FOX - Maintenance Handbook PDF

Service
Maintenance
FOX 2004 ➤
AG. Volkswagen AG d
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Service Department. Technical Information

Service
Maintenance
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2. Service plans orised
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3. General remarks ss a ra
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4. Service descriptions
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5. Additional tasks due to country legislation
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2010 Volkswagen AG, Wolfsburg BRA5R005420

FOX 2004 ➤
Maintenance - Edition 07.2010
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
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2.2 Delivery inspection . . . . . . . . .Vo. lk. . . . . . . . . . . . . . . . . . d. o.e.s .no.t . . . . . . . . . . . . . . . . . . . . . . .
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2.3 Oil Change Service . . . . is.e.d b. . . . . . . . . . . . . . . . . . . . . . . . . . . u.ar.an. . . . . . . . . . . . . . . . . . . 7
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2.4 Intermediate service Models ut
ho ▸2010 (Europe) and Models 2009▸ (except or Europe) . . . . . . 8
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2.5 Intermediate service sModels
s 2011▸ (Europe) . . . . . . . . . . . . . . . . . . . .c . . . . . . . . . . . . . . 10
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2.6 Inspection Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.7 Supplementary services based on time elapsed and/or kilometers traveled . . . . . . . . . . . . 18
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3 General remarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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3.1 Rear license plate (only CrossFox Europe) - install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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3.2 Lifting the vehicle with a workshop lift and jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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3.3 Service tag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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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
3.8 Engine oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3.9 Identification letters and engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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3.10 Push starting (pushing the vehicle to start)/towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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4 Service descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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4.1 Clock - set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

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4.2 Maintenance interval indicator (if available) : reset with the Vehicle Diagnosis, Measurement
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and Information System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

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4.3 Spare wheel support stop: lubricate - (CrossFox) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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4.4 Fire extinguisher - check the charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

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4.5 Power window drive - reprogram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
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4.6 Radio - activate the anti-theft code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
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4.7 Reading radio code using Diagnosis, measurement and information system . . . . . . . . . . cted
38
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4.8 Wheel fastening screws - tighten to correct torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.9 Battery - check terminals for proper seating and fastening . . . . . . . . . . . . . . . . . . . . . . . . 40
4.10 Battery - check the charge capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.11 Engine oil level - check and replenish if necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.12 Sunroof: check operation, clean and lubricate the guide rails . . . . . . . . . . . . . . . . . . . . . . 46
4.13 Transport safety devices - remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.14 Driver and passenger airbags - visual inspection of Airbag units . . . . . . . . . . . . . . . . . . . . 48
4.15 Windshield and rear window wiper and washer - check the operation . . . . . . . . . . . . . . . . 49
4.16 Windscreen and rear window wiper blades - check the resting position . . . . . . . . . . . . . . 51
4.17 Wiper blade - check the incidence angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.18 Tire pressure (including spare wheel), condition, tread, sides and groove depth - check . . 53
4.19 Engine oil - drain and fill; change the oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4.20 Engine and components in engine compartment (from above and below) - make a visual
inspection for leaks and damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.21 Poly-V belt - check the condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.22 Constant velocity joint bellows - visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4.23 Gearbox - check the oil level and replenish if necessary . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4.24 Brake system - visual inspection for damage and leaks . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.25 Front brake pads - check the thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.26 Lower body section protection - make a visual inspection for damage . . . . . . . . . . . . . . . . 73
4.27 Steering bar tips - check clearance, fastening and sealing bellows . . . . . . . . . . . . . . . . . . 73
4.28 Rear wheels: adjust the roller bearing clearance (only for vehicles without ABS and equipped
with the engines: AQZ, BAH, ASY, BLH, and CFZA from 07/01/2007. . . . . . . . . . . . . . . . . 74
4.29 Suspension arm joints - visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.30 Cooling system - check the antifreeze additive and the coolant level . . . . . . . . . . . . . . . . 76
Contents i
FOX 2004 ➤
4.31 Spark plugs - replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

