Volkswagen FOX 2004 Service Manual
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Volkswagen FOX 2004 Service Manual

Fox 2004
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Service
Maintenance
FOX 2004 ➤
Edition 07.2010
Service Department. Technical Information

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  • Page 1 Service Maintenance FOX 2004 ➤ Edition 07.2010 Service Department. Technical Information...
  • Page 2 In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed. All rights reserved. No reproduction without prior agreement from publisher. Copyright © 2010 Volkswagen AG, Wolfsburg BRA5R005420...

  • Page 3: Table Of Contents

    FOX 2004 ➤ Maintenance - Edition 07.2010 Contents Engine overview ............
  • Page 4 FOX 2004 ➤ Maintenance - Edition 07.2010 4.31 Spark plugs - replace ............

  • Page 5: Engine Overview

    FOX 2004 ➤ Maintenance - Edition 07.2010 Engine overview Identification letters CFZA Engines petrol engine petrol engine petrol engine petrol engine → Production from 08.04.03 from 11.24.03 from 11.17.03 from 11.08 Limit value for ex‐ Phase 3 of resolu‐ Phase 3 of resolu‐...
  • Page 6 FOX 2004 ➤ Maintenance - Edition 07.2010 Identification letters Self-diagnosis Catalytic converter Lambda adjustment Recirculation of exhaust gases Exhaust gas turbocharger Identification letters CHFB En‐ petrol engine petrol engine petrol engine gines → Production from 11.22.04 from 11.22.04 from 03.09 Limit value for exhaust gases accord‐...

  • Page 7: Service Plans

    FOX 2004 ➤ Maintenance - Edition 07.2010 Service plans This chapter contains information on the following subjects: Delivery inspection ⇒ page 5 Oil change service ⇒ page 7 Intermediate service Models ▸2010 (Europe) and Models 2009▸ (except Europe) ⇒ page 8 Intermediate service Models 2011▸...
  • Page 8 FOX 2004 ➤ Maintenance - Edition 07.2010 Replacement intervals for the filter Diesel comply‐ Diesel not com‐ Bio-diesel (RME) diesel engines ing with Europe‐ plying with Euro‐ an Standard 590 pean Standard Chang Drain Chang Drain Chang Drain at ev‐...

  • Page 9: Delivery Inspection

    FOX 2004 ➤ Maintenance - Edition 07.2010 Intervals according to the maintenance in‐ Service terval indicator (not flexible) – Inspection service according to the maintenance interval indicator ♦ at every 1 year, every 30,000 km and every 60,000 km 7) In vehicles using diesel with high sulfur content, the oil must be changed at ⇒...
  • Page 10 FOX 2004 ➤ Maintenance - Edition 07.2010 ♦ Vehicles on the yard for a long time: In vehicles with manu‐ facturing date exceeding 5 months, the engine oil, oil filter, and oil draining plug sealing ring must be changed! ♦ If the battery is disconnected, the power window drive auto‐...

  • Page 11: Oil Change Service

    FOX 2004 ➤ Maintenance - Edition 07.2010 Work volume Service – Vehicle interior: check for cleaning and, if necessary, clean: front and back seats, internal linings, carpet/mats and windows. – Vehicle exterior: check and clean: paintwork, decoration elements, win‐ dows, front and rear window wipers.

  • Page 12: Intermediate Service Models ▸2010 (Europe) And Models 2009▸ (Except Europe)

    FOX 2004 ➤ Maintenance - Edition 07.2010 Application Windshield/rear window washer Proportion additive -G 052 184 A2- from 08/2005 100 ml additive for 990 ml water. Oil Change Service Service Engine compartment – Engine oil: fill ⇒ page 58 Diesel engine: Identification letter BNM, filling capacity 4,2 l; standard 505 01 (VW).
  • Page 13 FOX 2004 ➤ Maintenance - Edition 07.2010 If the battery is disconnected, the power window drive automatic closing function will not operate. Thus, this function must be re‐ programmed before delivering the vehicle. The vehicle battery cannot be disconnected after reprogramming. Power window drive - reprogram ⇒...

  • Page 14: Intermediate Service Models 2011▸ (Europe)

    FOX 2004 ➤ Maintenance - Edition 07.2010 Intermediate service Models ▸2010 (Europe) and Models 2009▸ (except Eu‐ Service rope) – Engine oil: fill ⇒ page 58 Diesel engine: Identification letter BNM, filling capacity 4,2 l; standard 505 01 (VW). Diesel engine: Identification letters ASY, 4.3-l filling volume, standard 505 00 (VW) or 505 01 (VW).
  • Page 15 FOX 2004 ➤ Maintenance - Edition 07.2010 Note In countries with high sulfur content on the diesel fuel, the engine oil must be changed every 7,500 km. The countries with higher sulfur content on the diesel are listed on ⇒ page 28...
  • Page 16 FOX 2004 ➤ Maintenance - Edition 07.2010 Intermediate service Models 2011▸ (Europe) Service Vehicle exterior – Windshield: check for damage – Windshield and rear window wiper: check operation. ⇒ page 49 – Windshield/rear window washer: adjust the water jet from ejectors and re‐...

