate selector cable.
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter;
olkswagen AG
– Remove clutch slave cylinder -arrows-, lay to side and asecure.
gen AG
.V
does
ksw
Do not disconnect pipes. by
Vol not
gu
ara
ed nte
ris
tho eo
Caution au ra
c
ss
ce
le
un
pt
Do not operate clutch pedal any more.

an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Remove upper engine/gearbox securing bolts -arrows A- and

-arrows B-.
rrectne
– Loosen bolts -arrows A- if necessary using insert tool, 18 mm

- T10509- .
ss o
cial p
– Remove foam pieces or seal from upper edge of left and right
inform
wings ⇒ General body repairs, exterior; Rep. gr. 50 ; Wings;

mer
Assembly overview – wings .

atio
om
n
c
i
or
n thi
te
sd
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cum
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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! 2012 ➤ , up! 2017 ➤
– Set up support bracket - 10-222 A- behind bonnet support.

Required material:
♦ Adapter - 10 - 222 A /8-
♦ Tensioning strap - T10038-
– Both adapters - 10 - 222 A /8- :
• need to be fitted directly in front of plenum chamber cover
-arrow-.
– Make sure not to damage paint on edges -arrows-.

– Secure both adapters - 10 - 222 A /8- with tensioning straps -
T10038- .
– Then, attach spindle to lifting eye of engine.
– Take up weight of engine/gearbox assembly on spindle .
AG. Volkswagen AG d
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During subsequent work process, the drive shafts must be re‐ s
ce
le
moved.
un
pt
an
d
itte
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– Loosen securing nuts -arrow- for drive shafts ⇒ Running gear,

erm
ab
axles, steering; Rep. gr. 40 ; Drive shaft; Removing and in‐

ility
ot p
stalling drive shaft .

wit
is n
h re
ole,

spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
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Cop py
ht. rig
rig ht
py by
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co Vo
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cted
agen
Prote AG.
Polo 2014 ➤ , up! 2012 ➤ , 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.
– Remove drive shafts ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Drive shaft; Removing and installing drive shaft .
– Install sealing caps in gearbox.

– Remove cable retainer at front on gearbox ⇒ Electrical sys‐
tem; Rep. gr. 27 .
AG. Volkswagen AG d
agen oes
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nl
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– If fitted, separate connectors.

erm
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ility
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– Pull connector -1- off gearbox neutral position sender - G701- .

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
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ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
– Pull connector -1- off oil level and oil temperature sender -
G266- .
– Remove pendulum support.
Caution
Risk of damage to flexible joint.

♦ Observe ⇒ Rep. gr. 26 ; Emission control; Assembly
overview - emission control .
– Detach exhaust system ⇒ Rep. gr. 26 ; Emission control;

Assembly overview – emission control .
– Remove hexagon bolts -arrows- for left assembly mounting

from gearbox mounting.
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– Tilt engine/gearbox assembly.
hole
spec
es, in part or in w
• Securing bolts for gearbox bracket -A- must be accessible.

– Remove gearbox bracket -A-. t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
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or
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ate
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priv
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for
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
– Unscrew engine/gearbox connecting bolt -arrow- in area of

right-hand drive shaft seal.
en AG . Volkswag
Gearbox support - 3282-ksw
isagaligned
en AG with adjustment
does plate -
not
3282/70- for removal
by of gearbox.
Vol
gu
a d ran
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– Insert gearbox
tho support - 3282- into engine and gearbox jack
r tee
o . u ra
sa c
– Align arms
s of gearbox support according to holes in adjust‐
ce
e
ment plate .
nl
pt
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itte
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ab
ility
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wit
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hole
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es, in part or in w
– Align adjustment plate parallel to gearbox. t to the co

rrectness of i
l purpos

nf
ercia
– Remove lower engine/gearbox connecting bolts.

orm
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atio
– Carefully press gearbox off dowel sleeves.

om
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– When lowering gearbox, change position of gearbox using

thi
e
spindles of gearbox support - 3282- .

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Note
Co
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rig ht
Observe connecting lines, hoses and radiator when moving en‐
py by
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gine/gearbox assembly. Prote
cted AG.
agen
⇒ “2.3.2 Installing gearbox, Polo”, page 106
2.3 Installing gearbox

⇒ “2.3.1 Installing gearbox, up!”, page 101
⇒ “2.3.2 Installing gearbox, Polo”, page 106
2.3.1 Installing gearbox, up!
Note
Refer to procedure “Removing gearbox” for required special tools

⇒ page 85 .
– If the gearbox is to be renewed, the gearbox selector lever and

relay lever must be transferred to the new gearbox.

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
– All threaded holes into which self-locking bolts are to be

screwed must be cleaned of residual locking fluid carefully with
a thread tap.
– 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.
– If no dowel sleeves for aligning engine and gearbox are fitted
in cylinder block, 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.
3282/63- for installation of gearbox.
ment plate .
– Align gearbox parallel to adjustment plate and set on engine

and gearbox jack . en AG. V
olkswagen AG
ag does
lksw n
– Then screw pin - 3282/29-byintoVo rear hole on gearbox for se‐
ot g
ua
d
curing bolt of pendulum
o
ir sesupport.
ran
te
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– Secure gearbox with
ss
a adapter - 3282/64- . c
ce
le

un
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d

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pe
ility
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es, in part or in w
t to the co
Gearbox ends in area of 5th gear (-area A-) and in area of differ‐
ential (-arrow B-) are facing downwards.
– Then raise gearbox carefully and guide past subframe.
rrectness of i
l purpos
Note
nform
ercia
Be careful of all lines when installing gearbox.

m
a
com
tion in
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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! 2012 ➤ , up! 2017 ➤
– Line up gearbox and install.

– Screw in engine/gearbox connecting bolt -arrow- in area of
right drive shaft seal ⇒ page 85 .
– Install lower engine/gearbox securing bolts ⇒ page 85 .
– After gearbox has been bolted to engine, remove engine and
gearbox jack from gearbox.
– Fit gearbox bracket -A- with new bolts ⇒ page 110 .
AG. Volkswagen AG d
agen oes
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– Align engine and gearbox in installation position.
ility
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wit
– Install new bolt -arrow- for left assembly mounting in gearbox
, is n
mounting ⇒ page 110 . h re

hole
spec
– Do not remove engine support bracket - 10 - 222 A- until all
es, in part or in w
t to the co
bolts securing the assembly mounting have been tightened to

specified torque.
– If previously removed, fit bonnet seal to lock carrier.
rrectness of i
l purpos
nform
mercia
at
om
– Install upper engine/gearbox securing bolts -arrows A- and

ion
c
-arrows B- ⇒ page 85 .
in t
or
his
te
– Bolts -arrows A- can be tightened using insert tool, 18 mm -

a
do
riv
T10509- .
p
cum
for
en
ng
t.
– Fit earth strap if necessary. Cop
yi Co
py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
– Install pendulum support using new bolts ⇒ Rep. gr. 10 ; As‐

sembly mountings; Assembly overview – assembly mount‐
ings .
– Install exhaust system ⇒ Rep. gr. 26 ; Emission control; As‐
sembly overview – emission control .
AG. Volkswagen AG d
agen oes
– Install drive shafts ⇒ Running gear, axles, steering; Rep. gr. olks
w not
yV gu
40 ; Drive shaft; Removing and installing drive shafts .sed b ara
nte
ri
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
– Install coupling rod -1- to anti-roll bar on both sides ⇒ Running
wit
, is n
gear, axles, steering; Rep. gr. 40 ; Subframe; Assembly over‐
h re
hole
view – subframe .
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
– If present, join connectors as follows:
r
te o
thi
s
iva
– Fit connector -1- to gearbox neutral position sender - G701- .
do
r
rp
cum
fo
– Fit connector -2- to reversing light switch - F4- .
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Fit connector -1- to oil level and oil temperature sender -

G266- .

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
– Install clutch slave cylinder -arrows- ⇒ page 41 .

– Install cable support bracket to gearbox ⇒ page 65 .

AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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– Install gearbox selector lever
aut and tighten hexagon nut -4- to
h
ra
specified torque ⇒ pages65 .
s c
ce
e
nl
pt
– Install relay lever -3- together with cable end-piece

du
an
itte
⇒ page 74 ⇒ page 74 .
y li
erm
ab
ility
– Spread a small amount of grease on pin of gearbox selector

ot p
wit
lever.
, is n
h re
hole
Allocate grease using ⇒ Electronic parts catalogue (ETKA) .

spec
es, in part or in w
– Attach gear selector cable -2- to gearbox selector lever.

t to the co
– Install new clip -1-.

rrectness of i

l purpos
– Fill with gear oil ⇒ page 134 .

nf
ercia

orm
m

atio
m

o
n in
or c
necting battery .
thi
te
sd
iva
– Install engine cover and air filter ⇒ Rep. gr. 24 ; Air filter;
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! 2012 ➤ , up! 2017 ➤
2.3.2 Installing gearbox, Polo
Note
Refer to procedure “Removing gearbox” for required special tools

⇒ page 93 .
– 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 bolts are to be
screwed must be cleaned of residual locking fluid carefully with
a thread tap.
– 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.
– If no dowel sleeves for aligning engine and gearbox are fitted
in cylinder block, 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.
3282/70- for installation of gearbox.
ment plate .
AG. Volkswagen AG d
agen
– Attach support elements -A- to adjustment
Vol
ksw plate as illustrated.oes not g
by ua
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oris tee
th or
au ac
ss
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un
pt
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d
itte
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ab
– Align gearbox parallel to adjustment plate and set on engine

ility
ot p
and gearbox jack .

wit
is n
h re
ole,
spec

t to the co

rrectne

– Then raise gearbox carefully and guide past subframe.
ss o
cial p
f inform
Note
mer
atio
om
Be careful of all lines when installing gearbox.

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! 2012 ➤ , up! 2017 ➤
– Line up gearbox and install.