4.32 ATF oil reservoir for power steering - replenish the level . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.33 Dust and pollen filter - replace the filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.34 Timing belt - replace; Semi-automatic camshaft tensioning pulley - check . . . . . . . . . . . . 85
4.35 Camshaft activation timing belt - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
4.36 Air filter - clean the case and replace the filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
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4.37 Fuel filter - replace . . . . . . . . . . . . . . . . . o.lk.s.w.ag. e. . . . . . . . . . . . . . d. o.e.s n. o. . . . . . . . . . . . . . . . 87
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4.38 Fuel filter - drain . . . . . . . . . . . . . . . e.d.b.y . . . . . . . . . . . . . . . . . . . . . . . . . . u.a.ra.n . . . . . . . . . . . 89
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4.39 Brake fluid - replace . . . . . . . . .ut.ho. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ee. o.r . . . . . . . . 90
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4.40 Brake fluid level (depending onssbrake pad/lining wear) - check . . . . . . . . . . . . . . .c . . . . . . . 93
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4.41 Headlight adjustment - check and adjust headlights if necessary . . . . . . . . . . . . . . . . . . . . 94
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4.42 Perform a test run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
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5 Additional tasks due to country legislation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
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5.1 Exhaust gas test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
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5.2 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
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ii Contents
FOX 2004 ➤
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)
Exhaust gas warning light no no yes yes

Number of cylinders/Valves 4/2 4/2 4/2 4/2
per cylinder
Cylinder volume l 1.0 1.6 1.6 1.6
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Max. output kW/rpm 52,0/6000Volk sw 74/5750 o es74,0/5750
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Engine torque Nm/rpm 89,0/4500 edb 140,0/3250 140,0/3250
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Diameter ∅ mm s au67,11 76,5 76,5 ra
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Stroke mm 70,6 87,0 87,0 87,0
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Compression rate 10,8;1 10,8:1 10,8:1 10,8:1
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Injection/ignition 4BV1) ME 7.5.102) ME 7.5.102) ME 07.05.30
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Octane rating min. 95 lead-free 95 lead-free 95 lead-free 95 lead-free
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Electronic accelerator yes yes yes yes
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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
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Recirculation of exhaust no no no no
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Exhaust gas turbocharger no no no no
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1) 4BV injection system with immobilizer

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Identification letters ASY BNM
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Engines Diesel engine Diesel engine
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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 ➤
Identification letters ASY BNM

Self-diagnosis yes yes
Catalytic converter yes yes
Lambda adjustment no no
Recirculation of exhaust gases yes yes
Exhaust gas turbocharger no yes
Identification letters BKR BMD CHFB

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Production from 11.22.04 ofrom
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Cylinder volume l 1,4 1,2 1,2
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Max. output kW/ 55,0/5600 40,0/4750 40,0/4750
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Engine torque Nm/ 110,0/4000 106,0/3000 106,0/3000
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Diameter ∅ 76,5 76,5 76,5
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Stroke mm 75,6 86,9 86,9
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Compression rate 10,5 10,3 10,3
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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
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Electronic accelerator yes yes yes

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Self-diagnosis yes yes yes
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Catalytic converter yes yes yes
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Lambda adjustment yes yes yes
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Recirculation of exhaust gases no no no

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Exhaust gas turbocharger no no no
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2 1. Engine overview
FOX 2004 ➤
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
2.1 Service table

VW standards on engine oil ⇒ page 3
Replacement intervals for the filters ⇒ page 3
Replacement intervals for the timing belt ⇒ page 4
Replacement intervals for spark plugs ⇒ page 4
Service intervals - Models ▸ 2008 (except Europe) ⇒ page 4
Service intervals - Models ▸ 2007 (Europe) ⇒ page 5
Service intervals - Models 2008▸ (Europe) and Models 2009▸
(except Europe) ⇒ page 5
Service intervals – table ⇒ page 28
2.1.1 VW standards on engine oil

Petrol engines
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Diesel engines VW standards

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With injector - pump 505 01

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2.1.2 Replacement intervals for the filters

