Volkswagen Workshop Manual (6-Speed Manual Gearbox 02U LUPO 3L&GTI)

Service
Workshop Manual
Lupo 3L 1999 ➤
6-speed manual gearbox 02U, Lupo GTI
Edition 01.2006
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
30 - Clutch
34 - Controls, housing
35 - Gears, shafts
39 - Final drive - differential
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.
Lupo 3L 1999 ➤
6-speed manual gearbox 02U, Lupo GTI - Edition 01.2006
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Location on gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Identification code, assembly allocation, capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Overview - power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Calculating overall gear ratio “i” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4 General repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1 Repairing clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1 Assembly overview - pedal cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2 Distinguishing between clutch pedal switches F36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3 Removing and installing clutch pedal switch with rectangular housing . . . . . . . . . . . . . . . . 11
1.4 Removing and installing clutch pedal switch with round housing . . . . . . . . . . . . . . . . . . . . 12
1.5 Removing and installing over-centre spring (left hand drive) . . . . . . . . . . . . . . . . . . . . . . . . 13
1.6 Removing and installing over-centre spring (right hand drive) . . . . . . . . . . . . . . . . . . . . . . 13
1.7 Removing and installing clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.8 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.9 Assembly overview - hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.10 Removing and installing master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.11 Removing and installing slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.12 Removing and installing pipe/hose line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.13 Bleeding clutch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2 Repairing clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3 Repairing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1 Repairing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.1 Installation position of selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.2 Removing and installing selector lever knob and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.3 Repairing selector lever and selector lever housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.4 Assembly overview - removing and installing selector cables . . . . . . . . . . . . . . . . . . . . . . 39
1.5 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.6 Adjusting selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.1 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.2 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.3 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3 Checking gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4.1 Overview - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4.2 Removing and installing cover for gearbox housing and 5th and 6th gear . . . . . . . . . . . . 60
4.3 Removing and installing clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.4 Removing and installing input shaft, output shaft (drive pinion), differential, selector
mechanism and selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.5 Dismantling and assembling procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5 Repairing gearbox housing and clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
6 Repairing gearbox housing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
7 Repairing selector unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
8 Dismantling and assembling selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Contents i
Lupo 3L 1999 ➤
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
1 Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
1.1 Dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2 Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
2.1 Dismantling and assembling output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

1 Renewing oil seals for flange shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
1.1 Renewing oil seal for left flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
1.2 Renewing seal for right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
2 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
2.1 Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
2.2 Adjusting differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
ii Contents
Lupo 3L 1999 ➤
00 – Technical data
1 Gearbox identification
The 6-speed manual gearbox 02U is installed in the Lupo GIT in
conjunction with a 4-cylinder (4 valves per cylinder) injection en‐
gine.
Allocation ⇒ page 1 .
1.1 Location on gearbox

Code letters and date of manufacture -arrow 1-
Manual gearbox 02U -arrow 2-
Manual gearbox 02U -arrow 2-
Identification code and date of gearbox manufacture

Example: FUT 25 04 1
I I I I
I I I I
Identification Day Month Year 2001 of man‐
code ufacture
Additional data depend on manufacture.
Note
The gearbox code also appears on the vehicle identification

plates.
1.2 Identification code, assembly allocation, capacities

Manual gearbox 6-speed 02U
Identification code FUT GEZ GPF
Manufactured from 05.01 01.03 01.03
to 02.03 01.03 03.03
Allocation Model Lupo GTI Lupo GTI Lupo GTI
Volkswagen Technical Site: https://vwts.ru 1. Gearbox identification 1

Lupo 3L 1999 ➤

Identification code FUT GEZ GPF
Engine 1.6 l - 92 kW 1.6 l - 92 kW 1.6 l - 92 kW
Ratio Final drive 67 : 16 = 4.188 67 : 16 = 4.188 67 : 16 = 4.188
Z1 : Z2
Capacity 2.1 l 2.1 l 2.1 l
Drive shaft flange ∅ 90 mm 90 mm 90 mm
GEZ = magnesium gearbox housing

From 01.03, enlarged tapered roller bearing for differential.
The following data can be found in the ⇒ Electronic parts cata‐
logue (ETKA) .
♦ Individual gear ratios
♦ Gear oil
♦ Clutch plate allocation
Identification code GSN GVX HBK
Manufactured from 03.03 03.03 08.04
to 09.03 08.04
Allocation Model Lupo GTI Lupo GTI Lupo GTI
Engine 1.6 l - 92 kW 1.6 l - 92 kW 1.6 l - 92 kW
Ratio Final drive 67 : 16 = 4.188 67 : 16 = 4.188 67 : 16 = 4.188
Z1 : Z2
Capacity 2.1 l 2.1 l 2.1 l
Drive shaft flange ∅ 90 mm 90 mm 90 mm
From 01.03, enlarged tapered roller bearing for differential.

From 03.03, modified selector fork for 5th and 6th gears. Alloca‐
tion ⇒ Electronic parts catalogue “ETKA”
GVX and HBK: additional securing bolt for gearbox housing cover
The following data can be found in the ⇒ Electronic parts cata‐
logue (ETKA) .
♦ Individual gear ratios
♦ Gear oil
♦ Clutch plate allocation
Volkswagen Technical Site: https://vwts.ru
2 Rep. Gr.00 - Technical data

Lupo 3L 1999 ➤
2 Overview - power transmission

Designation
Arrows indicate direction of travel.
1 - Engine
2 - Clutch
3 - Manual gearbox
4 - Input shaft
5 - Output shaft
6 - Differential
Gears
Arrows indicate direction of travel.
2. Overview - power transmission 3

Lupo 3L 1999 ➤
I - 1st gear
II - 2nd gear
III - 3rd gear
IV - 4th gear
V - 5th gear
VI - 6th gear
R - Reverse gear
A - Final drive
T - Speedometer drive

Lupo 3L 1999 ➤
3 Calculating overall gear ratio “i”

Example:
6th gear Final drive
Drive gear ZG1 = 49 ZA1 = 16
Driven gear ZG2 = 38 ZA2 = 67
i = Z2 : Z1 1)
iG = Gear ratio = ZG2 : ZG1 = 38 : 49 = 0.776
iA = Final drive ratio = ZA2 : ZA1 = 67 : 16 = 4.188
itotal = Overall ratio = iG x iA = 0.776 x 4.188 = 3.250
1) Z1 = No. of teeth on driving gear, Z2 = No. of teeth on driven gear
3. Calculating overall gear ratio “i” 5

Lupo 3L 1999 ➤
4 General repair notes

To ensure perfect and successful gearbox repairs, the greatest
care and cleanliness as well as the use of good and proper tools
is essential. Of course, the basic rules for safety also apply during
repair work.
A number of instructions generally applicable to the various repair
procedures - which were previously repeated a number of times
at various places in the workshop manual are summarised under
the topic “components” ⇒ page 6 . They apply to this workshop
manual.
4.1 Components
4.1.1 Gearbox
♦ The gearbox with code letters GEZ is made of magnesium. All
other gearboxes are made of aluminium.
♦ Clutch housing and gearbox housing must be made of the
same materials.
♦ If the incorrect components are used, contact corrosion will
develop. The gearbox will be damaged.
♦ Allocate bolts and other components using ⇒ Electronic parts
catalogue “ETKA” .
♦ When installing the manual gearbox, ensure that the dowel
sleeves between the engine and gearbox are correctly seated.
♦ When installing mounting brackets or waxed components,
clean the contact surfaces. Contact surfaces must be free of
wax and grease.
♦ When changing a gearbox, fill with gear oil to lower edge of
filler hole.
♦ Capacity ⇒ page 1 .
4.1.2 Seals and sealing rings

♦ Thoroughly clean parting surfaces and apply sealant -AMV
188 200 03- .
♦ Apply sealant uniformly but not too thick.
♦ Renew O-rings.
♦ Radial oil seals.
Before installing:
Lightly oil outer diameter and half-fill space between sealing lips
-arrow- with grease -G 052 128 A1- .
After installation:
Check gear oil level and top up to lower edge of oil filler hole if
necessary.
Gearbox oil ⇒ Electronic parts catalogue (ETKA)

Lupo 3L 1999 ➤
4.1.3 Locking devices

♦ Renew retaining rings.
♦ Do not overstretch retaining rings.
♦ Retaining rings must locate properly in grooves.
♦ Renew spring pins. Installation position: slot longitudinal to line
of force.
4.1.4 Nuts and bolts

♦ Loosen and tighten securing bolts and nuts for covers and
housings diagonally.
♦ Do not cant especially delicate parts, such as clutch pressure
plates. Loosen and tighten bolts and nuts in stages in a diag‐
onal sequence.
♦ Torque settings are specified for unoiled bolts and nuts.
♦ Always renew self-locking bolts and nuts.
♦ 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.
4.1.5 Bearings
♦ Lubricate all gearbox bearings with gear oil before installing.
♦ 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 maximum 100° C before installing.
♦ Do not interchange outer or inner races of bearings of the
same size. The bearings are matched in pairs.
4.1.6 Shims
♦ Measure shims at several points with a micrometer. The var‐
ious thicknesses of shims make it possible to achieve the
exact thickness required.
♦ Check for burrs and damage.
♦ Install only flawless shims.
4.1.7 Synchro-rings
♦ Do not interchange. When reusing synchro-rings, always fit to
the same gear.
♦ Check for wear and renew if necessary.
♦ Moisten with gear oil before installing.
4. General repair notes 7

Lupo 3L 1999 ➤
4.1.8 Synchro-rings
♦ Do not interchange. When reusing synchro-rings, always fit to
the same gear.
♦ Check for wear and renew if necessary.
♦ Check grooves -arrow 1- of synchro-ring -A- and inner ring for
flat spots (worn grooves).
♦ If synchro-rings are coated, coating must not be damaged.
♦ If an intermediate ring -B- is installed, check the outer friction
surface -arrow 2- and inner friction surface -arrow 3- of this
intermediate ring for “scoring”, “signs of abnormal wear” and
“blue discolouration (due to overheating)”.
♦ Check cone of synchromeshed gear for “scoring” and “signs
of abnormal wear”.
♦ Moisten synchromesh mechanism with gear oil before instal‐
ling.
4.1.9 Gear wheels

♦ Before installing, clean and heat on a hot plate to maximum
100° C.
♦ The temperature can be checked with thermometer -
V.A.G 1558- , ignition tester -V.A.G 1767- or diesel tester -
V.A.G 1743- .

Lupo 3L 1999 ➤
30 – Clutch
1 Repairing clutch mechanism
Note
♦ Disconnect battery earth strap.

♦ Note radio code for vehicles with coded radio.
♦ Lubricate all bearings and contact surfaces with grease -G 000 450 02- .
I - Assembly overview - pedal

cluster ⇒ page 10
II - Assembly overview - hy‐
draulics ⇒ page 19
1. Repairing clutch mechanism 9

Lupo 3L 1999 ➤
1.1 Assembly overview - pedal cluster
1 - Mounting bracket
❑ Removing and installing
⇒ page 17
2 - Hexagon bolt, 25 Nm
3 - Brake light switch
⇒ Brake system; Rep.
Gr. 46
4 - Self-locking hexagon nut,
25 Nm
❑ Qty. 6
❑ For mounting bracket to
stud of brake servo and
bulkhead.
❑ Always renew
5 - Clutch pedal switch -F 36-
❑ Distinguishing
⇒ page 11
clutch pedal switch with
rectangular housing
⇒ page 11
clutch pedal switch with
round housing
⇒ page 12
6 - Rubber buffer
❑ Push into mounting
bracket.
7 - Over-centre spring mount‐
ing
❑ To remove, turn 90° to
right.
❑ To install, turn 90° to left.
8 - Over-centre spring
❑ Removing and installing ⇒ page 13
9 - Stop
❑ For clutch pedal
❑ Installation position ⇒ page 24
10 - Bulkhead
11 - Seal
❑ Self-adhesive
❑ Always renew
12 - Supply hose
13 - Master cylinder
14 - Self-locking hexagon nut, 25 Nm
❑ Always renew
10 Rep. Gr.30 - Clutch

Lupo 3L 1999 ➤
15 - Retainer
❑ Removing and installing ⇒ Item 6 (page 20)
16 - Pivot pin for clutch and brake pedal
17 - Washer
18 - Bearing bush
❑ For clutch pedal
Lubricate all bearings and contact surfaces with grease -G 000 450 02- .
19 - Clutch pedal
20 - Bearing bush
❑ For supporting steering column.
21 - Bearing bush
❑ Push into bearing bush ⇒ Item 20 (page 11) and then install brake pedal.
22 - Washer
23 - Hexagon nut, 25 Nm
24 - Brake pedal
1.2 Distinguishing between clutch pedal

switches -F36-
-A- = clutch pedal switch with rectangular housing -arrow-
– Removing and installing ⇒ page 11
-B- = clutch pedal switch with round housing -arrow-
– Removing and installing ⇒ page 12
1.3 Removing and installing clutch pedal

switch with rectangular housing
To ensure sufficiently secure seating, clutch pedal switch may be
installed only once.
1.3.1 Removing
– Remove lower footwell cover on driver side ⇒ General body
repairs, interior; Rep. Gr. 70 ; Removing and installing dash
panel .
– Pull connector off clutch pedal switch -F36- .

