Professional Documents
Culture Documents
FOX - Maintenance Handbook PDF
FOX - Maintenance Handbook PDF
Maintenance
FOX 2004
AG. Volkswagen AG d
agen oes
olksw not
y V gu
Edition 07.2010 rise
d b ara
nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Heading
AG. Volkswagen AG d
1. Engine overview agen oes
olksw not
byV gu
ara
2. Service plans orised
nte
h eo
ut
3. General remarks ss a ra
c
ce
e
4. Service descriptions
nl
pt
du
an
itte
5. Additional tasks due to country legislation
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
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.
Contents
1 Engine overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Service plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Service table . . . . . . . . . . . . . . . . . . . . A. G. ..V.o.lk.sw. a. g.e.n.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
gen G
2.2 Delivery inspection . . . . . . . . .Vo. lk. . . . . . . . . . . . . . . . . . d. o.e.s .no.t . . . . . . . . . . . . . . . . . . . . . . .
sw a 5
y g
2.3 Oil Change Service . . . . is.e.d b. . . . . . . . . . . . . . . . . . . . . . . . . . . u.ar.an. . . . . . . . . . . . . . . . . . . 7
r tee
2.4 Intermediate service Models ut
ho 2010 (Europe) and Models 2009 (except or Europe) . . . . . . 8
a a
2.5 Intermediate service sModels
s 2011 (Europe) . . . . . . . . . . . . . . . . . . . .c . . . . . . . . . . . . . . 10
ce
e
2.6 Inspection Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
nl 13
pt
du
an
2.7 Supplementary services based on time elapsed and/or kilometers traveled . . . . . . . . . . . . 18
itte
y li
erm
ab
3 General remarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
ility
ot p
wit
, is n
h re
3.2 Lifting the vehicle with a workshop lift and jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
hole
spec
3.3 Service tag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
es, in part or in w
t to the co
3.4 Self-diagnosis - refer to the fault memory of all systems . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.5 Vehicle identification data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.6 Service intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
rrectness of i
3.7 Countries with high sulfur content in diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
l purpos
nf
3.10 Push starting (pushing the vehicle to start)/towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
ercia
orm
4 Service descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
m
atio
m
n in
or c
4.2 Maintenance interval indicator (if available) : reset with the Vehicle Diagnosis, Measurement
thi
te
sd
a
o
r
rp
cu
4.3 Spare wheel support stop: lubricate - (CrossFox) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
o
m
f
en
ng
Contents i
FOX 2004
Maintenance - Edition 07.2010
ce
le
4.41 Headlight adjustment - check and adjust headlights if necessary . . . . . . . . . . . . . . . . . . . . 94
un
pt
an
d
4.42 Perform a test run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
itte
y li
erm
ab
5 Additional tasks due to country legislation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
ility
ot p
wit
is n
h re
5.2 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ii Contents
FOX 2004
Maintenance - Edition 07.2010
1 Engine overview
Identification letters AQZ BAH BLH 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 Tier 1 EU 2 MVEG23)
haust gases ac tion number 15 tion number 15 Tier 1 ME s/OBD
cording to from CONAMA from CONAMA 4)
ce
le
un
pt
an
Compression rate 10,8;1 10,8:1 10,8:1 10,8:1
d
itte
y li
erm
ab
Injection/ignition 4BV1) ME 7.5.102) ME 7.5.102) ME 07.05.30
ility
ot p
wit
is n
(ROZ)
h re
ole,
spec
Electronic accelerator yes yes yes yes
urposes, in part or in wh
t to the co
Self-diagnosis yes yes yes yes
Catalytic converter yes yes yes yes
Lambda adjustment 1 Lambda probe 1 Lambda probe 2 Lambda probes 2 Lambda probes
rrectne
Recirculation of exhaust no no no no
gases
ss o
cial p
f
Exhaust gas turbocharger no no no no
inform
mer
atio
om
n
c
n thi
te
sd
o
pr
cum
en
ng
t.
yi
4) Mexico from the start.
Co
Cop py
t. rig
gh
Identification letters ASY BNM
ht
pyri by
Vo
o
by c lksw
cted
Engines Diesel engine Diesel engine
agen
Prote AG.
Production from 11.24.03 from 01.24.05
Limit value for exhaust gases according to EURO 3 diesel EURO 3 diesel
Number of cylinders/Valves per cylinder 4/2 3/2
Cylinder volume l 1,9 1,4
Max. output kW/rpm 47,0/4000 51,0/4000
Engine torque Nm/rpm 125,0/1600 155.0/1600 to 2800
Diameter mm 79,5 79,5
Stroke mm 95,5 95,5
Compression rate 19,5:1 19,5
Injection/ignition Direct diesel injection Direct diesel injection (TDI
(SDI) PD)
Cetane coefficient min. 49 49
Electronic accelerator no no
1. Engine overview 1
FOX 2004
Maintenance - Edition 07.2010
ce
le
der
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
rpm
wit
, is n
h re
Engine torque Nm/ 110,0/4000 106,0/3000 106,0/3000
hole
spec
rpm
es, in part or in w
t to the co
Diameter 76,5 76,5 76,5
mm
Stroke mm 75,6 86,9 86,9
rrectness of i
Compression rate 10,5 10,3 10,3
l purpos
Injection/ignition 4 EV 6)
Simos 3 PG Simos 9.1
Octane rating (ROZ) min. 5)
95 lead-free 5)
95 lead-free 5)
95 lead-free
nform
ercia
a
com
t
Self-diagnosis yes yes yes
ion in
r
te o
thi
s
iva
do
Lambda adjustment yes yes yes
r
rp
cum
fo
t.
yi Co
Exhaust gas turbocharger no no no
Cop py
ht. rig
rig ht
py by
5) in exceptional cases, octane rating of at least 91, but with reduced power. co Vo
by lksw
cted agen
6) Simos 3 PG installed up to week 29, Simos 9.1 started in week 30. Prote AG.
2 1. Engine overview
FOX 2004
Maintenance - Edition 07.2010
2 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 (Europe) page 10
Inspection service page 13
pt
an
d
itte
y li
ab
ility
wit
is n
spec
urposes, in part or in wh
t to the co
f inform
mer
AIR FILTER
atio
m
n
c
i
or
sd
iva
o
pr
cum
r
fo
FUEL FILTER
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Service plans 3
FOX 2004
Maintenance - Edition 07.2010
pump
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
h re
hole
spec
t to the co
at
om
in t
or
t.
yi
tries)
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
4
cted agen
Prote AG.
2. Service plans
FOX 2004
Maintenance - Edition 07.2010
7) In vehicles using diesel with high sulfur content, the oil must be changed at
every 7,500 km. Countries with high sulfur content in diesel, page 28
Inspection Service
at every 30,000 km or every 2 years,
whichever occurs first.
pt
an
y li
ab
ility
ot p
tries)
t to the co
Intermediate service
at every 30,000 km or every 2 years,
rrectne
Inspection Service
inform
n
c
i
or
n thi
te
sd
a
9) In vehicles using diesel with high sulfur content, the oil must be changed at
iv
o
pr
every 7,500 km. Countries with high sulfur content in diesel, page 28 .
um
r
fo
en
ng
t.
2.2 Delivery inspection
yi Co
Cop py
t. rig
gh ht
yri
The Delivery Inspection is valid for both service plans for models
p by
o Vo
by c
2007 and 2008 and service plans for models 2008 and 2009.
lksw
cted agen
Prote AG.
The sequence of each service operation was tested and opti
mized. It shall be adhered to so as to prevent unnecessary
service interruptions.
For delivery inspection, it is mandatory that the vehicle is
washed and has no wax residues.
2. Service plans 5
AG. Volkswagen AG d
agen oes
ksw
FOX 2004 by
Vol not
gu
d ara
Maintenance - Edition 07.2010 orise nte
h eo
aut ra
c
Vehicles on the yard for a longstime: In vehicles with manu
s
ce
le
facturing date exceeding 5 months, the engine oil, oil filter, and
un
pt
an
oil draining plug sealing ring must be changed!
d
itte
y li
rm
ab
If the battery is disconnected, the power window drive auto
pe
ility
matic closing function will not operate. Thus, this function must
ot
wit
, is n
be reprogrammed before delivering the vehicle. The vehicle
h re
battery cannot be disconnected after reprogramming. Power
hole
spec
window drive - reprogram page 36
es, in part or in w
t to the co
Work volume Service
Self-diagnosis: refer to the fault memory of all systems with the Diagnosis, page 24
rrectness of i
measurement and information system .
l purpos
nform
ercia
a
com
tio
Ignition cables and spark plug connectors: check the condition and fasten
n in
r
ing.
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
eration.
yi Co
Cop py
t.
Install all vehicle components (if available): mats, wipers, spoiler, roof an
rig
gh ht
yri by
tenna, hub caps, coverings, super hub caps and caps. op Vo
by c lksw
cted agen
Rear license plate (only Fox Europe): install. Prote
page 22
AG.
Clock (if available): check the operation and set the time. page 33
Radio: activate the anti-theft code page 36
Reading radio code using Diagnosis, measurement and information system page 38
Fire extinguisher: check connection and charge and remove the plastic pro page 35
tection (identification letters AQZ and BAH).
Radio tag (part of the radio's Instruction Manual): get the sticker with the
serial number and the fixed code.
Windshield/rear window wiper and washer: check operation; if necessary, page 50
adjust the ejectors and replenish the reservoir with additive liquid up to the
maximum level.
Engine oil: complete the level (only for vehicles manufactured within the last page 45
5 months).
Engine oil and oil draining plug sealing ring: replace (only for vehicles man page 58
ufactured within the last 5 months).
Engine oil filter: replace (only for vehicles manufactured within the last 5 page 61
months).
Engine and components in the engine compartment (upper section): visually page 65
check for damages and leakages.
Cooling system coolant: replenish the level. page 76
ATF oil reservoir for power steering: replenish the level. page 82
Brake fluid level: check the level and replenish, if necessary. page 93
Safety devices for transport: remove page 47
Vehicle bottom section; engine and engine compartment components, page 65
brakes, axles, gearbox/differential shafts, steering wheel, joint bellows, flex
ible tubes, liquid reservoir: check visually for possible damage and leaks
(without removing the lower noise insulation from the engine compartment).
Lower body section protection - check visually for damage. page 73
Plastic protection for seats, on the lower section of door linings, sun visors
and carpets: remove.
Tyres (including spare wheel): check. page 53
Tyre pressure (including spare wheel): calibrate page 55
6 2. Service plans
AG. Volkswagen AG d
agen
Volksw
oes
not FOX 2004
by gu
nte Maintenance - Edition 07.2010
d ara
ise
or eo
th
au ra
Work volume ss c Service
ce
le
un
pt
Vehicle interior: check for cleaning and, if necessary, clean: front and back
an
d
itte
seats, internal linings, carpet/mats and windows.
y li
rm
ab
Vehicle exterior: check and clean: paintwork, decoration elements, win
pe
ility
ot
wit
, is n
h re
Maintenance interval indicator (if available) : reset. page 34
hole
spec
Maintenance and Warranty book: record the delivery inspection and write
es, in part or in w
t to the co
the next service.
Service tag: write the date of the next service (including brake fluid change) page 23
and attach the tag to the left side of the command panel or to the left door
rrectness of i
pillar (B).
l purpos
Check the integrity of onboard literature and prepare for delivery to cus
tomer.
nform
Perform a test run. page 98
mercia
a
com
tion in
r
thi
s
iva
do
r
rp
c
The oil change service is valid for both service plans for models
um
fo
2007 and 2008 and service plans for models 2008 and 2009.
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
Note op Vo
by c lksw
cted agen
Prote AG.
Use oils with high lubrication performance according to spec
ifications VW 502 00 (petrol) and VW 505 00 or 505 01 (SDI),
(diesel PD) and VW 505 01 (TDI).
For countries with high sulfur content in Diesel, the Engine Oil
Change Service must be carried out every 7500 km. Countries
where the sulfur content is higher page 28 .
2. Service plans 7
FOX 2004
Maintenance - Edition 07.2010 n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
Application ir se Windshield/rear window washer Proportion
tee
ho
aut
additive or
ac
ss
-G 052 184 A2- from 08/2005 100 ml additive for 990 ml water.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
Engine compartment
hole
spec
Engine oil: fill page 58
es, in part or in w
t to the co
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
rrectness of i
(VW) or 505 01 (VW).
l purpos
Petrol engines: Identification letters AQZ, filling capacity 3.3 l; standard 502 00
(VW).
Petrol engines: Identification letters BAH, BLH, and CFZA, filling capacity 4.0 l;
nform
ercia
at
om
i
(VW).
on
c
in t
Petrol engine: Identification letter BKR, filling capacity 3,3 l; standard 502 00
or
his
e
(VW).
at
do
priv
c
Engine oil filter: replace. page 58
um
for
en
g
Battery: fill the electrolyte up to the level (except for maintenance-free bat
n
t.
yi Co
op
teries and Europe). C py
t. rig
gh ht
yri
Fuel filter: drain the water (Vehicles with diesel engine using bio-diesel ac page 89
p by
co Vo
cording to the DIN E 51 606 or diesel vehicles that do not comply with the
by lksw
cted agen
Prote
DIN EN 590).
AG.
8 2. Service plans
FOX 2004
Maintenance - Edition 07.2010
olkswagen AG
en AG. V
If the battery is disconnected, the power window drive automatic ksw
ag does
not
Vol
closing function will not operate. Thus, this function must ebed b re
y gu
ara
programmed before delivering the vehicle. The vehiclehobattery
ris nte
eo
cannot be disconnected after reprogramming. Powerauwindowt ra
c
drive - reprogram page 36 . ss
ce
e
nl
pt
du
an
itte
y li
Note
erm
ab
ility
ot p
wit
In countries with high sulfur content on the diesel fuel, the engine
, is n
h re
oil must be changed every 7,500 km. The countries with higher
hole
spec
sulfur content on the diesel are listed on page 28 .
es, in part or in w
t to the co
Where faults are detected during the Interval Service, take the
required actions to repair them and inform the customer about the
events.
rrectness of i
Ask the customer about installing new Windshield wiper blades
l purpos
and adding window cleaning -G 052 131 A1- until 07/2005 and
window cleaning -G 052 184 A2- until 08/2005 or cleaning and
nf
ercia
or
wiper system.
m
m
atio
om
n in
Application Windshield/rear window washer Proportion
or c
additive
thi
te
sd
iva
o
EUROPE only -G 052 164 A1- or -G 052 164 A2- 300 ml additive to 700 ml water
r
rp
cu
o
m
f
Tropical climate countries -G 052 131 A1- until 07/2005 1.69 fl oz additive for 32.12 fl oz wa
en
ng
t.
yi Co
ter. t. Cop py
rig
-G 052 184 A2- from 08/2005 100 ml additive for 990 ml water.