  • Page 17: Inspection Service

    FOX 2004 ➤ Maintenance - Edition 07.2010 Inspection Service Service based on time or kilometers traveled Vehicles with “Service based on time or kilometers traveled” have the PR numbers: QG0. Inspection intervals Vehicles with service depending on time or kilometers traveled, every 30,000 km or 2 years and every 60,000 km or 4 years (for Europe on vehicles model ▸2007).
  • Page 18 FOX 2004 ➤ Maintenance - Edition 07.2010 Application Windshield/rear window washer Proportion additive -G 052 184 A2- from 08/2005 100 ml additive for 990 ml water. Service for vehicles with “service based on time and kilometers traveled” Service Electrics – Battery: check with Battery tester with printer -VAS 5097A- .
  • Page 19 FOX 2004 ➤ Maintenance - Edition 07.2010 Service for vehicles with “service based on time and kilometers traveled” Service – Sunroof: check operation, clean the guide rails and lubricate them with Spe‐ ⇒ page 46 cial grease -G 000 450 02- .
  • Page 20 FOX 2004 ➤ Maintenance - Edition 07.2010 Service for vehicles with “service based on time and kilometers traveled” Service – Anti-roll bar buffers and front/rear suspension arm joints rubber bushings: check for damage ♦ for Europe on vehicles model 2011▸...
  • Page 21 FOX 2004 ➤ Maintenance - Edition 07.2010 Service for vehicles with “service based on time and kilometers traveled” Service – Timing belt for camshaft drive: replace. Additional work with separate pay‐ ⇒ page 85 ment! ♦ Diesel engine: identification letters BNM ♦...

  • Page 22: Supplementary Services Based On Time Elapsed And/Or Kilometers Traveled

    FOX 2004 ➤ Maintenance - Edition 07.2010 Service for vehicles with “service based on time and kilometers traveled” Service – Power steering: check the oil level. ⇒ page 82 ♦ at every 60,000 km (except for maintenance-free). – Carry out an exhaust gas inspection/additional work with separate payment! ⇒...
  • Page 23 FOX 2004 ➤ Maintenance - Edition 07.2010 Supplementary services Page – Air cleaner: replace the filtering element and clean the filter case. ⇒ page 87 ♦ Identification letters CFZA. ♦ for vehicles with kilometers traveled over 30,000 km, within a 2-year period –...
  • Page 24 FOX 2004 ➤ Maintenance - Edition 07.2010 Supplementary services Page – Sunroof: check operation, clean the guide rails and lubricate them with Special ⇒ page 46 grease -G 000 450 02- ♦ for vehicles with kilometers traveled over 60,000 km, within a 3-year period and, then, every 2 years.
  • Page 25 FOX 2004 ➤ Maintenance - Edition 07.2010 Supplementary services Page – Brake fluid: replace ⇒ page 90 ♦ for Europe on vehicles model ▸2007 and except Europe on vehicles model ▸2008 3 years after the delivery inspection; then, every 2 years...

  • Page 26: General Remarks

    FOX 2004 ➤ Maintenance - Edition 07.2010 General remarks Rear license plate (only CrossFox Eu‐ rope) - install Note For the “CrossFox”Europe versions, position the license plate aligned with the line -1- in the rear protector and fasten the plate...

  • Page 27: Service Tag

    FOX 2004 ➤ Maintenance - Edition 07.2010 3.2.1 Support points for workshop lift and jack Front section: In the longitudinal reinforcement of the central lon‐ gitudinal member. Rear section: In the welded flange reinforcement of the lower lon‐ gitudinal member.

  • Page 28: Self-Diagnosis - Refer To The Fault Memory Of All Systems

    FOX 2004 ➤ Maintenance - Edition 07.2010 – Attach the tag to the left side of the command panel or to the driver's door pillar (pillar B). The stamp or tag may also be attached to the left lower corner (internal side) of the Windscreen, with the “FRONT”...
  • Page 29 FOX 2004 ➤ Maintenance - Edition 07.2010 3.4.2 Connect the Diagnosis, Measurement and Information System – Operate the parking brake. – Mechanical transmission: Selector lever in neutral gear posi‐ tion. Connect the Diagnosis, Measurement and Information System to the Diagnosis cable -VAS 5051/3- or -VAS 5051/6- with the igni‐...

  • Page 30: Vehicle Identification Data

    FOX 2004 ➤ Maintenance - Edition 07.2010 – The Diagnosis, Measurement and Information System sends all known keywords in sequence. If a command unit replies with its identification, the display informs the number of faults or “No fault detected”. Any faults stored in a system will be listed. Then, the Diagnosis, Measurement and Information System -VAS 5051A/52- sends the next keyword.

  • Page 31: Identification Plate

    FOX 2004 ➤ Maintenance - Edition 07.2010 The first VIS tag -arrow- is on the right side suspension housing. The second VIS tag -arrow- is on the left seat's cross member and is visible from the rear side through an opening in the floor carpet.

  • Page 32: Service Intervals

    FOX 2004 ➤ Maintenance - Edition 07.2010 3.5.5 Meaning of vehicle identification number: 000 001 Manufacturer Complemen‐ Type Complemen‐ 2004 year Manufactur‐ Sequential brand tary tary model number digit digit locations Service intervals 3.6.1 (The PR number is QG0) Note Use oils with high lubrication performance according to spec‐...