Replacement intervals for the filter
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ENGINE OIL FILTER

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For all countries: every 15,000 km or 1 year

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Europe only every 60,000 km or 4 years

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Except Europe every 18,641.14 mi or 2 years

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2. Service plans 3
FOX 2004 ➤
Replacement intervals for the filter

all Diesel comply‐ Diesel not com‐ Bio-diesel (RME)
diesel engines ing with Europe‐ plying with Euro‐
an Standard 590 pean Standard
590
Chang Drain Chang Drain Chang Drain
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at ev‐ 30,000 at ev‐ at ev‐ at ev‐ at every
ery and ev‐ ery ery ery 9,320.57 mi
37,282. ery 30.000 9,320.5 30.000
27 mi 60,000 km 7 mi km
km
Engines with identification let‐ at every 30,000 km
ters AQZ, BAH, BLH, and BKR
DUST AND POLLEN FILTER

All engines ▸2007 for Europe at every 30,000 km
and except Europe ▸2008
All engines 2008▸ for Europe every 18,641.14 mi or 2 years
and 2009▸ except Europe
2.1.3 Replacement intervals for the timing belt

Replacement intervals for the timing belt
Diesel engines
En‐ MKB Time period Replacement Tensioning
gine interval roller
type
1.9 l ASY - at every at every
SDI 93,205.68 mi 93,205.68 mi
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2.1.4 Replacement intervals for spark plugs

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All petrol engines every 60,000 km or 4 years

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2.1.5 Service intervals - Models ▸ 2008 (ex‐

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Intervals according to the maintenance in‐ Service

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2. Service plans
FOX 2004 ➤

– Inspection service according to the
♦ at every 1 year, every 30,000 km and
every 60,000 km
7) In vehicles using diesel with high sulfur content, the oil must be changed at
every 7,500 km. Countries with high sulfur content in diesel, ⇒ page 28
2.1.6 Service intervals - Models ▸ 2007 (Eu‐

rope)

tries)
– Inspection Service
♦ at every 30,000 km or every 2 years,
whichever occurs first.
8) In vehicles using diesel withahigh lkswagenthe

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2.1.7 Models 2008▸ (Europe) and Models
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– Intermediate service
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– Inspection Service
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♦ at every 60,000 km or 3 years and,

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9) In vehicles using diesel with high sulfur content, the oil must be changed at
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every 7,500 km. Countries with high sulfur content in diesel, ⇒ page 28 .
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The Delivery Inspection is valid for both service plans for models
p by
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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
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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
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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
– Battery - check the battery terminals for proper seating. ⇒ page 40

– Battery: check the charge capacity (the vehicle must have been turned off ⇒ page 43
for at least 2 hours).
nform
ercia
– Airbag: check turn on.

m
a
com
tio
– Ignition cables and spark plug connectors: check the condition and fasten‐
n in
r
ing.
te o
thi
s
iva
– Wheel fastening screws: apply the recommended torque. ⇒ page 39
do
r
rp
cum
fo
– Switches, electric consumers, indicators and other commands: check op‐
en
ng
t.
eration.
yi Co
Cop py
t.
– Install all vehicle components (if available): mats, wipers, spoiler, roof an‐
rig
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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
dows, front and rear window wipers.
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
2.3 Oil Change Service

te o
thi
s
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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.
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Cop py
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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 .
Oil change service performed at every 15,000 km or 1 year.

Notes for carrying out tasks
The sequence of each service operation was tested and opti‐
mized. It shall be adhered to so as to prevent unnecessary service
interruptions.
If the battery is disconnected, the power window drive automatic
closing function will not operate. Thus, this function must be re‐
programmed before delivering the vehicle. The vehicle battery
cannot be disconnected after reprogramming. Power window
drive - reprogram ⇒ page 36 .
Inform the customer in case of problems within a service scope
that require a Repair action.
Ask the customer about installing new Windscreen 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 Windscreen/rear window
wiper system.
A tolerance of “up to 1,000 km” is acceptable, above or below the
indicated mileage, in services based on mileage, and “one
month”, after or before the indicated time, for services based on
time.
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 50 ml of additive for 950 ml of water.
2. Service plans 7
FOX 2004 ➤
Maintenance - Edition 07.2010 n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
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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
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nl
pt
du
an
itte
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erm
ab
ility
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Oil Change Service Service
wit
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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
standard 502 00 (VW).