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
Intermediate service Models 2010 (Europe) and Models 2009 (except Eu Service
rope)
Tyres and wheels
Battery: check with Battery tester with printer -VAS 5097A- . page 43
Spare wheel support stop: lubricate. page 35
CrossFox only
Spare wheel tyre: check the state of tread, sides and depth of grooves _____ page 53
mm.
Left front wheel tyre: check the state of tread, sides and depth of grooves page 53
_____ mm
Left rear wheel tyre: check the state of tread, sides and depth of grooves page 53
_____ mm.
Right rear wheel tyre: check the state of tread, sides and depth of grooves page 53
_____ mm.
Front right wheel tyre: check the state of tread, sides and depth of grooves page 53
_____ mm.
Tyres: calibrate, including the spare wheel. page 55
Engine compartment
2. Service plans 9
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).
Petrol engines: Identification letters AQZ, filling capacity 3.3 l; standard 502 00
(VW).
Petrol engines: Identification letters BAH, BLH, and CFZA, filling capacity 4.0 l;
standard 502 00 (VW).
Petrol engine: Identification letter BMD, filling capacity 2.85 l; standard 502 00
(VW).
Petrol engine: Identification letter BKR, filling capacity 3,3 l; standard 502 00
(VW).
Engine oil filter: replace. page 58
Brake fluid level: check the level and replenish, if necessary. page 93
Fuel filter: drain the water (Vehicles with diesel engine using bio-diesel ac page 89
cording to the DIN E 51 606 or diesel vehicles that do not comply with the
DIN EN 590).
Vehicle on raised platform
Engine oil: drain or aspirate. page 58
Brake system: perform a visual check for leaks and damage. page 67
Rear pads and linings: check the thickness. page 67
. Volkswagen AG
Brake discs: check the level of wear and corrosion wagen AG doe page 69
olks s no
yV t gu
Shock absorbers: verify for leaks (except Europe) ise
d b ara
nte
or eo
Concluding tasks auth
ra
ss c
Maintenance interval indicator (if available) : reset. page 34
ce
le
un
pt
Maintenance and Warranty book: record the date and kilometers traveled for
an
d
itte
y li
the next service.
rm
ab
pe
ility
Service tag: write the date of the next service (including brake fluid change) page 23
ot
and attach the tag to the left side of the command panel or to the left door wit
, is n
h re
pillar (B).
hole
spec
es, in part or in w
t to the co
tio
years.
n in
r
te o
thi
do
r
rp
en
g
t.
yi Co
interruptions. Cop py
t. rig
gh ht
yri
If the battery is disconnected, the power window drive automatic p by
co Vo
closing function will not operate. Thus, this function must be re
by lksw
cted agen
Prote
programmed before delivering the vehicle. The vehicle battery
AG.
10 2. Service plans
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 .
Where faults are detected during the Interval Service, take the
required actions to repair them and inform the customer about the
events.
Ask the customer about installing new Windshield wiper blades
and adding window cleaning -G 052 131 A1- until 07/2005 and
window cleaning -G 052 184 A2- until 08/2005 or cleaning and
antifreeze product -G 052 164- to the Windshield/rear window
wiper system.
Application Windshield/rear window washer Proportion
additive
EUROPE only -G 052 164 A1- or -G 052 164 A2- 300 ml additive to 700 ml water
Tropical climate countries -G 052 131 A1- until 07/2005 1.69 fl oz additive for 32.12 fl oz wa
ter.
-G 052 184 A2- from 08/2005 100 ml additive for 990 ml water.
Note
pt
du
Battery: check with Battery tester with printer -VAS 5097A- . page 43 an
itte
y li
erm
ab
Passenger compartment's lighting, cigarette lighter, horn and control lights: ility
ot p
check operation.
wit
, is n
Front lighting: check operation of parking lights, low beam, high beam, fog
h re
hole
Rear lighting: check operation of brake lights (including the third brake light),
t to the co
rear lights, reversing lights, fog light, license plate light, boot lighting, indi
cator lights and warning lights.
Tyres and wheels
rrectness of i
CrossFox only
nform
ercia
Spare wheel tyre: check the state of tread, sides and depth of grooves _____ page 53
mm.
m
at
om
Left front wheel tyre: check the state of tread, sides and depth of grooves page 53
on
c
in t
_____ mm
or
his
ate
Left rear wheel tyre: check the state of tread, sides and depth of grooves page 53
do
priv
_____ mm.
um
for
en
ng
Right rear wheel tyre: check the state of tread, sides and depth of grooves page 53
t.
yi Co
op
_____ mm. C py
t. rig
gh ht
yri
Front right wheel tyre: check the state of tread, sides and depth of grooves page 53
p by
co Vo
by lksw
_____ mm. Prote
cted AG.
agen
2. Service plans 11
FOX 2004
Maintenance - Edition 07.2010
ce
le
un
pt
Engine compartment
an
d
itte
y li
Engine oil: fill
erm
page 58
ab
ility
ot p
wit
Diesel engine: Identification letter BNM, filling capacity 4,2 l; standard 505 01
is n
h re
(VW).
ole,
Diesel engine: Identification letters ASY, 4.3-l filling volume, standard 505 00
spec
urposes, in part or in wh
t to the co
Petrol engines: Identification letters AQZ, filling capacity 3.3 l; standard 502 00
(VW).
Petrol engines: Identification letters BAH, BLH, and CFZA, filling capacity 4.0
rrectne
l; standard 502 00 (VW).
Petrol engine: Identification letter BMD, filling capacity 2.85 l; standard 502 00
(VW).
ss
Petrol engine: Identification letter BKR, filling capacity 3,3 l; standard 502 00
o
cial p
f i
(VW).
nform
mer
Engine and components in engine compartment (from above): check visu page 65
atio
m
n
c
i
or
n
Engine cooling system fluid: correct the proportion of antifreeze and fill up page 76
thi
te
to the level.
sd
iva
o
pr
cum
r
fo
t.
(value measured) ____ C.
yi Co
Cop py
. rig
Engine oil filter: replace. page 58
ht ht
rig by
opy Vo
Brake fluid level: check the level and replenish, if necessary. page 93
by c lksw
cted agen
Prote AG.
Fuel filter: drain the water (Vehicles with diesel engine using bio-diesel ac page 89
cording to the DIN E 51 606 or diesel vehicles that do not comply with the
DIN EN 590).
Headlight adjustment: check. page 94
Vehicle on raised platform
Engine oil: drain or aspirate. page 58
Engine and components in engine compartment (from below): perform a page 65
visual check for leaks and damage.
Brake system: perform a visual check for leaks and damage. page 67
Rear pads and linings: check the thickness. page 67
Brake discs: check the level of wear and corrosion page 69
Shock absorbers: verify for leaks (except Europe)
Concluding tasks
Maintenance interval indicator (if available) : reset. page 34
Maintenance and Warranty book: record the date and kilometers traveled
for the next service.
Service tag: write the date of the next service (including brake fluid change) page 23
and attach the tag to the left side of the command panel or to the left door
pillar (B).
12 2. Service plans
FOX 2004
Maintenance - Edition 07.2010
ce
le
Note
un
pt
an
d
itte
y li
Inform the customer in case of problems within a service scope
rm
ab
pe
ility
that require a Repair action.
ot
wit
, is n
h re
hole
spec
(diesel PD) and VW 505 01 (TDI).
es, in part or in w
t to the co
For countries with high sulfur content in Diesel, the Engine Oil
Change Service must be carried out every 7500 km. Countries
where the sulfur content is higher page 28 .
rrectness of i
l purpos
a
com
tio
t.
yi Co
op
Ask the customer about installing new Windshield wiper blades
C py
t. rig
gh
and adding window cleaning -G 052 131 A1- until 07/2005 and
ht
pyri by
Vo
o
window cleaning -G 052 184 A2- until 08/2005 or cleaning and by c lksw
cted agen
antifreeze product -G 052 164 A1- to the Windshield/rear window Prote AG.
wiper system.
Application Windshield/rear window washer Proportion
additive
EUROPE only -G 052 164 A1- or -G 052 164 A2- 300 ml of additive for 700 ml of wa
ter.
Tropical climate countries -G 052 131 A1- until 07/2005 1.69 fl oz additive for 28.74 fl oz wa
ter.
2. Service plans 13
FOX 2004
Maintenance - Edition 07.2010
AG. Volkswagen AG d
agen oes
ksw
Service for vehicles with service based bon y V time and kilometers traveled t gua
o l no
Service
ed ran
Electrics ris tee
tho or
au ac
Battery: check with Battery tester
ss with printer -VAS 5097A- . page 43
for Europe on vehicles model 2011
ce
e
nl
pt
du
an
itte
y li
Passenger compartment's lighting, cigarette lighter, horn and control lights:
erm
ab
check operation.
ility
ot p
wit
Front lighting: check operation of parking lights, low beam, high beam, fog
, is n
h re
lights, indicator system and warning lights
hole
spec
Rear lighting: check operation of brake lights (including the third brake light),
es, in part or in w
t to the co
rear lights, reversing lights, fog light, license plate light, boot lighting, indi
cator lights and warning lights.
Driver and passenger airbag: make a visual inspection in relation to external page 48
rrectness of i
damages.
for Europe on vehicles model 2007 and except Europe on vehicles model
l purpos
2008)
nform
ercia
Self-diagnosis: Refer to the failure memory of every system with the Diag page 24
nosis, Measurement and Information System .
m
at
for Europe on vehicles model 2007 and except Europe on vehicles model
om
ion
2008
c
in t
or
his
ate
do
priv
c
at every 30,000 km
um
for
en
ng
t.
yi
for Europe on vehicles model 2007 and except Europe on vehicles model
Co
op py
2008
t. C rig
gh ht
pyri by
Vo
o
every 18,641.14 mi or 2 years by c lksw
cted agen
Prote AG.
for Europe in model 2008 vehicle and in model 2009 vehicles elsewhere
Vehicle exterior
Windshield: check for damage
for Europe on vehicles model 2011
14 2. Service plans
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se
tho tee
or FOX 2004
u
ss
a
Maintenance
ac
- Edition 07.2010
ce
le
un
pt
an
d
Service for vehicles with service based on time and kilometers traveled Service
itte
y li
erm
ab
Sunroof: check operation, clean the guide rails and lubricate them with Spe page 46
ility
ot p
cial grease -G 000 450 02- .
wit
at every 30,000 km is n
h re
ole,
spec
for Europe on vehicles model 2007 and except Europe on vehicles model
urposes, in part or in wh
2008
t to the co
every 60,000 km or 3 years and after every 2 years
for Europe in model 2008 vehicle and in model 2009 vehicles elsewhere
rrectne
Tyres and wheels
ss o
Spare wheel tyre: check the state of tread, sides and depth of grooves _____ page 54
cial p
f in
mm.
form
mer
Left front wheel tyre: check the state of tread, sides and depth of grooves page 53
atio
m
_____ mm
o
n
c
i
or
n
Left rear wheel tyre: check the state of tread, sides and depth of grooves page 53
thi
te
sd
a
_____ mm.
iv
o
pr
cum
r
Right rear wheel tyre: check the state of tread, sides and depth of grooves page 53
fo
en
ng
_____ mm.
t.
yi Co
op py
Front right wheel tyre: check the state of tread, sides and depth of grooves page 53
t. C rig
gh ht
yri
_____ mm. p by
co Vo
by lksw
cted
Tyres: calibrate, including the spare wheel. page 53
agen
Prote AG.
Transmission: check for damage and leaks, including the state of the con page 66
stant velocity joint bellows.
Mechanical transmission: check the oil level. page 66
at every 18,641.14 mi
for Europe on vehicles model 2007 and except Europe on vehicles model
2008
every 60,000 km or 3 years and after every 2 years
for Europe on vehicles model 2008 and except Europe on vehicles model
2009.
Brake system: perform a visual check for leaks and damage. page 67
Rear pads and linings: check the thickness. page 67
Brake discs: check the level of wear and corrosion page 69
Lower floor protection: make a visual inspection for damage. page 73
Steering bar swivel tips: check the clearance, fastening and state of pro page 73
tection bellows.
Front suspension arm joints: check for fastening and clearance, as well as page 76
for damage and leakages in sealing bellows.
2. Service plans 15
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
Engine compartment
Engine oil filter: replace. page 58
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).
Petrol engines: Identification letters AQZ, filling capacity 3.3 l; standard 502 00
(VW).
Petrol engines: Identification letters BAH, BLH, and CFZA, filling capacity 4.0
l; standard 502 00 (VW).
Petrol engine: Identification letter BMD, filling capacity 2.85 l; standard 502 00
(VW).
Petrol engine: Identification letter BKR, filling capacity 3,3 l; standard 502 00
(VW).
Engine and components in engine compartment (from above): check visu page 65
AG. Volkswagen AG d
ally for damage and leakage. ksw agen oes
not
y Vol gu
Windshield/rear window washer: adjust the water jet ise
dfrom
b ejectors and re page 49 ara
nte
plenish the reservoir additive liquid level. thor eo
au ra
Engine oil: replenish with oil (inspection service s without oil change).
s page 45 c
ce
for Europe on vehicles model 2008 and except Europe on vehicles model
e
nl
pt
du
2009.
an
itte
y li
erm
ab
Engine cooling system fluid: correct the proportion of antifreeze and fill up page 76
ility
ot p
to the level.
wit
, is n
h re
hole
t to the co
Timing belt and tensioning pulley for camshaft drive: replace. Additional page 85
work with separate payment!
l purpos
at every 93,205.68 mi
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
16 2. Service plans
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
every 90,000 km.
for Europe on vehicles model 2007
at every 93,205.68 mi
for Europe on vehicles model 2008.
Air cleaner: replace the filtering element and clean the filter case. page 86
identification letters BAH and BLH.
at every 60,000 km or every 4 years, whichever occurs first.