  • Page 33: Engine Oils

    FOX 2004 ➤ Maintenance - Edition 07.2010 Bulgaria Kyrgyzstan Peru Uruguay Mainland China Colombia Philippines Uzbekistan Costa Rica Croatia Poland United Arab Emirates Dominican Republic Kuwait Russia (Eastern & West‐ Vietnam ern) El Salvador Malaysia Saudi Arabia Zimbabwe Ecuador Morocco...

  • Page 34: Identification Letters And Engine Number

    FOX 2004 ➤ Maintenance - Edition 07.2010 Multi-purpose oil, according to standards VW 505 01 and VW 506 ♦ Engine protection between long maintenance intervals. ♦ Protection against residue build-up. ♦ High viscosity for constant fuel saving in all conditions of use.

  • Page 35: Push Starting (Pushing The Vehicle To Start)/Towing

    FOX 2004 ➤ Maintenance - Edition 07.2010 3.9.3 BMD engine The engine identification letters and engine number are engraved on the engine block in the area between the engine and the gear‐ box. Additionally, there is on the right engine support side -arrow- a sticker with the engine identification letters and serial number.
  • Page 36 FOX 2004 ➤ Maintenance - Edition 07.2010 ♦ Both drivers must be experienced in towing vehicles. Inexper‐ ienced people should not try push starting or towing a vehicle. ♦ When using a tow cable, the driver of the towed vehicle must carefully release the clutch when starting to move and when shifting gears.

  • Page 37: Service Descriptions

    FOX 2004 ➤ Maintenance - Edition 07.2010 Service descriptions Clock - set Set the clock as follows: Set the hours (2-line display): – With the ignition on, select the clock function, pressing the button -arrow- for less than 2 seconds. There will be a clock symbol beside the time.

  • Page 38: Maintenance Interval Indicator (If Available) : Reset With The Vehicle Diagnosis, Measurement And Information System

    FOX 2004 ➤ Maintenance - Edition 07.2010 New Fox Set the hours (3-line display): – There will be a clock symbol beside the hour. – To set the hour, with the ignition on and without the radio in‐ formation on the display, slightly turn the button -arrow- coun‐...

  • Page 39: Spare Wheel Support Stop: Lubricate - (Crossfox)

    FOX 2004 ➤ Maintenance - Edition 07.2010 New Fox – Turn the ignition on. – Hold the button at the right of speedometer during approxi‐ mately 10 seconds. The display resumes the normal indication. Spare wheel support stop: lubricate - (CrossFox) –...

  • Page 40: Power Window Drive - Reprogram

    FOX 2004 ➤ Maintenance - Edition 07.2010 ♦ Green range -2-= the extinguisher is charged. ♦ Red range -1-= the extinguisher is discharged. ♦ Inviolability seal -arrow-. Note Check for possible oxidation and for fastening of components. ♦ The vehicle fire extinguisher is designed to be used only once, ♦...
  • Page 41 FOX 2004 ➤ Maintenance - Edition 07.2010 – Press the keys TP and TA -1- simultaneously until “1000” ap‐ pears on the digital display. Release the keys! – Enter the code number attached to the radio card with the help of the tuning buttons -1-.

  • Page 42: Reading Radio Code Using Diagnosis, Measurement And Information System

    FOX 2004 ➤ Maintenance - Edition 07.2010 – Enter the code number attached to the radio card with the help of the pre-tuning buttons 1 to 4-2-. The first digit of the code number is entered with the key 1, the second digit with the key 2, and so forth.

  • Page 43: Wheel Fastening Screws - Tighten To Correct Torque

    FOX 2004 ➤ Maintenance - Edition 07.2010 – Confirm vehicle identification. – Select one after the other: ♦ “Radio system”. ♦ “Reading radio code” – Read code according to the information of “GUIDED FUNC‐ TIONS”. – Finish code reading as follows: –...

  • Page 44: Battery - Check Terminals For Proper Seating And Fastening

    FOX 2004 ➤ Maintenance - Edition 07.2010 4.8.3 Super hub cap assembly (if available) – Install the super hub cap so that the tire inflation valve is posi‐ tioned in the notch -arrow-. Battery - check terminals for proper seating and fastening 4.9.1...
  • Page 45 FOX 2004 ➤ Maintenance - Edition 07.2010 ♦ Torque wrench - 5 to 50 Nm (fit. 1/2") -VAG 1331- Carry out work sequence as follows: – Press the locks and tilt the positive battery pole cover -arrow- – With alternate movements of the positive and negative battery cables, check if the terminals -arrows- are firmly fastened to the battery poles.
  • Page 46 FOX 2004 ➤ Maintenance - Edition 07.2010 – Tighten the terminal screws in the battery poles to a torque of 5 Nm -arrow-. Note The tightening torque for the additional battery terminals is 6 ♦ The battery poles cannot be lubricated.