Petrol engine: Identification letter BMD, filling capacity 2.85 l; standard 502 00
m
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
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– 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.
– Spare wheel support stop: lubricate. ⇒ page 35

♦ CrossFox only
Vehicle on raised platform

– Engine oil: drain or aspirate. ⇒ page 58
– Rear pads and linings: check the thickness. ⇒ page 67
– Brake disks: check the level of wear and corrosion ⇒ page 69
Concluding tasks
– Maintenance and Warranty book: record the date and kilometers traveled for
the next service.
pillar (B).
2.4 Intermediate service Models ▸2010 (Eu‐

rope) and Models 2009▸ (except Eu‐
rope)
Service based on time or kilometers traveled
Vehicles with “Service based on time or kilometers traveled” have
the PR numbers: QG0.
The Intermediate Service is performed every 30,000 km or 2
years.
interruptions.
8 2. Service plans
FOX 2004 ➤
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
nf
ercia
antifreeze product -G 052 164- to the Windshield/rear window
or
wiper system.
m
m
atio
om
n in
or c
additive
thi
te
sd
iva
o
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
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pyri by
Vo
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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
♦ 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 ➤
Intermediate service Models ▸2010 (Europe) and Models 2009▸ (except Eu‐ Service
rope)
(VW).
(VW) or 505 01 (VW).
(VW).
Petrol engines: Identification letters BAH, BLH, and CFZA, filling capacity 4.0 l;
standard 502 00 (VW).
(VW).
(VW).
DIN EN 590).
– Brake system: perform a visual check for leaks and damage. ⇒ 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
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
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
2.5 Intermediate service Models 2011▸ (Eu‐

rope)
rrectness of i
l purpos

nform
ercia

m
The Intermediate Service is performed every 30,000 km or 2

com
tio
years.
n in
r
te o
thi

s
iva
do
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rp

um
fo
en
g

n
t.
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interruptions. Cop py
t. rig
gh ht
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If the battery is disconnected, the power window drive automatic p by
co Vo
by lksw
cted agen
Prote
AG.

10 2. Service plans
FOX 2004 ➤
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.
antifreeze product -G 052 164- to the Windshield/rear window
wiper system.
additive
ter.
Note

. Volkswagen AG
♦ For countries with high sulfur content in Diesel, the Engine
ksw
agOil
en AG does
Change Service must be carried out every 7500 km. by Countries
not
Vol gu
ara
where the sulfur content is higher ⇒ page 28 o.rised
nte
th eo
au ra
c
ss
Intermediate service Models 2011▸ (Europe) Service ce
e
nl
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
lights, indicator system and warning lights

spec
es, in part or in w
– 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

l purpos
♦ CrossFox only
nform
ercia
mm.
m
at
om
on
c
in t
_____ mm
or
his
ate
do
priv
_____ mm.
um
for
en
ng
t.
yi Co
op
_____ mm. C py
t. rig
gh ht
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p by
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by lksw
_____ mm. Prote
cted AG.
agen
2. Service plans 11
FOX 2004 ➤
Intermediate service Models 2011▸ (Europe) Service

Vehicle exterior
– Windshield: check for damage
– Windshield and rear window wiper: check operation. ⇒ page 49
AG. Volkswagen AG
– Windshield/rear window washer: adjust the water lksw
jet
ag from ejectors anddore‐
e n
es n ⇒ page 49
plenish the reservoir additive liquid level. d by Vo ot g
ua
e ran
– Windshield and rear window wiper blades: ris check the resting position and, ⇒ page tee51
tho or
if necessary, adjust it; for malfunctioning
au wiper blades: correct the sweeping ac
ss
angle.
ce
le
un
pt
Engine compartment
an
d
itte
y li
– Engine oil: fill
erm
⇒ page 58
ab
ility
ot p
wit
is n
h re
(VW).
ole,
spec
(VW) or 505 01 (VW).
t to the co
(VW).
Petrol engines: Identification letters BAH, BLH, and CFZA, filling capacity 4.0
rrectne
l; standard 502 00 (VW).
(VW).
ss
o
cial p
f i
(VW).
nform
mer
– Engine and components in engine compartment (from above): check visu‐ ⇒ page 65
atio
m
ally for damage and leakage.