Air cleaner: replace the filtering element and clean the filter case. page 87
Identification letters CFZA. gen AG
. Volkswagen AG
d wa oes
olks not
at every 30,000 km or every
d b 2 years, whichever occurs first
yV gu
ara
e nte
ris
ho e
Air cleaner: replaces element and clean the athe
u filtering
t
filter case. or ac page 86
identification letterss AQZ and BKR.
ce
le
un
pt
at every 30,000 km or every 2 years, whichever occurs first an
d
itte
y li
erm
ab
Air cleaner: replace the filtering element and clean the filter case. page 87
ility
ot p
h re
ole,
Only for bio diesel vehicles in compliance with DIN E 51606 and for diesel
s o
cial p
at every 30.000 km
atio
om
i
or
n thi
Only for diesel engine vehicles according to DIN EN 590 (only for ASY en
te
sd
a
gines).
iv
o
pr
cum
r
fo
t.
yi Co
Cop py
Brake fluid: replace every 2 years (additional work with separate payment!) page 90 ht. rig
rig ht
at every 2 years.
py by
co Vo
by lksw
cted agen
for Europe on vehicles model 2007 and except Europe on vehicles model
Prote AG.
2008).
at 3 years and after every 2 years for Europe on vehicles model 2008 and
except Europe on vehicles model 2009.
2. Service plans 17
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 99
3 years after initial licensing, and then every two years.
Concluding tasks
Headlight adjustment: check. page 94
every 18,641.14 mi.
for Europe on vehicles model 2007 and except Europe on vehicles model
2008
at every 60,000 km or 3 years and, then, every 2 years
agen AG olksw
for Europe on vehicles model 2008 and except Europe on
ag vehicles
en AG. V model does
ksw
2009. by Vol not
gu
ara
ed nte
o ris
Maintenance interval indicator (if available)
au
t : reset.
page 34
h e or
ac
ss
Maintenance and Warranty book: record the date and kilometers traveled
ce
le
pt
an
d
itte
y li
Service tag: write the date of the next service (including brake fluid change) page 23
erm
ab
and attach the tag to the left side of the command panel or to the left door
ility
ot p
pillar (B).
wit
is n
h re
Perform a test run. page 98
ole,
spec
urposes, in part or in wh
t to the co
2.7 Supplementary services based on time
elapsed and/or kilometers traveled
rrectne
Besides the oil change or inspection service which depends
ss
on the conditions of usage and optional equipments in the vehicle
o
cial p
f
performing supplementary maintenance works is necessary.
inform
mer
atio
records in the service plan (or on the adhesive tag: Your next
om
i
or
n thi
te
At every 30,000 km
sd
iva
o
pr
cum
r
fo
t.
yi Co
op
Dust and pollen filter: clean case and change filter element page 84
C py
t. rig
for Europe on vehicles model 2007 and except Europe on vehicles model 2008 gh ht
pyri by
Vo
o
by c lksw
for vehicles with kilometers traveled over 30,000 km, within a 2-year period Prote
cted AG.
agen
for Europe in model 2008 vehicle and in model 2009 vehicles elsewhere
Sunroof: check operation, clean the guide rails and lubricate them with Special page 46
grease -G 000 450 02-
for Europe on vehicles model 2007 and except Europe on vehicles model 2008
Fuel filter: replace (vehicles with engine AQZ, BAH, BLH, and CFZA only) page 87
Air cleaner: replace the filtering element and clean the filter case. page 86
identification letters AQZ and BKR.
for vehicles with kilometers traveled over 30,000 km, within a 2-year period
18 2. Service plans
FOX 2004
Maintenance - Edition 07.2010
ce
e
nl
pt
at 30,000 km and after every 60,000 km
du
an
itte
y li
erm
ab
Fuel filter: replace page 88
ility
ot p
Only for biodiesel vehicles in compliance with DIN E 51606 and for diesel vehicles
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
At every 37,282.27 mi
rrectness of i
Supplementary services Page
l purpos
nf
ercia
or
for Europe in model 2008 vehicle and in model 2009 vehicles elsewhere
m
m
atio
om
n in
c
thi
e
for vehicles with kilometers traveled over 60,000 km, within a 3-year period and, then,
t
sd
iva
every 2 years.
o
r
rp
cu
o
m
f
for Europe in model 2008 vehicle and in model 2009 vehicles elsewhere
en
ng
t.
yi Co
Cop py
t. rig
Air cleaner: replace the filtering element and clean the filter case.
yri
gh by
ht
page 86
identification letters BAH and BLH.
cop Vo
by lksw
cted agen
Prote
for vehicles with kilometers traveled over 37,282.27 mi, within a 4-year period
AG.
Air cleaner: replace the filtering element and clean the filter case. page 87
Engine identification letters ASY, BKR, BNM, and BMD.
for vehicles with kilometers traveled over 60,000 km, within a 4-year period.
Poly-V belt: check condition: In vehicles without automatic tensioning element, adjust page 65
tension.
for Europe on vehicles model 2007 and except Europe on vehicles model 2008
for vehicles with kilometers traveled over 60,000 km, within a 3-year period and, then,
every 2 years.
for Europe in model 2008 vehicle and in model 2009 vehicles elsewhere
2. Service plans 19
FOX 2004
Maintenance - Edition 07.2010
At every 55,923.41 mi
Supplementary services Page
Timing belt for camshaft drive: check state page 85
Diesel engine: identification letters BNM
for Europe on vehicles model 2007
pt
du
an
Timing belt and tensioning roll for camshaft drive: replace page 85
itte
y li
erm
h re
hole
t to the co
At every 2 years
nf
ercia
Dust and pollen filter: clean case and change filter element page 84
atio
m
for Europe in model 2008 vehicle and in model 2009 vehicles elsewhere
o
n in
or c
thi
te
Air cleaner: replace the filtering element and clean the filter case. page 86
sd
iva
o
r
cu
o
m
f
en
ng
for vehicles with kilometers traveled over 30,000 km, within a 2-year period
t.
yi Co
Cop py
t. rig
gh
Air cleaner: replace the filtering element and clean the filter case. page 87
ht
pyri by
Vo
o
Identification letters CFZA. by c lksw
cted agen
Prote AG.
for vehicles with kilometers traveled over 30,000 km, within a 2-year period
20 2. Service plans
FOX 2004
Maintenance - Edition 07.2010
ce
le
un
pt
Supplementary services Page
an
d
itte
y li
erm
ab
Headlights: adjust the beams page 94
ility
ot p
for Europe in model 2008 vehicle and in model 2009 vehicles elsewhere
wit
is n
h re
ole,
Poly-V belt: check condition: In vehicles without automatic tensioning element, adjust page 65
spec
tension.
urposes, in part or in wh
for Europe in model 2008 vehicle and in model 2009 vehicles elsewhere
t to the co
Mechanical transmission: check oil level. page 66
for Europe in model 2008 vehicle and in model 2009 vehicles elsewhere
rrectne
Brake fluid: replace page 90
ss
for Europe in model 2008 vehicle and in model 2009 vehicles elsewhere
o
cial p
f inform
Carry out an exhaust gas inspection/additional work with separate payment! page 99
mer
atio
in function of the country's legislation
om
n
c
i
or
n
Sunroof: check operation, clean the guide rails and lubricate them with Special page 46
thi
te
sd
a
o
pr
for vehicles with kilometers traveled over 60,000 km, within a 3-year period and, then, cum
r
fo
every 2 years.
en
ng
t.
yi Co
op py
for Europe in model 2008 vehicle and in model 2009 vehicles elsewhere t. C rig
gh ht
pyri by
Vo
co
Body and paintwork: check for damage.
by lksw
cted agen
Prote
for vehicles with kilometers traveled over 60,000 km, within a 3-year period and, then,
AG.
every 2 years.
for Europe in model 2008 vehicle and in model 2009 vehicles elsewhere
At every 4 years
Supplementary services Page
Air cleaner: replace the filtering element and clean the filter case. page 86
identification letters BAH and BLH
for vehicles with kilometers traveled over 60,000 km, within a 4-year period.
Air cleaner: replace the filtering element and clean the filter case. page 87
Engine identification letters ASY, BKR, BNM, and BMD.
for vehicles with kilometers traveled over 60,000 km, within a 4-year period.
2. Service plans 21
FOX 2004
Maintenance - Edition 07.2010
3 General remarks
Note
WARNING
pt
an
d
y li
of the lift.
erm
ab
ility
ot p
wooden support.
h re
ole,
spec
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
22
c by lksw
cted agen
3. General remarks Prote AG.
FOX 2004
Maintenance - Edition 07.2010
Note
pt
du
an
itte
ab
ility
ot p
wit
, is n
h re
spec
ery inspection)
es, in part or in w
t to the co
Write on the service tag the date of the next service (including
brake fluid change) and attach the tag to the left side of the
command panel or to the left door pillar (B).
rrectness of i
The stamp or tag may also be attached to the left lower corner
l purpos
ual).
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. General remarks 23
FOX 2004
n AG. Volkswagen AG do
Maintenance - Edition 07.2010 lkswage es n
o ot g
byV ua
ed ran
Attach the tag to the left side of thethorcommand panel or to the
is tee
or
driver's door pillar (pillar B). au ac
ss
ce
le
The stamp or tag may also be attached to the left lower corner
un
pt
(internal side) of the Windscreen, with the FRONT facing outside
an
d
itte
y li
the vehicle (check instructions in the Service Organization Man
erm
ab
ual).
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
e
sd
iva
o
pr
c
service plan (in the delivery inspection):
um
r
fo
en
ng
t.
yi Co
Please paste the upper data holder on both -arrow-. t. Cop py
rig
gh ht
yri
1 - planning week. p by
co Vo
by lksw
cted agen
2 - PR number. Prote AG.
24 3. General remarks
FOX 2004
Maintenance - Edition 07.2010
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
Indicated on display:
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
3.4.3 Select the operation mode:
mercia
at
On the display, press the key for Vehicle self-diagnosis
om
ion
-arrow-.
c
in t
or
his
ate
do
priv
Note
um
for
en
ng
t.
yi Co
op
If the messages indicated with the operation sequence in the dis C py
t. rig
play do not appear on display: Vehicle diagnosis, testing and
gh ht
yri by
information system VAS 5051.
op Vo
by c lksw
cted agen
Prote AG.
Indicated on display:
3. General remarks 25
FOX 2004
Maintenance - Edition 07.2010
Indicated on display:
On the display press the End key -arrow-. AG. Volkswagen AG d
agen oes
olksw not
yV gu
Press the End key on the conclusion menu. sed b ara
nte
ri
ho eo
Switch the ignition off and disconnect the diagnosis
aut connector. ra
c
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
3.5.1 Vehicle identification numberVIN- lo rrectness of i
l purpos
cation
The vehicle identification number (chassis number) -arrow- is
nform
ercia
marked on the floor plate below the back seat and close to the
m
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
26 3. General remarks
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eFOX 2004
aut or
ac
ss Maintenance - Edition 07.2010
ce
e
nl
pt
du
The first VIS tag -arrow- is on the right side suspension housing.
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
The second VIS tag -arrow- is on the left seat's cross member and
orm
is visible from the rear side through an opening in the floor carpet.
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
The third VIS tag -arrow- is on the right pillar B for two-door ve
hicles. It becomes visible with the right door opened.
Note
3. General remarks 27
FOX 2004
Maintenance - Edition 07.2010
Note
pt
du
an
y li
ab
ility
wit
, is n
spec
t to the co
io
in t
or
his
ate
do
riv
cum
for
en
ng
t.
Egypt Indonesia New Zealand Taiwan
yi Co
Cop py
t.
Argentina Jamaica Oman Trinidad Tobago
rig
gh ht
pyri by
Vo
o
Armenia Yugoslavia10) Pakistan Turkey
c by lksw
cted agen
Prote AG.
Australia Kazakhstan Panama Tunisia
Bolivia Qatar Papua-New Guinea Ukraine
28 3. General remarks
FOX 2004
Maintenance - Edition 07.2010
pt
du
an
itte
y li
erm
ab
wit
, is n
spec
TDI
t to the co
505 01
rrectness of i
atio
n in
or c
engine load.
t
sd
iva
o
r
rp
cu
m
f
en
ng
t.
yi
Multipurpose oils according to VW 502 00 standard:
Co
Cop py
t. rig
gh ht
It is particularly suitable for use in severe operating conditions, yri
p by
o Vo
for instance, in poorly maintained roads under maximum load by c lksw
cted agen
conditions and towing, constant traveling in mountain areas
Prote AG.
3. General remarks 29
FOX 2004
Maintenance - Edition 07.2010
n AG. Volkswagen AG do
Multi-purpose oil, according to standards VW 505 01 and
olks
wageVW 506 es n
ot g
01 db
y V ua
ran
e
ris tee
Engine protection between long maintenance
ut
ho intervals. or
a ac
ss
Protection against residue build-up.
ce
le
un
pt
an
High viscosity for constant fuel saving in all conditions of use.
d
itte
y li
rm
ab
Everlasting stability for constant use in high rotation rates and
pe
ility
loads through long distances. ot
wit
, is n
h re
Reduced emission of pollutants because of lower fuel con
hole
spec
sumption.
es, in part or in w
t to the co
WARNING
rrectness of i
Follow the rules for disposal!
l purpos
nform
mercia
a
com
tio
3.9.1 ASY engine
n in
r
te o
thi
s
iva
do
r
rp
c
on the engine block -arrow- in the engine/gearbox separation
um
fo
en
ng
t.
yi Co
sticker with the engine identification letters and serial number. Cop py
The engine identification letters are also indicated on the vehicle ht. rig
rig ht
identification tag.
py by
co Vo
by lksw
cted agen
Prote AG.
30 3. General remarks
FOX 2004
Maintenance - Edition 07.2010
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
start)/towing
rrectness of i
a
com
tio
Note
n in
r
te o
thi
s
iva
t.
yi
tow bar!
Co
Cop py
t. rig
gh ht
First, make sure there are no inadequate drive forces and no yri
p by
o Vo
impact loads. On towing maneuvers on dirt roads, there is al
c by lksw
cted agen
ways the risk of overloading and, therefore, damaging the
Prote AG.
fastening parts.
Before push starting a vehicle (pushing the vehicle), try to push
start by using the battery from another vehicle.