– Screw in engine/gearbox connecting bolt -arrow- in area of
right drive shaft seal ⇒ page 85 .
– Install lower engine/gearbox securing bolts ⇒ page 85 .
– After gearbox has been bolted to engine, remove engine and
gearbox jack from gearbox.
– Fit gearbox bracket -A- with new bolts ⇒ page 112 .
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
– Align engine and gearbox in installation position.
hole
spec
es, in part or in w
– Install new bolts -arrows- for left assembly mounting in gear‐
t to the co
box mounting ⇒ page 112 .
– After having tightened all assembly mounting bolts to specified
rrectness of i
torque, remove engine and gearbox jack .
l purpos
– If previously removed, fit bonnet seal to lock carrier.

nform
mercia
at
om
ion
c
in t
or
his
ate
– Install upper engine/gearbox securing bolts -arrows A- and

do
priv
-arrows B- ⇒ page 85 .
um
for
en
ng
t.
yi
– Bolts -arrows A- can be tightened using insert tool, 18 mm -
Co
op py
T10509- .
t. C rig
gh ht
pyri by
Vo
– Fit earth strap if necessary.
o
by c lksw
cted agen
Prote AG.

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
– Install pendulum support using new bolts ⇒ Rep. gr. 10 ; As‐

sembly mountings; Assembly overview – assembly mount‐
ings .
– Install exhaust system ⇒ Rep. gr. 26 ; Emission control; As‐
sembly overview – emission control .
– Install drive shafts ⇒ Running gear, axles, steering; Rep. gr.
40 ; Drive shaft; Removing and installing drive shafts .
– 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
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ss c
– If present, join connectors as follows:
ce
e
nl
pt
du
an
– Fit connector -1- to gearbox neutral position sender - G701- .
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
– Fit connector -1- to oil level and oil temperature sender -

nf
ercia
G266- .
orm
m
atio
– Install cable retainer at front on gearbox ⇒ Electrical system;

om
Rep. gr. 27 .
n in
or c
thi
te
sd
iva
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rp
cu
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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! 2012 ➤ , up! 2017 ➤
– Install clutch slave cylinder -arrows- ⇒ page 41 .

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
– Install cable support bracket to gearbox ⇒ page 65 .

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
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f
en
– Install gearbox selector lever and tighten hexagon nut -4- to

ng
t.
yi Co
specified torque ⇒ page 65 . ht. Cop py
rig
rig ht
– Install relay lever -3- together with cable end-piece py by
co Vo
⇒ page 74 ⇒ page 74 .
by lksw
cted agen
Prote AG.
lever.
necting battery .
– Install engine cover and air filter ⇒ Rep. gr. 24 ; Air filter;
– 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 .

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
3 Assembly mountings
⇒ “3.1 Assembly overview - assembly mountings”, page 110
3.1 Assembly overview - assembly mount‐

ings
⇒ “3.1.1 Assembly overview – assembly mountings, up!”,
page 110
⇒ “3.1.2 Assembly overview – assembly mountings, Polo”,
page 112
3.1.1 Assembly overview – assembly mountings, up!
1 - Engine mounting
❑ ⇒ Rep. gr. 10 ; Assem‐
bly mountings; Assem‐
bly overview - assembly
mountings
2 - Bolt agen
AG. Volkswagen AG d
oes
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❑ Pendulum support d by to
V o gu
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subframe orise nte
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❑ ⇒ Rep. gr. s a 10 ; Assem‐
u ra
c
s
ce
le

un
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an
d
mountings
itte
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erm
ab
3 - Pendulum support
ility
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is n
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ole,
spec

mountings
t to the co
4 - Bolt
❑ Pendulum support to
rrectne
gearbox
ss

o
cial p

inform
mountings
mer
atio
5 - Bolt
om
n
c

i
or
n thi
te
sd
❑ Gearbox bracket to
iva
o
r
gearbox
p
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ng
❑ 40 Nm +90°
t.
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Cop py
6 - Gearbox bracket
t. rig
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pyri by
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o
7 - Gearbox mounting
c by lksw
cted agen
Prote AG.
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

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
10 - Bolt
❑ Gearbox bracketento
AGgearbox
. Volkswagmounting
en AG
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❑ 60 Nm +180°
y Volks not
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Gearbox bracket
s -A- to gearbox
ce
e
nl
pt
du
– Renew bolts.
an
itte
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ab
– Screw in all bolts hand-tight.
ility
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– Tighten bolts to specified torque ⇒ Item 5 (page 110) .
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Gearbox to body
nf
ercia
– Renew bolt.
orm
m
atio
– Tighten bolts by hand.
om
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– Tighten bolt to specified torque ⇒ Item 10 (page 111) .

thi
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t.
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Cop py
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Prote AG.
3. Assembly mountings 111

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
3.1.2 Assembly overview – assembly mountings, Polo
1 - Bolt
❑ Qty. 2
❑ Gearbox bracket to
gearbox mounting
❑ 40 Nm +90°
2 - Bolt
❑ Gearbox mounting to
body
mountings
3 - Gearbox mounting
mountings
4 - Gearbox bracket
5 - Bolt
❑ Qty. 3 agen
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❑ Renew after removal d by V gu
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❑ Gearbox bracket to thor eo
gearbox ss au ra
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❑ 40 Nm +90°
ce
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nl
pt
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an
itte
6 - Pendulum support
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ab
ility
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wit
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hole
mountings
spec
es, in part or in w
7 - Bolt
t to the co
❑ Pendulum support to
subframe rrectness of i
l purpos
8 - Bolt
❑ Pendulum support to gearbox
nform
ercia

m
at
9 - Engine mounting
om
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10 - Bolt
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❑ Qty. 4
f
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❑ Engine mounting to body
Co
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by
11 - Bolt Prote
cted AG.
agen
❑ Engine mounting to engine

12 - Bolt
❑ Qty. 2
❑ Engine mounting to engine

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
Gearbox bracket -A- to gearbox

– Renew bolts.
– Screw in all bolts hand-tight.
– Tighten bolts to specified torque ⇒ Item 5 (page 112) .
Gearbox bracket to gearbox mountingn AG. Volkswagen AG

wage does
– Renew bolts. Volks not
gu
by ara
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– Tighten bolts by hand.
tho eo
au ra
c
– Tighten bolt to specified torque ⇒ Item 1 (page 112) . ss
ce
e
nl
pt
du
an
itte
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Note
erm
ab
ility
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wit
Install engine and gearbox mounting free of tension ⇒ Rep. gr.
, is n
h re
10 ; Removing and installing engine .
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
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atio
om
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
3. Assembly mountings 113

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
4 Transporting gearbox
♦ Gearbox mounting support - 3336-
♦ Workshop hoist - VAS 6100-
– Bolt gearbox lifting tackle - 3336- to clutch housing.
lkswage es n
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d ran
ir se tee
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a ac
ss
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ab
ility
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wit
, is n
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hole
– Adjust support beam on sliding piece using locking pin

spec
-arrow-.
es, in part or in w
t to the co
Number of holes visible = 5.

– Lift gearbox using workshop crane and gearbox lifting tackle -
rrectness of i
3336- .
l purpos
– Set gearbox aside, for example in a transport container.

nform
mercia
at
om
ion
c
in t
or
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ate
do
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cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
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co lksw
by
114
cted agen
Prote AG.
Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
5 Dismantling and assembling gearbox

⇒ “5.1 Schematic overview - gearbox”, page 115
⇒ “5.2 Assembly overview - gearbox”, page 116
⇒ “5.3 Assembly overview - clutch housing”, page 117
⇒ “5.4 Assembly overview - selector unit”, page 118
⇒ “5.5 Assembly overview - shafts, differential, selector mecha‐
nism”, page 119
⇒ “5.6 Removing and installing selector unit with gearbox instal‐
led”, page 119
⇒ “5.7 Renewing selector shaft sleeve”, page 123
⇒ “5.8 Dismantling and assembling gearbox”, page 124
5.1 Schematic overview - gearbox
1 - 1st gear
2 - 2nd gear
3 - 3rd gear
4 - 4th gear AG. Volkswagen AG d
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5 - 5th gear olksw not
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6 - Reverse gear wheel rise nte
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7 - Gearbox housing ss c
ce
le
un
pt
8 - Clutch housing
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9 - Input shaft
ab
pe
ility
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10 - Output shaft
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11 - Differential
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
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5. Dismantling and assembling gearbox 115

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
5.2 Assembly overview - gearbox
I-
clutch housing”, page 117
II -
⇒ “5.4 Assembly overview - se‐
lector unit”, page 118
II -
shafts, differential, selector
mechanism”, page 119
II -
⇒ “5.7 Renewing selector shaft
sleeve”, page 123
II -
⇒ “1.14 Renewing selector
shaft seal”, page 83
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es, in part or in w
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rig ht
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Prote AG.

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
5.3 Assembly overview - clutch housing

AG. Volkswagen AG d
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1 - Clutch housing d by gu
ara
rise nte
❑ Allocation ⇒ Electronic utho eo
ra
ss a c
ce
le
❑ Repairing ⇒ page 131
un
pt
an
d
itte
2 - Oil drain plug
y li
rm
ab
pe
❑ 30 Nm
ility
ot
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3 - Bolt
h re
hole
spec
es, in part or in w
t to the co
ther
4 - Gearbox housing
rrectness of i
l purpos
nform
ercia
5 - Clutch release lever

m
❑ With guide sleeve and
a
com
tio
release bearing
n in
r
te o
thi
s
iva
remove gearbox
do
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rp
cum
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⇒ page 51
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6 - Bolt
rig
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⇒ page 24 Prote AG.