o
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
Theoretical value – 25° C (in Arctic climate countries – 35° C) actual value
en
ng
t.
(value measured) ____ °C.
yi Co
Cop py
. rig
ht ht
rig by
opy Vo
by c lksw
cted agen
Prote AG.
DIN EN 590).
– Headlight adjustment: check. ⇒ page 94
– Engine and components in engine compartment (from below): perform a ⇒ page 65
visual check for leaks and damage.
– Brake discs: check the level of wear and corrosion ⇒ page 69
– Shock absorbers: verify for leaks (except Europe)
Concluding tasks
– Maintenance and Warranty book: record the date and kilometers traveled
for the next service.
pillar (B).
12 2. Service plans
FOX 2004 ➤
2.6 Inspection Service

Inspection intervals
Vehicles with service depending on time or kilometers traveled,
every 30,000 km or 2 years and every 60,000 km or 4 years (for
Europe on vehicles model ▸2007).
every 60,000 km or 3 years and, then, every 2 years (for Europe
on vehicles model 2008▸ , except Europe on vehicles 2009▸) .
every 1 year, 30,000 km, and 60,000 km (except Europe for ve‐
hicles model ▸2008).
If the vehicle runs 30.000 km, 60.000 km, etc. before elapsing 1
year, the Inspection Service for 30,000 km, 60,000 km, etc. shall
be performed together with the inspection service for 1 year.
If the vehicle runs 30.000 km or 60.000 km after the performance
of the Inspection Service for 1 year, perform only the items ex‐
clusive for the Inspection Service for 30,000 km or 60,000 km.
A tolerance of “up to 1,000 km” is acceptable, above or below the AG. Volkswagen
indicated kilometer traveled, in services based on kilometerslktrav‐wage
n AG do
es n
o s
eled, and “one month”, after or before the indicated time,d by Vfor ot g
ua
services based on time. or
ise ran
te
th eo
s au ra
c
s
ce
le
Note
un
pt
an
d
itte
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♦ 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
es, in part or in w
t to the co
rrectness of i
l purpos

nform
ercia

interruptions.
m
a
com
tio
If the battery is disconnected, the power window drive automatic

n in
r
te o
thi
s
iva

do
r
rp

um
fo

en
ng
t.
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op
C py
t. rig
gh
ht
pyri by
Vo
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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.
additive
EUROPE only -G 052 164 A1- or -G 052 164 A2- 300 ml of additive for 700 ml of wa‐
ter.
ter.
2. Service plans 13
FOX 2004 ➤

additive
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
om
ion
▸2008
c
in t
or
his
ate
– Dust and pollen filter: Replace the filter element. ⇒ page 84
do
priv
c
♦ at every 30,000 km
um
for
en
ng
t.
yi
Co
op py
▸2008
t. C rig
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Vo
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♦ 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

♦ CrossFox only
Vehicle exterior
– Windshield: check for damage
– Windshield and rear window wiper: check operation. ⇒ page 49

– Windshield and rear window wiper blades: check the resting position and, ⇒ page 51
if necessary, adjust it; for malfunctioning wiper blades: correct the sweeping
angle.
– Body and paintwork: check for damage.
▸2008.
♦ every 60,000 km or 3 years and after every 2 years
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
▸2008
t to the co
rrectne
Tyres and wheels
ss o
cial p
f in
mm.
form
mer
atio
m
_____ mm
o
n
c
i
or
n
thi
te
sd
a
_____ mm.
iv
o
pr
cum
r
fo
en
ng
_____ mm.
t.
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op py
t. C rig
gh ht
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_____ mm. p by
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by lksw
cted
agen
Prote AG.
Underside of the vehicle

