Transmission 6-MKP 02S — general information KP designation The mechanical 6-speed gearbox 02S is installed in combination with 4-cylinder engines. Location at the checkpoint Letter designation and date of production - see. arrow 1-. KP designation - see. arrow...
General Mounting Diagram — Pedal Mechanism 1. Master cylinder 2. Support sleeve 3. Clamp: to remove and install the hose line, pull out the clamp as far as it will go 4. Sealant: self-adhesive; replace after removing the clutch master cylinder; glued to the...
Removing and installing top dead center spring Disconnect battery wire to ground. If fitted, remove knee airbag -1- for driver. Remove vent -1- in footwell on driver's side. Remove data bus diagnostic interface -J533- -1- from holder and place to one side. Unscrew...
Removal and installation of the clutch pedal Disconnect battery wire to ground. If present in area of bracket, remove retainer -arrow- together with parking pilot control unit -J446- and place to one side. Remove the top dead center spring or top dead center...
Removing and installing clutch pedal support bracket Remove the air cleaner housing assembly if it interferes with access to the clutch hydraulic lines. Disconnect battery wire to ground. Remove battery. Carefully! Danger of escaping brake fluid. When carrying out the...
Removal and installation of the clutch master cylinder Note: Before replacing a clutch master cylinder that is suspected to be defective, a check must first be carried out using -Guided Fault Finding-. When working in the footwell, protect the floor covering from escaping...
Removal and installation of the support sleeve Disconnect battery wire to ground. Press catches -arrows- together and pull pin -1- to right. Turn tappet of master cylinder until notches -1- or pin -2- are visible. Notches -1- and pin -2- point in the same direction....
Removing and installing clutch pedal position sender -G476- Move the driver's seat as far back as possible. Unplug connector -arrow- at clutch pedal position sender -G476-. Open retainer -arrow- for clutch pedal position sender -G476- -2- on clutch master cylinder -1- and...
General Installation Diagram — Hydraulic System 1. Hex head screw 2. Bleeding port, 4.5 Nm 3. Rubber cap 4. Hose for work after switching off 5. Hydraulic brake reservoir 6. Seal: must be in the hose for operation after shutdown 7. Clutch master cylinder 8. Clamp: to...
Disconnecting/Connecting Clutch Lines Open clip -3- with a screwdriver and remove hose -1- from connection -4-. Connection Note: An O-ring can be used instead of the O-ring -2-. Replace damaged O-ring -2-. Press hose line -1- against socket -4- until clamp...
Checking the hydraulic clutch Note: If the master cylinder or slave cylinder must be replaced due to a fault, first check the hydraulic clutch actuation. If the slave cylinder is removed with the tubing connected to the gearbox, do not depress the...
Checking the entire hydraulic system for leaks Inspect the following hydraulic clutch actuator components for leaks. Checking the brake fluid level in the hydraulic brake reservoir. After-run hose between hydraulic brake reservoir and master cylinder. Clutch master...
Removal and installation of the clutch slave cylinder Note: Before replacing a clutch master cylinder that is suspected to be defective, a check must first be carried out using -Guided Fault Finding-. If the slave cylinder is removed with the tubing connected to the...
Removal and installation of pipelines of a drive of coupling Remove the air cleaner housing assembly if it interferes with access to the clutch hydraulic lines. Remove battery and battery bracket. All Carefully! Danger of escaping brake fluid. When carrying out the following...
Removing air from the clutch actuator Note: After working on the hydraulic clutch actuator, the system must be bled. When carrying out the following work, make sure that brake fluid does not get into the gearbox. Preliminary removal of air from the system...
Clutch Release Repair — Sequence 1. KP 2. Spherical pin, 25 Nm: The initial grease must be removed from the contact surface of the clutch release lever; lubricate with grease -G 000 100- 3. Drive shaft sealing ring: replace 4. Guide bushing: with...
Removing and installing clutch release lever with release bearing Disconnect the spring - see arrow 1-. Remove the clutch release lever - see arrow 2- and release bearing. Installation in reverse order. Removal and installation of release bearing Remove the locking tabs - see arrows -...