  • Page 47: Battery - Check The Charge Capacity

    FOX 2004 ➤ Maintenance - Edition 07.2010 4.10 Battery - check the charge capacity Note The vehicle must have remained turned off for at least 2 hours. 4.10.1 Check the charge indicator “inspection glass” at Delivery inspection Carry out a visual inspection on the charge indicator “inspection glass”...
  • Page 48 FOX 2004 ➤ Maintenance - Edition 07.2010 ♦ -VAS 5097- Battery test with printer, converted (modification- software recognized by logo -1-) Note When using the Battery test device, with printer -VAS 5097A- or -VAS 5097- , it is not necessary to remove the battery. Also, it is not necessary to disconnect the battery.

  • Page 49: Engine Oil Level - Check And Replenish If Necessary

    FOX 2004 ➤ Maintenance - Edition 07.2010 – Carry out the battery charge test according to the instructions of use for the battery test device and compare the test printout -arrow- with the following table. Clarifications concerning the test printout: 1 - measurement range adjusted on the test device.

  • Page 50: Sunroof: Check Operation, Clean And Lubricate The Guide Rails

    FOX 2004 ➤ Maintenance - Edition 07.2010 – Pull the oil dipstick out again and check the oil level for the following conditions: Condition 1 Area -a- Minimum marking region. Replenish the oil. It is sufficient for the oil level to be anywhere within area -b-.

  • Page 51: Transport Safety Devices - Remove

    FOX 2004 ➤ Maintenance - Edition 07.2010 – Clean the guide rails -arrows- and lubricate with Special grease -G 000 450 02- . 4.13 Transport safety devices - remove 4.13.1 Engine identification letters ASY, BLH, BNM, BKR, BMD, and CFZA –...

  • Page 52: Driver And Passenger Airbags - Visual Inspection Of Airbag Units

    FOX 2004 ➤ Maintenance - Edition 07.2010 – Remove the blocking device -arrow- from the shock absorber rod. – Move the shock absorber rod protection bellow downwards. 4.14 Driver and passenger airbags - visual inspection of Airbag units 4.14.1 Driver's airbag The identification feature of the Airbag is the “AIRBAG”...

  • Page 53: Windshield And Rear Window Wiper And Washer - Check The Operation

    – Check the concentration of additive for front/rear window wip‐ ers with Refractometer for cooling system liquid analysis -EQ 7093 (VWB) - ou - T 10007- (follow the instruction manual). The refractometer scale -1- is based on the original Volkswagen product according to the table: ⇒ page 49 The scale -2- is based on commercially available cleaning prod‐...
  • Page 54 The Windscreen washer fluid reservoir must be replenished to the top. Note The original Volkswagen product Windscreen/rear window ♦ washer additive -G 052 164 A1- or the -G 052 164 A2- have cleaning properties that protect the ejectors, the reservoir and connection hoses against freezing.

  • Page 55: Windscreen And Rear Window Wiper Blades - Check The Resting Position

    FOX 2004 ➤ Maintenance - Edition 07.2010 Note If the ejector does not enable adjustment, due to impurities, ♦ remove the ejector, ⇒ Electrical system; Rep. Gr. 92 ; Wind‐ shield, rear window and headlight wiper and washer and wash with water in the opposite direction of the nozzle jet direction.

  • Page 56: Wiper Blade - Check The Incidence Angle

    FOX 2004 ➤ Maintenance - Edition 07.2010 ♦ Torque wrench - 5 to 50 Nm (fit. 1/2") -VAG 1331- 4.16.1 Windscreen wiper blades - adjust the resting position Driver side – -a- = 30 ± 5 mm (measured in the wiper blade). The adjustment can also be made by using the round marking on the glass, which corresponds to the blade installation position (only Eu‐...

  • Page 57: Tire Pressure (Including Spare Wheel), Condition, Tread, Sides And Groove Depth - Check

    FOX 2004 ➤ Maintenance - Edition 07.2010 Special tools and workshop equipment required ♦ Adjustment device -3358B- Carry out work sequence as follows: – Place the wiper arm in the resting position. – Remove the wiper blade. – Place the wiper arm -2- on Adjustment device -3358B- and fasten with the screw -3-.
  • Page 58 FOX 2004 ➤ Maintenance - Edition 07.2010 Delivery inspection: – Check the tread and sides for damage and, if necessary, re‐ move foreign bodies, such as nails and pieces of glass, for example. Note In case of faults, please check if it is necessary to install a new tire.
  • Page 59 FOX 2004 ➤ Maintenance - Edition 07.2010 B - Tread wear indicators -arrows-. It is necessary to replace the tyres when the tread wearing rea‐ ches the indicators -position 1- at the bottom of the grooves. The points where tread wear indicators are found are identified by the acronym TWI (Tread Wear Indicators), distributed at every 60 degrees -a- on tire perimeter.
  • Page 60 FOX 2004 ➤ Maintenance - Edition 07.2010 Note Please notice that the tire pressure values mentioned in the ♦ table are valid for cold tires. Heated tyres should not be ex‐ cessively deflated. The pressure values for the respective model can also be ♦...
  • Page 61 FOX 2004 ➤ Maintenance - Edition 07.2010 half load front and full load front and rear rear 185/60 R14 82T 195/55 R15 85V Engine identification letters BNM 185/60 R14 82T 195/55 R15 85V CrossFox Engine identification letters BKR 205/60 R15 91V...