Lupo 3L 1999 ➤
– Turn clutch pedal switch -F36- on housing 90° anti-clockwise

and pull out of support.
1.3.2 Installing and adjusting new clutch pedal

switch
– Pull out plunger to stop.
– Push down clutch pedal by hand as far as possible.
– Place clutch pedal switch in mounting and turn 90° to right.
– Install footwell cover on driver side ⇒ General body repairs,
interior; Rep. Gr. 70 ; Removing and installing dash panel .

switch with round housing
To ensure sufficiently secure seating, clutch pedal switch may be
installed only once.
1.4.1 Removing
panel .
– Pull connector off clutch pedal switch -F36- .
– Turn clutch pedal switch -F36- on housing 45° anti-clockwise
and pull out of support.
1.4.2 Installing and adjusting new clutch pedal

switch
The clutch pedal must always remain in rest position (do not de‐
press) during the installation of the clutch pedal switch.
Note
♦ First check clutch pedal switch.

♦ Stop -A- must be located in front of shoulder -B-.
♦ The stop is then located directly behind the mounting hook
-C-.
If this is not the case, do not pull out the plunger.

This will destroy the clutch pedal switch.
The positions of stops -A- and -C- must be changed:
– Press plunger in to stop -arrow 1-.

– At the same time, turn upper part of clutch pedal switch to stop
in -direction of arrow 2-.
– Now, before installing clutch pedal switch , pull plunger out
completely.
– Now insert clutch pedal switch -F36- in access hole.
– To lock clutch pedal switch -F36- on housing, turn 45° clock‐
wise.
– Push connector onto clutch pedal switch -F36- .
– Install footwell cover on driver side ⇒ General body repairs,
interior; Rep. Gr. 70 ; Removing and installing dash panel .

Lupo 3L 1999 ➤
1.5 Removing and installing over-centre

spring (left hand drive)
Special tools and workshop equipment required
♦ Assembly clip -3317-
1.5.1 Removing
panel .
– Tension over-centre spring with clutch pedal and press on re‐
taining clamp -3317- from below.
Note
The drilling -arrow- faces bulkhead.
– Move clutch pedal towards bulkhead to stop, removing over-

centre spring downwards together with assembly clip -3317- .
1.5.2 Installing
– Move clutch pedal towards bulkhead to stop.
– First insert over-centre spring with assembly clip in rear
mounting from below -arrow B-.
– Then pull back clutch pedal until over-centre spring with as‐
sembly clip contacts mounting pin of clutch pedal -arrow A-.
– Pull clutch pedal further back to rest position, removing as‐
sembly clip downwards.
1.6 Removing and installing over-centre

spring (right hand drive)

Lupo 3L 1999 ➤
♦ Assembly tool -T10178-
1.6.1 Removing
panel .
– Unscrew nut from clutch pedal and push axle to right to stop.
– Remove stop -A- for clutch pedal.
– Depress clutch pedal.
– Carefully pry off over-centre spring -arrows-.
1.6.2 Installing
– Set over-centre spring into receptacle in mounting bracket
-arrow 1- and apply assembly tool -T10178- in notches of over-
centre spring.
– Press over-centre spring forcefully -direction of arrow 2- and
-direction of arrow 3- until mounting pin of clutch pedal locates
in receptacle of over-centre spring.
– Reassemble clutch pedal mounting.
– Tighten nut to 25 Nm.

Lupo 3L 1999 ➤
– Install stop -A- for clutch pedal.

♦ Torque wrench -V.A.G 1331-
Additional required information

♦ Workshop manual Lupo1999 ▸ General body repairs, interior
1.7.1 Removing
– First check whether a coded radio is fitted. If so, obtain anti-
theft code.
– With ignition switched off, disconnect battery earth strap.
– Remove lower trims from light switch and steering column and
remove driver side compartment ⇒ General body repairs, in‐
terior; Rep. Gr. 68 ; Compartments, covers and trims; Re‐
moving driver side compartment .
panel .
– Remove over-centre spring ⇒ page 13 .
– Turn clutch pedal switch 90° anti-clockwise and pull out of
support.
– Separate clutch pedal from master cylinder ⇒ page 21 .

Lupo 3L 1999 ➤
– Unbolt fuse holder, separate from lower attachment and push

up -arrow 1-.
– Unhook wiring harness and pull downwards -arrow 2-.
– Separate connector station -1- from retainers -2- and -3- and
carefully move downwards.
– Move relay carrier -4- in direction of arrow by raising locking
lug -5- and carefully pull downwards out up upper guide -6-.
– Unscrew hexagon nut -arrow 1- for pivot pin of clutch pedal

and brake pedal and remove with washer.
– Carefully pull out pivot pin -arrow 2-. At the same time, hold
brake pedal from right -arrow 1- in place with an M8 bolt or a
drift.

Lupo 3L 1999 ➤
– Carefully guide pivot pin of clutch pedal carefully to left through

hole -7- of cover, being careful not to damage the electrical
wires.
Note
Do not move brake pedal or steering column. After the pivot pin
has been removed, they are not longer supported.
– Remove clutch pedal.
1.7.2 Installing
Install in the reverse order of removal, observing the following:
– Install over-centre spring ⇒ page 13 .
– Set clutch pedal with bearing sleeve and washer on pivot pin.
– Pull out M8 bolt or drift to right.
– At the same time, push in pivot pin for clutch pedal and brake
pedal to stop; brake pedal may move slightly in the process.
– Install washer and tighten hexagon nut.
– The retainer -A- must be fitted to the master cylinder operating
rod -B-.
– Press clutch pedal in direction of arrow until it engages, en‐
suring that it is correctly located.
– Place clutch pedal switch in mounting and turn 90° to right.
– Hook or bolt relay holder, connector station and fuse holder in
their mountings; check connectors for wires and relays and
push on if necessary.
Further installation is carried out in the reverse sequence.
– Install footwell cover below dash panel on driver side ⇒ Gen‐
eral body repairs, interior; Rep. Gr. 70 ; Removing and instal‐
ling dash panel .
– Install driver side compartment and lower trims for light switch
and steering column ⇒ General body repairs, interior; Rep.
Gr. 68 ; Compartments, covers and trims; Removing driver
side compartment .
1.7.3 Torque setting

Hexagon nut on pivot pin for clutch and brake pedal
⇒ Item 23 (page 11)
1.8 Removing and installing mounting

bracket

Lupo 3L 1999 ➤

♦ Workshop manual Lupo 1999 ▸ Running gear, axles, steering
- Lupo 3L, Lupo FSI, Lupo GTI
♦ Workshop manual Lupo 1999 ▸ Brake system - Lupo 3L, Lupo
FSI, Lupo GTI
1.8.1 Removing
theft code.
– Remove lower trims from light switch -2- with bolt -1- and trims
for steering column switch.
– Remove driver side compartment -3- with bolts -arrows- ⇒
General body repairs, interior; Rep. Gr. 68 ; Compartments,
covers and trims; Removing driver side compartment .
– Remove footwell cover on driver side -arrows- ⇒ General body

panel .
– Turn clutch pedal switch 90° to left and pull out of mounting.
– Remove master cylinder ⇒ page 21 .
– Remove steering column ⇒ Running gear, axles, steering -
Lupo 3L, Lupo FSI, Lupo GTI; Rep. Gr. 48 ; Airbag, steering
wheel, steering column; Removing and installing steering col‐
umn .
– Separate brake pedal from brake servo ⇒ Brake systems -
Lupo 3L, Lupo FSI, Lupo GTI; Rep. Gr. 46 ; Assembly over‐
view - brake pedal; Separating brake pedal from brake servo .
– Remove accelerator pedal position sender -G79- ⇒ Rep. Gr.
20 ; Electronic power control; Repairing parts of electronic
power control .

Lupo 3L 1999 ➤
– Remove hexagon bolts -1-.

– Remove hexagon nuts -2-.
– Remove brake master cylinder ⇒ Brake systems - Lupo 3L,
Lupo FSI, Lupo GTI; Rep. Gr. 47 ; Removing and installing
brake master cylinder .
– Remove brake servo ⇒ Brake systems - Lupo 3L, Lupo FSI,
Lupo GTI; Rep. Gr. 47 ; Removing and installing brake servo .
– Then remove mounting bracket.
1.8.2 Installing
– Bleed brake system ⇒ Brake systems - Lupo 3L, Lupo FSI,
Lupo GTI; Rep. Gr. 47 ; Bleeding brake system .
– Bleed clutch system ⇒ page 27 .
1.8.3 Torque settings

– Hexagon bolts -1- ⇒ Item 2 (page 10)
– Hexagon nuts -2- ⇒ Item 4 (page 10)
1.9 Assembly overview - hydraulic system

Lupo 3L 1999 ➤
1 - Brake fluid reservoir

2 - Supply hose
3 - Master cylinder
⇒ page 21
4 - Clip
❑ Pull out clip to stop to re‐
move and install pipe/
hose line
5 - Clutch pedal
⇒ page 15
6 - Retainer
❑ Renew only with master
cylinder removed
❑ Removing ⇒ page 21
❑ Pressing on
⇒ page 21
7 - Self-locking hexagon nut,
25 Nm
❑ Always renew
❑ Qty. 2
8 - Pipe/hose line
❑ Allocate according to ⇒
Electronic parts cata‐
logue “ETKA” .
❑ Moisten O-rings with
brake fluid before instal‐
ling.
❑ To remove, remove
ABS control unit with hy‐
draulic unit ⇒ Brake
systems - Lupo 3L, Lupo FSI, Lupo GTI; Rep. Gr. 45 ; Hydraulic unit; Assembly overview - brake server
and brake master cylinder; Removing and installing control unit and brake master cylinder .
9 - Retainer
❑ Secured to body.
10 - Retainer
❑ Secured to slave cylinder of gearbox.
12 - Clip
❑ Pull out clip to stop to remove and install pipe/hose line
13 - Slave cylinder
14 - Dust cap
15 - Bleeder valve
❑ Bleeding clutch system ⇒ page 27
16 - Gearbox

Lupo 3L 1999 ➤
Levering off retainer -A- in -direction of arrow-
Pressing master cylinder operating rod into retainer -A- in

-direction of arrow-
1.10 Removing and installing master cylinder

Lupo 3L 1999 ➤
Special tools and workshop

equipment required
♦ Removal lever -80 - 200-
♦ Hose clamps to 25 mm Ø
-3094-
♦ Torque wrench -
V.A.G 1331-
♦ Pliers -T10005-

FSI, Lupo GTI
1.10.1 Removing
– Lay sufficient lint-free cloths under master cylinder.
– Remove coolant expansion tank, pull off connector and swing
to side without opening hydraulic system.
– Remove ABS control unit with hydraulic unit ⇒ Brake systems
- Lupo 3L, Lupo FSI, Lupo GTI; Rep. Gr. 45 ; Hydraulic unit;
Assembly overview - brake server and brake master cylinder;
Removing and installing control unit and brake master cylin‐
der .

Lupo 3L 1999 ➤
– Clamp off supply hose -A- to brake fluid reservoir with hose
clamp -3094- .
– Then carefully press off supply hose -A- with removal lever -80
- 200- until it can be removed by hand.
1 - Open-jaw spanner 22 AF
– Seal supply hose -A-.
– Pull clip -B- for hose/pipe line out of master cylinder with
screwdriver -2- in direction of arrow to stop.
– Pull pipe/hose line -C- out of master cylinder and seal.
– Remove lower trims from light switch and steering column and
remove driver side compartment ⇒ General body repairs, in‐
terior; Rep. Gr. 68 ; Compartments, covers and trims; Re‐
moving driver side compartment .
panel .
– Remove over-centre spring ⇒ page 13 .
– Connect receptacle with bleeder hose -arrow- of brake filling

and bleeding device -V.A.G 1869- .
– Open bleed valve of slave cylinder.
Release master cylinder operating rod from clutch pedal as fol‐

lows:
– Pull clutch pedal gently into passenger compartment.
– Press sides of retainer inwards -arrows- using pliers -
T10005- .
– Pull piston rod with mounting out of pedal in direction of travel.
– Turn stop -A- for clutch pedal in direction of arrow -1- and re‐
move it.
– Turn mounting -B- for over-centre spring in direction of arrow
-2- and remove.
– Remove nuts for securing master cylinder.
– Then swing master cylinder in direction of arrow -3- out of
mounting bracket, guiding piston rod past clutch pedal on left.

Lupo 3L 1999 ➤
1.10.2 Installing
– The retainer -A- must be fitted to the master cylinder operating
rod -B-.
– Pull piston rod out of master cylinder slightly and hold using
pliers.
– At the same time, press clutch pedal in -direction of arrow- until
it engages. Ensure that it is properly locked.
– Fit stop -A- for clutch pedal again.