3. General remarks 31
FOX 2004
Maintenance - Edition 07.2010
ce
e
nl
pt
du
an
The ignition must be switched on so that the steering wheel is itte
y li
free and the warning lights, horn, Windscreen wipers and
erm
ab
washer are ready for use.
ility
ot p
wit
, is n
Once the servo brake only operates with the engine on, it is
h re
necessary to step much harder on the brake pedal when the
hole
spec
engine is turned off.
es, in part or in w
t to the co
Since the power steering does not work with the engine off,
are much harder to execute when the engine is off.
rrectness of i
If there is no lubricant in the automatic transmission, the ve
hicle can only be towed with the drive wheels lifted.
l purpos
nform
against our recommendation, please
ercia
at
om
io
with a mechanical transmission:
n
c
in t
or
his
ate
Before jump starting, press the clutch pedal and engage the
do
priv
c
2nd or 3rd gear.
um
for
en
ng
t.
yi
Turn the ignition on.
Co
Cop py
t. rig
Release the clutch pedal only when both vehicles are moving.
gh ht
pyri by
Vo
co lksw
by
As soon as the engine starts, press the clutch pedal and shift cted agen
Prote AG.
to dead center to avoid a collision with the vehicle ahead (trac
tor).
Note
32 3. General remarks
FOX 2004
Maintenance - Edition 07.2010
4 Service descriptions
ce
e
With the ignition on, select the clock function, pressing the
nl
pt
du
an
button -arrow- for less than 2 seconds. There will be a clock
itte
y li
symbol beside the time.
erm
ab
ility
ot p
To activate the hour set function, keep the button -arrow-
wit
pressed until the display starts flashing, then press the button , is n
h re
-arrow- quickly, the numbers will change sequentially in as
hole
spec
cending order.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
New Fox
c
in t
or
his
te
do
priv
cum
or
en
ng
pressed until the display starts flashing, then press the button
t.
yi Co
op
-arrow- quickly, the numbers will change sequentially in grow
C py
t. rig
gh
ing order.
ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
4. Service descriptions 33
AG. Volkswagen AG d
agen oes
olksw not
FOX 2004 d by V gu
ara
e nte
Maintenance horis
- Edition 07.2010 eo
aut ra
ss c
New Fox
ce
le
un
pt
an
d
Set the hours (3-line display):
itte
y li
erm
ab
There will be a clock symbol beside the hour.
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
To set the hour, with the ignition on and without the radio in
cial p
f in
formation on the display, slightly turn the button -arrow- coun
form
mer
atio
clockwise.
om
n
c
i
or
n
One small turn to the limit changes only one unit at a time. If
thi
e
the button is turned and kept pressed, the numbers will change
t
sd
iva
o
sequentially in ascending order.
pr
cum
r
fo
en
ng
34 4. Service descriptions
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.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
(CrossFox)
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
Lubricate the stop inside -2- with Silicone grease -G000 405
urposes, in part or in wh
A2-
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
4. Service descriptions 35
FOX 2004
Maintenance - Edition 07.2010
Note
ce
e
nl
pt
du
charged.
an
itte
y li
erm
ab
ility
poor condition of use is forbidden by law.
ot p
wit
, is n
h re
hole
spec
4.5 Power window drive - reprogram
es, in part or in w
t to the co
Note
rrectness of i
When the battery is disconnected and then reconnected, the
l purpos
nf
ercia
orm
m
atio
m
Carry out the following work sequence to start the power window
o
n in
c
drive:
or
thi
te
sd
a
Press the key until the window is fully closed, keeping it press
iv
o
r
rp
cu
m
f
en
ng
t.
yi
Repeat this operation for the other doors.
Co
Cop py
t. rig
gh
4.6 Radio - activate the anti-theft code
ht
pyri by
Vo
co lksw
by
cted agen
The radio equipment is supplied with a fixed code. This fixed code Prote AG.
36 4. Service descriptions
FOX 2004
Maintenance - Edition 07.2010
ce
e
nl
pt
du
If you have entered an incorrect code number, SAFE will start
an
itte
y li
blinking for a few seconds on the digital display.
erm
ab
ility
ot p
wit
, is n
Note
h re
hole
spec
This procedure can be repeated just once.
es, in part or in w
t to the co
If an incorrect code number is entered once again, the unit will
remain inactive for approximately 1 hour.
rrectness of i
Leave the unit on and the ignition key in the switch for one
l purpos
hour.
After 1 hour, enter the code number again.
nf
ercia
orm
On beta and gamma radios, the fixed code is activated as fol
m
atio
m
lows:
o
n in
or c
thi
te
sd
iva
o
The digital display will exhibit SAFE.
r
rp
cu
o
m
f
en
ng
forth.
Then, press the search button -1- or the manual tuner -2- for
more than 2 seconds. Release the button!
If the correct code is entered, the current frequency is displayed
after a short adjustment phase. During this pause, a list of the
strongest regional stations is recorded and will be available for
tuning. When the ignition key is removed, the LED in the radio's
lower left section must blink. If the LED blinks, the radio is ready
to play and the anti-theft code is activated.
On RCD 200 radios, the fixed code is activated as follows:
Turn the radio on
After approximately 3 seconds 1000 will appear on display.
4. Service descriptions 37
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.
If the correct code was entered, keep the button -7- or -8- pressed
for 2 seconds. When the ignition key is removed, the LED in the
radio's lower left section must blink. If the LED blinks, the radio is
ready to play and the anti-theft code is activated.
-A-number of attempts to activate the anti-theft code.
-B-anti-theft code in activation.
If you have entered an incorrect code number, SAFE will start
blinking for a few seconds on the digital display.
Note
ce
e
pt
du
an
itte
y li
Authorization prerequisites for the diagnostic tester
erm
ab
ility
ot p
Fazit). spec
es, in part or in w
Note
l purpos
The radio codes can be read in the central database and can
be displayed on diagnostic tester .
nform
ercia
For radio activation the codes must be entered via radio but
m
at
ion
c
in t
or
his
e
Procedure
at
do
priv
cum
en
g
page 25 .
n
t.
yi Co
Cop py
Switch on ignition.
t. rig
gh ht
pyri by
Vo
o
Touch the field or button on the screen for GUIDED FUNC by c lksw
cted agen
TIONS. Prote AG.
38 4. Service descriptions
FOX 2004
AG. Volkswagen AG d
ksw
agen oes
not
Maintenance - Edition 07.2010
Vol
y gu
db ara
Confirmorvehicle
ise identification. nte
eo
h
ut ra
Select
ss one after the other:
a c
ce
le
un
Radio system.
pt
an
d
itte
y li
Reading radio code
rm
ab
pe
ility
Read code according to the information of GUIDED FUNC
ot
wit
, is n
TIONS.
h re
hole
spec
Finish code reading as follows:
es, in part or in w
t to the co
Press GoTo button on display.
Press the End button on display.
rrectness of i
Press End button in End menu.
l purpos
nform
ercia
rect torque
m
a
com
tion in
Special tools and workshop equipment required
r
te o
thi
s
Torque wrench - 40 to 200 Nm (enc. 1/2") -VAG 1332-
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
Make sure that the wheel screws are tightened in a cross pattern
with the following tightening torque:
4. Service descriptions 39
FOX 2004
Maintenance - Edition 07.2010
Note
an
itte
y li
ab
wit
, is n
the contact with the cable connections. This may cause a fire
es, in part or in w
at
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
4.9.2 Terminal seating
t. rig
gh ht
pyri by
Vo
co lksw
by
Properly seated battery terminals ensure the perfect operation of cted agen
Prote AG.
the electrical system and a long battery life.
Special tools and workshop equipment required
40 4. Service descriptions
FOX 2004
Maintenance - Edition 07.2010
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
cables, check if the terminals -arrows- are firmly fastened to
the battery poles.
rrectne
WARNING
ss o
If the terminal is not firmly fastened to the battery pole, first you
cial p
f in
must disconnect the terminal connected to the negative battery
form
mer
atio
om
n
c
i
or
n thi
If the terminal is not firmly fastened to the positive battery pole:
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4. Service descriptions 41
FOX 2004
Maintenance - Edition 07.2010
Note
WARNING
Please follow the warning notes and safety rules for lead and
acid batteries, represented by symbols on the battery tag.
Warning notes and safety rules for lead and acid batteries agen
AG. Volkswagen AG d
oes
olksw not
V
1- Fires, sparks, open flame and smoking are prohibited: ed b y gu
ara
nte
ris
o eo
Avoid sparks and electrostatic discharges when handling
auth
ca ra
bles and electrical devices; ss c
ce
le
un
pt
Avoid short circuits (never lay a tool on top of a battery).
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
4 - Recycling:
hole
spec
es, in part or in w
6 - Risk of explosion:
l purpos
tion in
thi
s
iva
en
ng
t.
yi
Do not tilt the battery. Acid can leak from the degassing open
Co
op py
ings. t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
42 4. Service descriptions
FOX 2004
Maintenance - Edition 07.2010
Note
n AG. Volkswagen AG do
wage e n
The vehicle must have remained byV
olks
turned off for at least 2 shours.
ot g
ua
d ran
ir se tee
o
4.10.1 Check the charge indicator inspection
th or
au ac
ss
glass at Delivery inspection
ce
e
nl
pt
du
an
itte
y li
erm
ab
glass -arrow-.
ility
ot p
wit
The Charge indicator inspection glass informs the battery
, is n
h re
charge condition.
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
the indication only refers to this cell. A precise assessment on
the battery condition is only possible through a test to check
l purpos
nf
ercia
o
battery is charged during driving, air bubbles can form under
rm
m
atio
the inspection viewing glass. These bubbles change the color
om
n in
or c
thi
e
sd
iva
o
tions on the battery.
r
rp
cu
o
m
f
en
ng
t.
yi Co
Before making the visual inspection, tap lightly and carefully Cop py
with a screwdriver handle on the charge indicator glass
t. rig
gh ht
yri
-arrow- so that air bubbles do not interfere with the inspection.
p by
co Vo
by lksw
cted agen
This way, any air bubbles that could influence the indicator are
Prote AG.
4. Service descriptions 43
FOX 2004
Maintenance - Edition 07.2010
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
Note ss c
ce
e
nl
pt
du
When using the Battery test device, with printer -VAS 5097A- or
an
itte
y li
-VAS 5097- , it is not necessary to remove the battery. Also, it is
erm
ab
not necessary to disconnect the battery.
ility
ot p
wit
, is n
h re
Performing battery charge test sequence:
hole
spec
Turn ignition off.
es, in part or in w
t to the co
Connect the claws to the battery poles. Check the battery
test device operation instructions.
rrectness of i
The claws must have good contact with the battery poles.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
44 4. Service descriptions
FOX 2004
Maintenance - Edition 07.2010
n AG. Volkswagen AG do
wage es n
Carry out the battery charge test according yV
oto
lksthe instructions ot g
ua
of use for the battery test device and compare
ise
d b the test printout ran
-arrow- with the following table. uthor tee
or
sa ac
Clarifications concerning the test printout:
s
ce
e
nl
pt
du
1 - measurement range adjusted on the test device.
an
itte
y li
erm
ab
2 - diagram (the arrow indicates the battery state).
ility
ot p
wit
3 - test result.
, is n
h re
hole
4 - battery voltage during the charge test.
spec
es, in part or in w
t to the co
the test).
rrectness of i
Note
l purpos
nform
ercia
at
om
io
Very good starting power Battery OK
n
c
in t
or
his
Good starting power Battery OK
ate
do
riv
cum
for
en
g
t.
yi Co
op py
Very poor starting power Recharge the battery11)
t. C rig
gh ht
yri by
Unsuitable for tests Recharge the battery11)
op Vo
by c lksw
cted agen
Prote AG.
11) After recharging the battery, its charge test must be carried out again. If after
recharging the battery the following indications insufficient starting power, poor
starting power, very poor starting power or unsuitable for tests appear, then the
battery must be replaced.
4. Service descriptions 45
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-.
Area -b- It is not necessary to replenish the oil.
Area -c- Maximum marking region. Oil cannot be replen
ished.
Note
Pull the oil dipstick out again and check the oil level.
n AG. Volkswagen AG do
Condition 2 lkswage es n
o ot g
b yV ua
ed ran
Area -A- Oil must not be replenished. horis tee
ut or
Area -B- It is not necessary to replenish
ss
a the oil. ac
ce
Area -C- Replenish the oil level. It is sufficient for the oil
le
un
pt
level to be anywhere within area -B-.
an
d
itte
y li
Arrow -1- Maximum marking
erm
ab
ility
ot p
wit
is n
h re
Pull the oil dipstick out again and check the oil level.
ole,
spec
urposes, in part or in wh
t to the co
Condition 3
Area -a- Replenish the oil level. It is sufficient for the oil rrectne
level to be anywhere within area -b-.
ss o
f in
atio
om
n
c
Note
or
n thi
te
sd
iva
o
r
With the oil level below the minimum marking (area -a-), re
p
cum
r
fo
plenish the oil until it reaches (area -b-) according to the oil
en
ng
t.
yi
specification. page 58 .
Co
Cop py
t. rig
With the oil level above area -c- there is the risk of damaging
gh ht
pyri by
the catalytic converter.
co Vo
by lksw
cted agen
Prote AG.
During oil changes, you must add oil until the maximum mark
ing.
46 4. Service descriptions
FOX 2004
Maintenance - Edition 07.2010
WARNING
n AG. Volkswagen AG do
wage es n
Carry out the following tasks: yV
olks ot g
ua
d b ran
ir se tee
tho
u or
Note ss
a ac
ce
e
nl
pt
du
y li
erm
ab
ility
Relieve the load form the coil springs by lifting the vehicle with
ot p
wit
h re
hole
pension column.
es, in part or in w
t to the co
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4. Service descriptions 47
FOX 2004
Maintenance - Edition 07.2010
agen WARNING
AG. Volkswagen AG d
oes
olksw not
byV gu
ar
The steering wheel is padded plate must not be glued, coat ante
ed
or
ed, or undergoauany
th type of rework. This information must eo
ra
be emphasized
ss to the customer, to ensure the future Air c
bag's operation.
ce
e
nl
pt
du
an
itte
ab
wit
, is n
h re
hole
spec
t to the co
WARNING
nform
mercia
io
in t
r
his
te
do
priv
cum
or
en
ng
48 4. Service descriptions
FOX 2004
Maintenance - Edition 07.2010
Note
G. Volkswagen
If during the operating check it is verified lkthat
wagthe
en A wiper bladesAG doe
s no
o s
shake or make noises, you must verify by Vthe wiper blade support t gu
ara
angle. page 51 .
d
rise nte
o th e or
s au ac
4.15.1 Replenish the reservoir level
s
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
Refractometer for cooling system liquid analysis -EQ 7093
ot
(VWB) - ou - T 10007-
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
The exact value for the following checks may be read in the light-
r
te o
thi
s
iva
to put a water drop on the glass. Now, the light-dark limit may be
do
r
rp
c
easily recognized by the WATERLINE.
um
fo
en
ng
t.
yi
Check the concentration of additive for front/rear window wip
Co
op py
ers with Refractometer for cooling system liquid analysis -EQ t. C rig
gh ht
7093 (VWB) - ou - T 10007- (follow the instruction manual). yri
p by
o Vo
by c lksw
cted
The refractometer scale -1- is based on the original Volkswagen
agen
Prote AG.
product according to the table: page 49 .