  • Page 62: Engine Oil - Drain And Fill; Change The Oil Filter

    FOX 2004 ➤ Maintenance - Edition 07.2010 half load front and full load front and rear rear Engine identification letters BNM 165/70 R14 81T 185/60 R14 82T 195/55 R15 85V CrossFox Engine identification letters BKR 205/60 R15 91V Engine identification letters BNM...
  • Page 63 FOX 2004 ➤ Maintenance - Edition 07.2010 ♦ Torque wrench - 5 to 50 Nm (fit. 1/2") -VAG 1331- Carry out work sequence as follows: Engine identification letters BAH, BLH, and CFZA – Aspirate the engine oil with the Oil aspirator -VAG 1307 A- or Oil aspirator -VAG 1358 A- –...
  • Page 64 FOX 2004 ➤ Maintenance - Edition 07.2010 – Remove the oil draining plug -arrow-. – Remove the sealing ring from the oil draining plug and cut if necessary. – Drain the engine oil. – Tightening torque for the draining plug: seta - 3- and 4-cylinder engines 30 Nm.
  • Page 65 FOX 2004 ➤ Maintenance - Edition 07.2010 – Remove the oil draining plug -arrow-. – Remove the sealing ring from the oil draining plug and cut if necessary. – Drain the engine oil. – Tightening torque for the draining plug: seta - 4-cylinder engines 30 Nm.
  • Page 66 FOX 2004 ➤ Maintenance - Edition 07.2010 Engine identification letters AQZ, BAH, BLH, BKR, and CFZA – Loosen the filter through the hex section -arrow- with a Wrench -SW 30- and remove it. WARNING ♦ Follow the rules for disposal! –...
  • Page 67 FOX 2004 ➤ Maintenance - Edition 07.2010 – Loosen the filter through the hex section -arrow- with a 36 mm Wrench . WARNING ♦ Follow the rules for disposal! – Clean the engine sealing surface. – Replace the sealing ring.
  • Page 68 FOX 2004 ➤ Maintenance - Edition 07.2010 WARNING ♦ Follow the rules for disposal! – After replenishing the engine with oil, wait for at least 3 minutes and then check the level. – Pull the oil dipstick out, clean it with a clean cloth, and then push the oil dipstick in again up to the seat (stop).

  • Page 69: Engine And Components In Engine Compartment (From Above And Below) - Make A Visual

    FOX 2004 ➤ Maintenance - Edition 07.2010 Condition 3 Area -a- Replenish the oil level. It is sufficient for the oil level to be anywhere within area -b-. Area -b- It is not necessary to replenish the oil. Area -c-...

  • Page 70: Constant Velocity Joint Bellows - Visual Inspection

    FOX 2004 ➤ Maintenance - Edition 07.2010 – Turn the engine at the belt shock absorber/pulley -arrow- with a socket wrench. – Check the Poly-V belt from below for: ♦ Tears in the lower section (internal fractures, section frac‐ tures).

  • Page 71: Brake System - Visual Inspection For Damage And Leaks

    FOX 2004 ➤ Maintenance - Edition 07.2010 ♦ Torque wrench - 5 to 50 Nm (fit. 1/2") -VAG 1331- 4.23.1 02T 5-gear transmission – Remove the transmission oil filling plug -arrow-. – The oil level is correct when the transmission is full up to the lower edge of the oil filling hole.
  • Page 72 FOX 2004 ➤ Maintenance - Edition 07.2010 ♦ Torque wrench - 40 to 200 Nm (enc. 1/2") -VAG 1332- ♦ Torque wrench - 5 to 50Nm (fit. 1/2") -VAG 1331- 4.25.1 Brake cylinder Carry out work sequence as follows: – For better evaluation of the remaining pad thickness, remove the driver side wheel (the wear is more intense than on the passenger side).
  • Page 73 FOX 2004 ➤ Maintenance - Edition 07.2010 – Loosen the two screws -arrows- and remove the brake cylin‐ der. WARNING Remove the brake cylinder and fasten it with wire so that its weight does not stress and damage the flexible brake pipe.
  • Page 74 FOX 2004 ➤ Maintenance - Edition 07.2010 • Brake disc thickness: 18 mm for FSII and 22 mm for FSIII-a-. • Wear limit: 16 mm for FSII and 19 mm for FSIII. Note Always replace both discs from the same axle.
  • Page 75 FOX 2004 ➤ Maintenance - Edition 07.2010 ♦ Wear indicator -1- is located on the centre of the brake disc contact area. ♦ Wear indicator -2- is located close to the internal edge of the brake disc. Note If the front brake disc wear indicator markings (visual check) ♦...
  • Page 76 FOX 2004 ➤ Maintenance - Edition 07.2010 Replace the brake discs. Remove and install the front brake discs. 4.25.5 Vehicles with steel wheel Note In order to visualize the brake disc wear indicators (visual ♦ check) in vehicles with steel wheels, the front wheels must be removed.

  • Page 77: Lower Body Section Protection - Make A Visual Inspection For Damage

    FOX 2004 ➤ Maintenance - Edition 07.2010 The brake discs need not be replaced. Only wear indicator -2- is visible: The brake discs do not require replacement, but pay attention on the next change. No brake disc wear indicator is visible.