Installation position:
The retaining clip -arrow 1- points towards master cylinder -B-.
– Install mounting -C-.
– Lug -arrow 2- contacts lower left corner on locking arm of
master cylinder.
– Bleed clutch system after installing master cylinder
⇒ page 27 .
– Bleed brake system ⇒ Brake systems - Lupo 3L, Lupo FSI,

Hexagon nuts for securing master cylinder ⇒ Item 7 (page 20)
1.11 Removing and installing slave cylinder

1.11.1 Removing
theft code.

Lupo 3L 1999 ➤
– Pull locking mechanisms on gear selector cable and gate se‐

lector cable forward to stop -arrow 1- and then turn to left to
lock -arrow 2-.
– Pull securing clip -arrow 3- off relay lever -A- and remove relay
lever.
– Remove gearbox selector lever -B- by removing nut
-arrow 4-.
– Lay sufficient lint-free cloths under slave cylinder.
– Pull clip -A- for pipe/hose line out of slave cylinder to stop.
– Pull pipe/hose line out of support -C- on gearbox.
– Pull pipe/hose line -B- out from slave cylinder and seal hose.
– Remove bolts for slave cylinder -arrows- and remove slave
cylinder.
1.11.2 Installing
– Bolt slave cylinder to gearbox -arrows-.
– Insert pipe/hose line -B- into slave cylinder to stop.
– Press in clip -A- to stop.
– Press pipe/hose line into support -C- on gearbox.
– Install selector parts on gearbox.
– Bleed clutch system after installing slave cylinder
⇒ page 27 .
Adjust selector mechanism ⇒ page 44 .

Slave cylinder to gearbox ⇒ Item 11 (page 20)
Gearbox selector lever to selector shaft ⇒ Item 17 (page 40) .
1.12 Removing and installing pipe/hose line


Lupo 3L 1999 ➤
♦ Brake filling and bleeding equipment -V.A.G 1869-
♦ Hose clamps to 25 mm Ø -3094-

FSI, Lupo GTI
1.12.1 Removing
theft code.
– Remove cover from engine.
– Pull connector off coolant expansion tank.
– Unbolt coolant expansion tank and place to side. Do not open
cooling system.
– Lay sufficient lint-free cloths underneath.
– Remove ABS control unit with hydraulic unit ⇒ Brake systems
- Lupo 3L, Lupo FSI, Lupo GTI; Rep. Gr. 45 ; Hydraulic unit;
Assembly overview - brake server and brake master cylinder;
Removing and installing control unit and brake master cylin‐
der .
– Pull clip -A- for pipe/hose line out of slave cylinder to stop.
– Pull pipe/hose line out of support -C- on gearbox.
– Pull pipe/hose line -B- out from slave cylinder and seal hose.
– Remove pipe/hose line from retainer on body.

Lupo 3L 1999 ➤
– Clamp off supply hose -A- to brake fluid reservoir with hose
clamp -3094- .
– Pull clip -B- for hose/pipe line out of master cylinder with
screwdriver -1- to stop -arrow-.
– Pull pipe/hose line -C- out of master cylinder and seal open‐
ings.
1.12.2 Installing
– Push pipe/hose line -C- into master cylinder.
– Press clip -B- into master cylinder to stop -arrow-.
– Install pipe/hose line in retainer on body.
– Insert pipe/hose line -B- into slave cylinder to stop.

– Press in clip -A- to stop.
– Press pipe/hose line into support -C- on gearbox.
– Remove hose clamp 3094 from supply hose.
– Bleed clutch system after installing master cylinder pipe/hose
line ⇒ page 27 .
1.13 Bleeding clutch system


Lupo 3L 1999 ➤
♦ Brake filling and bleeding equipment -V.A.G 1869-
– Brake fluid specification ⇒ Brake systems Lupo 3L, Lupo FSI,

– Connect brake filling and bleeding unit -V.A.G 1869- .
– Lay sufficient lint-free cloths underneath.
Brake fluid must not be allowed to get onto gearbox.
– Connect bleeder hose to collector bottle of brake bleeding
equipment.
– Connect bleed hose -arrow- to slave cylinder and open bleed
valve.
– Depress clutch pedal several times after completion of bleed‐
ing process.

Lupo 3L 1999 ➤
2 Repairing clutch release mechanism
1 - Release bearing
❑ Remove and install to‐
gether with clutch re‐
lease lever
and guide sleeve
⇒ page 30 to
⇒ page 30
❑ Do not wash out bear‐
ing; wipe only
❑ Renew noisy bearings
2 - Bolt, 5 Nm + turn 90° further
❑ Always renew
3 - Clutch release lever
gether with release
bearing
⇒ Item 1 (page 29) and
guide sleeve
⇒ page 30 to
⇒ page 30
❑ Remove old grease
4 - Retaining spring
❑ Secure to clutch release
lever
5 - Guide sleeve
gether with release
bearing
⇒ Item 1 (page 29) and
clutch release lever
⇒ page 30 to
⇒ page 30
6 - Input shaft seal
❑ Renewing ⇒ Item 2 (page 78)
7 - Ball stud, 20 Nm
❑ Remove old grease from contact surface of clutch release lever
❑ Lubricate with grease -G 000 100-
8 - Gearbox
10 - Retainer
11 - Slave cylinder
2. Repairing clutch release mechanism 29

Lupo 3L 1999 ➤
Removing and installing clutch release lever with release bearing

and guide sleeve
– Remove bolts -arrows-.
– Pull clutch release lever with release bearing and guide sleeve
off input shaft and ball stud.
Install in reverse order of removal.
Removing and installing guide sleeve

– 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.
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 locking lugs -arrows- engage.

Lupo 3L 1999 ➤
3 Repairing clutch

equipment required
♦ Counterhold -3067-
♦ Centring mandrel -T10086-
♦ Torque wrench -
V.A.G 1331-
Note
♦ Check whether dowel sleeves for aligning engine and gearbox are fitted in cylinder block and install if nec‐
essary.
♦ If dowel sleeves are not fitted, difficulties shifting gears, clutch problems and possible noises from the gear‐
box (rattling of gears which are not engaged) could occur.
♦ Replace clutch plates and pressure plates having damaged or loose rivets.
♦ Select clutch plate and pressure plate according to ⇒ Electronic parts catalogue “ETKA” and engine code.
3. Repairing clutch 31
Lupo 3L 1999 ➤
1 - Flywheel
❑ Ensure that centring
pins fit tightly
❑ Contact surface for
clutch lining must be
free of grooves, oil and
grease
⇒ Rep. Gr. 13
2 - Clutch plate
❑ Allocate according to ⇒
Electronic parts cata‐
logue “ETKA” .
❑ Installation position:
spring cage faces pres‐
sure plate.
❑ Centring ⇒ page 33
❑ Lightly grease splines
Note
Clean input shaft splines and, on

used clutch plates, hub splines; re‐
move corrosion and apply only a
very thin coat of grease -G 000 100-
to the input shaft splines. Then
move clutch plate to and fro on input
shaft until hub moves freely on
shaft. Remove excessive grease.
3 - Pressure plate
⇒ page 33
❑ Check ends of dia‐
phragm spring
⇒ page 33
Note
Pressure plates are protected

against corrosion and greased.
Clean contact surface only; other‐
wise the service life of the clutch will
be considerably reduced.
4 - Bolt, 20 Nm
❑ Allocate according to ⇒ Electronic parts catalogue “ETKA” .
❑ Loosen or tighten diagonally and in steps

Lupo 3L 1999 ➤
Centring clutch plate and removing and installing pressure plate

– Loosen or tighten bolts diagonally in stages.
– Reverse position of counterhold -3067- when removing.
Note
Pressure plate contact surface and clutch plate lining must make
full contact with flywheel. Tighten securing bolts diagonally and
evenly to prevent damage to the pressure plate centring hole and
the flywheel centring pins.
Checking ends of diaphragm spring

• Wear up to half the thickness of the diaphragm spring is per‐
mitted.
3. Repairing clutch 33
Lupo 3L 1999 ➤
34 – Controls, housing
1 Repairing selector mechanism
1.1 Installation position of selector mechanism

Arrow -A- Gear selection movement
Arrow -B- Gate selection movement
A - Gear selector cable

B - Gate selector cable
C - Heat shield
❑ Remove before remov‐
ing gear selector mech‐
anism
1 - Gearbox selector lever
2 - Relay lever
34 Rep. Gr.34 - Controls, housing

Lupo 3L 1999 ➤
I - Removing and installing se‐

lector lever knob and cover
⇒ page 36
II - Repairing selector lever and
selector lever housing
⇒ page 38
III - Assembly overview - re‐
moving and installing selector
cables ⇒ page 39
Removing and installing selector mechanism ⇒ page 41

Adjusting selector mechanism ⇒ page 44
Note
♦ Before working on the selector mechanism, disconnect earth

strap from the battery.
♦ Note radio code for vehicles with coded radio.
1. Repairing selector mechanism 35

Lupo 3L 1999 ➤
♦ Hose clip pliers -V.A.G 1275-
1.2 Removing and installing selector lever knob and cover

Lupo 3L 1999 ➤
1 - Selector lever knob

gether with cover
2 - Cover
❑ Separating from selec‐
tor lever knob
⇒ page 37
❑ Connecting to selector
lever knob before instal‐
ling ⇒ page 37
gether with selector lev‐
er knob
3 - Clamp
4 - Clamp
❑ To secure selector lever
knob on selector lever
❑ Secure to selector lever
knob
⇒ Item 1 (page 37) using
hose clip pliers -V.A.G
1275-
5 - Frame
❑ Holds cover
⇒ Item 2 (page 37) .
❑ Does not need to be re‐
moved from centre con‐
sole.
Separating cover from selector lever knob and assembling with

selector lever knob
– Turn cover inside out.
– Carefully lever off clamping sleeve -arrow- with a screwdriver
while pulling selector lever knob out.
Installation is carried out in the reverse sequence. When doing
this, note the following:
– Insert selector lever knob in cover.
– Push clamping sleeve onto selector lever knob and engage.
– Install selector lever knob and cover together.

Lupo 3L 1999 ➤
1.3 Repairing selector lever and selector lever housing
Note
Lubricate bearing positions and sliding surfaces with grease -G 000 450 02- .
1 - Securing clip
⇒ page 39
2 - Bush
3 - Compression spring
4 - Bush
5 - Torx screw, 5 Nm
6 - Cover
7 - Damping
8 - Ball socket
9 - Selector lever guide
10 - Damping washer
11 - Seal
❑ Between selector lever
housing and underbody
❑ Self-adhesive
❑ Bond to selector lever
housing
12 - Selector lever
13 - Plastic nut
❑ For console to selector
lever housing.
14 - Damping
15 - Selector lever housing
16 - Bearing bush
17 - Bolt, 25 Nm
❑ Qty. 4
18 - Pivot pin
19 - Guide bush
20 - Compression spring
❑ Installing ⇒ page 39
21 - Gate selector lever
22 - Torx screw, 5 Nm
23 - Base plate
❑ Bend open tabs to remove
❑ Renew
24 - Securing clip
25 - Gate selector cable
❑ On gate selector lever

Lupo 3L 1999 ➤
26 - Gear selector cable
❑ Press onto selector lever guide
27 - Bearing bush
❑ Fits in one position only
28 - Securing clip
Removing and installing securing clip

– To remove or install securing clip, pull selector lever in
-direction of arrow A- and at same time push down spacer
bush in -direction of- -arrow B- to stop using screwdriver.
Note
♦ Do not cant spacer bush when pushing down.

♦ Slot in selector lever for securing clip must be visible.
♦ Carefully release tension from spring.
Installing compression spring

– Insert compression spring so that extension -A- lies on top of
pin -arrow-.
– Then pull extension -B- to selector lever so that it sits below
pin -arrow-.
1.4 Assembly overview - removing and in‐

stalling selector cables
Note
Lubricate all bearings and contact surfaces with grease -G 000

450 02- .

Lupo 3L 1999 ➤
1 - Gear selector cable

❑ Press onto selector lev‐
er guide
❑ Installation position
⇒ page 34
2 - Gate selector cable
❑ On gate selector lever
⇒ page 34
3 - Securing clip
4 - Securing clip
❑ Do not damage cables
when removing
5 - Selector lever housing
6 - Support bracket
❑ With washer.
❑ For support bracket
8 - Grommet
❑ Support bracket mount‐
ing on gearbox
9 - Spacer
10 - Cable end-piece
❑ After installing, adjust
selector mechanism
⇒ page 44
❑ For gate selector cable
to relay lever
❑ Always renew after re‐
moving from relay lever.
11 - Cable end-piece
❑ After installing, adjust selector mechanism ⇒ page 44
❑ For gear selector cable to selector lever
❑ Always renew after removing from gearbox selector lever.
12 - Relay lever
13 - Bearing bush
14 - Securing clip
15 - Shoe
❑ With damper weight
❑ Install so that master spline aligns with selector shaft
❑ After installing, adjust selector mechanism ⇒ page 44
17 - Self-locking hexagon nut, 20 Nm
❑ Always renew

Lupo 3L 1999 ➤
Installation position of gearbox selector lever and relay lever

1 - Gearbox selector lever with damper weight
2 - Relay lever, engages in guide rail of gearbox selector lever via
shoe -arrow-
1.5 Removing and installing selector mech‐

anism
♦ Workshop manual Lupo 1999 ▸ 4-cylinder injection engine (4
valve), mechanics
1.5.1 Removing
– Pull locking mechanisms on selector cable end pieces forward
to stop in direction of arrow -1- and then turn to left to lock in
direction of arrow -2-.
– Only if the gear selector cable, the gate selector cable or the
cable end piece is to be renewed, may the cable end piece
-A- or -B- be levered out with 13 mm open jaw spanner -1-
– Lay a second open jaw spanner or appropriate pliers -2- be‐
neath it.

Lupo 3L 1999 ➤
– Remove cable support bracket from gearbox -arrows-.

Gearbox selector lever and relay lever with cable end pieces are
shown removed for clarity of illustration.
– Pull selector lever cover off centre console.
– Then destroy clamp -arrow- and pull off selector lever knob
with cover.
– Remove nuts for console -arrows-.