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
5.4 Assembly overview - selector unit
1 - Sleeve
❑ For selector shaft
⇒ page 123
2 - Reversing light switch - F4-
❑ Switch without seal: gen AG. Volkswagen AG d
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with sealant c
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❑ For allocation of seal‐
itte
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erm
ab
parts catalogue (ET‐
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KA) .
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❑ Switch with encapsula‐
hole
spec
ted seal: renew switch
es, in part or in w
❑ Switch with separate
t to the co
seal: renew seal
❑ Lightly coat lug with
rrectness of i
MoS2 grease
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❑ Tighten to 20 Nm
3 - Selector unit
nf
ercia
❑ (Selector shaft with se‐

orm
lector shaft cover)

m
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⇒ page 118
o
n in
or c

thi
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sd
with gearbox installed

iva
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⇒ page 119
rp
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4 - Relay lever
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⇒ Item 16 (page 66) p by
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5 - Clip Prote AG.
6 - Hexagon nut
❑ Self-locking
❑ 25 Nm
7 - Gearbox selector lever
❑ Illustration may differ from original component.
❑ Install so that master spline aligns with selector shaft
❑ Can be renewed with the selector mechanism installed
8 - Seal
9 - Cap
❑ For gearbox breather

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
5.5 Assembly overview

en AG. V
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1 - Gearbox housing oris nte
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th
❑ With reverse
ss
au shaft ra
c
-arrow-
ce
le
un
pt
❑ It is not necessary to re‐
an
d
itte
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move reverse shaft to
erm
ab
allow for removal of re‐
ility
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verse gear wheel
wit
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❑ Repairing gearbox
ole,
housing ⇒ page 131
spec
t to the co
2 - Selector unit
rrectne
❑ (Selector shaft with se‐
lector shaft cover)
s
⇒ page 118
s o
cial p
f
inform
mer
⇒ page 119
atio
om
n
c
3 - Bolt
i
or
n thi
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❑ Self-locking
t
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4 - Gearbox neutral position cop Vo
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sender - G701- cted agen
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❑ Installed depending on
version.
5 - Bolt
❑ 6 Nm
❑ (Selector forks)
7 - Input shaft
❑ Dismantling and assembling ⇒ page 136
8 - Output shaft
9 - Differential
10 - Thrust washer
11 - Needle bearing
12 - Reverse gear wheel
13 - Thrust washer
5.6 Removing and installing selector unit


AG. Volkswagen AG d
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ise ➤ , up! 2017 ➤ nte
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5-speed manual aut gearbox 0CF - Edition 06.2018 ra
c
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nl
♦ Torque wrench - VAS 6583-
pt
du
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itte
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spec
es, in part or in w
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rrectness of i
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nform
ercia
Removing
m
at
If installed above selector unit, remove following components:
om
ion
c
in t
r
– Complete air filter housing ⇒ Rep. gr. 24 ; Air filter; Removing

o
his
e
and installing air filter housing .

at
do
priv
cum
– Battery and battery tray ⇒ Electrical system; Rep. gr. 27 ;
for
en
g
Battery; Removing and installing battery tray .

n
t.
yi Co
Cop py
• Gearbox in neutral position (arrows).
t. rig
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box selector lever.
⇒ page 74 .
– Separate connectors:
– If present: pull off connector -1- from gearbox neutral position
sender - G701- .
– Remove gearbox neutral position sender - G701- -1-.

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
– 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.
– Pull off selector unit -A-.

The selector unit is located just under the clutch slave cylinder
-B- -arrow-.
The selector unit may come into contact with the clutch slave cyl‐
inder slightly. wage
e
olks s no
t gu
– Pull off selector unit from relay ed
lever
by
V
mounting -1- and mount‐ ara
ing for reversing light switch
horis- F4- -2-. nte
eo
t
au ra
– Clean all sealing surfaces.
ss c
ce
le
un
pt
– Cover gearbox.
an
d
itte
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Installing
wit
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es, in part or in w
t to the co
rrectness of i
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nform
mercia
a
com
tion in
• The selector shaft is in the neutral position (shown here with

r
te o
thi
the selector unit installed).

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• The selector rods -A- of the gearbox are in neutral position.

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• All sealing surfaces are cleaned.
Co
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• Apply sealant evenly at several points to the sealing surfaces rig ht
py by
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of the selector unit.
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Prote AG.

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
Installation position: The selector unit -A- is located just under the
clutch slave cylinder -B- (-arrow-).
– Press the selector unit on the relay lever mounting -1- and the
mounting for the reversing light switch - F4- -1-.
– Tighten selector unit with new bolts -arrows- ⇒ page 119 .
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– If fitted, install gearbox neutral position sender - G701- -1-
h re
ole,
⇒ page 119 .
spec
– Fit electrical connectors:
t to the co
– If present: fit connector -1- to gearbox neutral position sender
- G701- . rrectne
ss
– Slightly pull on connector to ensure it is properly engaged.

o
cial p
f inform
mer
atio
om
n
c
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or
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Cop py
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Vo
co lksw
by
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Prote AG.

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
– Install gearbox selector lever and tighten hexagon nut -4- to

specified torque ⇒ page 118 .
– Install relay lever -3- together with cable end-piece
⇒ page 74 .
lever.
– If removed, install battery ⇒ Electrical system; Rep. gr. 27 ;
AG. Volkswagen AG d
Battery; Removing and installing
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agen battery . oes
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– Connect battery and edfollow procedure after connecting battery
b ara
nte
ris
⇒ Electrical system;
utho Rep. gr. 27 ; Disconnecting and con‐ eo
necting battery
ss .
a ra
c
ce
le
– If removed, assemble engine cover panel and air filter ⇒ Rep.

un
pt
an
d
gr. 24 ; Air filter, Removing and installing air filter housing .

itte
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rm
ab
Specified torques
pe
ility
ot
wit
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♦ Selector unit to gearbox ⇒ page 119
h re
hole
spec
5.7 Renewing selector shaft sleeve
es, in part or in w
t to the co
♦ Drift - VW 222 A-
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
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Cop py
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co
♦ Drift - 3264-
by lksw
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Prote AG.

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
– Remove selector shaft with selector mechanism cover, input

shaft, output shaft, differential and selector mechanism
⇒ page 124 .
Driving out selector shaft sleeve -A-
Driving in selector shaft sleeve -A- to stop

– Assembling gearbox ⇒ page 124 .
AG. Volkswagen AG d
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olksw not
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un
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itte
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ab
ility
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wit
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ole,
5.8 Dismantling and assembling gearbox
spec
t to the co
Removing and installing clutch housing, differential, selector shaft
with selector mechanism cover, reverse gear wheel, input shaft,
output shaft and selector forks rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
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sd
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Cop py
t. rig
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co lksw
by
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Prote AG.

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤

equipment required
AG. Volkswagen AG d
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d by ara
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♦ Support clamps a-u VW 313- ra
c
s
ce
♦ Gearbox support - T10484-

e
nl
pt
du
an
itte

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ab
ility
♦ Drip tray - V.A.G 1306-

ot p
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♦ or drip tray for workshop hoist - VAS 6208-

h re
hole
spec
♦ Sealant
es, in part or in w
t to the co
♦ Allocation ⇒ Electronic parts catalogue (ETKA)

Dismantling gearbox
rrectness of i
– Secure gearbox on gearbox support ⇒ page 133 .

l purpos
– Place drip tray underneath.

nf
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orm
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5. Dismantling and assembling gearbox
AG.
Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
– Remove clutch release lever -A- together with release bearing

and guide sleeve -arrows-.
– Unscrew bolts 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.
– Remove differential -A- from gearbox housing.

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un
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itte
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ab
ility
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wit
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ole,
spec
t to the co
– If fitted, remove gearbox neutral position sender - G701-
-arrow-.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
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en
ng
t.
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– Remove selector shaft with selector cover -A-. Place selector Cop py
shaft in neutral. Then remove bolts -arrows- and pull selector
t. rig
gh ht
yri
shaft out of gearbox housing.
p by
o Vo
by c lksw
cted agen
Prote AG.

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
– One after other, remove thrust washer -1-, reverse gear wheel
-2-, roller bearing -3- and thrust washer -4-.
Note
To remove the reverse gear wheel, slightly lift the input shaft, and
push it away from the reverse gear wheel.
Proceed as follows to remove the input and output shafts together

with selector forks from gearbox housing:
– Swivel gearbox housing in assembly stand as shown in illus‐
tration.
– Slightly pull out shaft -1- for selector forks.
♦ Hold the input shaft and selector forks with your right hand
-2-.
♦ With your left hand, grasp the output shaft at the splines -3-,
and pull it out.
♦ Then, hold output shaft in area -4- behind locking collar
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Note tho or
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Do not press off the locking collar -arrow-. Otherwise, the locking
un
pt
an
d
pieces will be pushed out and might spring out uncontrolled.

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pe
ility
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Assembling gearbox
, is n
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hole
– Push selector forks -A-, -B- and -C- onto shaft.

spec
es, in part or in w
Installation position:
t to the co
• Position selector fork for 1st and 2nd gears -A- below selector
fork for 3rd and 4th gears -B-.
rrectness of i
• 5th gear/reverse selector fork -C- must be positioned above

l purpos
selector fork for 3rd and 4th gears -B-.

nform
mercia
a
com
tion in
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by c lksw
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Prote AG.

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
– Complete output shaft -A- and input shaft -B- with selector
forks -C-.
• The selector forks are located in the locking collars -arrows-.
Proceed as follows to install the input and output shafts together

with selector forks into gearbox housing:
– Swivel gearbox housing in assembly stand as shown in illus‐
tration. n AG. Volkswagen A ge G do
swa es
♦ Hold the input shaft and by
Vselector
olk forks with your right nhand
ot g
ua
-2-. rised ran
te
tho eo
♦ With your left shand,
sa
u
grasp the output shaft in area -4- behind ra
c
locking collar -arrow-.
ce
e
nl
pt
du
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erm
ab
Note
ility
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wit
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Do not press off the locking collar -arrow-. Otherwise, the locking
h re
pieces will be pushed out and might spring out uncontrolled.

hole
spec
es, in part or in w
t to the co
Then, grasp the output shaft at the splines -3-.

– Bring gearbox housing in assembly stand back into vertical
position.
rrectness of i
– Push input shaft, output shaft and shaft -1- for selector forks
l purpos
into their seats.

nform
mercia
at
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ion
c
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or
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ate
do
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co lksw
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Prote AG.

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
– One after other, fit thrust washer -1-, reverse gear wheel -2-,
roller bearing -3- and thrust washer -4-.
Installation position of reverse gear wheel:
♦ Chamfer -arrow- faces towards gearbox housing. AG. Volkswagen AG d
agen oes
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spec
es, in part or in w
t to the co
rrectness of i
– Place selector plates in neutral.
l purpos
– Apply sealant evenly to sealing surface of selector mechanism

cover.
nform
ercia
– Install selector shaft with selector mechanism cover -A-. Then,

m
at
om
i
tighten bolts -arrows- to specified torque.
on
c
in t
or
his
ate
do
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cum
for
en
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t. rig
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by c lksw
cted agen
Prote AG.
– Gearbox for vehicles with start/stop system: insert gearbox
neutral position sender - G701- -arrow- and tighten securing
bolt to specified torque.
– Fit differential -A-.

– Apply sealant evenly to sealing surface for clutch housing.
– Secure clutch housing to gearbox housing.