  • Page 78: Rear Wheels: Adjust The Roller Bearing Clearance

    FOX 2004 ➤ Maintenance - Edition 07.2010 4.28 Rear wheels: adjust the roller bearing clearance (only for vehicles without ABS and equipped with the engines: AQZ, BAH, ASY, BLH, and CFZA from 07/01/2007. Special tools and workshop equipment required ♦ Supporting tube -40-21- ♦...
  • Page 79 FOX 2004 ➤ Maintenance - Edition 07.2010 – Release or tighten nut by applying less or more pressure on the washer -arrow-, and simultaneously check its radial move‐ ment with light pressure of your index applied on a screwdriv‐ – Never turn -arrows- or leverage the screwdriver.

  • Page 80: Suspension Arm Joints - Visual Inspection

    FOX 2004 ➤ Maintenance - Edition 07.2010 4.29 Suspension arm joints - visual inspec‐ tion – Check the sealing bellows in the suspension arm joints -arrow- for damage and leaks. 4.30 Cooling system - check the antifreeze additive and the coolant level...
  • Page 81 FOX 2004 ➤ Maintenance - Edition 07.2010 ♦ Refractometer for cooling system liquid analysis -EQ 7093 (VWB) - ou - T 10007- Note The exact value for the following checks may be read in the light- dark limit. To better see the light-dark limit, use a dropper/pipette to put a water drop on the glass.
  • Page 82 FOX 2004 ➤ Maintenance - Edition 07.2010 Antifreeze protection up to º F Difference quantity in liters Actual value Nominal value 12) Actual value: it is the result achieved when measuring the concentration of coolant on the measured vehicle. 13) Nominal value: is the value applied to the locality where the vehicle is being used.

  • Page 83: Spark Plugs - Replace

    FOX 2004 ➤ Maintenance - Edition 07.2010 Note The coolant additive -G12- prevents damage from corrosion ♦ and freezing, limestone build-up and also increases the boiling point. For these reasons, the cooling system must always be replenished with antifreeze and anti-corrosion agent through‐...
  • Page 84 FOX 2004 ➤ Maintenance - Edition 07.2010 4.31.1 Engine identification letters BAH and – Remove the crankcase air vent hose -1- from the air filter case. – Remove the air filter case from the supports and the butterfly valve command unit -arrows- and remove the air filter case.
  • Page 85 FOX 2004 ➤ Maintenance - Edition 07.2010 – First, remove the air filter case from its supports and the but‐ terfly valve command unit and, then, from the front supports -arrow-. Carry out work sequence as follows: – Remove the spark plug connectors -arrows- with the Assem‐...

  • Page 86: Atf Oil Reservoir For Power Steering - Replenish The Level

    FOX 2004 ➤ Maintenance - Edition 07.2010 – Install the Extractor -T10094- over the ignition coil with final power stage.-arrow- – Remove the ignition coil with the final power stage a little out‐ wards. – Install the Hook -T10118- as illustrated.
  • Page 87 FOX 2004 ➤ Maintenance - Edition 07.2010 – Remove the cover with a screwdriver -arrow-. – Clean the oil dipstick with a clean cloth. – Manually install the cover and remove it again. Note The oil level inspection must only be considered in the second measurement.

  • Page 88: Dust And Pollen Filter - Replace The Filter Element

    FOX 2004 ➤ Maintenance - Edition 07.2010 – Check oil level: the oil level must be between the -MIN- and -MAX- marks. Note If the oil level is above the -MAX- mark, you must drain the oil. ♦ If the oil level is below the -MIN- mark, you must check the ♦...

  • Page 89: Timing Belt - Replace; Semi-Automatic Camshaft Tensioning Pulley - Check

    FOX 2004 ➤ Maintenance - Edition 07.2010 – Loosen the filter compartment cover screw-arrow-. – Remove the dust and pollen filter -arrow- with the filter support. – Separate the filter from its support. WARNING ♦ Follow the rules for disposal! –...

  • Page 90: Air Filter - Clean The Case And Replace The Filter Element

    FOX 2004 ➤ Maintenance - Edition 07.2010 Note If there are faults, you must replace the timing belt. This will avoid failures and faults during operation. When checking the timing belt condition, pay special attention to the following damage: A - Tears (on the cover side).

  • Page 91: Fuel Filter - Replace

    FOX 2004 ➤ Maintenance - Edition 07.2010 Remove the crankcase venting hose -1- from the air filter case. First, remove the air filter case from its supports and the butterfly valve command unit and, then, from the front supports -arrow-.
  • Page 92 FOX 2004 ➤ Maintenance - Edition 07.2010 4.37.2 Engine identification letters ASY Note Make sure that the fuel does not reach the cooling system ho‐ ♦ ses. If necessary, clean the hoses immediately! Do not dispose of the fuel filter with fuel inside.

  • Page 93: Fuel Filter - Drain

    FOX 2004 ➤ Maintenance - Edition 07.2010 Removal – Remove the intake-a- and outlet -b- hose clamps from the filter with the Spring clamp pliers -VAS 5024 A- . – Remove the hoses. – Move the filter up and remove it.