The scale -2- is based on commercially available cleaning prod
ucts as well as on the mix of the commercial cleaning product with
the original Volkswagen product according to table:
page 49 .
4. Service descriptions 49
FOX 2004
Maintenance - Edition 07.2010
ce
le
pt
an
d
ditive
itte
y li
rm
ab
- 1 part 99 parts
pe
ility
ot
wit
, is n
Complete:
h re
hole
spec
The Windscreen washer fluid reservoir must be replenished to the
es, in part or in w
top. t to the co
Note
rrectness of i
l purpos
tion in
washer additive -G 052 184 A2- from 08/2005, which does not
do
r
rp
en
ng
t.
yi
The antifreeze protection for the Windshield washer should be
Co
op py
guaranteed at approximately -15 C (for Arctic climate coun t. C rig
gh ht
tries, approx. -31.00 ?). pyri by
Vo
o
by c lksw
cted agen
Prote AG.
4.15.5 Windshield washer - check and adjust
the ejectors
Check the Windshield washer's system Electrical system; Rep.
Gr. 92 ; Windshield, rear window and headlight washer and wip
er .
50 4. Service descriptions
FOX 2004
Maintenance - Edition 07.2010
Note
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
Adjust the jet through the nozzle tab-1-, by moving it slightly ss c
ce
e
pt
du
closed.
an
itte
y li
erm
ab
ility
ot p
Note
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
orm
m
atio
Note
om
n in
or c
thi
sd
a
ure).
iv
o
r
rp
cu
o
m
f
t.
yi
used, since this might damage the ejector water passage.
Co
Cop py
t. rig
gh ht
yri by
Check the ejector projection.
op Vo
by c lksw
cted agen
Prote AG.
The ejector jet must fall on the centre of the washer area.
4. Service descriptions 51
FOX 2004
Maintenance - Edition 07.2010
Passenger's side
-a- = 65 5 mm (measured in the wiper blade) or 3rd. serig
raphy trace.
-a- = 50 5 mm (measured in the wiper blade, only Europe).
Tightening torque of the wiper arm and blade set 15.5 Nm.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
4.16.2 Rear window wiper blade - adjust the
pe
ility
ot
h re
hole
The distance -a- between rear window wiper rubber and the
spec
t to the co
To adjust the final rear window wiper position, move the wiper
rod.
rrectness of i
nform
mercia
tion in
r
te o
thi
s
iva
do
Note
r
rp
cum
fo
en
ng
Check the incidence angle only when the wipers are vibrating or
t.
yi Co
op
noisy. C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
52 4. Service descriptions
FOX 2004
Maintenance - Edition 07.2010
olkswagen AG
wag en AG. V
Carry out work sequence asVfollows:
olks
does
not
y gu
db ara
Place the wiper arm
or
isin
e the resting position. nte
h eo
ut ra
Remove the wiper
ss
a blade. c
ce
le
pt
an
d
y li
rm
ab
Check the incidence angle according to the following table:
pe
ility
ot
wit
, is n
h re
hole
spec
Driver's side - 5,0
es, in part or in w
t to the co
Passenger's side -5,0
Tolerance 2,0
If necessary, adjust the incidence angle to the nominal value as rrectness of i
follows:
l purpos
a
com
thi
nominal value.
s
iva
do
r
rp
blade.
en
ng
t.
yi Co
op py
Check the wiper for smooth operation. t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
For driving safety reasons, only tyres of the same type and profile
version must be installed on a vehicle!
4. Service descriptions 53
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
Inspection service:
Check the tread, sides and groove depth for damage and, if
necessary, remove foreign bodies, such as nails and pieces
of glass, for example.
Check the tyres for wearing, treads worn on only one side,
porosity on the toothed sides, cuts and perforations.
Note
ce
le
pt
an
fault.
d
itte
y li
rm
ab
If there is such type of wearing, the cause must be determined by
pe
ility
measuring the axle geometry (repair measure).
ot
wit
, is n
h re
4.18.3 Check the tyre profile depth (including
hole
spec
spare wheel)
es, in part or in w
t to the co
Check the groove's depth
A - Minimum groove depth -at-1.6 mm.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
54 4. Service descriptions
FOX 2004
Maintenance - Edition 07.2010
pt
du
an
reaches 3 mm.
itte
y li
erm
ab
ility
ot p
Note
wit
, is n
h re
hole
spec
requirements.
t to the co
a profile.
l purpos
The tires must also be replaced when they are cut, deformed,
or display other damage.
m
at
om
ion
c
in t
or
do
riv
cum
for
en
ng
t.
yi
Special tools and workshop equipment required
Co
Cop py
ht. rig
Tire inflation device -VAS 5216- rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
4. Service descriptions 55
FOX 2004
Maintenance - Edition 07.2010
Note
ce
Note
e
nl
pt
du
an
itte
y li
On the CrossFox, the spare wheel has an anti-theft screw, which
erm
ab
socket is located on the tool bag.
ility
ot p
wit
, is n
h re
4.18.5 Tyre pressure table
hole
spec
es, in part or in w
t to the co
Pressure values in PSI (pounds/sq-in)
rrectness of i
Note
l purpos
nform
mercia
at
half load front and full load front and
om
ion
rear rear
c
in t
or
his
e
do
riv
steering
p
cum
for
en
175/65 R14 82T 31 27 33 39
ng
t.
yi Co
op
Engine identification letters AQZ, BJE, BNX
C py
t. rig
gh ht
yri
175/65 R14 82T 29 28 31 36
p by
o Vo
by c lksw
cted agen
185/60 R14 82H 30 29 33 37 Prote AG.
56 4. Service descriptions
FOX 2004
Maintenance - Edition 07.2010
Note
pt
du
y li
erm
ab
h re
spec
t to the co
n in
c
thi
te
o
r
rp
cu
m
f
en
ng
t.
Engine identification letters BKR
yi Co
Cop py
165/70 R14 81T 2,2
.
2,0 2,4 2,8
ht rig
rig ht
py by
o Vo
185/60 R14 82T 2,2 2,0 2,4 2,8 by c lksw
cted agen
Prote AG.
195/55 R15 85V 1,9 1,9 2,1 2,5
4. Service descriptions 57
FOX 2004
Maintenance - Edition 07.2010
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
58 4. Service descriptions
FOX 2004
Maintenance - Edition 07.2010
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
Carry out work sequence as follows:
es, in part or in w
t to the co
Engine identification letters BAH, BLH, and CFZA
Aspirate the engine oil with the Oil aspirator -VAG 1307 A- or
rrectness of i
Oil aspirator -VAG 1358 A-
l purpos
nform
ercia
necessary.
m
ion
c
his
ate
cum
for
en
ng
t.
yi Co
Note Cop py
ht. rig
rig ht
py by
Please note that the tightening torque must not be exceeded.
co Vo
by lksw
cted
A very high tightening torque may lead to damage or even
agen
Prote AG.
leaks in the oil draining plug area.
Install a new sealing ring in the oil draining plug.
WARNING
4. Service descriptions 59
FOX 2004
Maintenance - Edition 07.2010
WARNING
Note
WARNING
n AG. Volkswagen AG do
Follow the rules for disposal! lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
Engine identification letters ASY ss
a ac
ce
le
Aspirate the engine oil with the Oil aspirator - VAG 1307 A- or
un
pt
an
d
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
60 4. Service descriptions
FOX 2004
Maintenance - Edition 07.2010
Note
ce
le
un
pt
an
d
itte
y li
Engine identification letters BNM
rm
ab
pe
ility
Aspirate the engine oil with the Oil aspirator - VAG 1307 A- or
ot
wit
, is n
h re
hole
spec
Remove the oil draining plug -arrow-.
es, in part or in w
t to the co
Remove the sealing ring from the oil draining plug and cut if
necessary.
rrectness of i
Drain the engine oil.
l purpos
a
com
tio
Note
n in
r
te o
thi
do
r
cum
fo
t.
yi Co
op
Install a new sealing ring in the oil drainage plug
C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote
WARNING
AG.
4. Service descriptions 61
FOX 2004
Maintenance - Edition 07.2010
WARNING
Unscrew the sealing cover -1- with the Wrench -SW 36- and
remove the cover with the filter.
Remove the old filter from the fastening cover.
Note
WARNING
pt
du
y li
erm
ab
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
m
f
en
ng
t.
yi Co
36 mm wrench t. Cop py
rig
gh ht
pyri by
Vo
o
by c lksw
62
cted agen
Prote
4. Service descriptions
AG.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
orise nte FOX 2004
h eo
aut ra
c
Maintenance - Edition 07.2010
ss
ce
e
nl
Loosen the filter through the hex section -arrow- with a 36 mm
pt
du
an
Wrench .
itte
y li
erm
ab
ility
ot p
WARNING
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Clean the engine sealing surface.
rrectness of i
Replace the sealing ring.
l purpos
Lightly lubricate the new filter rubber sealing. With this, the
filter is better seated and ideal sealing condition is achieved.
nf
ercia
orm
m
atio
om
n in
c
thi
te
sd
a
Loosen the cover -5- with a Wrench -SW 36- and remove the
iv
o
r
rp
cu
cover with the filter.
o
m
f
en
ng
t.
yi
Remove the filter -1-.
Co
Cop py
t. rig
gh
Replace the cover sealing ring -4-.
ht
pyri by
Vo
o
by c lksw
cted agen
Prote
Replace the sealing rings -2- and -3-.
AG.
WARNING
4. Service descriptions 63
FOX 2004
Maintenance - Edition 07.2010
WARNING
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).
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-.
AG. Volkswagen AG d
Area -b- It is not necessaryoto agen
replenish the oil. oes
lksw not
yV gu
Area -c- Maximum marking ed b region. Oil cannot be replen ara
nte
ris
ished. tho eo
au ra
c
ss
ce
e
nl
pt
du
Note
an
itte
y li
erm
ab
There is danger of damaging the catalytic converter when oil
ility
ot p
h re
The oil level must be between the minimum and maximum
hole
markings. Make sure that the oil level does not exceed the spec
es, in part or in w
maximum marking.
t to the co
Pull the oil dipstick out again and check the oil level.
rrectness of i
Condition 2
l purpos
Area -C- Replenish the oil level. It is sufficient for the oil
atio
m
n in
or c
thi
sd
iva
cu
o
m
f
en
ng
Pull the oil dipstick out again and check the oil level.
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
64 4. Service descriptions
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.
AG. Volkswagen AG d
Area -c- The oil cannot be replenished agen oes
olksw not
yV g b ua
ed ran
oris tee
th or
Note au ac
ss
ce
e
nl
pt
du
With the oil level below the minimum marking (area -a-), you
an
itte
must replenish the oil until it reaches the (area -b-) according
y li
erm
ab
to the oil specification. page 58
ility
ot p
wit
With the oil level above area -c- there is the risk of damaging
, is n
h re
the catalytic converter.
hole
spec
During oil changes, you must add oil until the maximum mark
es, in part or in w
t to the co
ing.
rrectness of i
4.20 Engine and components in engine com
l purpos
nf
ercia
damage
orm
m
atio
m
n in
or c
thi
Check the engine and components in the engine compartment
te
sd
a
o
r
rp
cu
o
m
Check the cables, hoses and connections of the following sys
f
en
ng
t.
yi
tems for leaks, wearing, porosity and brittleness:
Co
Cop py
t. rig
gh
fuel supply system.
ht
pyri by
Vo
o
by c lksw
cooling and heating system.
cted agen
Prote AG.
brake system.
Note
Make sure that all existing faults are properly eliminated during
repair.
In case of movement of brake fluid not caused by pad wearing,
you must determine and eliminate the cause (repair measure).
4. Service descriptions 65
FOX 2004
Maintenance - Edition 07.2010
Note
If faults are verified, the Poly-V belt must be replaced. This will
avoid failures and faults during operation. The Poly-V belt re
placement is a repair measure.
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
66 4. Service descriptions
FOX 2004
Maintenance - Edition 07.2010
pt
du
an
y li
erm
ab
Brake cylinder.
ility
ot p
wit
Make sure that the brake system hoses are not twisted.
, is n
h re
hole
Additionally, you must make sure that the brake system hoses
spec
t to the co
fully turned.
Check the hoses for porosity and brittleness.
rrectness of i
Check the brake system hoses and pipes for wearing points.
l purpos
WARNING
m
at
om
ion
c
in t
r
his
ate
do
priv
cum
for
t.
yi Co
Cop py
t.
Special tools and workshop equipment required
rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
4. Service descriptions 67
FOX 2004
Maintenance - Edition 07.2010
pt
an
d
y li
erm
ab
connector -1-.
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
68 4. Service descriptions
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.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
pt
an
d
itte
y li
External pad thickness including rear plate-a-.
erm
ab
ility
ot p
wit
is n
h re
Wear limit: 7 mm with the rear plate.
ole,
spec
urposes, in part or in wh
t to the co
Note
rrectne
brake pads have reached their wear limit and must be replaced
(repair measure). The customer must be informed
ss o
If the disc brake pads are replaced, you must also check the
cial p
f in
brake discs for wear! Checking and occasionally replacing the
form
mer
n
c
n thi
te
sd
a
o
pr
system).
um
r
fo
en
ng
t.
yi
Torque the brake cylinder fastening screws to 25 Nm (FS II
Co
op py
brake system).
. C rig
ht ht
rig by
py
Torque the brake cylinder fastening screws to 30 Nm (FS III
co Vo
by lksw
cted
brake system).
agen
Prote AG.
Install the super hub cap so that the tire inflation valve passes
through the opening -arrow- for this purpose.