– Remove noise insulation tray.
– Unhook exhaust pipe from subframe -arrows-.

Lupo 3L 1999 ➤
– Remove front cross member -1- below exhaust system.

– Remove rear cross member -2-.
– Unclip wire for lambda probe -arrow- from floor and heat
shield.
– Remove protective cover -4- for lambda probe connector.
– Separate exhaust system behind front exhaust pipe at double
clamp -3- ⇒ 4-cylinder injection engine (4 valve), mechanics;
Rep. Gr. 26 ; Removing and installing parts of exhaust sys‐
tem .
– Tie up exhaust pipe with lambda probe -5-.
– Remove front shield -A-, observing lambda probe wire.
– Remove rear shield -B-.
– Unbolt selector lever housing from body.
– Swing selector lever housing down and remove with selector
cables.
1.5.2 Installing
– Guide selector cable and gate cable into respective end
pieces.
Only if gear selector cable or gate selector cable or the end pieces
are to be renewed and the end pieces have been levered off:
– Before installing, spread a small amount of grease -G 000 450
02- in recesses of cable end-pieces -A- and -B-.
– Press on cables with new cable end pieces.

Adjust selector mechanism ⇒ page 44 .

Selector lever housing to body ⇒ Item 17 (page 38)
Double clamp to exhaust pipe ⇒ 4-cylinder fuel injection engine
(4 valve), mechanics; Rep. Gr. 26 ; Removing and installing parts
of exhaust system

Lupo 3L 1999 ➤
Cross member to body ⇒ 4-cylinder fuel injection engine (4

valve), mechanics; Rep. Gr. 26 ; Removing and installing parts
of exhaust system
Selector cable support bracket to gearbox ⇒ Item 7 (page 40)
1.6 Adjusting selector mechanism

♦ Locking pin -T10027-
Note
♦ The following points are essential to ensure correct adjust‐

ment of selector mechanism:
♦ Moving parts of selector mechanism and elements transferring
force must be in proper condition.
♦ Selector mechanism must move freely.
♦ Gearbox, clutch and clutch mechanism must also be in proper
condition.
• Gearbox must be in neutral.

– Pull locking mechanisms on gate selector cable and gear se‐
lector cable forward to stop in direction of arrow -1- and then
turn to left to lock in direction of arrow -2-.
Set selector shaft as follows:

– Press selector shaft down in -direction of arrow 1- to stop.
– Pull selector shaft upwards slightly while carefully turning an‐
gled rod -A- 90° in -direction of arrow 2- until it engages
audibly.
This locks the selector shaft and it cannot be moved any more.
– Pull selector lever cover off centre console.
Now set selector lever as follows:

Lupo 3L 1999 ➤
– Guide locking pin -T10027- through hole -A- into hole -B-.
– Now turn locking mechanisms on gear selector cable and gate

selector cable clockwise to stop in -direction of arrow-.
Spring presses locking mechanism into original position.
– Now turn angled rod -A- back to original position

-direction of arrow-.
• Angled rod -A- must point straight up.
– Pull locking pin -T10027- out of holes -A- and -B-.

– Clip gaiter into frame.
1.6.1 Functional check

• With gearbox in neutral, selector lever must rest in gate for 3rd
and 4th gear.
– Operate clutch.
– Select all gears several times. Pay particular attention to op‐
eration of reverse gear lock.

Lupo 3L 1999 ➤
– If it continues to be difficult to engage a gear after repeated

attempts, repeat adjustment procedure of selector mechanism
⇒ page 44 .

Lupo 3L 1999 ➤
2 Removing and installing gearbox

equipment required
♦ Support bracket -10 - 222
A-
♦ Adapter -10 - 222 A/8-
♦ Gearbox support -3282-
♦ Adjustment plate -3282/31-
♦ Gearbox mounting support
-3336-
2. Removing and installing gearbox 47

Lupo 3L 1999 ➤
♦ Torque wrench -
V.A.G 1331-
♦ Torque wrench -
V.A.G 1332-
♦ Engine and gearbox jack -
V.A.G 1383 A-

♦ Workshop Manual Lupo 1999 ▸, Electrical system
♦ Workshop manual Lupo 1999 ▸ 4-cylinder injection engine (4
valve), mechanics
2.1 Removing gearbox

theft code.
– Remove cover from engine.
– Remove air filter housing with intake hose ⇒ Rep. Gr. 24 ;
Repairing injection; Dismantling and assembling air filter .

Lupo 3L 1999 ➤
– Remove retainer from left assembly mounting -arrows-.
– Pull locking mechanisms on gear selector cable and gate se‐

lector cable forward to stop -arrow 1- and then turn to left to
lock -arrow 2-.
– Pull securing clip -arrow 3- off relay lever -A- and remove relay
lever.
– Remove gearbox selector lever -B- by removing nut
-arrow 4-.
– Remove cable support bracket from gearbox -arrows-.

– Then tie up selector cable and gate cable.
– Pull pipe/hose line -A- out of support -B- on gearbox.
– Remove slave cylinder -C-, lay to side and secure with wire.
Do not open hydraulic system.
Note
Do not depress clutch pedal.
– Remove earth strap at upper engine/gearbox connecting bolt.

– Remove upper engine/gearbox connecting bolts.
– Then remove upper securing bolt on starter.
– Remove heat shield from exhaust manifold ⇒ 4-cylinder in‐
jection engine (4-valve), mechanics; Rep. Gr. 26 ; Removing
and installing parts of exhaust system; Exhaust manifold, front
exhaust pipe with ancillaries .

Lupo 3L 1999 ➤
– Fit support bracket -10 - 222 A- together with supports -10 -

222 A/8- .
– Take up weight of engine/gearbox assembly on spindles.
– Remove front left wheel bolts.
– Raise vehicle.
– Remove left wheel.
– Pull off reversing light connector -1-.

– Remove bracket -2- from starter -arrow-.
– Remove starter ⇒ Electrical system; Rep. Gr. 27 ; Starter;
Removing and installing starter .
– Separate exhaust system behind front exhaust pipe at double
clamp ⇒ 4-cylinder injection engine (4 valve), mechanics;
Rep. Gr. 26 ; Removing and installing parts of exhaust sys‐
tem .
– Unhook rubber mountings -1- from subframe.

– Secure front exhaust pipe near catalytic converter to body with
wire.
– Remove pendulum support -2-, -arrows A- and -B-.
– Disconnect drive shafts from gearbox flange shafts.
– Raise right drive shaft and secure.
– Pull connector off speedometer sender -arrow-.

– Remove engine/gearbox connecting bolt -A- above right
flange shaft.

Lupo 3L 1999 ➤
– Mark installation position of bolts -arrows-.

– Remove bolts -arrows- ⇒ Running gear, axles, steering - Lupo
3L, Lupo FSI, Lupo GTI; Rep. Gr. 40 ; Repairing front sus‐
pension, Lupo GTI .
– Swing wheel bearing housing outwards.
– Guide out left drive shaft between subframe and gearbox.
– When doing this, guide drive shaft into wheel housing and se‐
cure to suspension strut with wire.
– Remove hexagon bolt -arrow- for left-hand hand assembly

mounting from gearbox mounting.
– Tilt engine/gearbox assembly by lowering left spindle of sup‐
port bracket -10 - 222 A- until pulley contacts right longitudinal
member.
Note
When lowering engine and gearbox assembly, ensure that gear‐

box does not contact subframe in region of differential.
• Securing bolts -arrows- for gearbox bracket -A- must be ac‐

cessible.
– Remove gearbox bracket -A- -arrows-.

– Push gearbox bracket -A- upwards until gearbox is free.
– Remove lower engine/gearbox connecting bolts (bolts remain
on engine sump).
– Assemble engine and gearbox support -V.A.G 1383 A- , gear‐
box support -3282- , adjustment plate -3282/31- for “02T”
gearbox and mounting elements as follows:
– Fit adjustment plate -3282/31- on gearbox support -3282- (ad‐
justment plate fits in only one position).
– Align arms of gearbox support according to holes in adjust‐
ment plate.
– Screw in support elements -A- as illustrated on adjustment

plate.

Lupo 3L 1999 ➤
– Position engine and gearbox jack under vehicle, -arrow B-

( ⇒ page 51 , fig. A34-0349) on adjustment plate points in
forwards.
– Align adjustment plate parallel to gearbox and lock safety sup‐
port on gearbox.
– Remove engine/gearbox connecting bolt -arrow-.
– Press gearbox off dowel sleeves and carefully swing towards
subframe.
– Have a second mechanic press engine forwards.
– When doing this, observe radiator.
– Turn gearbox downwards in vicinity of differential.
– Then lower gearbox carefully, guiding with right-hand flange

shaft -A- in area of flywheel and intermediate plate as shown
and with left-hand flange shaft -B- in area of subframe.
– When lowering gearbox, change position of gearbox using
spindles of gearbox support -3282- .
2.2 Transporting gearbox

– Bolt gearbox lifting tackle -3336- to clutch housing.
– Adjust support beam on sliding piece using locking pin

-arrow-.
No. of holes visible = 5
– Lift gearbox using workshop crane and gearbox lifting tackle
-3336- .
– Set gearbox aside, for example in a transport container.
2.3 Installing gearbox

– Clean input shaft splines and lightly grease with grease -G 000
100- .
The clutch plate must slide easily to and fro on the input shaft.

Lupo 3L 1999 ➤
– Check whether dowel sleeves for aligning engine and gearbox

are fitted in cylinder block and install if necessary.
If dowel sleeves are not fitted, difficulties shifting gears, clutch
problems and possible noises from the gearbox (rattling of gears
which are not engaged) could occur.
– Ensure that intermediate plate is correctly seated on engine.
– Assemble engine and gearbox support -V.A.G 1383 A- , gear‐
box support -3282- , adjustment plate -3282/31- for “02T”
gearbox and mounting elements as follows:
– Fit adjustment plate -3282/31- on gearbox support -3282- (ad‐
justment plate fits in only one position).
– Align arms of gearbox support according to holes in adjust‐
ment plate.
– Screw in support elements -A- as illustrated on adjustment
plate.
– Place gearbox on engine and gearbox jack .
– Align adjustment plate parallel to gearbox and lock safety sup‐
port on gearbox.
– Position engine and gearbox jack under vehicle, -arrow B-
( ⇒ page 53 , fig. A34-0349) on adjustment plate points in
forwards.
– Using spindles of gearbox support -3282- , tilt gearbox down‐
wards in vicinity of differential.
– Have a second mechanic press engine forwards. When doing
this, observe radiator.
– Then raise gearbox carefully, guiding with right-hand flange

shaft -A- in area of flywheel and intermediate plate as shown
and with left-hand flange shaft -B- in area of subframe.
– Insert gearbox.
Note
Observe coolant hose between engine and heat exchanger for

heater.
– Screw in engine/gearbox connecting bolt -arrow- and tighten

to specified torque ⇒ page 56 .
– Screw in lower engine/gearbox securing bolts and tighten to
specified torque ⇒ page 56 .
– After gearbox has been bolted to engine, remove engine and
gearbox jack from gearbox.

Lupo 3L 1999 ➤
– Install gearbox bracket -A- with new bolts -arrows-, tighten to

40 Nm and turn 90° (1/4 turn) further.
– Moisten bonded rubber mounting of left assembly mounting
and upper section of gearbox bracket with assembly lubrica‐
tion oil ⇒ Electronic parts catalogue “ETKA” .
– Align engine and gearbox in installation position. To do this,
tighten left spindle of support bar -10 - 222 A- .
– Install new hexagon bolt -arrow- for left assembly mounting in

gearbox mounting, tighten to 60 Nm and turn 90° (1/4 turn)
further.
WARNING
Do not remove support bracket -10 - 222 A- until all bolts se‐
curing the assembly mounting have been tightened to speci‐
fied torque.
Note
Install engine/gearbox mounting stress-free ⇒ 4-cylinder injection

engine (4 valve), mechanics; Rep. Gr. 10 ; Removing and instal‐
ling engine .
– Screw in upper engine/gearbox securing bolts and tighten to

specified torque ⇒ page 56 .
– Install engine/gearbox connecting bolt -A- above right flange

shaft and tighten to specified torque ⇒ page 56 .
– Attach connector to speedometer sender -arrow-.
– Guide left drive shaft between subframe and gearbox.
– Bolt swivel joint to suspension link at old impression using new
bolts ⇒ Running gear, axles, steering - Lupo 3L, Lupo FSI,
Lupo GTI; Rep. Gr. 40 ; Repairing front suspension - Lupo
GTI; Removing and installing swivel joint .
– Attach drive shafts to gearbox ⇒ Running gear, axles, steering
- Lupo 3L, Lupo FSI, Lupo GTI; Rep. Gr. 40 ; Repairing drive
shafts - Lupo GTI; Removing and installing drive shafts .
– Install pendulum support -2- -arrows A- and -B- ⇒ Running

gear, axles, steering - Lupo 3L, Lupo FSI, Lupo GTI; Rep. Gr.
40 ; Repairing front suspension - Lupo 3L, Lupo FSI, Lupo GTI;
I - Assembly overview - subframe, anti-roll bar, suspension
link .
– Hook rubber mountings -1- into subframe.
– Assemble exhaust system ⇒ 4-cylinder fuel injection engine
(4 valve), mechanics; Rep. Gr. 26 ; Removing and installing
parts of exhaust system .
– Install starter ⇒ Electrical system; Rep. Gr. 27 ; Starter; Re‐
moving and installing starter .