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
– Tighten oil drain plug -arrow-. (Shown here with gearbox in‐
stalled.)
Specified torques
♦ ⇒ “5.5 Assembly overview - shafts, differential, selector mech‐
anism”, page 119
♦ Gearbox housing to clutch housing
⇒ “5.3 Assembly overview - clutch housing”, page 117 .
AG. Volkswagen AG d
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spec
t to the co
rrectness o
cial p
f inform
mer
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rig ht
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co Vo
by lksw
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Prote AG.

wage es n
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b
ir se
d 5-speed manual gearbox ara
nte0CF - Edition 06.2018
tho eo
au ra
ss c
6 Gearbox housing, clutch housing
ce
le
un
pt
an
d
itte
y li
⇒ “6.1 Assembly overview - gearbox housing and clutch housing”,
rm
ab
page 131
pe
ility
ot
wit
, is n
⇒ “3.1 Removing and installing reverse shaft”, page 170
h re
hole
spec
6.1 Assembly overview - gearbox housing and clutch housing
es, in part or in w
t to the co
1 - Gearbox housing
rrectness of i
❑ If renewed: adjust input
shaft, output shaft and
l purpos
differential
⇒ page 185 .
nform
ercia
2 - Sleeve
m
a
com
tion in
r
te o
⇒ page 123
thi
s
iva
do
r
3 - Dowel sleeve
rp
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fo
en
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❑ Qty. 2
n
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op py
4 - Tapered roller bearing outer
t. C rig
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race p by
co Vo
by lksw
❑ For input shaft
cted agen
Prote AG.
❑ Pulling out of and press‐
ing into clutch housing
⇒ page 136
❑ If renewed: adjust input
shaft ⇒ page 144
race
❑ For output shaft
❑ Pulling out of and press‐
ing into clutch housing
⇒ page 151
❑ If replaced: Adjust out‐
put shaft ⇒ page 165 .
race
❑ Pulling out of clutch
housing and pressing
into clutch housing
⇒ page 151
❑ If replaced: Adjust output shaft ⇒ page 165 .
7 - Shim
❑ Adjustment overview ⇒ page 185
8 - Tapered roller bearing outer race
❑ For input shaft
❑ Pulling out of clutch housing and pressing into clutch housing ⇒ page 136
❑ If renewed: adjust input shaft ⇒ page 185
9 - Shim
❑ For input shaft
6. Gearbox housing, clutch housing 131

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
10 - Input shaft seal

11 - Ball-head pin
12 - Seal for right drive shaft
❑ Renewing with gearbox installed ⇒ page 173
13 - Oil drain plug
❑ 30 Nm
14 - Clutch housing
❑ If renewed: adjust input shaft, output shaft and differential ⇒ page 185 .
15 - Baffle plate
16 - Shim
❑ For differential
❑ Pulling out of clutch housing and pressing into clutch housing ⇒ page 174
❑ If renewed, adjust differential ⇒ page 182
18 - Reverse shaft
❑ Is damaged during removal
❑ Pulling out of and pressing into clutch housing ⇒ page 174
❑ If renewed, adjust differential ⇒ page 182 en AG. V
olkswagen AG
ag does
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20 - Baffle plate y Vol gu
b ara
ed nte
ris
21 - Solenoid tho eo
au ra
❑ Held in place by housing joint surface ss c
ce
e
nl
pt
22 - Left drive shaft seal

du
an
itte
y li

erm
ab
ility
❑ Renewing with gearbox installed ⇒ page 171

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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
nf
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orm
m
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Prote
132
AG.
Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
7 Securing to engine and gearbox support

wage es n
Special tools and workshop yV
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equipment required ir se
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wit
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spec
es, in part or in w
t to the co
rrectness of i
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nform
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a
com
tion in
r
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s
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Cop py
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by
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Prote AG.
♦ Support clamp - VW 313-

♦ Drip tray for workshop hoist - VAS 6208-
– Secure gearbox on gearbox support - T10484- -arrows-.
-A- = bolts M10 x 35.
7. Securing to engine and gearbox support 133

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
8 Gear oil olkswage

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⇒ “8.1 Checking gear oil level”, ir se page 134
d ran
tee
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or
⇒ “8.2 Draining and filling
ss
au
gear oil”, page 134 ac
ce
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8.1 Checking gear oil level
nl
pt
du
an
itte
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The oil level in the gearbox can only be checked by completely
erm
ab
ility
draining the gear oil and then refilling it ⇒ page 134 .
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wit
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8.2 Draining and filling gear oil
h re
hole
spec
es, in part or in w
t to the co
♦ Torque wrench - VAS 6583-
rrectness of i
l purpos
nf
ercia
orm
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or c
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sd
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rp
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♦ Commercially available hose (length of approx. 600 mm; ex‐ t. C rig
gh ht
ternal diameter: max. 22 mm) pyri by
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♦ Funnel, commercially available Prote AG.
♦ Receptacle (capacity 2.0 l) with graduated scale

Preparing
Gear oil ⇒ Electronic parts catalogue (ETKA) .
– During subsequent work process, sealing plug -arrow- will be
removed for filling gearbox oil.
– Clean area around sealing plug -arrow-.
Drain gear oil -arrow-.- -

Use a clean container with a scale and a capacity of approx. 2.0 l
to catch the gear oil when draining.
– Tighten oil drain plug -arrow- to specified torque.

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
Fill with gear oil

• The oil drain plug is tightened to specified torque.
Gear oil ⇒ Electronic parts catalogue (ETKA)
Topping up gear oil in container ⇒ page 8
The gearbox oil is filled through the sealing plug hole -arrow-.
It is accessible from beneath vehicle.
– Remove sealing plug -arrow-.
Note
The area beneath the sealing plug -arrow- must be covered with
a cloth.
– Use a commercially available hose (length of approx. 600 mm,

external diameter: max. 22 mm) , and a commercially available
funnel for filling oil.
– Route hose -A- through engine compartment.
– Fit hose -A- into sealing plug hole, and fill gearbox with oil.
AG. Volkswagen AG d
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ility
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– Install sealing cap, and tighten securing bolt -arrow- to speci‐

h re
fied torque.
hole
spec
es, in part or in w
• If oil should get on gearbox and other components, remove it

t to the co
thoroughly.
Specified torques
rrectness of i
Securing bolt for sealing plug 5 Nm +90°

l purpos
Oil drain plug 30 Nm

nf
ercia
orm
m
atio
om
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thi
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t.
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Cop py
t. rig
gh ht
pyri by
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135
c by lksw
cted agen
Prote AG. 8. Gear oil
Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
35 – Gears, shafts
1 Input shaft
⇒ “1.1 Assembly overview - input shaft”, page 136
⇒ “1.2 Dismantling and assembling input shaft”, page 138 .
⇒ “1.3 Adjusting input shaft”, page 144 .
⇒ “1.4 Renewing input shaft seal”, page 149 .
1.1 Assembly overview - input shaft
Note
♦ When installing new gear wheels or a new input shaft, refer to technical data ⇒ page 6 and the ⇒ Electronic
♦ Heat gear wheels to max. 120°C.
♦ Always renew both tapered roller bearings together as a set.
♦ Install all bearings on input shaft with gear oil.
♦ Heat tapered roller bearing inner races to 100°C before installing.
olks
wage es n
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nl
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
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at
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ion
c
in t
or
his
ate
do
priv
cum
for
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t.
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Cop py
t. rig
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pyri by
Vo
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by
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Prote AG.
136 Rep. gr.35 - Gears, shafts

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
1 - Gearbox housing
race
❑ Removing ⇒ page 141
❑ Pressing in
⇒ page 142 .
3 - Tapered roller bearing inner
race
❑ Pressing off
⇒ page 142
❑ Pressing on
⇒ page 142
4 - Input shaft
❑ Adjusting ⇒ page 144
5 - Gear wheel for 3rd gear
❑ Pressing off
⇒ page 143
❑ Installation position:
shoulder faces 4th gear
⇒ page 143
❑ Pressing on
⇒ page 143
Volkswagen AG
6 - Retaining ring agen
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7 - Retaining ringautho eo
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❑ Renew after
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8 - Gear wheel for 4th gear

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itte
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❑ Press off together with

erm
ab
ility
gear wheel for 5th gear

ot p
wit
⇒ page 142
, is n
h re
❑ Installation position:
hole
spec
shoulder faces 3rd gear

es, in part or in w
⇒ page 143
t to the co
❑ Pressing on ⇒ page 144

9 - Gear wheel for 5th gear
rrectness of i
❑ Press off together with gear wheel for 4th gear ⇒ page 142
l purpos
❑ Installation position: higher shoulder faces towards 4th gear ⇒ page 144
nform
ercia
10 - Retaining ring
m
at
om

on
c
in t
or
11 - Tapered roller bearing inner race

his
ate
do
riv
❑ Pressing off ⇒ page 141

p
cum
for

en
ng
t.
yi Co
op py
12 - Tapered roller bearing outer race t. C rig
gh ht
yri by
❑ Removing ⇒ page 140 cop Vo
by lksw
cted agen
❑ Pressing in ⇒ page 141 . Prote AG.
13 - Shim
❑ Determining thickness ⇒ page 144
14 - Clutch housing
1. Input shaft 137

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
1.2 Dismantling and assembling input shaft

equipment required
AG. Volkswagen AG d
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♦ Thrust plate - VW 401-

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nform

mercia
♦ Press tool - VW 408 A-

a
com
tion in

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t.
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Cop py
t. rig
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pyri by
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by c lksw
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Prote AG.

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
AG. Volkswagen AG d
agen oes
olksw not
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tho eo
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un
pt
an
d
itte
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erm
ab
ility
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wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
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or
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pr
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Cop py
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Prote AG.
♦ Not applicable: -Kukko1-

♦ Press tool - T10428-
♦ Thrust plate - 40 - 105-
♦ Tube - 32 - 109-
♦ Extension - 30 - 23-
♦ Tube - VW 426-
1. Input shaft 139

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
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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un
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an
d
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spec
t to the co
rrectne
♦ Internal puller - VAS 251 613- , or e.g. -Kukko 21/6-

s
♦ Splitter - VAS 251 409- or e.g. splitter - Kukko 17/1-

s o
cial p
f i

nform
mer

atio
om
♦ Counter support - VAS 251 623- , or e.g. counter support -

c
i
or
n thi
Kukko 22/2-
te
sd
iva
o
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Pulling tapered roller bearing outer race out of clutch housing

p
cum
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fo
en
ng
A - Counter support - VAS 251 623- or counter support , e.g. -

t.
yi Co
op
Kukko 22/2- C py
t. rig
gh ht
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B - Internal puller - VAS 251 613- , or e.g. internal puller 37…46
op Vo
by c lksw
mm - Kukko 21/6- cted agen
Prote AG.