4. Service descriptions 69
FOX 2004
Maintenance - Edition 07.2010
Note
AG. Volkswagen AG d
Note lksw
agen oes
not
Vo gu
b y ara
ed
The wear indicators horison the front brake discs (visual check) inntee
dicate when thes abrake discs must be changed. This check is or ac
ut
made by usings the marks on the contact surface of the brake
ce
le
discs.
un
pt
an
d
itte
y li
Always check both discs on the same axle and, if necessary,
rm
ab
replace them.
pe
ility
ot
wit
, is n
spec
es, in part or in w
Position the wheel so that the brake disc wear indicators (visual
t to the co
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
70 4. Service descriptions
FOX 2004
Maintenance - Edition 07.2010
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Wear indicator -1- is located on the centre of the brake disc
contact area.
rrectness of i
Wear indicator -2- is located close to the internal edge of the
brake disc.
l purpos
Note
nform
mercia
tion in
removed.
thi
s
iva
do
cum
fo
t.
yi Co
Cop py
.
Checking conditions of front brake disc wear:
ht rig
rig ht
py by
co Vo
1- Wear indicators -1- and -2- are visible:
by lksw
cted agen
Prote AG.
The brake discs need not be replaced.
2- Only wear indicator -2- is visible:
The brake discs do not require replacement, but be aware if the
next change is close.
3- No brake disc wear indicator is visible.
4. Service descriptions 71
FOX 2004
Maintenance - Edition 07.2010
Note
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
io
in t
or
contact area.
his
ate
do
riv
cum
or
brake disc.
f
en
ng
t.
yi Co
op
Checking conditions of front brake disc wear: C py
ht. rig
rig ht
1- Wear indicators -1- and -2- are visible:
py by
co Vo
by lksw
cted agen
Prote AG.
72 4. Service descriptions
FOX 2004
Maintenance - Edition 07.2010
WARNING
n AG. Volkswagen AG do
lkswage es n
o ot g
If the wear limit has been reached, ereplace
d byV the linings (re ua
ran
placement measure). The client should
horis be informed! Brake tee
system; Rep. Gr. 46 ; Brakes - Mechanical
aut
systems or
ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
During a visual inspection, you must check the floor, the wheel
spec
housing and the lower longitudinal members!
es, in part or in w
t to the co
Note
rrectness of i
The existing faults must be eliminated (repair measure). This may
l purpos
atio
n in
or c
sd
iva
o
r
With the vehicle lifted (with wheels hanging freely), check the
rp
cu
o
en
ng
t.
yi Co
op
Check the fastening. C py
t. rig
gh ht
yri by
Check the sealing bellows for damage and proper adjustment. cop Vo
by lksw
cted agen
Prote AG.
4. Service descriptions 73
FOX 2004
Maintenance - Edition 07.2010
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
1 - Ring gear.
t to the co
rims.
s o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
a
Remove wheel hub protector -2-, with the extractor of the hub
iv
o
pr
en
ng
t.
yi
Remove cotter pin -3- and ring gear -1-.
Co
Cop py
t. rig
gh ht
pyri by
Vo
Caution
o
by c lksw
cted agen
Prote AG.
74 4. Service descriptions
FOX 2004
Maintenance - Edition 07.2010
WARNING
The screwdriver should touch only the washer and never the
outer roller bearing of the wheel. swa
gen AG
. Volkswagen AG
does
k not
Vol
Never rotate or leverage with the screwdriver,
d b assuring that the
y gu
ara
ise
screwdriver does not touch the brake tdrum hub on no account.
r nte
ho eo
au ra
If the notes above are not strictly sfollowed,
s
the adjustment of c
ce
e
pt
du
an
itte
y li
erm
ab
ility
ot p
Install the ring gear in order to allow assembling the cotter pin.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
index applied on a screwdriver.
rrectness of i
Note
l purpos
orm
m
n in
or c
thi
te
Note
sd
iva
o
r
rp
cu
o
m
f
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4. Service descriptions 75
FOX 2004
Maintenance - Edition 07.2010
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
4.30 Cooling system - check the antifreeze
hole
spec
additive and the coolant level
es, in part or in w
t to the co
Note
rrectness of i
All engines are supplied with radiator antifreeze additive and
l purpos
nform
ercia
a
colors.
com
tion in
r
te o
thi
s
iva
WARNING
do
r
rp
cum
fo
en
g
t.
yi Co
op
When they are mixed, severe damage is caused to the engine. C py
t. rig
If a mix is detected (brown color), the coolant must be imme
gh ht
pyri by
diately replaced (repair measure).
o Vo
by c lksw
cted agen
Prote AG.
Note
76 4. Service descriptions
FOX 2004
Maintenance - Edition 07.2010
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. Now the light-dark limit may be
easily recognized by the WATERLINE.
pt
du
y li
ab
h re
hole
WARNING
l purpos
at
om
io
in t
or
his
ate
cum
or
en
ng
t.
13) yi Co
Cop py
3,0
t.
0 -25
rig
gh ht
pyri by
Vo
o
by c
-35 3,5
lksw
cted agen
Prote AG.
-5 -25 2,5
-35 3,5
4. Service descriptions 77
FOX 2004
Maintenance - Edition 07.2010
AG. Volkswagen AG d
-10 -25 2,0 agen oes
olksw not
y V gu
b
-35 3,0 rised ara
nte
ho eo
-15 -25 a1,5
ut ra
c
ss
-35 2,5
ce
le
un
pt
-20 -25 1,0
an
d
itte
y li
erm
ab
-35 2,5
ility
ot p
wit
is n
h re
-30 -35 1,0
ole,
spec
urposes, in part or in wh
t to the co
12) Actual value: it is the result achieved when measuring the concentration of
coolant on the measured vehicle.
rrectne
13) Nominal value: is the value applied to the locality where the vehicle is being
used. For example, in Brazil, the nominal value is -25 C; in arctic countries, the
value is -35 C.
ss
14) Difference quantity in liters: is the amount removed from the cooling system
o
cial p
f
and replenished in the same quantity only with additive.
inform
mer
After the test run, you must check the antifreeze additive con
atio
centration in the cooling system again.
om
n
c
i
or
n
4.30.3 Check the coolant level and, if necessa
thi
te
sd
va
o
pr
cum
r
fo
en
ng
Check the coolant level in the reservoir with the cold engine.
t.
yi Co
Cop py
t.
Delivery inspection: With cold engine, the coolant level must
rig
gh ht
yri by
be in the middle area between the maximum and minimum cop Vo
by lksw
reservoir markings. If it is above the middle area, remove the cted agen
Prote AG.
excess until it reaches the level in the middle area between
the maximum and minimum reservoir markings. With the heat
ed engine, the coolant may reach the maximum reservoir
marking.
Inspection service: With cold engine, the coolant level can be
between the reservoir maximum marking and middle area. If
it is above the middle area, remove the excess until it reaches
the level in the middle area between the maximum and mini
mum reservoir markings. With the heated engine, the coolant
may reach the maximum reservoir marking.
If during the inspection service the coolant level is below the
minimum level marking, it is necessary to replenish the system
according to the specified mixture ratio until the middle area
between the maximum and minimum reservoir markings.
Note
78 4. Service descriptions
FOX 2004
Maintenance - Edition 07.2010
Note
ce
le
4.31 Spark plugs - replace un
pt
an
d
itte
y li
rm
ab
Special tools and workshop equipment required
pe
ility
ot
wit
Spark plug wrench -3122B-
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
Assembly tool -T10029-
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4. Service descriptions 79
FOX 2004
Maintenance - Edition 07.2010
ce
le
valve command unit -arrows- and remove the air filter case.
un
pt
an
d
itte
y li
Carry out work sequence as follows:
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
Remove the spark plugs with the Spark plug wrench -3122B- .
m
a
com
tio
Install the new spark plugs with the Spark plug wrench -3122B-
n in
r
te o
thi
s
iva
cum
fo
en
ng
t.
yi Co
op py
Note
. C rig
ht ht
rig by
copy Vo
by lksw
The air filter case assembly is initially carried out by fitting the
Prote
cted AG.
agen
butterfly valve command unit nozzle, side supports, and then
the front supports.
Apply neutral soap or coolant additive to the fastening bear
ings and to the butterfly valve control unit nozzle packing for
easier installation.
WARNING
80 4. Service descriptions
FOX 2004
AG. Volkswagen AG d
lksw
agen Maintenance
oes
not - Edition 07.2010
Vo gu
d by ara
First, remove the air filter case from ise supports and the but
rits nte
ho eo
terfly valve command unit and, then, aut from the front supports ra
c
-arrow-. ss
ce
le
un
pt
Carry out work sequence as follows:
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectne
Remove the spark plug connectors -arrows- with the Assem
bly tool -T10029- .
ss o
Remove the spark plugs with the Spark plug wrench -3122B- .
cial p
f inform
Install the new spark plugs with the Spark plug wrench -3122B-
mer
atio
and the Torque wrench - 5 to 50 Nm (enc. 1/2") -VAG 1331- .
om
n
c
i
Tightening torque: 30 Nm.
or
n thi
te
sd
iva
o
pr
cum
r
fo
Note
en
ng
t.
yi Co
op py
The air filter case assembly is initially carried out by fitting the
t. C rig
gh ht
yri
butterfly valve command unit nozzle, side supports, and then p by
o Vo
by c
the front supports.
lksw
cted agen
Prote AG.
Apply neutral soap or coolant additive to the fastening bear
ings and to the butterfly valve control unit nozzle packing for
easier installation.
WARNING
4. Service descriptions 81
FOX 2004
Maintenance - Edition 07.2010 AG. Volkswagen AG d
agen oes
olksw not
V gu
Install the Extractor -T10094- over the ignition coil with final
ed by ara
nte
power stage.-arrow- horis
eo
aut ra
Remove the ignition coil with the final power stage a little out ss c
ce
le
wards.
un
pt
an
d
itte
Install the Hook -T10118- as illustrated.
y li
erm
ab
ility
Unlock the connector block carefully and remove the connec
ot p
wit
tor.
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectne
Remove the spark plugs with the Spark plug wrench -3122B- .
Install the new spark plugs with the Spark plug wrench -3122B-
s
and the Torque wrench - 5 to 50 Nm (enc. 1/2") -VAG 1331- .
s o
cial p
f in
Tightening torque: 30 Nm.
form
mer
Install the Extractor -T10094- over the ignition coil with final
atio
m
power stage.
o
n
c
i
or
n thi
e
sd
va
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Install the ignition coil with final power stage in the -arrow- di
o Vo
by c lksw
cted agen
rection on the engine cylinder head. Prote AG.
WARNING
82 4. Service descriptions
FOX 2004
Maintenance - Edition 07.2010
Note
Note
If the oil level is above region -A-, drain the exceeding oil.
If the oil level is below region
agen
A-A-,
G. Voyou
lkswmust check
agen AG
do the hydraulic
system for possible Voleaks
lksw (repair measure), it is not
es n
ot genough to
just replenishisthe
ed bylevel. ua
ran
r tee
ho
If the hydraulic
au
t system is leak proof, for Brazil, fill only withor aoil
-325 029ss 901 1- . For other countries, when filling, you must
c ce
le
pay attention to the oil color, red oil -325 029 901 1- or yellow
un
pt
y li
rm
ab
pe
ility
wit
, is n
h re
spec
The engine must be turned off and the front wheels, aligned.
es, in part or in w
t to the co
nform
ercia
Note
m
a
com
ti
measurement.
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4. Service descriptions 83
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
hydraulic system for possible leaks (repair measure), it is not
enough to just replenish with oil.
If the hydraulic system is leak proof, for Brazil, fill only with oil
-325 029 901 1- . For other countries, when filling, you must
pay attention to the oil color, red oil -325 029 901 1- or yellow
oil -G 002 000- .
ce
le
un
pt
4.33.1 Behr box
an
d
itte
y li
rm
ab
Carry out the following work sequence:
pe
ility
ot
wit
, is n
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
Remove the dust and pollen filter -arrow- with the filter support.
thi
s
iva
do
cum
fo
en
ng
t.
yi Co
op
WARNING C py
t. rig
gh ht
pyri by
Vo
Follow the rules for disposal!
o
by c lksw
cted agen
Prote AG.
84 4. Service descriptions
FOX 2004
Maintenance - Edition 07.2010
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
is nte
Remove the dust and pollen filter -arrow- withuthe
th filter support.
or eo
a ra
s c
Separate the filter from its support. s
ce
e
nl
pt
du
an
itte
y li
WARNING
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
moval.
rrectness of i
4.34 Timing belt - replace; Semi-automatic
l purpos
nform
mercia
at
4.34.1 Engine identification letters ASY
om
ion
c
in t
or
his
ate
do
priv
cum
for
t.
yi Co
Cop py
Carry out the work sequence Engine; Rep. Gr. 15 ; Cylinder
ht. rig
rig ht
by
head, camshaft mechanism . copy Vo
by lksw
cted agen
Prote
4.35 Camshaft activation timing belt - check
AG.
4. Service descriptions 85
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.
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
t to the co
WARNING
l purpos
ion
c
his
al.
ate
do
priv
cum
or
en
ng
t.
yi Co
BKR Cop py
t. rig
gh ht
pyri by
Carry out work sequence as follows:
co Vo
by lksw
cted agen
Prote AG.
86 4. Service descriptions
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-.
WARNING
ce
le
al.
un
pt
an
d
itte
y li
erm
ab
4.36.3 Engine identification letters ASY, BNM,
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
Loosen the screws -arrows- and remove the air filter cover.
t to the co
Clean the filter's case and install a new filtering element.
rrectne
The installation is performed in the reverse order from remov
al.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
4. Service descriptions 87
FOX 2004
Maintenance - Edition 07.2010
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.
Comply with the waste disposal standards!
ce
e
nl
pt
du
Fill the new filter with new diesel fuel. Thus, the engine works
an
itte
y li
faster.
erm
ab
ility
ot p
spec
Lock the -arrows- small hooks.
es, in part or in w
t to the co
Install the fuel hoses -1- and -2- and lock with hose clamps.
nform
ercia
Note
m
at
om
io
The fuel flow direction is marked by -arrows-: (Do not invert the
n
c
in t
r
connections).
o
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4.37.3 Engine identification letters BNM
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.
Comply with the waste disposal standards!
88 4. Service descriptions
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.
Installing
Fill the new filter with new diesel fuel. Thus, the engine works
faster.
Install the filter.