Lupo 3L 1999 ➤
– Install bracket -2- on starter -arrow-.

– Push on reversing light connector -1-.
– Install heat shield on exhaust manifold ⇒ 4-cylinder injection
engine (4-valve), mechanics; Rep. Gr. 26 ; Removing and in‐
stalling parts of exhaust system; Exhaust manifold, front ex‐
haust pipe with ancillaries .
– Install earth strap at upper engine/gearbox connecting bolt.
– Install slave cylinder -C- and tighten bolts to specified torque

⇒ Item 11 (page 20) .
– Press pipe/hose line -A- into retainer -B- on gearbox.
– Install selector cable support bracket on gearbox and tighten
bolts -arrows- to specified torque ⇒ Item 7 (page 40) .
– Install gearbox selector lever -B-.

– Tighten hexagon nut -arrow 4- to specified torque
⇒ Item 17 (page 40) .
– Insert relay lever -A- and secure with securing clip -arrow 3-.
– Connect gear selector cable and gate selector cable to re‐
spective cable end-pieces.
– Adjust selector mechanism ⇒ page 44 .
– Install wheel ⇒ Running gear, axles, steering - Lupo 3L, Lupo
FSI, Lupo GTI; Rep. Gr. 44 ; Torque settings for wheel bolts .
– Install air filter ⇒ Rep. Gr. 24 ; Repairing injection; Dismantling
and assembling air filter .
– Connect earth strap to battery.
Note
Note radio code for vehicles with coded radio.
– Attach retainer to left assembly mounting.

– Check gear oil ⇒ page 57 .
– Install engine cover.
– Install noise insulation.

Lupo 3L 1999 ➤

Gearbox to engine
Item Bolt Quantity Nm
1 M 12 x 55 3 80
2 M 12 x 130 2 80
♦ Addi‐
tional‐
ly,
starter
to
gear‐
box
3 M 12 x 70 1 80
4 M 10 x 50 2 40
Item -A- dowel sleeves for centring

Lupo 3L 1999 ➤
3 Checking gear oil

♦ Socket, 27 mm -3257-
Gearbox oil ⇒ Electronic parts catalogue (ETKA)

– To check gear oil, remove oil plug -arrow-.
Oil level is correct when gearbox is filled to lower edge of filler
hole.
– Tighten bolt -arrow- to specified torque ⇒ Item 6 (page 78) .
When filling with oil, note the following:
– Remove oil plug -arrow-.
– Fill with gear oil to lower edge of filler hole.
– Screw in plug -arrow-.
– Start engine, engage gear and allow gearbox to turn for ap‐
prox. 2 minutes.
– Stop engine and remove plug -arrow-.
– Top up with gear oil to lower edge of filler hole.
– Tighten bolt -arrow- to specified torque ⇒ Item 6 (page 78) .
3. Checking gear oil 57

Lupo 3L 1999 ➤
4 Dismantling and assembling gearbox
4.1 Overview - gearbox
1 - 1st gear
2 - 2nd gear
3 - 3rd gear
4 - 4th gear
5 - 5th gear
6 - 6th gear
7 - Gearbox housing cover
8 - Gearbox housing
9 - Reverse gear
10 - Selector mechanism
❑ (Selector forks)
11 - Clutch housing
12 - Input shaft
13 - Output shaft
14 - Differential
Dismantling and assembling procedure ⇒ page 64

Lupo 3L 1999 ➤
I - Removing and installing

cover for gearbox housing and
5th and 6th gear ⇒ page 60 .
II - Removing and installing
clutch housing ⇒ page 62 .
III - Removing and installing in‐
put shaft, output shaft, differ‐
ential, selector mechanism
and selector forks
⇒ page 63 .
4. Dismantling and assembling gearbox 59

Lupo 3L 1999 ➤
4.2 Removing and installing cover for gearbox housing and 5th and 6th gear
1 - Gearbox housing
❑ Repairing ⇒ page 76
2 - 5th gear wheel
⇒ page 72
3 - Sleeve
4 - 6th gear wheel
⇒ page 73
5 - Cylindrical roller bearing in‐
ner race
❑ For output shaft
❑ Mark before removing
❑ Do not interchange with
cylindrical roller bearing
inner race of input shaft
❑ Can be renewed individ‐
ually.
6 - Bolt
❑ M8: 30 Nm and then turn
90° further
❑ M10: 75 Nm and then
turn 45° further
❑ Self-locking
❑ Always renew
❑ With cylindrical roller
bearing for input and
output shafts.
Note
If gearbox housing cover is installed

with gearbox installed, check oil lev‐
el and top up with gear oil
⇒ page 57 .

❑ Always renew
9 - Bolt
❑ M8: 30 Nm and then turn 90° further
❑ M10: 75 Nm and then turn 45° further
❑ For input shaft
❑ Self-locking
❑ Always renew
10 - Cylindrical roller bearing inner race
❑ For input shaft

Lupo 3L 1999 ➤
❑ Do not interchange with cylinder roller bearing inner race of output shaft
❑ Can be renewed individually.
11 - Thrust washer
12 - Synchromeshed gear for 6th gear
13 - Synchro-ring for 6th gear
14 - Needle bearing
❑ For 6th gear
❑ Renew together with ⇒ Item 15 (page 61)
15 - Sleeve
❑ For 6th gear needle bearing
16 - Locking collar with synchro-hub for 5th and 6th gears
❑ Dismantling and assembling ⇒ page 92
17 - Selector fork for 5th and 6th gear
18 - Pivot pin
❑ For 5th gear selector fork.
❑ Will be damaged when removed.
❑ Always renew
21 - Needle bearing
❑ For 5th gear

Lupo 3L 1999 ➤
4.3 Removing and installing clutch housing
1 - Countersunk bolt, 25 Nm
2 - Flange shaft with compres‐
sion spring
⇒ page 64
❑ Assembling
⇒ page 114
❑ Always renew
4 - Clutch housing
5 - Gearbox housing
6 - Clutch release lever
❑ With guide sleeve and
release bearing
⇒ page 64
7 - Bolt
❑ ⇒ Item 2 (page 29)

Lupo 3L 1999 ➤
4.4 Removing and installing input shaft, output shaft (drive pinion), differential,
selector mechanism and selector forks
1 - Differential
❑ Dismantling and assem‐
bling ⇒ page 114
2 - Gearbox housing
3 - Oil drain plug, 25 Nm
4 - Flange shaft with compres‐
sion spring
⇒ page 64
❑ Assembling
⇒ page 114
❑ Self-locking
❑ Always renew
❑ To secure bearing
mounting with deep
groove ball bearing for
input and output shafts
⇒ Item 16 (page 64) .
7 - Hexagon collared nut,
23 Nm
❑ For selector mechanism
⇒ Item 15 (page 63) .
❑ Self-locking
❑ Always renew
8 - O-ring
❑ Always renew
9 - Pivot pin
10 - Bolt, 5 Nm + turn 90° fur‐
ther
❑ Always renew
11 - Selector shaft with selector shaft cover
❑ (Selector unit).
❑ Always renew
13 - Reversing light switch, 20 Nm
❑ Changed to captive seal shortly after introduction of gearbox.
14 - Seal
❑ Always renew, if part of original equipment
15 - Selector mechanism
❑ (Selector forks)

Lupo 3L 1999 ➤
16 - Input shaft and output shaft with bearing mounting and deep groove ball bearing
❑ If bearing mounting is separated from gearbox housing, then it must always be renewed
❑ Pressing bearing mounting off and on ⇒ Item 14 (page 96) .
❑ Dismantling and assembling input shaft ⇒ page 92 .
❑ Dismantling and assembling output shaft ⇒ page 102 .
17 - Reverse gear shaft
18 - Reverse gear
19 - Bolt, 25 Nm then turn 90° further
❑ Always renew
4.5 Dismantling and assembling procedure

Removing and installing gearbox housing cover, clutch housing,
selector shaft with selector mechanism cover, input shaft, output
shaft, differential and selector mechanism

equipment required
♦ Support clamp -VW 313-
♦ Thrust plate -VW 401-
♦ Press tool -VW 412-
(modifying ⇒ page 66 )
♦ Guide pin -T10079-

Lupo 3L 1999 ➤

♦ Tube -VW 418 A-
♦ Thrust pad -3074-
♦ Thrust piece -T10080-
♦ Drip tray -V.A.G 1306-

Lupo 3L 1999 ➤
♦ Torque wrench -
V.A.G 1331-
♦ -2- Puller -Kukko 18/1-
♦ -3- Splitter -Kukko 17/1-
♦ -1- Two arm puller -Kukko
20/10-
♦ Hexagon socket head bolts
M 8 x 15
♦ Sealant -AMV 188 200 03-
4.5.1 Modifying gearbox support 3221

A new hole is required to secure gearbox 02U on gearbox sup‐
port.
Dimensions are given in mm.
– Drill an 11.0 mm ∅ hole -arrow- in gearbox support -3221- .

Lupo 3L 1999 ➤
4.5.2 Dismantling
– Secure gearbox to repair stand -arrows-.
– Place drip tray -V.A.G 1306- underneath.
– Drain gear oil.
– Remove clutch release lever -A- together with release bearing

and guide sleeve -arrows-.
– Remove right flange shaft securing bolt -B-. Screw two bolts
into flange and counterhold flange shaft using a lever.
– Remove flange shaft along with spring, thrust washer and ta‐
pered ring.
– Unscrew gearbox housing cover -arrow- and carefully pull it

off.
– Pull out pivot pin -1- for 5th and 6th gear selector fork -2- and
remove selector fork.

Lupo 3L 1999 ➤
– Remove bolts -A- for inner bearing races from input and output
shafts, engaging 5th gear -arrow 1- and 1st gear -arrows 2-
and -3-.
– Input shaft and output shaft are locked when both gears are
engaged. Both bolts can now be loosened.
Note
If shafts are not to be renewed, clean residual locking material out

of threaded holes using a thread chaser.
– Pull off 6th gear wheel with cylindrical roller bearing inner race
for output shaft.
A - Two arm puller , e.g. -Kukko 20/10-
B - Hexagon socket head bolts M 8 x 15
– Position splitter -A- behind constant mesh teeth of synchro‐

meshed gear for 6th gear (not dog teeth) and tighten -arrow-.
A - Splitter, 12...75 mm , e.g. -Kukko 17/1-
C - Puller , e.g. -Kukko 18/1-
– Pull off 6th gear wheel with cylindrical roller bearing inner race
for input shaft and thrust washer.
– Remove locking collar for 5th and 6th gear with locking pieces.

Lupo 3L 1999 ➤
– Tighten splitter -A- below synchro-ring for 5th gear -1-. This
presses synchro-ring against synchro-hub -2-.
A - Splitter, 12...75 mm , e.g. -Kukko 17/1-
C - Puller , e.g. -Kukko 18/1-
– Pull off synchro-hub for 5th and 6th gear with 6th gear needle
bearing inner race and 5th gear synchro-ring.
Note
The synchro-ring for 5th gear must always be renewed after it is

pulled off.
– Remove flange shaft securing bolts by screwing two bolts into

flange and counterholding flange shaft with a lever.
– Pull out flange shaft -1- with spring.

– Remove sleeve -2-, gear wheel for 5th gear -3- and synchro‐
meshed gear for 5th gear with needle bearing -4-.
– Unscrew hexagon collared nut -5- for securing reverse gear
selector mechanism.
– Remove bearing mounting securing bolts -6- from input and
output shafts.
– Turn gearbox in support bracket so that clutch housing is up‐
wards.
– Remove securing bolts from clutch housing side for securing
clutch housing to gearbox housing.
– Remove clutch housing, if necessary carefully levering up all
around along protruding housing flange and alternating be‐
tween sides, being careful not to damage sealing surfaces.
– Do not cant the clutch housing. This prevents damage to roller
bearings and their bearing seats on the input and output
shafts.
– Remove differential -A- from gearbox housing.

Lupo 3L 1999 ➤
– Remove selector shaft with selector cover -A-. Place selector

shaft in neutral. Then remove bolts -arrows- and pull selector
shaft out of gearbox housing.
– Remove pivot pins -B- located on underside of gearbox.
– Remove reversing light switch -C-.
– Remove bolt -A- for securing reverse gear wheel shaft.

– Remove pivot pins -B- located on top of gearbox.
Note
Do not remove sealing cover -arrow- when dismantling gearbox.
– Press out input shaft, output shaft with bearing mounting, se‐
lector mechanism (selector forks) and reverse gear together.
Note
♦ Set gearbox housing on thrust plates -VW 401- and -VW 402-
so that dowel sleeves in gearbox housing are not damaged.
♦ When pressing out, get help from second mechanic to ensure
components do not fall out.
– Press input shaft and output shaft off bearing mounting with
deep groove ball bearing ⇒ page 92 .
4.5.3 Assembling
Note
♦ Press bearing mounting with deep groove ball bearing onto

input shaft and output shaft ⇒ page 92 .
♦ Press needle roller bearing inner race for 5th gear synchro‐
meshed onto input shaft ⇒ page 92 .