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
Pressing tapered roller bearing outer race into clutch housing

– Insert shim.
AG. Volkswagen AG d
agen oes
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Press off tapered roller bearing inner race on side facing clutch s
ce
le
housing
un
pt
an
d
itte
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A - Splitter - VAS 251 409- or splitter 12 … 75 mm , e.g. -Kukko
erm
ab
17/1-
ility
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wit
is n
h re
ole,
spec
t to the co
rrectness
Press on tapered roller bearing inner race on side facing clutch
o
cial p
f
housing
inform
mer
atio
om
n
c
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pr
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Cop py
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rig ht
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Prote AG.
Pulling outer race for tapered roller bearing out of gearbox hous‐
ing
Kukko 22/2-
B - Splitter - VAS 251 413- or splitter 25 … 155 mm , e.g. -Kukko
17/3-
C - Internal puller - VAS 251 613- , or e.g. internal puller 37…46
mm - Kukko 21/6-
1. Input shaft 141

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
Pressing tapered roller bearing outer race into gearbox housing
Pressing off tapered roller bearing inner race on side facing to‐
wards gearbox housing
17/1-
Press on tapered roller bearing inner race on side facing gearbox

housing
Dismantling input shaft agen
AG. Volkswagen AG d
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Note utho eo
ra
s a c
s
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e
Pressing off the tapered roller bearing inner race for bearing the
nl
pt
du
input shaft in the clutch housing ⇒ page 141

an
itte
y li
erm
ab
ility
– Remove retaining ring.

ot p
wit
, is n
h re
hole
spec
Pressing off gear wheel for 5th gear together with gear wheel for
es, in part or in w
4th gear
t to the co

15/2-
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
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ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
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Prote AG.

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
– Remove retaining rings -arrows-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
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s c
Pressing off gear wheel for 3rd gear s
ce
le
un
pt
Assembling input shaft
an
d
itte
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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
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Installation position of 3rd gear and 4th gear
nform
ercia
Shoulders -arrow- of gear wheels for 3rd gear -A- and 4th gear
-B- face towards each other.
m
a
com
tion in
They are secured by means of retaining rings -1- and -2-.
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Cop py
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Prote AG.
Pressing on gear wheel for 3rd gear
1. Input shaft 143

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
– Insert new retaining rings -arrows-.
Pressing on gear wheel for 4th gear
lkswage es n
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Installation position of 5th gear wheel orised ran
tee
th or
u
Higher shoulder -arrow- faces towardsss
a gear wheel for 4th gear. ac
ce
e
nl
pt
du
an
itte
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ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
Pressing on gear wheel for 5th gear

l purpos
– Fit retaining ring.

nform
ercia
Note
m
at
om
ion
c
Press on tapered roller bearing inner race for bearing in clutch

in t
or
his
housing ⇒ page 141 .

ate
do
priv
cum
for
en
ng
t.
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Cop py
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pyri by
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by
1.3 Adjusting input shaft
cted agen
Prote AG.
(Determining input shaft shim)

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤

equipment required
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
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aut ra
ss c
ce
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nl
pt
du
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ility
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h re
hole
spec
♦ End dimension plate - VW 385/17-

es, in part or in w
t to the co
♦ Universal dial gauge holder - VW 387-

rrectness of i

l purpos

♦ Dial gauge - VAS 6080A-
nform
ercia
♦ 30 mm dial gauge extension

m
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do
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for
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Cop py
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Prote AG.
1. Input shaft 145

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
♦ Internal puller - VAS 251 613- , or internal puller , e.g. -Kukko

21/6-
♦ Counter support - VAS 251 623- or counter support , e.g. -

Kukko 22/2-
AG. Volkswagen AG d
agen oes
olksw not
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It is necessary to readjust the input shaftuthoonly when the following eo
ra
components are renewed: ss a c
ce
le
♦ Gearbox housing
un
pt
an
d
itte
♦ Clutch housing y li
erm
ab
ility
ot p
♦ Input shaft wit

is n
h re
or the
ole,
spec
♦ Tapered roller bearing

t to the co
Adjustment overview ⇒ page 185

Requirement:
rrectne
• Sealing surfaces of clutch and gearbox housings must be free

of sealant .
ss o
cial p
• Both inner races for tapered roller bearings are pressed onto
inform
input shaft ⇒ page 142 and ⇒ page 141 .

mer
atio
• Tapered roller bearing outer race is pressed into gearbox

om

c
i
or
n thi
te
– Press tapered roller bearing outer race without shim into gear‐
sd
iva
o
r
box housing to stop.

p
cum
r
fo
en
ng
– Install input shaft in gearbox housing and set clutch housing

t.
yi Co
op
in place. Tighten hexagon bolts to specified torque C py
t. rig
⇒ Item 3 (page 117) .
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
– Fit measuring appliance and dial gauge in clutch housing.

– Before taking any measurements, rotate input shaft to allow
bearings to settle. Set dial gauge to “O” with 1 mm preload.
Note
This step must be repeated for each subsequent measurement,

or the dial gauge will not return to the starting position.
– Pull input shaft in direction of dial gauge.

– Read and note clearance indicated on dial gauge (example
0.930).
– Determine thickness of shim according to table; (e.g. 0.930);
refer to ⇒ Electronic parts catalogue (ETKA) for part numbers.
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es, in part or in w
t to the co
rrectness of i
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nform
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at
om
ion
c
in t
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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 147

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
Removing gearbox housing, and pulling tapered roller bearing

outer race out of clutch housing
Kukko 22/2-
mm - Kukko 21/6-
– Fit gearbox housing, and tighten new hexagon bolts to speci‐
fied torque ⇒ Item 3 (page 117) .
Table of shims
Bearing play Shim
Measured value (mm) Thickness (mm)
0.800 to 0.824 0.650
0.825 to 0.849 0.675
0.850 to 0.874 0.700
0.875 to 0.899 0.725
0.900 to 0.924 0.750
0.925 to 0.949 0.775
0.950 to 0.974 0.800
Bearing play Shim agen

AG. Volkswagen AG d
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Measured value (mm) Thickness (mm) d by
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0.975 to 0.999 0.825
ut
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a
1.000 to 1.024 0.850
ss c
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le
un
pt
1.025 to 1.049 0.875
an
d
itte
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1.050 to 1.074 0.900
erm
ab
ility
1.075 to 1.099 0.925
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1.100 to 1.124 0.950
h re
ole,
spec
Bearing play Shim
t to the co
1.125 to 1.149 0.975
rrectne
1.150 to 1.174 1.000
1.175 to 1.199 1.025
ss o
1.200 to 1.224 1.050

cial p
f inform
1.225 to 1.249 1.075

mer
atio
m
Bearing play Shim

o
n
c
i
or

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1.250 to 1.274 1.100

i
o
pr
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1.275 to 1.299 1.125

en
ng
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1.300 to 1.324 1150 C py
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1.325 to 1.349 1.175 p by
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1.350 to 1.347 1.200
agen
Prote AG.

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
Bearing play Shim

1.375 to 1.399 1.225
1.400 to 1.424 1.250
1.425 to 1.449 1.275
1.450 to 1.474 1.300
1.475 to 1.499 1.325
1.500 to 1.524 1.350
Carrying out check measurement
– Set up measuring appliance and dial gauge.

– Rotate input shaft so that tapered
wage
n roller
AG. Volbearings
kswagen AGsettle.
doe
ks s no
Vol t gu
– Pull input shaft in direction
ed
by of dial gauge. ara
is nte
or
– Bearing play should
au
th be min. 0.140 … max. 0.184 mm. eo
ra
ss c
ce
e
nl
pt
du
an
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erm
ab
ility
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es, in part or in w
1.4 Renewing input shaft seal
t to the co
♦ Removal tool - T20143/2- rrectness of i
l purpos
nform
mercia
at
om
ion
c
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ate
do
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for
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Cop py
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♦ Press tool - T40008- Prote AG.
♦ Sealing grease
– Remove manual gearbox.
1. Input shaft 149

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤

Levering out input shaft seal
AG. Volkswagen AG d
Note lksw
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not
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Do not damage oil seal runninghoris surface on input shaft. nte
eo
aut ra
ss c
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un
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an
d
itte
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erm
ab
ility
ot p
– Half-fill space between sealing lip and dust lip of new seal with
wit
is n
sealing grease .
h re
ole,
spec
– Lightly moisten outer circumference of oil seal with gear oil.
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
Driving in input shaft oil seal flush
or
n thi
te
sd
a

iv
o
pr

um
r
fo
en
ng
t.
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– Install manual gearbox.
Co
Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
2 Output shaft
⇒ “2.1 Assembly overview - output shaft”, page 151
⇒ “2.2 Dismantling and assembling output shaft”, page 154
⇒ “2.3 Adjusting output shaft”, page 165
2.1 Assembly overview - output shaft
Note
♦ When installing new gear wheels or a new output shaft, consult technical data ⇒ page 6 and ⇒ Electronic
♦ Heat gear wheels to max. 120°C.
♦ Install all bearings, synchromeshed gears and synchro-rings on output shaft with gear oil.
♦ Heat tapered roller bearing inner races to 100°C before installing.
♦ Do not interchange synchro-rings. When reusing always fit to the original gear.
1 - Clutch housing
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⇒ page 144
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❑ Distinguishing
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⇒ page 157
❑ Diameter of bearing
seat in clutch housing =
rrectness of i
51 mm, pressing in
⇒ page 158
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❑ Diameter of bearing
seat in clutch housing =
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56 mm, pressing in
⇒ page 158
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❑ Diameter according to
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❑ Pressing off
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⇒ page 158
❑ Pressing on
⇒ page 158
5 - Output shaft
❑ Adjusting ⇒ page 144
2. Output shaft 151