General installation scheme — company clutch repair «Sachs» Note: Before replacing the clutch disc and clutch pressure plate, take into account the troubleshooting of the transmission - complaints about the clutch and clutch drive. Replace clutch discs and clutch pressure plates...
Removal and installation of the company's clutch «Sachs» To prevent deformation of the clutch pressure plate when removing (what leads to jerks when starting off) Loosen the screws securing the clutch pressure plate as follows: To loosen the screws, install counterhold -MP1...
General installation scheme — company clutch repair «LuK» Note: Before replacing the clutch disc and clutch pressure plate, take into account the troubleshooting of the transmission - complaints about the clutch and clutch drive. Replace clutch disc and clutch pressure plate...
Removal and installation of the company's clutch «LuK» To prevent deformation of the clutch pressure plate when removing (what leads to jerks when starting off) Loosen the screws securing the clutch pressure plate as follows: To loosen the screws, install counterhold...
Transmission Troubleshooting — Clutch and Clutch Drive Complaints Before each repair of the clutch, it is imperative to check the claims of the owner and take them into account. In this case, it must be determined in each individual case whether it is really a complaint about the...
General Mounting Diagram — Shift Knob with Shift Lever Boot 1. Shift handle: with cover; shift handle and cover are not separated from each other; the gear lever plaque can be separated from the shift handle, for example, with a screwdriver; always change together 2. Case: with...
General wiring diagram — switching mechanism Note: Lubricate all bearing and contact surfaces with grease -G 000 450 02-. 1. Overlay: to remove, bend the tongues; must be replaced 2. Seal: must be replaced 3. Gear lever 4. O-ring; push on the selector lever...
Switch mechanism repair Removal and installation of a lock ring Hold gear lever -2-. Press spacer sleeve -3- in direction of arrow. Remove lock washer -1-. Removing and installing the damper - see. arrow- Press the jumper -A- of the...
Disassembly and assembly of the switching mechanism Remove switch mechanism. Bend the tongues - see. arrows - switch mechanism cover with a screwdriver and remove the cover. Remove seal. Remove lock washers -2 and 3- (lock washers -1 and 4- are now missing), hook the...
General Mounting Diagram — Drive Cables Note: Lubricate all bearing and contact surfaces with grease -G 000 450 02-. 1. Gearshift cable; disconnect from the shift lever guide on the gear shift mechanism; press into the shift lever guide on the gear shift...
Installing the shift lever When installing the gear lever, make sure that the gap between the teeth - see. arrow A- mated with the interrupted tooth pitch of the gearshift rod - see. arrow B-. Installation position of the shift lever/intermediate...
Removal and installation of the switching mechanism Disconnect the battery cable to ground with the ignition off. Remove the air filter if installed above the gearbox. Open clamp - see arrow - and remove, the shift handle together with the cover. Remove ashtray. Loosen...
Shift mechanism adjustment Note: The conditions for correct adjustment of the shift mechanism are as follows. Gearbox, clutch and clutch drive in perfect condition. The shift mechanism is easy to move. Serviceable elements of management and...
Removing the gearbox — front-wheel drive Remove engine cover. Note: All bandages loosened or cut during removal must be reattached to the same positions during installation. When disconnecting and connecting the battery cable to ground, additional work must be...
Tightening torques Mounting of the engine-gearbox assembly on vehicles with a 1.4 l / 103 kW FSI engine 1) Screw with full thread M8. Pos. -A-: Relief sleeves for centering Mounting of the engine-gearbox assembly on vehicles with a 1.8 l...
Gearbox installation The gearbox is installed in the reverse order of removal. Make sure that the vehicle assemblies are installed without tension. Press the clutch release lever before installing the gearbox to the gearbox housing and fix...
Checking the transmission oil level Note: The oil level in the gearbox can only be checked by completely draining the gear oil and then refilling it. To drain the transmission oil, it is necessary to remove the journal of the shift fork shaft in the...