  • Page 94: Brake Fluid - Replace

    FOX 2004 ➤ Maintenance - Edition 07.2010 – Check the fuel system tightness (visual inspection). 4.39 Brake fluid - replace Special tools and workshop equipment required ♦ Brake pedal pressing device -VAG 1869/2- ♦ Brake filler and bleeder -VAS 5234- ♦...
  • Page 95 FOX 2004 ➤ Maintenance - Edition 07.2010 Authorized brake fluid specifications in vehicles from model until year 2005: ♦ Brake fluid corresponds to the USA rule FMVSS 116 DOT 4 (brake fluid used up to the date) ♦ Brake fluid corresponds to the VW rule, VW 501 14 (new brake fluid).
  • Page 96 FOX 2004 ➤ Maintenance - Edition 07.2010 – Connect the adapter -1- to the brake fluid reservoir. – Connect the hose from the Brake filler and bleeder -VAS 5234- or the Brake bleeding device - VAG 1869- to the adapter.

  • Page 97: Brake Fluid Level (Depending On Brake Pad/Lining Wear) - Check

    FOX 2004 ➤ Maintenance - Edition 07.2010 – Tighten the bleeding screw. – Press the clutch pedal several times. Sequence Wheel brake cyl‐ Amount of brake fluid that must be inder brake shoes drained from the wheel brake cyl‐ inders, that is, from the brake fit‐...

  • Page 98: Headlight Adjustment - Check And Adjust Headlights If Necessary

    FOX 2004 ➤ Maintenance - Edition 07.2010 Please note the following: Delivery inspection: In the delivery inspection, the fluid level must be at the maximum marking. Note In order to prevent the brake fluid from overflowing, the maximum marking must not be exceeded.
  • Page 99 FOX 2004 ➤ Maintenance - Edition 07.2010 Fuel reservoir indicator filling Additional weight in kg level full Example: If the fuel reservoir is half full, you must put an additional weight of 20 kg in the boot. Note As additional weight, it is preferable to use fuel containers filled with water (one fuel container with a 5-liter capacity corresponds to a weight of approximately 5 kg).
  • Page 100 FOX 2004 ➤ Maintenance - Edition 07.2010 – Check if the point of inflexion -2- between the left horizontal part and the right ascending part of the light-dark limit runs vertically through the central mark -3-. In this case, the light core of the light beam is at the right of the vertical line.
  • Page 101 FOX 2004 ➤ Maintenance - Edition 07.2010 – Check if the light-dark limit reaches the adjustment line and runs vertically over the entire measuring device line. Note The light-dark separation mark is the measurement from the ♦ ground to the centre of the headlight minus 5.00 cm in for 10.94 yd of distance.

  • Page 102: Perform A Test Run

    FOX 2004 ➤ Maintenance - Edition 07.2010 Long reach headlights (CrossFox) – Release the screws-1- and -2-only enough to slightly move the headlight. – Press the headlight or move it forward -c- to the vertical ad‐ justment (height). – Press the headlight in -a- or -b- for horizontal adjustment (right and left).