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
6 - Stop ring
❑ Prevents locking pieces from drifting out
❑ Remove ⇒ page 163
❑ Installing ⇒ page 163
7 - Locking collar with synchro-hub for 5th and reverse gears
❑ To be removed after removal of retaining ring ⇒ Item 9 (page 152)
❑ Installation position and fitting onto shaft ⇒ page 164
8 - Synchro-ring for 5th gear
❑ Check for wear ⇒ page 161
9 - Retaining ring
10 - Needle bearing
❑ For 5th gear agen
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12 - Shim aut
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❑ Holds thrust washers ⇒ Item 13 (page 152) in position on output shaft s
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13 - Thrust washers
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❑ For 4th and 5th gears
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❑ Qty. 2
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❑ Insert lugs of thrust washer in holes of output shaft
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spec
14 - Needle bearing
es, in part or in w
t to the co
❑ For 4th gear
15 - Synchromeshed gear for 4th gear
rrectness of i
16 - Retaining ring
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17 - Synchro-ring for 4th gear
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18 - Locking collar with synchro-hub for 3rd and 4th gears

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❑ To be pulled off ⇒ page 161 after removal of retaining ring ⇒ Item 20 (page 152)
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❑ Dismantling ⇒ page 162

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❑ Assembling locking collar and synchro-hub ⇒ page 162 and ⇒ page 162
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19 - Synchro-ring for 3rd gear rig ht
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20 - Retaining ring
21 - Needle bearing
❑ For 3rd gear
22 - Synchromeshed gear for 3rd gear
23 - Shim
❑ Holds thrust washers ⇒ Item 24 (page 152) in position on output shaft
24 - Thrust washers
❑ For 2nd and 3rd gears
❑ Qty. 2
❑ Insert lugs of thrust washer in holes of output shaft

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
25 - Needle bearing
❑ For 2nd gear
26 - Synchromeshed gear, 2nd gear
27 - Retaining ring
28 - Synchro-ring (inner ring for 2nd gear)
❑ 1st/2nd gears synchronisation
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29 - Outer bearing lkracewagefor 2nd gear
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❑ 1st/2nd ed gears synchronisation
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❑ Fitting
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30 - Synchro-ring for 2nd gear
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❑ 1st/2nd gears synchronisation
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31 - Locking collar with synchro-hub for 1st and 2nd gears
ole,
spec
❑ To be removed after removal of retaining ring ⇒ Item 33 (page 153)
t to the co
❑ Dismantling ⇒ page 162
❑ Assembling locking collar and synchro-hub ⇒ page 162
❑ Fitting position ⇒ page 165 rrectne
32 - Synchro-ring for 1st gear
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33 - Retaining ring
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34 - Needle bearing
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❑ For 1st gear

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35 - Synchromeshed gear, 1st gear

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❑ Remove together with tapered roller bearing inner race ⇒ Item 37 (page 153) ⇒ page 159
Co
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36 - Thrust washer
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❑ For 1st gear
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❑ Pressing off ⇒ page 159
38 - Retaining ring
❑ If tapered roller bearing and output shaft are renewed, redetermine ⇒ page 160
❑ Pressing in ⇒ page 159 .
40 - Gearbox housing
2. Output shaft 153

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2.2 Dismantling and assembling output shaft
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♦ Tube - 2010-

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♦ Not applicable: -Kukko 1-

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♦ Thrust plate - 40 - 105-

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♦ Drift sleeve - 30 - 100-

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♦ Extension - 30 - 23-
♦ Removing tool - VW 460/2-
rrectness of i
♦ Thrust piece - T10428- ⇒ page 158 or

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2. Output shaft 155

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21/6-
Kukko 22/2-
♦ Splitter - VAS 251 411- , or e.g. splitter 22 … 115 mm - Kukko
17/2-
♦ Press tool - VW 473- ⇒ page 158

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
♦ Support rails - VW 457-
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Pulling tapered roller
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clutch housing
A - Counter support -
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VAS 251 623- , or e.g.

counter support , e.g. -
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B - Internal puller - VAS

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Note various diameters of bearing seat for tapered roller bearing
AG.
outer race.
Dimension -a-
51 mm 56 mm
Pressing tapered roller bearing Pressing tapered roller bearing
outer race into clutch housing outer race into clutch housing
⇒ page 158 ⇒ page 158
2. Output shaft 157

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
Bearing seat diameter = 51 mm; pressing tapered roller bearing

outer race into clutch housing
Bearing seat diameter = 56 mm; pressing tapered roller bearing

outer race into clutch housing
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Pressing off tapered roller bearing inner race for bearing in clutch
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Pressing on tapered roller bearing inner race for bearing in clutch

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Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
ing
Kukko 22/2-
mm - Kukko 21/6-
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Press off tapered roller bearing inner race on side facing towards
gearbox housing together with synchromeshed gear for 1st gear:
nform
ercia
– First, remove retaining ring -A- for tapered roller bearing inner
m
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race.
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– Fit support rails - VW 457- behind constant mesh teeth of syn‐

his
ate
chromeshed gear for 1st gear (not dog teeth).

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Below the tapered roller bearing inner race, the thrust washer for
f
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t.
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the synchromeshed gear for 1st gear is located.
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– Note thrust washer ⇒ Item 36 (page 153) for synchromeshed
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gear for 1st gear.
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Press on tapered roller bearing inner race on side facing gearbox

housing
– First, fit synchromeshed gear for 1st gear with thrust washer
⇒ Item 36 (page 153) for synchromeshed gear for 1st gear.
– Determine retaining ring for tapered roller bearing inner race
(⇒ illustration on next page) and install.
2. Output shaft 159

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Determining thickness of retaining ring
nl
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– Determine the thickest circlip which will just fit and install it.
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– Determine retaining ring from table. Part number ⇒ Electronic
wit
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hole
Following retaining rings are available:
spec
es, in part or in w
t to the co
Thickness (mm)
2.00 2.20 2.40
rrectness of i
2.10 2.30
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Dismantling output shaft
nform
ercia
– Remove retaining ring -A- for tapered roller bearing inner race.
m
at
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io
– Fit support rails - VW 457- behind constant mesh teeth of syn‐
n
c
in t
or
chromeshed gear for 1st gear (not dog teeth).
his
ate
do
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– Press off synchromeshed gear for 1st gear together with ta‐
p
cum
or
pered roller bearing inner race.

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Below the tapered roller bearing inner race, the thrust washer for C py
ht. rig
the synchromeshed gear for 1st gear is located. rig ht
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– Remove thrust washer ⇒ Item 36 (page 153) for synchro‐ Prote
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meshed gear for 1st gear.
– Remove needle bearing for synchromeshed gear for 1st gear.
– Remove synchro-ring for 1st gear.
– Remove retaining ring for synchro-hub for 1st and 2nd gears.
– Remove locking collar and synchro-hub for 1st and 2nd gears.
– Remove synchromeshed gear for 2nd gear together with syn‐
chro-rings for 2nd gear.
– Remove retaining ring for needle bearing.
– Remove synchromeshed gear for 2nd gear.
– Remove needle bearing for synchromeshed gear for 2nd gear.
– Remove thrust washers for 2nd and 3rd gears with washer
⇒ Item 23 (page 152) .
– Remove synchromeshed gear for 3rd gear.
– Remove synchro-ring for 3rd gear with needle bearing.
– Remove retaining ring for synchro-hub and locking collar for
3rd and 4th gears.

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
Pressing off synchro-hub and locking collar for 3rd and 4th gears
with synchro-ring for 4th gear
A - Splitter - VAS 251 411- , or e.g. splitter 22 … 115 mm - Kukko
17/2-
– Apply splitter -A- below synchro-ring for 4th gear.
– Renew synchro-ring for 4th gear when assembling.
– Remove synchro-ring for 4th gear.
– Remove synchromeshed gear for 4th gear.
– Remove retaining ring located above needle bearing for syn‐
chromeshed gear for 4th gear.
– Remove needle bearing for synchromeshed gear for 4th gear.
– Remove thrust washers for 4th and 5th gears, with washer
⇒ Item 12 (page 152) .
– Remove synchromeshed gear for 5th gear.
– Remove needle bearing for synchromeshed gear for 5th gear.
– Remove synchro-ring for 5th gear.
– Remove retaining ring for locking collar and synchro-hub for
5th and reverse gears.
– Remove locking collar and synchro-hub for 5th and reverse
gears.
Assembling output shaft
Checking synchro-rings for 1st and 3rd to 5th gears for wear
– Press synchro-ring onto cone of synchromeshed gear, and
measure gap -a- at 3 points offset by 120° using a feeler
gauge.
– Make a note of average value.
swage es n
Gap -a- Installation
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1st and 3rd tos 5th
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Prote AG.
2. Output shaft
Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
Checking 2nd gear synchro-ring, outer ring and inner ring togeth‐
er for wear
– Check inner contact surface of synchro-ring -arrow- for scoring
and radial contact scoring; if necessary, renew inner race,
outer race and synchro-ring
– Place inner ring, outer ring and synchro-ring on cone of inner
ring.
– Press down and simultaneously rotate synchro-ring to achieve
proper seating.
– 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
2nd gear 1.0 … 1.9 mm 0.9 mm
Note
Always renew inner ring, outer ring and synchro-ring together.
Dismantling and assembling locking collar and synchro-hub for

1st, 2nd, 3rd and 4th gears
1- Spring
2- Locking piece
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4- Synchro-hub ir se
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– Slide locking
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Assembling locking collar and synchro-hub for 1st, 2nd, 3rd and
ot
wit
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4th gears
h re
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spec
Locking collar has been pushed over synchro-hub.

es, in part or in w
t to the co
– Insert locking pieces and install springs offset 120°. Angled

end of spring must locate in hollow locking piece.
rrectness of i
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Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
Dismantling and assembling locking collar and synchro-hub for

5th and reverse gears
1- Spring
2- Locking piece
3- Synchro-hub
4- Sliding sleeve
5- Stop ring: removing ⇒ page 163 ; installing ⇒ page 163
– Slide locking collar over synchro-hub.
• Teeth -arrow A- and flat shoulder -arrow B- are facing in same
direction
• Deeper notches -arrow C- for locking pieces in synchro-hub
and notches -arrow D- in locking collar must align.
– Insert locking pieces -2-, and install springs -1- offset by 120
degrees.
• Angled end of spring must locate in hollow locking piece.
– Install stop ring -5- ⇒ page 163 .
Removing stop ring for locking pieces of locking collar with syn‐
chro-hub for 5th and reverse gears
– Press tube - 2010- into stop ring of synchro-hub. In the proc‐
ess, lever stop ring on alternating sides out of synchro-hub.
– Stop ring must be completely on tube - 2010- ⇒ page 163 .
– Remove stop ring together
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Removing stop ring for locking pieces on locking collar with syn‐
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chro-hub for 5th and reverse gears

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– Insert stop ring together with tube - 2010- into synchro-hub

h re
hole
with locking collar for 5th gear.

spec
es, in part or in w
The 3 lugs -arrow 1- engage in the 3 recesses -arrow 2- for the

t to the co
synchro-hub locking pieces. (The illustration shows only 2 lugs

and 2 recesses.)
rrectness of i
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– Remove tube - 2010- , making sure that the lugs -arrow- en‐
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gage in the synchro-hub.