Install the filter intake -a- and outlet-b- hoses and, then, the
clamps with the help of the Spring clamp pliers -VAS 5024 A-
n AG. Volkswagen AG do
lkswage es n
o ot g
4.38 Fuel filter - drain ir se
d byV ua
ran
o tee
th or
au ac
ss
4.38.1 Engine identification letters ASY
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
Note
ot p
wit
, is n
h re
Make sure that no diesel fuel reaches the coolant hoses. If nec
hole
spec
essary, clean the hoses immediately!
es, in part or in w
t to the co
WARNING
rrectness of i
Follow the rules for disposal!
l purpos
nf
ercia
orm
m
Remove the fastening clip -3- and remove the regulating valve
atio
m
n in
or c
thi
Install the hose to the draining screw connection coupling
te
sd
iva
cu
o
m
f
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4. Service descriptions 89
FOX 2004
Maintenance - Edition 07.2010
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
Brake bleeding device -VAG 1869-
p by
co Vo
by lksw
cted agen
Prote AG.
90 4. Service descriptions
FOX 2004
Maintenance - Edition 07.2010
WARNING
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Aspirate with a hose from the Brake filler and bleeder -VAS
5234- -1-, or Brake bleeding device -VAG 1869- or with an
rrectness of i
nform
ercia
Note
m
at
om
io
in t
or
his
ate
tween the driver's seat and the brake pedal, pressing it.
um
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
4. Service descriptions 91
FOX 2004
Maintenance - Edition 07.2010
ce
e
nl
pt
du
Install the venting hose -1- of the draining bottle in the rear
an
itte
y li
section of the bleeding screw, loosen the bleeding screw and
erm
ab
drain a corresponding quantity of brake fluid (check the table
ility
ot p
below).
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
For vehicles with steering wheel to the left, start bleeding in the
right rear wheel; with the steering wheel to the right, start bleeding
rrectness of i
in the left rear wheel.
l purpos
Repeat the work procedure on the other rear side of the vehi
cle.
nf
ercia
atio
Remove the protection cover from the clutch drive piston
om
bleeding screw
n in
or c
thi
e
Couple the hose from -VAG 1793- -arrow- to the clutch drive
t
sd
iva
cu
o
0.1 liter.
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
92 4. Service descriptions
FOX 2004
Maintenance - Edition 07.2010
pt
an
d
itte
y li
ab
between the driver's seat and the brake pedal, by pressing it.
pe
ility
ot
wit
, is n
Check the brake pedal's pressure and its free clearance. Max.
h re
spec
es, in part or in w
t to the co
WARNING
reservoir.
l purpos
Never let it reach the minimum level, otherwise air may enter
the system.
nform
ercia
a
com
tion in
r
te o
thi
do
r
cum
fo
en
ng
t.
yi Co
Use only new, original VW brake fluid.
. Cop py
rig
ht ht
rig by
opy Vo
WARNING
by c lksw
cted agen
Prote AG.
4. Service descriptions 93
FOX 2004
Maintenance - Edition 07.2010
ce
e
nl
pt
du
an
itte
y li
marking must not be exceeded.
erm
ab
ility
ot p
wit
Inspection service:
, is n
h re
hole
spec
pad wear. With the vehicle in operation, the fluid level lowers
es, in part or in w
t to the co
due to wear and the automatic seating of the brake pads.
With the fluid level at the minimum marking and slightly above
it, it becomes necessary to replenish the fluid when the brake
rrectness of i
pad wear limit has almost been reached.
l purpos
If the pads are new, or far from their wear limit, the fluid level
must be within the minimum and maximum markings.
nf
ercia
o
If the fluid level drops below the minimum marking, check the
rm
m
atio
m
fluid.
o
n in
or c
thi
e
sd
iva
o
r
rp
headlights if necessary cu
o
m
f
en
ng
t.
yi Co
Special tools and workshop equipment required t. Cop py
rig
gh ht
yri
Headlight aligner -VAS 5046- or -VAS 5047- p by
co Vo
by lksw
cted agen
In principle, the following checking and adjustment description is Prote AG.
valid for every country. However, it is necessary to consider the
guidelines and standards of each country.
Checking and adjustment conditions:
Tyre inflation pressure OK.
The headlight lenses must never be damaged or dirty.
Reflectors and lamps OK.
The vehicle load must be known.
Load: With a person or 75 kg on the driver's seat of empty vehicles
(empty weight):
The weight of an empty vehicle is the weight of the vehicle ready
for operation and with a full fuel tank (at least 90%), including the
weight of every component required to operation (e.g: spare
wheel, tools, towing hook, fire extinguisher, etc).
If the fuel tank is not at least 90% full, then simulate the load as
follows:
Check the tank level on the fuel gauge. Establish the additional
weight according to the table below and put this weight in the
luggage compartment.
94 4. Service descriptions
FOX 2004
Maintenance - Edition 07.2010
Note
pt
an
d
itte
Main headlights:
y li
erm
ab
ility
wit
is n
Check if, with the low beam on, the horizontal light-dark limit
h re
ole,
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4. Service descriptions 95
AG. Volkswagen AG d
agen oes
ksw
FOX 2004 by
Vol not
gu
d ara
Maintenance - Edition 07.2010 orise nte
h eo
aut ra
c
Check if the point of inflexion -2- between the left horizontal ss
ce
e
part and the right ascending part of the light-dark limit runs
nl
pt
du
an
vertically through the central mark -3-. In this case, the light
itte
y li
core of the light beam is at the right of the vertical line.
erm
ab
ility
ot p
wit
, is n
h re
Note
hole
spec
es, in part or in w
Line -1- is the measurement from the ground to the centre of
t to the co
the headlight minus 4.72 in for a distance of 10.94 yd.
Line -1- is the measurement from the ground to the centre of
rrectness of i
the headlight minus 60 mm for a distance of 5 m.
l purpos
For an easier determination of the breaking point -2-, cover
and then release the left half of the headlight (seen from the
driver's side). Then, test the low beam once more.
nf
ercia
or
After correctly adjusting the low beam, the high beam is auto
m
m
atio
matically adjusted. This means that the high beam centre must
om
n in
be on the headlight central mark -3-. A 200-mm deviation to
or c
thi
te
sd
a
wards is acceptable.
iv
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
For the current checking viewer with an adjustment line of 15, t. Cop py
the same adjustment as for new checking viewer applies. To
rig
gh ht
yri by
avoid incorrect adjustments, the 15 line will no longer be con op Vo
by c lksw
sidered. cted agen
Prote AG.
Fog lights
Note
96 4. Service descriptions
FOX 2004
Maintenance - Edition 07.2010
Note
ce
le
un
pt
Additional headlights from other systems, installed afterwards,
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
Main headlights
spec
urposes, in part or in wh
t to the co
positioned symmetrically).
Adjust the headlights from the front, with a suitable Philips
rrectne
wrench.
On the left headlight, both set screws are arranged symmetrically.
ss o
cial p
f inform
mer
Note
atio
om
n
Please check also if both headlights move symmetrically when
c
i
or
n thi
positioning the light range.
te
sd
iva
o
pr
cum
r
fo
Fog lights
en
ng
t.
yi Co
To reduce the beam focus, turn the setscrew to the right. A Cop py
t. rig
side adjustment is not expected. gh ht
pyri by
Vo
co lksw
by
cted agen
On the left headlight, the setscrew is arranged symmetrically. Prote AG.
4. Service descriptions 97
FOX 2004
Maintenance - Edition 07.2010
pt
an
d
itte
y li
ab
ility
ot p
h re
spec
urposes, in part or in wh
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
98 4. Service descriptions
FOX 2004
Maintenance - Edition 07.2010
agen Note
AG. Volkswagen AG d
oes
olksw not
y V gu
b
The exhaust gas rise tests are valid only for countries that do
d ara
ntenot have
specific guidelines
utho for the exhaust gas test. eo
ra
s a c
s
ce
e
pt
du
an
itte
y li
erm
ab
ility
ot p
Note
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
compliance with the rules in force in Germany.
rrectness of i
Intervals for the exhaust gas test in Germany:
l purpos
nf
ercia
n in
or c
thi
e
sd
iva
o
r
rp
cu
m
f
en
ng
t.
yi
5.1.1 Exhaust gas test for petrol engines
Co
Cop py
t. rig
gh ht
yri
Exhaust gas test for petrol engines without OBD p by
co Vo
by lksw
cted agen
Exhaust gas test for petrol engines with OBD Prote AG.
The test sequence was prepared for the test execution with the
combination of test devices for analyzing exhaust gases, com
prised of:
Note
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
vices from the Gas tester - 4 components (CO, CO2, HC and
O2) or GAS TESTER -VAS 6300- are working and connected
l purpos
nform
ercia
at
om
ion
c
in t
or
his
ate
do
riv
cum
or
haust gas test are available on the exhaust gas test datasheet
f
en
ng
t.
for the respective engine Data sheets for exhaust emission
yi Co
op py
test. t. C rig
gh ht
pyri by
The exhaust gas test datasheet must be printed to enable the
o Vo
by c lksw
cted
barcode reading.
agen
Prote AG.
The general view for selecting the respective type of exhaust gas
test is displayed.
Select Petrol exhaust gas test -arrow-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
The indication for the heating period is displayed.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
en
ng
t.
When the selection of the theoretical value of exhaust gases
yi Co
op py
is displayed, select Selection of theoretical value of exhaust t. C rig
gh ht
gases, -arrow-. yri
p by
o Vo
by c lksw
cted
Select Pre-defined value when it is related to the first exhaust
agen
Prote AG.
gas test,
Or, when it is necessary to perform an exhaust gas test again,
select last vehicle.
Press the indication Continue, -1-.
Vehicle's data entering:
When the vehicle data entering menu is displayed:
ce
le
un
pt
an
d
y li
erm
ab
Entering nominal data for the exhaust gas test:
ility
ot p
wit
is n
h re
ole,
Note spec
urposes, in part or in wh
t to the co
All conditions for test and data necessary for the exhaust gas
test are included on the exhaust gas test datasheet for the
respective engine.
ss o
cial p
f in
entering.
atio
om
n
c
n thi
e
sd
va
o
pr
cum
r
fo
t.
yi Co
op py
2- Period of catalytic converter heating t. C rig
gh ht
pyri by
3- Engine temperature
co Vo
by lksw
cted agen
Prote AG.
4- High idle speed rotation
5- Content of CO with high idle speed rotation
6- Lambda probe with high idle speed rotation
7- Idle speed rotation
8- Select the type of adjustment probe, enter Enrichment
probe or Broad range probe -1-.
9- Lambda probe value
After entering all data correctly, press the Continue key
-arrow-.
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
sheet with the reading pencil.
The screen displays the indication with all necessary data.
Press the key -arrow- to continue the process.
Visual inspection:
AG. Volkswagen AG d
Follow the indications on the screen. agen oes
olksw not
y V gu
b ara
Perform the visual inspections. rise d
nte
tho eo
If there are no problems, press
ss a OK on the screen -arrow-.
u ra
c
ce
le
un
pt
an
d
itte
Note
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
You can see beside the test inspection indicator, where it is nec
essary to connect the diagnosis connector -A -, as well as check
the MI lamp - B -.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
Follow the indications on the screen.
yi Co
Cop py
t. rig
Turn ignition off.
gh ht
pyri by
Vo
co lksw
by
Connect the diagnosis cable to the EOBD socket. Prote
cted AG.
agen
AG. Volkswagen AG d
agen oes
olksw not
Follow the indications on ethed b screen, - arrow C - and
y V gu
ara
-arrow A -. horis nte
eo
ut ra
a
Start the engine. ss c
ce
le
un
pt
Perform an inspection with the MI lamp.
an
d
itte
y li
Insert the exhaust gas probe in the exhaust gas exit tube.
erm
ab
ility
ot p
wit
is n
h re
Note
ole,
spec
urposes, in part or in wh
t to the co
is in the exhaust gas exit tube.
rrectness o
It automatically switches to readiness code.
cial p
f inform
atio
om
n
c
i
or
Note
thi
te
sd
iva
o
pr
performed.
en
ng
t.
yi Co
op
If not all indication values are at zero, a probe inspection test
C py
t. rig
gh
is further performed.
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Confirm the condition of the MI lamp -arrow B-.
Condition of the catalytic converter:
It switches automatically to the catalytic converter heating phase.
ce
le
un
Follow the indications on the screen.
pt
an
d
itte
y li
rm
ab
pe
ility
Note
ot
wit
, is n
h re
This indication appears just before the engine temperature rea
hole
spec
ches 80 degrees Celsius.
es, in part or in w
t to the co
The engine temperature must reach the necessary level.
rrectness of i
Measurement in high idle speed rotation:
l purpos
nform
ercia
a
com
t
The measurement starts as soon as the engine rotation reaches
ion in
the necessary level.
r
te o
thi
s
iva
do
r
rp
cum
Note
fo
en
ng
t.
yi Co
op
With the key it is possible to cancel the measurement,
C py
t. rig
gh ht
that is, not perform the exhaust gas test. yri
p by
co Vo
by lksw
cted
With the key the measurement values are reset and the
agen
Prote AG.
test can be repeated.
Note
Note
pt
du
After the exhaust gas test, the report will be displayed on the
an
itte
y li
screen.
erm
ab
ility
ot p
h re
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
e
nl
After the confirmation, two TEST CERTIFICATES are automat
pt
du
an
ically printed.
itte
y li
erm
ab
To get other certificates, press the -arrow A - Print button.
ility
ot p
wit
, is n
Follow the indications on the screen.
h re
hole
spec
Remove the exhaust gas probe from the final exhaust gas
es, in part or in w
tube.
t to the co
Then, press - arrow B-.
The exhaust gas test is concluded. It is possible to perform a new
rrectness of i
exhaust gas test. l purpos
nf
ercia
orm
Note
m
atio
om
n in
c
All test conditions and data necessary for the exhaust gas test:
or
thi
e
sd
iva
o
r
rp
cu
The ignition point is determined by the Engine control unit -
o
m
f
en
J623- and will not be indicated. It is not possible to make an
ng
t.
yi Co
adjustment. t. Cop py
rig
gh ht
The idle speed rotation and the content of CO cannot be ad pyri by
Vo
o
by c
justed (just checked). If there are divergences between the
lksw
cted agen
Prote
actual and the theoretical values: perform a Repair Measure!
AG.
Note
or
Rotation adapter -VAS 5087/ A-
Exhaust gas test requester
Note
Startup screen:
AG. Volkswagen AG d
Select the function-arrow-, Exhaust gas test. lksw
agen oes
not
Vo gu
by ara
d
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
The general view for selecting the respective type of exhaust gas
test will be displayed.