Lupo 3L 1999 ➤
– Position assembled components, input shaft -2- and output

shaft -1- with bearing mounting for deep groove ball bearing,
in thrust piece -T10080- .
– Insert selector mechanism (selector forks) -4- in the shaft lock‐
ing collars.
– Install reverse gear shaft -3- with reverse gear.
– Screw guide pin -T10079- onto stud (secures reverse gear)
-arrow-.
– Install components together into gearbox, when doing this

guide guide pin -T10079- through hole to secure selector
mechanism in gearbox housing.
– Remove guide pin -T10079- .
– Before pressing bearing mounting check selector forks are
engaged correctly in locking collar.
– Press bearing mounting together with input shaft and output

shaft in to stop.

Lupo 3L 1999 ➤
– Install bolt -A- for securing reverse gear wheel shaft.

– Install pivot pin -B- in bottom of gearbox.
– Install reversing light switch -C-.

– Install pivot pin -B- in top of gearbox.
– Place selector plates in neutral.
– Apply sealant -AMV 188 200 03- evenly to sealing surface of
selector mechanism cover.
– Install selector shaft with selector cover -A-. Then tighten bolts
-arrows-.
– Using new bolts -A- tighten bearing mounting for input and
output shafts.
Note
Tighten bolts to specified torque, working from centre outwards

using alternate sequence.
– Tighten hexagon collared nut -B- for securing selector mech‐

anism (selector forks).
– Insert input and output shafts together with gearbox housing
into thrust block -T10083- .
– Install gear wheel for 5th gear -1- and sleeve -2-.
Installation position of 5th gear wheel:
The high shoulder -arrow- faces gearbox housing cover.
– Install 5th gear synchromeshed gear -3- with needle bearing.
– Place 5th gear synchro-ring on synchromeshed gear.
– Press on synchro-hub and locking collar for 5th and 6th gear
(installation position ⇒ page 101 ).

Lupo 3L 1999 ➤
– Heat needle bearing for 6th gear to maximum 100° C and

press on.
WARNING
Wear protective gloves!
– Install 6th gear synchromeshed gear with needle bearing and

synchro-ring.
– Install thrust washer -A-.
Note
Do not interchange inner races of cylindrical roller bearings of in‐

put and output shafts.
– Heat cylindrical roller bearing inner race -B- to maximum

100° C and press onto input shaft.
WARNING
– Heat gear wheel for 6th gear to maximum 100° C.
WARNING
Installation position, 6th gear wheel

High collar faces sleeve.
– Shift locking collar -A- for 5th and 6th gear to freewheel posi‐
tion to enable 6th gear synchromeshed gear to turn while 6th
gear wheel is being pressed on.
– Press on gear wheel for 6th gear, being careful that teeth of
gear wheel -B- and synchronized gear -C- for 6th gear mesh.

Lupo 3L 1999 ➤
– Heat cylindrical roller bearing inner race -A- to maximum

100° C and press onto output shaft.
WARNING
– Install differential -A-.

– Apply sealant -AMV 188 200 03- evenly to sealing surface.
– Secure clutch housing to gearbox housing.
– Turn gearbox in support bracket so that gearbox housing is
upwards.
– Before tightening securing bolts -A-, engage 2 gears

(-arrows 1- through -3-).

Lupo 3L 1999 ➤
– Insert selector fork for 5th and 6th gear -2- and push pivot pin
-1- in to stop -direction of arrow-.
– Apply sealant -AMV 188 200 03- evenly to sealing surface.
– Tighten gearbox housing cover.
– Install both flange shafts with springs, thrust washers and ta‐
pered rings.
– Install clutch release lever together with release bearing and
guide sleeve.

Lupo 3L 1999 ➤
5 Repairing gearbox housing and clutch housing

equipment required
♦ Press tool -VW 408 A-
♦ Spacer sleeve -VW 472/2-
♦ Centring mandrel -12 - 551-
♦ Thrust piece -30 - 555-
♦ Spindle from assembly tool
-3066-
♦ Thrust piece -3124-

Lupo 3L 1999 ➤

(modifying ⇒ page 66 )
♦ Multi-point bit -3357-
♦ Torque wrench -
V.A.G 1331-
♦ -2- Puller -Kukko 18/1-
♦ -3- Splitter -Kukko 17/1-
5. Repairing gearbox housing and clutch housing 77

Lupo 3L 1999 ➤
1 - Clutch housing
❑ If renewed, adjust differ‐
ential ⇒ page 123
2 - Input shaft seal
❑ Lever out with a screw‐
driver
❑ Driving in ⇒ page 79
3 - Ball stud, 20 Nm
❑ Remove old grease
from contact surface of
clutch release lever
❑ Lubricate with grease -
G 000 100-
4 - Oil seal for right flange shaft
❑ Renewing with gearbox
installed ⇒ page 112
5 - Sleeve
❑ For oil seal.
❑ Pulling out ⇒ page 80
❑ Pulling in ⇒ page 80
6 - Oil filler plug, 25 Nm
❑ Remove and install with
multi-point bit -3357- .
7 - O-ring
❑ Always renew
8 - Speedometer sender -G22-
9 - Bolt, 5 Nm then turn 90° fur‐
ther
❑ Always renew
10 - Shim S2
❑ For differential
❑ Determining thickness ⇒ page 123
11 - Tapered roller bearing outer race
❑ Pressing out ⇒ page 121
❑ Pressing in ⇒ page 121
❑ If renewed, adjust differential ⇒ page 123
12 - Bolt, 5 Nm then turn 90° further
❑ Always renew
14 - Shim S1
❑ Always 1 mm thick
15 - Dowel sleeve
❑ Qty. 2

Lupo 3L 1999 ➤
16 - Gearbox housing
17 - Oil drain plug
❑ ⇒ Item 3 (page 63)
18 - Oil seal for left flange shaft
❑ Renewing with gearbox installed ⇒ page 110
19 - Sleeve
❑ For selector shaft
❑ Driving out ⇒ page 80
20 - Magnet
❑ Held in place by housing joint surface
21 - Sealing cover
❑ Coat sealing surfaces with -AMV 188 200- before bolting on
22 - Retaining ring
❑ Insert in groove of cylindrical roller bearing ⇒ Item 25 (page 79) .
23 - Retaining ring
❑ Insert in groove of cylindrical roller bearing ⇒ Item 24 (page 79) .
24 - Cylindrical roller bearing
❑ For input shaft
26 - Plug
❑ Installed on some gearboxes
❑ Insert into hole in clutch housing.
Driving in input shaft oil seal flush
5. Repairing gearbox housing and clutch housing 79

Lupo 3L 1999 ➤
Pulling out sleeve for seal

– Fit spacer sleeve -VW 472/2- and press tool -30 - 555- onto
differential.
A - Puller , e.g. -Kukko 18/1-
B - Splitter, 12...75 mm , e.g. -Kukko 17/1-
Pulling in sleeve for seal

A - Screw spindle from assembly device -3066- into threaded
piece of differential.
B - Nut M12 with washer.
– Pull sleeve in to stop using thrust piece -3124- by turning nut
-B-.
Note
With gearbox dismantled, press sleeve in to stop using thrust

piece -3124- .
Driving out selector shaft sleeve -A-
Driving in selector shaft sleeve -A-

Lupo 3L 1999 ➤
6 Repairing gearbox housing cover

equipment required
♦ Drift sleeve -40 - 21-
♦ Support bridge -2011-
♦ -1- Internal puller -Kukko
21/6-
♦ -4- Counterhold -Kukko
22/2-
♦ Torque wrench -
V.A.G 1783-
6. Repairing gearbox housing cover 81

Lupo 3L 1999 ➤
1 - Countersunk head bolt,

2 Nm
❑ Tighten diagonally and
alternately
2 - Mounting plate
❑ For cylindrical roller
bearing
countersinks for coun‐
ter-sunk head bolts face
gearbox housing
❑ For input shaft
for output shaft
ually.
❑ Pressing in
⇒ page 83
for input shaft
ually.
❑ Pressing in
⇒ page 83
Pulling cylindrical roller bearing out of gearbox housing cover

A - Internal puller, 37...46 mm , e.g. -Kukko 21/6-
B - Counter support , e.g. -Kukko 22/2-

Lupo 3L 1999 ➤
Pressing cylindrical roller bearing into gearbox housing cover.

– Heat gearbox housing cover with hot air blower, e.g. -
V.A.G 1416- in vicinity of bearing seat to about 100° C.
– Insert cylindrical roller bearing in heated housing and press in
using workshop press until heat exchange has taken place.
Note
Cylindrical roller bearings must be pressed into cover to stop. Do

not use mounting plate to press bearings by tightening bolts.
6. Repairing gearbox housing cover 83

Lupo 3L 1999 ➤
7 Repairing selector unit

♦ Tube -VW 423-

Lupo 3L 1999 ➤
1 - Sleeve
❑ For selector shaft
❑ Driving out ⇒ page 80
2 - Selector shaft with selector
shaft cover
❑ Renew together
3 - Relay lever
⇒ page 41
4 - Bearing bush
5 - Seal
❑ Lever out with a screw‐
driver
6 - Cap
❑ For gearbox breather
❑ Install so that master
spline aligns with selec‐
tor shaft
❑ Can be renewed with
the selector mechanism
installed
⇒ page 41
8 - Hexagon nut
❑ ⇒ Item 17 (page 40)
9 - Securing clip
Inserting oil seal -A- onto stop
7. Repairing selector unit 85

Lupo 3L 1999 ➤
8 Dismantling and assembling selector forks

equipment required
♦ Thrust piece -3290/1-
♦ Assembly tool -3301-
♦ Thrust piece -VW 431-
♦ Drift -10 - 206-
♦ Removal lever -80–200-

Lupo 3L 1999 ➤
♦ Drift -10 - 508-
♦ Tensioning device -2070-
Note
It is not necessary to dismantle the selector fork group ⇒ Item 1 (page 88) in order to dismantle and assemble
selector segments, lock washers and angular contact ball bearings.
8. Dismantling and assembling selector forks 87

Lupo 3L 1999 ➤
1 - Selector fork group with se‐

lector plate
2 - Selector segment for 3rd
and 4th gear
❑ After installation selec‐
tor segment must still ro‐
tate freely
❑ Identification
⇒ page 89
❑ Separate selector seg‐
ments are installed in
some gearboxes
⇒ page 89 .
❑ Identification
⇒ page 89
3 - Angular contact ball bearing
❑ Qty. 4
❑ Press inner ring into out‐
er ring ⇒ page 90
4 - Lock washer
❑ Always renew
5 - 1st/2nd gear selector seg‐
ment
❑ Identification
⇒ page 89
❑ After lock washer is in‐
stalled, segment must
still rotate freely
❑ Selector shaft with se‐
lector segment.
6 - Selector fork for 5th and 6th gear with selector segments
❑ Selector segment is permanently connected to selector fork.
❑ Identification ⇒ page 89
7 - Pivot pin
❑ For 5th and 6th gear selector fork.

Lupo 3L 1999 ➤
Identification of selector segments and selector fork for 5th and

6th gear with selector segments.
Dimension -a-
1- 1st and 2nd gear selector segment = 10.2 mm.
2- Selector segment for 3rd and 4th gear = 78.6 mm.
3- 5th and 6th gear selector fork with selector segments =
79.5 mm.
Separate selector segments for 3rd and 4th gear -A-.

After installation selector segments must still rotate freely.
Identification of separate selector segments for 3rd and 4th gear

1- Short selector segment for 3rd and 4th gear = 10.2 mm
2- Long selector segment for 3rd and 4th gear = 10.2 mm
1st and 2nd gear selector fork with selector segments

Dimension -a- = 75 mm

Lupo 3L 1999 ➤
Removing lock washer

– Clamp selector fork in vice with protective jaws -B-.
– Lever off lock washer -A- in direction of arrow.
Installing lock washer

– Press lock washer into groove of selector segment using sock‐
et and spinner handle.
Note
After lock washer is installed, selector segment must still rotate

freely.
A - Spinner handle with 10 mm socket

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

bend selector forks.
Pressing inner race -A- of angular contact ball bearing into outer
race
Inner race must engage in outer race.

Lupo 3L 1999 ➤
Pulling angular contact ball bearing into selector fork to stop

Depression in thrust piece -3290/1- faces ball bearing.

Lupo 3L 1999 ➤
35 – Gears, shafts
1 Input shaft
1.1 Dismantling and assembling input shaft

equipment required
♦ Tube -VW 415 A-
♦ Tube -VW 422-
92 Rep. Gr.35 - Gears, shafts

Lupo 3L 1999 ➤

♦ Tube -VW 516-
1. Input shaft 93
Lupo 3L 1999 ➤

♦ Thrust plate -T10084 A-
21/5-
22/1-
Note
♦ When installing new gear wheels, consult technical data ⇒ page 1 and ⇒ Electronic parts catalogue “ETKA” .
♦ Install all bearings, synchromeshed gears and synchro-rings on input shaft with gear oil.
♦ Do not interchange synchro-rings. When reusing always fit to the original gear.