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2. Output shaft 163

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AG.2017
Volksw➤
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Installation position ofuthlocking
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♦ The support -arrow 1- for the selector fork faces towards the e
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ility
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stalled ⇒ page 163 .
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– Fit locking collar and synchro-hub for 5th and reverse gears.
hole
spec
es, in part or in w
– Install retaining ring.
t to the co
– Insert synchro-ring for 5th gear.
– Install 5th gear synchromeshed gear with needle bearing.
rrectness of i
– Install thrust washers for 4th and 5th gears
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⇒ Item 13 (page 152) and ⇒ Item 12 (page 152) .

– Fit needle bearing for 4th gear synchromeshed gear.
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– Fit synchromeshed gear for 4th gear.
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– Fit synchro-ring for 4th gear.

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Pressing on synchro-hub with locking collar for 3rd and 4th gears
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– Install retaining ring. t. C rig
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– Insert synchro-ring for 3rd gear.
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– Set 3rd gear synchromeshed gear with needle bearing in
place.
– Install thrust washers for 2nd and 3rd gears
⇒ Item 24 (page 152) and ⇒ Item 23 (page 152) .
– Set 2nd gear synchromeshed gear with needle bearing in
place.
Installation position of outer ring, inner ring and synchro-ring for

2nd gear
– Place inner ring -A- on synchromeshed gear.
♦ Lugs -1- point away from synchromeshed gear.
– Fit outer ring -B-.
♦ Lugs -2- engage in notches -3- of synchromeshed gear.
– Fit synchro-ring -C-.
♦ Larger notches -4- engage in lugs -1- of inner ring -A-.
– Fit synchro-ring for 2nd gear.

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
Installation position of locking collar with synchro-hub for 1st and

2nd gears
♦ The chamfer -arrow 1- points away from synchromeshed gear
for 2nd gear -arrow 2-. wage
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– Fit locking collar and synchro-hub
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– Insert synchro-ring for 1st gear.
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– Install synchromeshed gear for 1st gear with needle bearing.
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– Fit thrust washer for 1st gear ⇒ Item 36 (page 153) .
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Note
spec
es, in part or in w
t to the co
Pressing on tapered roller bearing inner race for bearing in gear‐
box housing ⇒ page 159 .
rrectness of i
– Install retaining ring ⇒ page 160 .
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2.3 Adjusting output shaft
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Prote AG.
2. Output shaft 165

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤

♦ Gearbox support - T10484- AG. Volkswagen AG d
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♦ End dimension plate - VW 385/17- by Vo gu
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♦ Universal dial gauge holder - VW u387-
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♦ Press tool - VW 412- s
ce
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♦ Thrust piece - T10428- ⇒ page 158 or
an
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♦ Press tool - VW 473- ⇒ page 158
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Kukko 22/2-

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
♦ Adapter - T10480-

(Determining shim for output shaft)
It is necessary to readjust the output shaft when the following
components are renewed:
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♦ Gearbox housing
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♦ Clutchs ahousing
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♦ Output shaft
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♦ Tapered roller bearing for output shaft

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Requirement:
h re
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spec

es, in part or in w
of sealant .
t to the co
• Both inner races for tapered roller bearings are pressed onto
output shaft ⇒ page 158 and ⇒ page 159 .
rrectness of i
• Tapered roller bearing outer race is pressed into gearbox

l purpos

– Remove reverse shaft ⇒ page 170 .
nform
ercia
– Press tapered roller bearing outer race with 1.4 mm thick shim
m
into clutch housing ⇒ page 158 or ⇒ page 158 .

com
tion in
r
– Fit output shaft into gearbox housing.

te o
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– Fit clutch housing, and diagonally tighten bolts to specified

r
rp
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torque ⇒ Item 3 (page 117) .

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2. Output shaft 167

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
– Set up measuring tools.

– Set dial gauge (3 mm measuring range) to “0” with 1 mm pre‐
load.
– Loosen clutch housing/gearbox housing securing bolts diag‐
onally until the bolts release the clutch housing or output shaft.
• Do not move the clutch housing by hand
– Read and note value on dial gauge (example: 0.6 mm).
Determining thickness of shim
The specified bearing preload will be attained by subtracting the
measured value (0.60 mm) from the inserted shim (1.40 mm) and
adding a constant value for preload (0.15 mm).
AG. Volkswagen AG d
Example: agen oes
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Installed shim orise 1.40 mm nte
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- Measured value aut 0.60 mm ra
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+ Preload (constant) 0.15 mm
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Shim thickness 0.95 mm

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– Determine thickness of shim from table.
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– For part number of shim, refer to ⇒ Electronic parts catalogue
h re
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(ETKA) .
spec
t to the co
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Cop py
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Prote AG.

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
– Remove clutch housing, and pull out tapered roller bearing

outer race.
Kukko 22/2-
mm - Kukko 21/6-
– Remove inserted shim (1.40 mm thick) from clutch housing.
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 table,
insert two shims totalling the correct figure.
Table of shims
Thickness (mm)
0.650 0.800 0.950
0.675 0.825 0.975
0.700 0.850 1.000
0.725 0.875 1.025
0.750 0.900
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0.775 se
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1.100 1.250 1.400

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1.125 1.275 y li
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1150 1.300
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1.200 1.350
spec
es, in part or in w
1.225 1.375
t to the co
– Press tapered roller bearing outer race with 1.4 mm thick shim
into clutch housing ⇒ page 158 or ⇒ page 158 .
rrectness of i
Carrying out check measurement

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• Determined shim installed.

nf
ercia
– Set up measuring tools.

rm
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– Set dial gauge (3 mm measuring range) to “0” with 1 mm pre‐

o
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c
load.
or
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sd
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– Loosen clutch housing/gearbox housing securing bolts diag‐

iv
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rp
cu
onally until the bolts release the clutch housing or output shaft.
o
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t.
– If correct shim has been selected, dial gauge will indicate a
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2. Output shaft 169

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
3 Reverse shaft
⇒ “3.1 Removing and installing reverse shaft”, page 170
3.1 Removing and installing reverse shaft

– Remove clutch housing ⇒ page 124 .
– Remove reverse gear wheel with roller bearing and thrust
washers ⇒ page 124 .
– Using pliers, pull reverse shaft out of gearbox housing.
The reverse shaft will be damaged when removed.
– Using plastic hammer, carefully drive in new reverse shaft.
Dimension - a - = 41.5 mm
– Install reverse gear wheel, roller bearing and thrust washers
⇒ page 124 .
– Install clutch housing ⇒ page 124 .
AG. Volkswagen AG d
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Cop py
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Prote AG.

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
39 – Final drive - differential

1 Oil seals
⇒ “1.1 Overview of fitting locations - seals”, page 171
⇒ “1.2 Renewing left seal”, page 172
⇒ “1.3 Renewing right oil seal”, page 173
1.1 Overview of fitting locations - seals

The illustration of gearbox is different from the original gearbox.
1 - Seal
❑ For input shaft
⇒ page 149
2 - Seal
❑ For right drive shaft
❑ Renew after removal AG. Volkswagen AG d
⇒ page 173 lksw
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3 - Seal rised b ara
nte
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❑ For left drive shaft aut
h
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nl
⇒ page 172
pt
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4 - Seal
erm
ab
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hole
⇒ page 83
spec
es, in part or in w
t to the co
rrectness of i
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1. Oil seals 171

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
1.2 Renewing left seal

⇒ “1.2.1 Renewing seal for left drive shaft”, page 172
1.2.1 Renewing seal for left drive shaft

equipment required
AG. Volkswagen AG d
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aut ra
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Cop py
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Prote AG.
♦ Multi-purpose tool - VW 771-

♦ Extractor hook - VW 771/37-
♦ Drip tray - V.A.G 1306-
♦ or drip tray for workshop hoist - VAS 6208-
♦ Sealing grease
Removing
– Place drip tray under gearbox.
172 Rep. gr.39 - Final drive - differential

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤

– Remove drive shaft ⇒ Running gear, axles, steering; Rep. gr.
40 ; Drive shaft; Removing and installing drive shaft .
– Pull out drive shaft seal using -VW 771- and -VW 771/37- .
AG. Volkswagen AG d
agen oes
olksw not
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pt
Installing
du
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– Drive in new seal to stop, being careful not to cant seal.
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ility
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– Half-fill space between sealing lip and dust lip with sealing
or
grease .
m
m
atio
m
– Install drive shaft ⇒ Running gear, axles, steering; Rep. gr.

o
n in
or c
40 ; Drive shaft; Removing and installing drive shafts .