Select Petrol exhaust gas test -arrow-.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
Continue the exhaust gas test according to the instructions on
ss
ce
e
the screen.
nl
pt
du
an
itte
y li
erm
ab
is displayed, select the respective Selection of theoretical val
ility
ot p
wit
, is n
h re
Select Pre-defined value when it is related to the first exhaust
hole
spec
gas test,
es, in part or in w
t to the co
Or, when it is necessary to perform an exhaust gas test again,
select last vehicle.
Charge in the indication Continue, inquire -1-.
rrectness of i
Vehicle's data entering:
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
AG. Volkswagen AG d
agen oes
lksw not
With the Skip key, it is possible to call y Vnew functions.
o gu
d b ara
ise nte
r
With the Skip key, it is possibleut to interrupt the test.
ho eo
ra
s a c
s
ce
e
pt
du
an
itte
y li
erm
ab
ility
Note
ot p
wit
, is n
h re
If the nominal values do not exist as barcode, they must be
hole
spec
entered manually.
es, in part or in w
t to the co
All conditions for test and data necessary for the exhaust gas
test are included on the exhaust gas test datasheet for the
respective engine.
rrectness of i
orm
m
atio
m
n in
c
thi
sd
iva
o
r
cu
o
m
f
en
ng
t.
2- Period of catalytic converter heating Cop
yi Co
py
ht. rig
3- Engine temperature rig ht
py by
co Vo
by lksw
4- Increased idle speed rotation Prote
cted AG.
agen
ce
le
un
pt
an
d
Entering nominal data for the exhaust gas test with the barcode:
itte
y li
rm
ab
If the nominal data for the exhaust gas test is available with
pe
ility
the barcode, read the barcode in the exhaust gas test data
ot
wit
, is n
h re
hole
spec
The screen displays the indication with all necessary data.
es, in part or in w
t to the co
Press the key -arrow- to continue the process.
rrectness of i
l purpos
nform
ercia
Visual inspection:
m
a
com
t
Follow the indications on the screen.
ion in
r
te o
thi
s
iva
do
If there are no problems, press the in order key -arrow-.
r
rp
cum
fo
en
ng
t.
yi Co
op py
Note t. C rig
gh ht
pyri by
Vo
co lksw
by
When the Not OK key is pressed, a test is originated. Prote
cted AG.
agen
Here you find the indication of visual inspection with the instruc
tion to connect the cable to the vehicle.
Follow the indications on the screen.
Turn ignition off.
Connect the adapter for old vehicles -VAS 5051/2- or rotation
number adapter -VAS 5087/- or the Diagnosis cable -VAS
5051/6A- to the vehicle.
Note
Note
Heating period:
It automatically switches to the engine temperature measurement
indication.
Follow the indications on the screen.
Note
pt
an
d
itte
y li
Note
erm
ab
ility
ot p
wit
h re
spec
urposes, in part or in wh
With the key, the measurement values are reset and the test
t to the co
can be repeated.
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
e
nl
pt
du
It switches automatically to the indication of idle speed rotation
an
itte
y li
measurement and content of CO.
erm
ab
ility
ot p
The measurement starts as soon as the engine rotation reaches
wit
, is n
the necessary level.
h re
hole
spec
The remaining time for performing the measurement is displayed
es, in part or in w
-arrow A-.
t to the co
Probe adjustment test:
It automatically switches to the probe adjustment test indication.
rrectness of i
The measurement starts as soon as the engine rotation reaches
the necessary level. l purpos
Keep the engine rotation on the necessary level.
nf
ercia
orm
The remaining time for performing the measurement is displayed
m
atio
m
-arrow A -.
o
n in
or c
thi
te
Assessment:
sd
iva
o
r
rp
cu
After the exhaust gas test, the report will be displayed on the
o
m
f
en
ng
screen.
t.
yi Co
Cop py
.
The test result is indicated.
t rig
gh ht
pyri by
Vo
co
In this location, remarks about the exhaust gas test can be en
by lksw
cted agen
Prote
tered -arrow A-. They are included on the test report.
AG.
or
Rotation adapter -VAS 6296-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
t to the co
or
Data reading device -V.A.G 1799-
rrectness of i
Note
nform
mercia
All test conditions and data necessary for the exhaust gas
a
com
tio
thi
do
cum
en
g
t.
yi Co
Cop py
During the measurement, the engine bonnet must be closed
t. rig
gh ht
yri by
until the first clutch, due to the noise. cop Vo
by lksw
cted agen
Prote AG.
Note
Test conditions
Minimum engine temperature of 80 C agen
AG. Volkswagen AG d
oes
olksw not
V gu
No fault in the memory d by ara
rise nte
o eo
Turn the test devices on auth
ra
ss c
Connect the Diesel engine test device -V.A.G 1743 - according
ce
le
un
pt
to the operation instructions.
an
d
itte
y li
erm
ab
ility
and operation Operation instructions V.A.G 1743
ot p
wit
is n
h re
ole,
spec
Note
urposes, in part or in wh
t to the co
In engines where the hole for the PMS sensor is not accessi
ble, has difficult access or is large, you can use the Rotation
adapter -VAS 5087 A- or the Rotation adapter -VAS 6296- in
rrectne
stead of the PMS sensor.
It is not possible to use the terminal transmitter (for cylinder 1)
from the Diesel engine test device -V.A.G 1743- . ss o
cial p
f inform
mer
atio
i
or
n thi
te
sd
iva
o
pr
Note
um
r
fo
en
ng
t.
yi Co
op
Follow the operation instructions for the Rotation adapter - C py
t. rig
VAS 5087 A- !
gh ht
pyri by
Vo
co lksw
by
You must mandatorily follow the safety indications in the op cted agen
Prote AG.
eration instructions!
Connect the Adapter cable -VAS 1587/3- from the output con
nection of the Rotation adapter -VAS 5087 A- to the terminal
transmitter input from the Diesel engine test device -V.A.G
1743-
Turn the cylinder number switch to 4 (4-cylinder engine).
Connect an Adapter -VAS 5087/1- cable to the Rotation adapt
er -VAS 5087 A- (VAS 5087/1 socket).
Note
When you use the Rotation adapter -VAS 5087 A- , press the
G. Volkswage
Start key. The red signaling lamp must ksw
agbe
en Aturned on for apoes n
n AG d
prox. 10 seconds. Then, the green y V signaling lamp must turn
o l ot g
ua
db
on. orise ran
te
h eo
ut
In the Diesel engine testssdevice
a -V.A.G 1743- , the engine ro ra
c
tation must be indicated now.
ce
e
nl
pt
du
an
If the engine rotation is indicated incorrectly or not indicated at
itte
y li
all: Operation instructions from VAS 5087
erm
ab
ility
ot p
wit
, is n
Test sequence
h re
hole
spec
es, in part or in w
t to the co
Press on the data reading device F2 the key for AU diesel.
Upon indication on display:
rrectness of i
Insert vehicle identification card!!
l purpos
nform
ercia
at
om
in t
or
do
riv
cum
for
en
g
t.
yi Co
Cop py
Code = for Number 3 (the first three digits)
t. rig
gh ht
pyri by
Vo
o
Vehicle identification number = Number 4
c by lksw
cted agen
Prote AG.
Engine identification letters
Kilometers traveled
Confirm the vehicle identification data provided through the
Q key.
Enter the theoretical values with the data reading device read
er, sliding it over the respective code in the datasheet on the
Exhaust gas analysis folder.
or
With the key, make manual inputs according to instructions
on the data reading device display.
ce
le
un
pt
an
d
itte
y li
Visual inspection Ok = j not Ok =
erm
ab
ility
Enter the visual inspection result. ot p
wit
is n
h re
Upon indication on display:
ole,
spec
urposes, in part or in wh
t to the co
sor
F2 enter manually the temperature meas-
urement
rrectne
Press the F1 key for temperature measurement with sensor.
When the engine oil temperature reaches 80 C, remove the
ss
sensor and insert the oil dipstick up to the stop.
o
cial p
f in
Proceed with the test by pressing the Q key.
form
mer
atio
Upon indication on display:
om
n
c
i
or
n thi
e
sd
a
>
iv
o
r
cum
r
en
ng
t.
yi
Press the key .
Co
Cop py
t. rig
gh ht
Idle speed rotation out of the theoretical value field: pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
The idle speed rotation and the maximum rotation can be tested,
but cannot be adjusted.
Press the accelerator pedal up to the end for the time required,
and keep it pressed.
WARNING
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.
Proceed with the test by pressing the Q key.
Upon indication on display:
Idle speed rotation 1 measurement 15 sec
ACTUAL rotation xxxx/
min THEORETICAL xxx...xxxx/min
ce
le
un
pt
an
d
itte
y li
With the indication on display:
rm
ab
pe
ility
ot
wit
Data transmission for the gas oil test de-
, is n
vice
h re
Free acceleration in movement
hole
spec
es, in part or in w
t to the co
Upon indication on display:
rrectness of i
Idle speed rotation 2 measurement 15 sec
ACTUAL rotation xxxx/
l purpos
nform
ercia
a
com
tion in
r
te o
thi
Data transmission for the gas oil test de-
s
iva
vice do
r
cum
fo
en
g
t.
yi Co
Cop py
With the indication on display:
ht. rig
rig ht
py by
co Vo
by lksw
Data transmission for the gas oil test de- cted agen
vice
Prote AG.
Free acceleration in movement
ce
le
un
pt
Data transmission for the gas oil test de-
an
d
itte
vice
y li
Free acceleration in movement
erm
ab
ility
ot p
h re
Upon indication on display:
ole,
spec
urposes, in part or in wh
>
ACTUAL x.xx/
m THEORETICAL x...x.xx/m
rrectne
>
o
ACTUAL x.xx/
c
i
or
m THEORETICAL x...x.xx/m
thi
te
sd
va
o
pr
cum
r
fo
en
ng
Note
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
If necessary, enter clarifications by pressing the key .
urposes, in part or in wh
t to the co
Press the key Q .
Upon indication on display:
rrectne
Select tester/manual input with F3
F1 XXXXX F2 XXXXX
ss o
cial p
f
With keys F1 to F3 select the tester or enter the name.
inform
mer
atio
om
n
Press the key .
c
i
or
n thi
te
o
pr
cum
r
fo
en
ng
5.2 Glossary
t.
yi Co
Cop py
t. rig
gh
These explanations refer only to the Maintenance Cares. They
ht
pyri by
Vo
are not intended to be universal!
co lksw
by
cted agen
Prote AG.
Concept Explanation
AU Exhaust gas test.
ABS (anti-blocking system), the ABS is a brake sys
tem adjustment that prevents the wheels from
blocking while braking. Thus, the stability and
the steering control are maintained.
ATF (Automatic Transmission Fluid) gear oil for au
tomatic gearboxes.
ATF level "Level" of the gear oil for automatic gearboxes.
Cetane rate (level of cetane) dimension of diesel's flamma
bility.
DIN Deutsches Institut fr Normung e.V (German
Institute for Standardisation).
EN Europe Norm
Concept Explanation
EOBD European On-Board Diagnosis
FAME Fatty Acid Methyl Ester
FSI Fuel Stratified Injection
TFSI Turbo Fuel Stratified Injection
MIL (Malfunction Indicator Light) American designation for exhaust gas light K83
NOX Nitric oxide
Concept Explanation
OBD On-Board Diagnosis; the OBD checks all components that influence the quality of the
exhaust gases
AG. Volkswagen AG d
agen oes
OBD-II American On-Board olkswDiagnosis not
byV gu
ara
PD Unit of pump oris - nozzle injection in diesel engines
ed
nte
th eo
PR number Abbreviation
s au for production control number. They identify, r a among others, additional
c
equipment,
s
specific differences of each country and data about the movement steering
ce
e
nl
pt
du
PM (English: particulate matter) particulate material in diesel engine exhaust gases
an
itte
y li
QG0. Vehicles not equipped in the factory with components for the LongLife service. For
erm
ab
ility
maintenance, the intervals that depend on time or kilometers traveled are applied (fixed
ot p
intervals).
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Concept Explanation
QG1 Vehicles equipped in the factory with the active LongLife service. It means that the ve
hicles have a flexible service interval indicator and are equipped with the following
rrectness of i
components:
l purpos
nform
ercia
at
om
ion
QG2 The LongLife service is not active from the factory. It means that the vehicles have a
c
in t
or
his
ate
do
priv
c
Fixed service interval indicator in the combined instrument
um
for
en
ng
t.
yi
Engine oil's level sensor
Co
Cop py
ht. rig
Brake pad's wearing indicator rig ht
py by
co Vo
by lksw
cted agen
Readiness code Binary 8-digit code that indicates if all relevant engine diagnoses were made in terms of
Prote AG.
exhaust gases
Octane rating (level of octane researched) dimension of petrol resistance to detonation
SAE (Society of Automotive Engineers) Association that provides recommendations/guide
lines about transposing legal requirements (for example, rules)
SD Aspirated diesel engine
SDI Aspirated diesel engine with direct injection
SIA Service interval indicator
SW Acronym for the key size
RR Turbo Diesel Engine
TDI Turbo diesel engine with direct injection
VEP Distributor injection pump
ULEV Ultra Low Emission Vehicles
Concept Explanation
WIV Extension of maintenance interval
Common - Rail Term that designates a general injection control by high pressure,
which injects fuel in all seat cylinders
DPF Diesel particle filter; this filter is assembled after the catalytic con
verter and filters particles from the exhaust gases
V engines The V engine has cylinders arranged in an angle from 60 to 120
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
Life service
Enrichment probe Also named (LSH- heated lambda probe), (LSF- flat lambda probe)
or oxygen sensor. The emission of the lambda value is made
through a tension curve with discontinuous growth. The lambda val
ue is determined based on a change of tension. The probe is used
as a post-catalytic converter probe.
olkswagen AG
Broad range probe Also named (LSU probe) universal en AG. V probe.
aglambda Thedoemission
es n of
lksw
the lambda value is made through byV
o a tension curve with an appa
ot g
ua
rently linear current intensity
ris
ed growth. The lambda value is deterran
te
mined based on a change tho of current intensity. Thus, the lambda e or a
au
value can be measured
ss on a large measurement field (broad range). c
The probe is used as a pre-catalytic converter probe.
ce
le
un
pt
an
d
Balance of ash mass The balance of ash mass informs about the level of the particle filter
itte
y li
volume filling.
rm
ab
pe
ility
RDK, RKA Control of tire pressure, indicator of tire control.
ot
wit
, is n
h re
hole
spec
es, in part or in w
07.10
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.