Lupo 3L 1999 ➤
1 - Bolt
⇒ page 60
2 - Cylindrical roller bearing in‐
ner race
cylinder roller bearing
inner race of output
shaft
ually.
⇒ page 64
3 - Thrust washer
4 - Synchromeshed gear for
6th gear
❑ Check for wear
⇒ page 99
6 - Needle bearing
❑ For 6th gear
❑ Renew together with
7 - Sleeve
❑ For 6th gear needle
bearing
❑ Renew together with
⇒ page 64
8 - Locking collar with synchro-
hub for 5th and 6th gears
❑ Dismantling ⇒ page 101
❑ Assembling locking collar and synchro-hub for 5th and 6th gear ⇒ page 101 ⇒ page 101 .
❑ Will be damaged during removal of input shaft
❑ Always renew
❑ Check for wear ⇒ page 99
11 - Needle bearing
❑ For 5th gear
12 - Sleeve
❑ Press off with bearing mounting with deep groove ball bearing ⇒ page 97 .
❑ Pressing on ⇒ page 100
1. Input shaft 95
Lupo 3L 1999 ➤
14 - Bearing mounting with deep groove ball bearing
❑ Renew deep groove ball bearing only together with bearing mounting
❑ Pressing off ⇒ page 97
15 - Input shaft
❑ Clean residual locking fluid from threaded hole in input shaft using a thread chaser
16 - Needle bearing
❑ For 3rd gear
17 - Synchromeshed gear for 3rd gear
18 - Synchro-ring for 3rd gear
19 - Locking collar with synchro-hub for 3rd and 4th gear
❑ Press off with 3rd gear synchromeshed gear ⇒ page 98
❑ Installation position, locking collar and synchro-hub ⇒ page 98
❑ Assembling ⇒ page 98
20 - Sleeve
❑ Renew together with ⇒ Item 21 (page 96) .
❑ Press off with 3rd gear synchromeshed gear ⇒ page 98
21 - Needle bearing
❑ For 4th gear
24 - Thrust washer
26 - Retaining ring
❑ Renew
❑ With retaining ring
❑ Installation position: retaining ring in bearing faces input shaft
28 - Clutch housing

Lupo 3L 1999 ➤
29 - Spring
30 - 3rd and 4th gear locking collar
31 - 3rd and 4th gear synchro-hub
32 - Locking pieces (Qty. 3)
33 - Spring
35 - 5th and 6th gear synchro-hub
36 - Locking collar for 5th and 6th gears
Pulling cylindrical roller bearing out of clutch housing

– When pulling out, squeeze together retaining ring -arrow- of
cylindrical roller bearing, using pliers -C-.
A - Counter support , e.g. -Kukko 22/1-
B - Internal puller, 30...37 mm , e.g. -Kukko 21/5-
Pressing cylindrical roller bearing into clutch housing

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

– Slide locking collar for 1st and 2nd gear towards 2nd gear.
– Then slide pressure plate -T10084 A- onto input shaft to stop
from side.
– Remove retaining ring.
1. Input shaft 97
Lupo 3L 1999 ➤
Pressing off cylindrical roller bearing inner race

– Press off cylindrical roller bearing inner race together with
♦ Thrust washer,
♦ 4th gear synchromeshed gear with needle bearing,
♦ Locking collar and synchro-ring for 3rd and 4th gears and
♦ 3rd gear synchromeshed gear.
Dismantling and assembling 3rd and 4th gear locking collar and
synchro-hub
1- Spring
2- Locking collar
3- Synchro-hub
4- Locking piece
– Slide locking collar over synchro-hub.
Deeper notches -arrow A- for locking pieces in synchro-hub and
notches -arrow B- in locking collar must align.
Assembling locking collar and synchro-hub for 3rd and 4th gears
• Locking collar has been pushed over synchro-hub.
– Insert locking pieces in deeper notches -arrows- and install
springs offset 120°. Angled end of spring must locate in hollow
locking piece.
Installation position of locking collar and synchro-hub for 3rd and

4th gears
Groove on top -arrow- faces 4th gear.

Lupo 3L 1999 ➤
Checking synchro-ring for wear

– Press synchro-ring onto cone of synchromeshed gear and
measure gap “a” using feeler gauge.
Gap “a” Installation (new) di‐ Wear limit
mension
3rd, 4th, 5th and 1.1…1.7 mm 0.5 mm
6th gear
Pressing on synchro-hub with locking collar for 3rd and 4th gears
Pressing on sleeve -A- for 4th gear needle bearing

– After pressing on sleeve -A-, fit 4th gear needle bearing, 4th
gear synchromeshed gear and thrust washer.
Pressing on inner race -A- for cylindrical roller bearing.
1. Input shaft 99
Lupo 3L 1999 ➤
Determining thickness of retaining ring

– Insert a 2.0 mm thick retaining ring -A- in groove of input shaft
and press upwards -arrow-.
– Measure distance between inner race -B- and installed retain‐
ing ring -A- using feeler gauge -C-.
– Remove retaining ring used for measuring purposes.
– Determine retaining ring from table.
Note
Allocate retaining rings according to ⇒ Electronic parts catalogue

“ETKA” .
Available retaining rings

Measured value Retaining ring thick‐ Axial play (mm)
(mm) ness (mm)
0.05 … 0.10 2.0 0.05 … 0.15
0.15 … 0.20 2.1 0.05 … 0.15
0.25 … 0.30 2.2 0.05 … 0.15
0.35 … 0.40 2.3 0.05 … 0.15
0.45 … 0.50 2.4 0.05 … 0.10
Pressing on bearing mounting with deep groove ball bearing.

– Heat inner bearing mounting to approx. 100 °C before press‐
ing on.
WARNING
Pressing on sleeve -A- for 5th gear needle bearing

Lupo 3L 1999 ➤
Dismantling and assembling locking collar and synchro-hub for

5th and 6th gear
1- Spring
2- Locking piece
3- Synchro-hub installation position: groove on face
-arrow A- and wider shoulder -arrow B- must face 5th gear.
4- Locking collar
Deeper notches -arrow C- for locking pieces in synchro-hub and
notches -arrow D- in locking collar must align.
Assembling locking collar and synchro-hub for 5th and 6th gear
– Insert locking pieces in deeper notches -arrows- and install
locking piece.
1. Input shaft 101

Lupo 3L 1999 ➤
2 Output shaft
2.1 Dismantling and assembling output shaft

equipment required
♦ Tube -VW 415 A-
♦ -1- Internal puller -Kukko 21/5-
♦ -4- Counterhold -Kukko 22/1-

Lupo 3L 1999 ➤
Note
♦ When installing new gear wheels or a new output shaft, consult technical data ⇒ page 1 and ⇒ Electronic
parts catalogue “ETKA” .
♦ Install all bearings, synchromeshed gears and synchro-rings on output shaft with gear oil.
♦ Do not interchange synchro-rings. When reusing always fit to the original gear.
1 - Clutch housing
❑ With retaining ring
❑ Pressing in
⇒ page 105
❑ Installation position: re‐
taining ring in bearing
faces output shaft
3 - Output shaft
❑ If an inner race as bear‐
ing seat for cylindrical
roller bearing (item
⇒ Item 2 (page 103) ) is
present, it cannot be re‐
moved from output
shaft.
❑ Check bearing seat or
inner race for cylindrical
roller bearing for scoring
and damage.
❑ If cylindrical roller bear‐
ing inner race or bearing
seat is damaged or
scored, renew output
shaft and cylindrical roll‐
er bearing together
4 - Gear wheel for 4th gear
shoulder faces 3rd gear
⇒ page 106
5 - Retaining ring
6 - Retaining ring
7 - Gear wheel for 3rd gear
❑ Installation position: shoulder faces 4th gear ⇒ page 106
8 - Retaining ring
9 - Synchromeshed gear for 2nd gear
10 - Needle bearing
❑ For 2nd gear
11 - Inner ring for 2nd gear
2. Output shaft 103

Lupo 3L 1999 ➤
12 - Outer ring for 2nd gear

❑ Place on inner ring ⇒ Item 11 (page 103)
❑ Renew if scored
13 - Synchro-ring for 2nd gear
14 - Locking collar with synchro-hub for 1st and 2nd gears
❑ After removing retaining ring ⇒ Item 15 (page 104) , press off with 2nd gear synchromeshed gear
⇒ page 106
❑ Assembling locking collar and synchro-hub ⇒ page 107 and ⇒ page 107
15 - Retaining ring
16 - Synchro-ring for 1st gear
❑ Assemble so that notches engage in locking pieces of locking collar ⇒ Item 14 (page 104)
17 - Outer ring for 1st gear
❑ Insert in synchro-ring ⇒ Item 16 (page 104) . Installation position ⇒ page 108 .
❑ Renew if scored
18 - Inner ring for 1st gear
❑ Check lugs for scoring
19 - Needle bearing
❑ For 1st gear
20 - Synchromeshed gear for 1st gear
21 - Bearing mounting with deep groove ball bearing
❑ Renew deep groove ball bearing only together with bearing mounting
23 - Bolt
❑ Do not interchange with cylindrical roller bearing inner race of input shaft
❑ Can be renewed individually.
25 - 6th gear wheel
❑ Installation position: collar faces sleeve ⇒ page 73 .

Lupo 3L 1999 ➤
26 - Sleeve
27 - 5th gear wheel
❑ Installation position: shoulder faces gearbox housing cover ⇒ page 72
28 - Spring
29 - Locking collar
30 - Synchro-hub
Pulling cylindrical roller bearing out of clutch housing

– When pulling out, squeeze together retaining ring -arrow- of
cylindrical roller bearing, using pliers -C-.
Pressing cylindrical roller bearing into clutch housing

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

A - Protective gloves
WARNING
Ensure retaining ring does not spring out uncontrolled.
2. Output shaft 105

Lupo 3L 1999 ➤
Pressing off 1st and 2nd gear locking collar and synchro-hub
– After removing retaining ring, press off synchromeshed gear
for 2nd gear together with locking collar and synchro-hub.
Installation position of 3rd gear and 4th gear

– Install 4th gear wheel -A- on output shaft.
Collar -arrow 1- faces 3rd gear wheel -B-.
– Install retaining rings -2- and -3-.
– Install 3rd gear wheel -B- on output shaft.
Collar -arrow 2- faces 4th gear wheel -A-.
– Install retaining ring -1-.
Checking 1st and 2nd gear inner ring for wear

– Press inner ring onto cone of synchromeshed gear and meas‐
ure gap -a- using a feeler gauge.
Gap -a- Installation (new) di‐ Wear limit
mension
1st and 2nd gears 0.75…1.25 mm 0.3 mm
Checking 1st and 2nd gear synchro-rings for wear

– Press synchro-ring, outer ring and inner ring onto cone of syn‐
chromeshed gear and measure gap -a- using a feeler gauge.
Gap -a- Installation (new) di‐ Wear limit
mension
1st and 2nd gears 1.2…1.8 mm 0.5 mm

Lupo 3L 1999 ➤
Installation position of outer ring, inner ring and synchro-ring for

2nd gear
– Place inner ring -A- on synchromeshed gear for 2nd gear.
Angled lugs -arrow 1- face outer ring -B-.
– Fit outer ring -B-.
Lugs -arrow 2- engage in notches -arrow 3- of synchromeshed
gear.
– Fit synchro-ring -C-.
Notches -arrow 4- engage in lugs -arrow 1- of inner ring -A-.
Dismantling and assembling locking collar and synchro-hub for

1st and 2nd gears
1- Spring
2- Locking collar
3- Synchro-hub
4- Locking piece
After installation, the groove on the face -arrow A- and the higher
shoulder -arrow B- face towards outer splines of the locking collar
-arrow C-.
Deeper cut-outs -arrow D- for locking pieces in synchro-hub and
notches -arrow E- in locking collar must align.
Assembling locking collar with synchro-hub for 1st and 2nd gears
– Insert locking pieces in deeper cut-outs -arrows- and install
locking piece.
2. Output shaft 107

Lupo 3L 1999 ➤
Pressing on locking collar and synchro-hub for 1st and 2nd gears
Groove in locking collar for selector fork faces 1st gear and teeth
for reverse gear face 2nd gear.
– Turn synchro-ring so that grooves align with locking pieces.
Fitting retaining ring

– Place 1st gear synchro-ring in locking collar/synchro-hub.
Installation position of 1st gear outer ring

Lugs -arrows- face reverse gear teeth.
Installation position of 1st gear -A-

Lugs -arrow 1- engage in notches -arrow 2- in synchro-ring -B-.

Lupo 3L 1999 ➤
Installation position of 1st gear synchromeshed gear

Higher shoulder -A- faces 2nd gear -B-. Notches in shoulder
-arrows- engage in lugs of outer ring (-arrow- ⇒ page 108 ).
2. Output shaft 109

Lupo 3L 1999 ➤
39 – Final drive - differential

1 Renewing oil seals for flange shafts
1.1 Renewing oil seal for left flange shaft

(Gearbox installed)

equipment required
♦ Multipurpose tool -VW 771-
♦ Puller hooks -VW 771/37-
♦ Torque wrench -
V.A.G 1331-
♦ Torque wrench -
V.A.G 1332-

1.1.1 Removing
– Remove left wheel.
– Turn steering to left lock.
– Unbolt drive shaft from flange shaft.
110 Rep. Gr.39 - Final drive - differential

Lupo 3L 1999 ➤
– Mark installation position of bolts -arrows-.

– Remove bolts -arrows- ⇒ Running gear, axles, steering - Lupo
3L, Lupo FSI, Lupo GTI; Rep. Gr. 40 ; Repairing front sus‐
pension, Lupo GTI .
– Swing wheel bearing housing outwards.
– Guide out left drive shaft between subframe and gearbox.
– When doing this, guide drive shaft into wheel housing and se‐
cure to suspension strut with wire.

– Pull out flange shaft with compression spring.
– Pull out flange shaft oil seal using -VW 771- and -VW 771/37- .
1.1.2 Installing
– Lightly oil outer circumference of oil seal.
1. Renewing oil seals for flange shafts 111

Lupo 3L 1999 ➤
– Drive in new seal to stop, being careful not to cant seal.