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1.3 Renewing right oil seal

⇒ “1.3.1 Renewing seal for right drive shaft”, page 173
1.3.1 Renewing seal for right drive shaft

For the removal of the right seal, the same procedure applies as
for the removal of the left seal ⇒ page 172 .
1. Oil seals 173

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
2 Differential
⇒ “2.1 Assembly overview - differential”, page 174
⇒ “2.2 Dismantling and assembling differential”, page 175
⇒ “2.3 Adjusting differential”, page 182
2.1 Assembly overview - differential
1 - Left drive shaft seal

⇒ page 172
2 - Gearbox housing
3 - Baffle plate
❑ Shoulder points away
from housing
race
❑ Pressing in
⇒ page 181 .
race
❑ Pulling off ⇒ page 179
❑ Pressing on
⇒ page 180
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6 - Differential cage Vol
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❑ With differential bevel orise nte
gears, one-piece aut thrust
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washer, differential
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❑ Removing differential
erm
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ility
bevel gears, one-piece

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thrust washer and differ‐

is n
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ential pinion pin

ole,
⇒ page 181
spec
❑ Installing differential
t to the co
bevel gears, one-piece thrust washer and differential pinion pin ⇒ page 181
rrectne
❑ Pulling off ⇒ page 179

ss o
cial p

inform
❑ Pressing out ⇒ page 179 .

mer
atio
❑ Pressing in ⇒ page 179 .

om
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i
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9 - Shim
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❑ Determining thickness ⇒ page 182

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174
agen
Prote AG.
Rep. gr.39 - Final drive - differential
Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
10 - Baffle plate
❑ Shoulder points away from housing
11 - Clutch housing
12 - Seal for right drive shaft
2.2 Dismantling and assembling

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olkswagen AG
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Special tools and workshop thori eo
equipment required ss
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rig ht
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Prote AG.
♦ Not applicable -Kukko 1-

♦ Counterhold tool - T10140- or 8 x 280 steel bar
♦ Press tool - VW 408 A-
2. Differential 175
Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
wage
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Vol t gu
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♦ Thrust plate - VW 401- ris
ed
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♦ Thrust plate - VW 402- ss
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♦ Internal puller - VAS 251 615- , or internal puller 46 … 58 mm ,
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nform
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m
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i
Kukko 22/2-
on
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AG. Volkswagen AG d
agen oes
Volksw Polo 2014 n➤
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y ua
rised b
5-speed manual gearbox ran0CF - Edition 06.2018
tee
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nl
pt
du
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Cop py
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Prote AG.
♦ Tapered roller bearing puller - V.A.G 1582-

♦ Grip tool - V.A.G 1582/4-
♦ Spacer sleeve - VW 472/2-
♦ Press tool - 3002-
2. Differential 177
Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
lkswage es n
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♦ Tube - 32 - 109-
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♦ Wedge - T10161- , qty. 2

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♦ Drift - 2074-
es, in part or in w
t to the co
♦ Socket - 3156 A-
rrectness of i
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Prote AG.

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
Note
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♦ Heat tapered
tho roller bearing inner races to 100°C beforeteeinstal‐
or
ling. ss au ac
ce
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un
pt
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♦ If tapered roller bearings, differential cage, gearbox housing
y li
erm
ab
or clutch housing is renewed, adjust differential ⇒ page 182 .
ility
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is n
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Pulling tapered roller bearing outer race out of clutch housing
ole,
spec

Kukko 22/2-
t to the co
B - Internal puller - VAS 251 615- , or internal puller 46 … 58 mm ,
e.g. -Kukko 21/7-
rrectne
– Clamp internal puller securely behind tapered roller bearing
outer race.
ss o
cial p
f in
Insert new baffle plate (shown here in conjunction with gearbox
form
mer
housing)
atio
om
Installation position: shoulder -arrow- faces away from housing
n
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Pressing tapered roller bearing outer race into clutch housing

– Fit counterhold tool - T10140- onto thrust plate - VW 402- .
– Use counterhold tool - T10140- to hold clutch housing in hor‐
izontal position.
Instead of counterhold tool - T10140- , an 8 x 280 steel bar can
be used.
Larger shoulder of thrust plate - VW 510- faces towards press tool
- VW 408 A- .
Pulling off tapered roller bearing inner race

– Before fitting extractor, position spacer sleeve - VW 472/2- and
thrust piece - 3002- on differential housing.
Note
Both tapered roller bearing inner races are pulled off the differ‐
ential cage in the same way.
2. Differential 179
Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
Pressing on tapered roller bearing inner race
WARNING
Wear protective gloves.
– Heat inner tapered roller bearing race to approx. 100°C before

pressing on.
Note
Both tapered roller bearing inner races are pressed onto the dif‐
ferential cage in the same way.
ing
Kukko 22/2-
B - Internal puller - VAS 251 615- , or internal puller 46 … 58 mm ,
e.g. -Kukko 21/7-
– Clamp internal puller securely behind tapered roller bearing
outer race. . Volkswage AG n AG d
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Insert new baffle plate
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Installation position: shoulder -arrow- faces away from housing

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Cop py
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by
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Prote AG.

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤

Larger shoulder of thrust plate - VW 510- faces towards press tool
- VW 412- .
– Support gearbox housing with tube - 32 - 109- directly below
bearing support.
– Use wedges - T10161- to hold gearbox housing in horizontal
position.
Pulling off tapered roller bearing inner race ⇒ page 179
Note
Both tapered roller bearing inner races are pulled off the differ‐
ential cage in the same way.
Pressing on tapered roller bearing inner race ⇒ page 180

AG. Volkswagen AG d
agen oes
olksw not
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Note ise
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th
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Both tapered roller bearing inner races are pressed onto the dif‐
s a c
s
ferential cage in the same way.
ce
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un
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an
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ab
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WARNING
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Wear protective gloves.
hole
spec
es, in part or in w
t to the co
– Heat inner tapered roller bearing race to approx. 100°C before
pressing on.
rrectness of i
Removing differential bevel gears, one-piece thrust washer and
l purpos
differential pinion pin

– Remove retaining ring for differential pinion pin.
nform
ercia
– Remove differential pinion pin.

m
a
com
tio
– Drive out differential pinion pin using plastic hammer and fitting
n in
r
drift - 2074- .
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If engagement factor is too high, press out differential pinion pin. do

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• In this case, have a second mechanic hold differential in po‐

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Splines of socket - 3156 A- point towards differential. yri
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Make sure not to damage splines.
agen
Prote AG.
Installing differential bevel gears, one-piece thrust washer and

differential pinion pin
– Lubricate one-piece thrust washer with gear oil and install.
– Insert both sun wheels.
– Hold upper sun wheel in position.
– Insert both planet pinions offset 180° and pivot into position.
– Drive in differential pinion pin -arrow- until it reaches its final
position, and secure it with retaining ring.
2. Differential 181
Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
2.3 Adjusting differential

equipment required
lkswage es n
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♦ End dimension plate - VW 385/17-

♦ Universal dial gauge holder - VW 387-
rrectness of i

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orm
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Cop py
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by
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Prote AG.

Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
♦ Internal puller - VAS 251 615- , or internal puller 46 … 58 mm ,

e.g. -Kukko 21/7-
AG. Volkswagen AG d
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olksw not
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ara
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Kukko 22/2-
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mer
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It is necessary to readjust the differential when the following com‐ Cop py
ht. rig
ponents are renewed: rig ht
py by
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♦ Gearbox housing Prote
cted AG.
agen
♦ Clutch housing
♦ Differential cage
♦ Tapered roller bearing of differential
Requirement:
of sealant .
• Both tapered roller bearings inner races are pressed onto dif‐
ferential cage ⇒ page 180 .
• New baffle plate is inserted into gearbox housing
⇒ page 180 .
• Tapered roller bearing outer race (gear wheel side) is pressed
into gearbox housing ⇒ page 181 .
– Press tapered roller bearing outer race (opposite side of gear
wheel) without shim and without baffle plate into clutch hous‐
ing ⇒ page 179 .
– Insert differential in gearbox housing.
– Fit clutch housing and tighten 5 bolts to specified torque
⇒ Item 3 (page 117) .
2. Differential 183
Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
– Fit dial gauge, and set it to “0” with 1 mm preload.

A - 30 mm dial gauge extension
– Before taking any measurements, rotate differential to allow
tapered roller bearings to settle. Set dial gauge to “0” with 1
mm preload.
– 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 (0.20 mm) to the reading obtained.
Example:
Measured value 1.30 mm
+ Preload (constant) 0.20 mm
Thickness of shim = 1.50 mm
– Remove gearbox housing, and pull tapered roller bearing out‐

er race out of clutch housing ⇒ page 179 .
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– Insert shim of determined thickness (in example 1.50 mm),

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rrectness of i
– Fit clutch housing and tighten bolts to specified torque.

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Polo 2014 ➤ , up! 2012 ➤ , up! 2017 ➤
3 Adjustment overview
Note
Adjustment of the input shaft, output shaft, or differential is only

necessary if components have been renewed which have a direct
effect on the adjustment of the gearbox. To prevent unnecessary
adjustments, refer to the following table:
To be adjusted:
Input shaft Output shaft Differential
⇒ page 144 ⇒ page 165 ⇒ page 182
Parts renewed: Gearbox housing x x x
Clutch housing x x x
Input shaft x
Output shaft x
Differential cage x
Input shaft tapered roller bearing x
Tapered roller bearing for output x
shaft
Tapered roller bearing for differen‐ x
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agen 3. Adjustment overview

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Service

up! 2017s ➤ sw does

Service Department. Technical Information

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Copyright © 2018 Volkswagen AG, Wolfsburg D3E8043DC69

1.3 Assembly overview - clutch hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4 Assembly overview - clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5 Removing and installing bearing bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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

1.9 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

1.11 Removing and installing clutch slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

1.12 Removing and installing lines for clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

1.13 Bleeding clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

1.14 Removing and installing clutch pedal switch F36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

1.15 Checking clutch master cylinder and clutch slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . 48

1.16 Removing and installing clutch position sender G476 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

1.17 Repairing clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

1.13 Removing and installing selector cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

4 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

5.1 Schematic overview - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

5.4 Assembly overview - selector unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

7 Securing to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

8.2 Draining and filling gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

1.3 Adjusting input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

1.1 Safety measures when working on ve‐

hicles with a start/stop system

2.1 Gearbox identification

Manual gearbox 0CF -arrow 2-.

Codes and production date of gearbox

Codes Day Month Year (2011)

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

ing repair work.

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

For a complete list of special tools used in this workshop manual,

♦ When installing the manual gearbox, ensure that the dowel

♦ Retaining rings must locate properly in grooves.

Nuts and bolts

4 Rep. gr.00 - Technical data

♦ Check grooves -arrow 1- of synchro-ring -A- and inner ring for

flat spots (worn grooves).

♦ 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

♦ Before installing, clean and heat with the inductive heater -

♦ Observe installation position

♦ After assembly, check synchromeshed gears for slight play, or

Ratio Final drive 74 : 19 = 3.895 75 : 18 = 4.1666 74 : 19 = 3.895

♦ Individual gear ratios

Manufactured from 08.11 02.12 02.12

Manual gearbox 5-speed, 0CF

6 Rep. gr.00 - Technical data

Manual gearbox 5-speed, 0CF

Manual gearbox 5-speed, 0CF

♦ Clutch allocation spec

4.1.2 Allocation gearbox - engine, Polo