  • Page 103: Additional Tasks Due To Country Legislation

    FOX 2004 ➤ Maintenance - Edition 07.2010 Additional tasks due to country legis‐ lation Note The exhaust gas tests are valid only for countries that do not have specific guidelines for the exhaust gas test. Exhaust gas test Note Follow the specific rules for the country.
  • Page 104 FOX 2004 ➤ Maintenance - Edition 07.2010 ♦ Gas tester - 4 components (CO, CO2, HC and O2) or GAS TESTER -VAS 6300- ♦ OBD adapter cable -VAS 5052/16- Note It is only possible to perform an exhaust gas test when all de‐...
  • Page 105 FOX 2004 ➤ Maintenance - Edition 07.2010 The general view for selecting the respective type of exhaust gas test is displayed. – Select “Petrol exhaust gas test” -arrow-. The indication for the heating period is displayed. – Continue the exhaust gas test according to the instructions on the screen.
  • Page 106 Maintenance - Edition 07.2010 – Enter in positions -1...7- the vehicle's data included on the ve‐ hicle's documentation. ♦ -1- Vehicle's manufacturer: “for example VOLKSWAGEN — VW” ♦ -2- Type of vehicle: “for example, 1J” ♦ -3- Code number for 2: “z.B. 0603”...
  • Page 107 FOX 2004 ➤ Maintenance - Edition 07.2010 Entering nominal data for the exhaust gas test with the barcode: – If the nominal data for the exhaust gas test is available with the barcode, read the barcode in the exhaust gas test data‐...
  • Page 108 FOX 2004 ➤ Maintenance - Edition 07.2010 – Turn the ignition on. – Perform the visual inspection of the “MI Lamp”. – When the light is turned on, press on the screen “Light on” - arrow C -. – Follow the indications on the screen, - arrow C - and -arrow A -.
  • Page 109 FOX 2004 ➤ Maintenance - Edition 07.2010 Heating period: It automatically switches to the engine temperature measurement indication. – Follow the indications on the screen. Note This indication appears just before the engine temperature rea‐ ches 80 degrees Celsius. – The engine temperature must reach the necessary level.
  • Page 110 FOX 2004 ➤ Maintenance - Edition 07.2010 Idle speed rotation measurement and content of CO: It automatically switches to the indication of idle speed rotation measurement and content of CO. The measurement starts as soon as the engine rotation reaches the necessary level.
  • Page 111 FOX 2004 ➤ Maintenance - Edition 07.2010 After the confirmation, two “TEST CERTIFICATES” are automat‐ ically printed. – To get other certificates, press the -arrow A - “Print” button. – Follow the indications on the screen. – Remove the exhaust gas probe from the final exhaust gas tube.
  • Page 112 FOX 2004 ➤ Maintenance - Edition 07.2010 ♦ Rotation adapter -VAS 5087/ A- ♦ Exhaust gas test requester Note It is only possible to perform an exhaust gas test when all de‐ ♦ vices from the Gas tester - 4 components (CO, CO2, HC and O2) or GAS TESTER -VAS 6300- are working and connected with one another, according to the operation instructions.
  • Page 113 FOX 2004 ➤ Maintenance - Edition 07.2010 The indication for the heating period will be displayed. – Continue the exhaust gas test according to the instructions on the screen. – When the selection of the theoretical value of exhaust gases is displayed, select the respective “Selection of theoretical val‐...
  • Page 114 Maintenance - Edition 07.2010 – Enter in positions -1...7- the vehicle's data included on the ve‐ hicle's documentation. ♦ -1- Vehicle's manufacturer: “for example VOLKSWAGEN — VW” ♦ -2- Type of vehicle: “for example, 1J” ♦ -3- Code number for 2: “z.B. 0603”...
  • Page 115 FOX 2004 ➤ Maintenance - Edition 07.2010 Entering nominal data for the exhaust gas test with the barcode: – If the nominal data for the exhaust gas test is available with the barcode, read the barcode in the exhaust gas test data‐...
  • Page 116 FOX 2004 ➤ Maintenance - Edition 07.2010 – Follow the indications on the screen. The measurement starts as soon as the engine rotation reaches the necessary level. – Keep the engine rotation on the necessary level. The remaining time for performing the heating phase is indicated -arrow A-.
  • Page 117 FOX 2004 ➤ Maintenance - Edition 07.2010 Idle speed rotation measurement and content of CO: It switches automatically to the indication of idle speed rotation measurement and content of CO. The measurement starts as soon as the engine rotation reaches the necessary level.
  • Page 118 FOX 2004 ➤ Maintenance - Edition 07.2010 ♦ Diesel engine test device -V.A.G 1743- ♦ Rotation adapter -VAS 5087 A- ♦ or ♦ Rotation adapter -VAS 6296- ♦ Data reading device -V.A.G 1798- ♦ or ♦ Data reading device -V.A.G 1799- ♦...
  • Page 119 FOX 2004 ➤ Maintenance - Edition 07.2010 Perform a visual inspection of the components that influence the exhaust gases – Perform the visual inspection in relation to: ♦ Existence time ♦ Integrity ♦ Tightness ♦ Damage Note When finding defects, they must be eliminated.
  • Page 120 FOX 2004 ➤ Maintenance - Edition 07.2010 – With the other Adapter -VAS 5087/1- cable, make a connec‐ tion to the vehicle's battery. For this purpose: ♦ red terminal on positive ♦ black terminal on negative. Note When you use the Rotation adapter -VAS 5087 A- , press the ♦...
  • Page 121 FOX 2004 ➤ Maintenance - Edition 07.2010 Upon indication on display: Check input with -> Key Continue with the - Q key – Confirm the vehicle data entered or read through the key. Upon indication on display: Visual inspection Ok = j not Ok = –...
  • Page 122 FOX 2004 ➤ Maintenance - Edition 07.2010 – Check the actual value; for this purpose, continue the actual value indication with the key → Engine cutting rotation out of the theoretical value field: – If the values are not in the theoretical value field, a Repair Measure must be performed.
  • Page 123 FOX 2004 ➤ Maintenance - Edition 07.2010 With the indication on display: Data transmission for the gas oil test de- vice Free acceleration in movement – Keep pressing the accelerator pedal. Upon indication on display: Idle speed rotation 4ª measurement 15 sec ACTUAL rotation xxxx/ min THEORETICAL xxx...xxxx/min...

  • Page 124: Glossary

    FOX 2004 ➤ Maintenance - Edition 07.2010 Note Upon indication on display: ♦ Press the key and repeat the test or perform a Repair ♦ Measure. Test not Ok continue with the - Q key Repeat the test with the - F1 key Upon indication on display: Input of clarifications with ->...
  • Page 125 FOX 2004 ➤ Maintenance - Edition 07.2010 Concept Explanation On-Board Diagnosis; the OBD checks all components that influence the quality of the exhaust gases OBD-II American On-Board Diagnosis Unit of pump - nozzle injection in diesel engines PR number Abbreviation for production control number. They identify, among others, additional...
  • Page 126 FOX 2004 ➤ Maintenance - Edition 07.2010 Concept Explanation LongLife service The LongLife service enables extremely long inspection and oil change intervals, depending on the driving mode and the conditions of use for each one. A special engine oil is necessary for the Long‐...

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