– Half-fill space between sealing lip and dust lip with grease -G
052 128 A1- .
– Secure flange shaft with countersunk bolt and tighten to speci‐
fied torque ⇒ Item 1 (page 118) .
– Bolt swivel joint to suspension link at old impression using new
bolts ⇒ Running gear, axles, steering - Lupo 3L, Lupo FSI,
Lupo GTI; Rep. Gr. 40 ; Repairing front suspension - Lupo
GTI; Removing and installing swivel joint .
– Attach left drive shaft to flange shaft ⇒ Running gear, axles,
steering - Lupo 3L, Lupo FSI, Lupo GTI; Rep. Gr. 40 ; Re‐
pairing drive shafts - Lupo GTI; Removing and installing drive
shafts .
– Install wheel ⇒ Running gear, axles, steering - Lupo 3L, Lupo
FSI, Lupo GTI; Rep. Gr. 44 ; Torque settings for wheel bolts .
– Check gear oil ⇒ page 57 .
1.2 Renewing seal for right flange shaft

(Gearbox installed)

equipment required
♦ Multipurpose tool -VW 771-
♦ Puller hooks -VW 771/37-
♦ Drift sleeve -3158-
♦ Torque wrench -
V.A.G 1331-

Lupo 3L 1999 ➤

1.2.1 Removing
– Turn steering to right to full lock.
– Unbolt drive shaft from flange shaft.
– Tie up drive shaft as high as is possible. Take care not to
damage paint on drive shaft in the process.
– Pull out flange shaft with compression spring.
– Remove flange shaft oil seal.
Note
♦ Do not damage sleeve -A-. Otherwise, leaks will occur.

♦ Replace sleeve if damaged ⇒ page 80 .
1.2.2 Installing
– Lightly oil outer circumference of oil seal.
– Drive in new seal to stop, being careful not to cant seal.
– Half-fill space between sealing lip and dust lip with grease -G
052 128 A1- .
– Insert flange shaft.
– Secure flange shaft using countersunk bolt and tighten to
specified torque ⇒ Item 1 (page 118) .
– Attach drive shaft to flange shaft ⇒ Running gear, axles,
steering - Lupo 3L, Lupo FSI, Lupo GTI; Rep. Gr. 40 ; Re‐
pairing drive shafts - Lupo GTI; Removing and installing drive
shafts .
– Check gear oil level and top up to lower edge of oil filler hole
if necessary ⇒ page 57 .
1. Renewing oil seals for flange shafts 113

Lupo 3L 1999 ➤
2 Differential
2.1 Dismantling and assembling differential

equipment required
♦ Tube -VW 418 A-

Lupo 3L 1999 ➤
♦ Installing sleeve -VW 455-

♦ Thrust pad -VW 510-
♦ Tube -30 - 14-
♦ Tube -2040-
♦ Thrust piece -3002-
2. Differential 115
Lupo 3L 1999 ➤
♦ Counterhold -3067-
♦ Tube -3259-
♦ Wheel bearing tube -3345-
♦ Puller -V.A.G 1582-
♦ Grip -V.A.G 1582/4-
21/7-
22/2-
From gearbox date 13 01 3, tapered roller bearing on gearbox

housing side is enlarged.

Lupo 3L 1999 ➤
♦ Thrust plate -30 - 205-

♦ Grip -V.A.G 1582/3-
♦ Torque wrench -
V.A.G 1331-
Note
♦ Heat tapered roller bearing inner race to 100° C before installing.

♦ Always renew both tapered roller bearings together as a set.
♦ If tapered roller bearings, differential cage, gearbox housing or clutch housing is renewed, adjust differential
⇒ page 123 .
2. Differential 117
Lupo 3L 1999 ➤
❑ Screw into threaded
piece
2 - Right flange shaft
❑ Do not interchange; left
and right flange shafts
differ
3 - Compression spring for
flange shaft
❑ Installed behind flange
shafts
4 - Thrust washer
shoulder towards spring
5 - Tapered ring
taper towards differen‐
tial cage
6 - Retaining ring
❑ Holds tapered ring,
thrust washer and
spring in position when
flange shaft is removed
7 - Sun wheel
8 - Threaded piece
9 - Differential pinion pin
❑ To remove, shear off
spring pin
⇒ page 121
10 - Planet pinion
11 - One-piece thrust washer
❑ Coat with gear oil when installing
❑ Modification of one-piece thrust washer ⇒ page 123 .
12 - Left flange shaft
❑ With dust plate.
❑ Do not interchange; left and right flange shafts differ
13 - Oil seal for left flange shaft
❑ Left and right diameters differ.
14 - Shim S1
❑ Always 1 mm thick
❑ Modification: adapted to enlarged tapered roller bearing seat on gearbox housing side ⇒ page 122 .

Lupo 3L 1999 ➤

❑ Modification: from gearbox date 13 01 3, enlarged ⇒ page 122 .
16 - Tapered roller bearing inner race
❑ Pulling off ⇒ page 120
❑ Modification: from gearbox date 13 01 3, enlarged ⇒ page 122 .
17 - Differential cage
❑ With final drive gear
❑ Modification: adapted to enlarged tapered roller bearing seat on gearbox housing side ⇒ page 122 .
❑ Adapted to modified one-piece thrust washer ⇒ page 123 .
18 - Spring pin
❑ For securing planet pinion pin
❑ Is sheared off when removed ⇒ page 121
19 - Tapered roller bearing inner race
❑ Pulling off ⇒ page 120
21 - Shim S2
22 - Oil seal for right flange shaft
❑ Left and right diameters differ.
❑ Modification: from gearbox date 13 01 3, bearing seat for differential tapered roller bearing enlarged
⇒ page 122 .
24 - Clutch housing
2. Differential 119
Lupo 3L 1999 ➤
Pulling tapered roller bearing outer race out of gearbox housing

Pressing tapered roller bearing outer race into gearbox housing

– Always fit a 1 mm thick shim S1 under outer ring.
– Support gearbox housing with tube -3259- directly below bear‐
ing support.
Pulling off tapered roller bearing inner races

– 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.
Pressing on tapered roller bearing inner race

– Support inner race on opposite side using sleeve -VW 455- .

Lupo 3L 1999 ➤
Pressing tapered roller bearing outer race -A- out of clutch hous‐
ing
– Clamp internal puller securely behind tapered roller bearing
outer race.
Pressing tapered roller bearing outer race into clutch housing

– Support clutch housing with tube -3345- directly below bearing
support.
Pressing out differential pinion pin

When pressed out, spring pin will be sheared off.
– Drive remainder of spring pin out of differential housing.
Installing differential bevel gears

– Lubricate one-piece thrust washer with gear oil and install.
– Install both sun wheels and secure (e.g. with flange shaft).
– Insert planet pinions offset 180° and pivot into position.
– Press in differential pinion pin (-arrow A-) to first planet pinion.
– Set threaded pieces (-arrows B-) in sun wheels. Installation
position: shoulder to bevel gear
– Drive differential pinion pin into final position and secure with
spring pin.
2. Differential 121
Lupo 3L 1999 ➤
2.1.1 Tapered roller bearing for differential

from date 13 01 3
From gearbox date 13 01 3, tapered roller bearing on gearbox
housing side is enlarged.
Following components were modified:
♦ A - Tapered roller bearing inner race
Removing ⇒ page 122 .
Installing ⇒ page 123 .
♦ B - Tapered roller bearing outer race
Removing ⇒ page 123 .
Installing ⇒ page 123 .
♦ C - New shim S1
♦ Bearing seat for tapered roller bearing outer race -arrow- in
gearbox housing.
The tapered roller inner bearing seat was likewise enlarged on

the differential.
Dimension -a-
New: 41 mm
Previous: 38 mm
– Allocate all components according to ⇒ Electronic parts cata‐
logue “ETKA” .
Pulling off tapered roller bearing inner race

– Before fitting extractor, position spacer sleeve -VW 472/2- and
thrust piece -3002- on differential housing.

Lupo 3L 1999 ➤
Pressing on tapered roller bearing inner race

– Support tapered roller bearing inner race on opposite side us‐
ing sleeve -VW 455- .
Pulling tapered roller bearing outer race out of gearbox housing

Pressing tapered roller bearing outer race into gearbox housing

– Always fit a 1 mm thick shim S1 under outer ring.
– Support gearbox housing with tube -3259- directly below bear‐
ing support.
2.1.2 Modified one-piece thrust washer for dif‐

ferential
If there is a ridge -A- on the one-piece thrust washer, it can only
be inserted in a differential cage having a groove -B-.
– Lubricate one-piece thrust washer with gear oil and install.
– Install one-piece thrust washer so that it engages in groove
-B- in differential cage.
2.2 Adjusting differential
2. Differential 123
Lupo 3L 1999 ➤

equipment required
♦ End dimension plate -
VW 385/17-
♦ Universal dial gauge brack‐
et -VW 387-

Lupo 3L 1999 ➤
♦ Thrust pad -VW 510-

♦ Tube -30 - 14-
♦ Tube -2040-
♦ Tube -3259-
♦ Wheel bearing tube -3345-
21/7-
♦ Dial gauge
It is necessary to readjust the differential when the following com‐

ponents are renewed:
♦ Gearbox housing
♦ Clutch housing
♦ Differential cage
or the
♦ Tapered roller bearings of differential
– Press tapered roller bearing outer race (gear wheel side) with
shim S1 (always 1 mm thick) into the gearbox housing.
Note
Inner and outer tapered roller bearing races are paired. Do not
interchange!
2. Differential 125
Lupo 3L 1999 ➤
– Press tapered roller bearing outer race (opposite gear wheel)

with no shim into gearbox housing.
– Insert differential in gearbox housing.
– Fit clutch housing and tighten 5 bolts to specified torque
– Set up measuring device and dial gauge (3 mm measuring

range, dial gauge extension -A- about 30 mm).
– 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 shim S2
The specified bearing preload is obtained for S2 by adding a con‐
stant value for preload (0.35 mm) to the measured value.
Example:
Measured value 1.50 mm
+ Preload (constant) 0.35 mm
Thickness of shim S2 = 1.85 mm
– Remove clutch housing and press out tapered roller bearing

outer race -A-.
– Allocate shim(s) using ⇒ Electronic parts catalogue “ETKA” .
The various thicknesses of shims make it possible to achieve the
exact thickness required.
If the size of shim required is larger than those listed in the table,
insert two shims totalling the correct figure.
– Insert correct S2 shim (in example 1.85 mm) and press ta‐
pered roller bearing outer race into clutch housing again.
– Fit clutch housing and tighten bolts to specified torque setting

Volkswagen Workshop Manual (6-Speed Manual Gearbox 02U LUPO 3L&GTI)

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Volkswagen Workshop Manual (6-Speed Manual Gearbox 02U LUPO 3L&GTI)

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Service

Service Department. Technical Information

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

1.1 Location on gearbox

Manual gearbox 02U -arrow 2-

Identification code and date of gearbox manufacture

The gearbox code also appears on the vehicle identification

1.2 Identification code, assembly allocation, capacities

Volkswagen Technical Site: https://vwts.ru 1. Gearbox identification 1

Manual gearbox 6-speed 02U

GEZ = magnesium gearbox housing

From 01.03, enlarged tapered roller bearing for differential.

Volkswagen Technical Site: https://vwts.ru

2 Rep. Gr.00 - Technical data

2 Overview - power transmission

2. Overview - power transmission 3

4 Rep. Gr.00 - Technical data

3 Calculating overall gear ratio “i”

3. Calculating overall gear ratio “i” 5

4 General repair notes

4.1.2 Seals and sealing rings

6 Rep. Gr.00 - Technical data

4.1.3 Locking devices

4.1.4 Nuts and bolts

4. General repair notes 7

4.1.9 Gear wheels

8 Rep. Gr.00 - Technical data

♦ Disconnect battery earth strap.

I - Assembly overview - pedal

1. Repairing clutch mechanism 9

1.1 Assembly overview - pedal cluster

10 Rep. Gr.30 - Clutch

1.2 Distinguishing between clutch pedal

1.3 Removing and installing clutch pedal

1. Repairing clutch mechanism 11

– Turn clutch pedal switch -F36- on housing 90° anti-clockwise

1.3.2 Installing and adjusting new clutch pedal

1.4 Removing and installing clutch pedal

1.4.2 Installing and adjusting new clutch pedal

♦ First check clutch pedal switch.

If this is not the case, do not pull out the plunger.

– Press plunger in to stop -arrow 1-.

12 Rep. Gr.30 - Clutch

1.5 Removing and installing over-centre

The drilling -arrow- faces bulkhead.

– Move clutch pedal towards bulkhead to stop, removing over-

1.6 Removing and installing over-centre

1. Repairing clutch mechanism 13

♦ Assembly tool -T10178-

– Carefully pry off over-centre spring -arrows-.

14 Rep. Gr.30 - Clutch

– Install stop -A- for clutch pedal.

1.7 Removing and installing clutch pedal

Additional required information

1. Repairing clutch mechanism 15

– Unbolt fuse holder, separate from lower attachment and push

– Unscrew hexagon nut -arrow 1- for pivot pin of clutch pedal

16 Rep. Gr.30 - Clutch

– Carefully guide pivot pin of clutch pedal carefully to left through

– Remove clutch pedal.

1.7.3 Torque setting

1.8 Removing and installing mounting

1. Repairing clutch mechanism 17