– 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.
– Poly-V belt: check state. ⇒ page 65
♦ at every 37,282.27 mi
▸2008
♦ for Europe on vehicles model 2008▸except Europe on vehicles model
2009▸.
– 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
▸2008
♦ for Europe on vehicles model 2008▸ and except Europe on vehicles model
2009▸.
– 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 ➤
– Anti-roll bar buffers and front/rear suspension arm joints rubber bushings:
check for damage
– Front/rear shock absorber springs and rubber buffers

– Rear wheels: adjust roller bearing gaps. ⇒ page 74

♦ only for vehicles without ABS and with the following engines: AQZ, BAH,
BLH, and CFZA from 07/01/2007.
– Exhaust system: make a visual inspection for leaks and damage.

– Fuel filter: replace. ⇒ page 87
♦ Identification letters AQZ, BAH, BLH, and CFZA.
♦ at every 30,000 km
Engine compartment
(VW).
(VW) or 505 01 (VW).
(VW).
Petrol engines: Identification letters BAH, BLH, and CFZA, filling capacity 4.0
l; standard 502 00 (VW).
(VW).
(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
Theoretical value – 25° C (in Arctic climate countries – 35° C) actual value
spec
(value measured) ____ °C.

es, in part or in w
t to the co
– Spark plugs: replace. ⇒ page 79

♦ at every 60,000 km or every 4 years, whichever occurs first.
rrectness of i
– Timing belt and tensioning pulley for camshaft drive: replace. Additional ⇒ page 85
work with separate payment!
l purpos
♦ Diesel engine: Identification letters ASY.

nform
♦ at every 93,205.68 mi
mercia
at
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ion
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16 2. Service plans
FOX 2004 ➤
– 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▸.
– Timing belt for camshaft drive: check state. ⇒ page 85

♦ 4-cylinder petrol engines.
♦ Identification letters AQZ, BAH, BLH, BKR, and CFZA
♦ at 90,000 km and at every 30,000 km
– 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.
♦ Identification letters CFZA. gen AG
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♦ at every 30,000 km or every
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– Air cleaner: replaces element and clean the athe
u filtering
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filter case. or ac ⇒ page 86
♦ identification letterss AQZ and BKR.
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♦ at every 30,000 km or every 2 years, whichever occurs first an
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♦ Engine identification letters ASY, BKR, BNM, and BMD.

wit
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♦ at every 37,282.27 mi or every 4 years, whichever occurs first.

spec

t to the co
♦ Only for diesel engine vehicles according to DIN EN 590.

♦ at every 37,282.27 mi
rrectne

s
♦ Only for bio diesel vehicles in compliance with DIN E 51606 and for diesel
s o
cial p
vehicles not covered by standard DIN EN 590.

f inform
mer
♦ at every 30.000 km
atio
om
– Fuel filter: drain the water ⇒ page 89

c
i
or
n thi
♦ Only for diesel engine vehicles according to DIN EN 590 (only for ASY en‐
te
sd
a
gines).
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♦ at 30,000 km and, then, every 60,000 km.

en
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t.
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– Brake fluid: replace every 2 years (additional work with separate payment!) ⇒ page 90 ht. rig
rig ht
♦ at every 2 years.
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▸2008).
♦ at 3 years and after every 2 years for Europe on vehicles model 2008▸ and
except Europe on vehicles model 2009▸.
– Brake fluid: replenish to the level (depending on pad wearing). ⇒ page 93

▸2008.
– Battery: fill the electrolyte level (except for maintenance-free batteries).
2. Service plans 17
FOX 2004 ➤
– 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.
▸2008
♦ at every 60,000 km or 3 years and, then, every 2 years
agen AG olksw
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ag vehicles
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– 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
for the next service.

un
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pillar (B).
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– Perform a test run. ⇒ page 98
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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
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— performing supplementary maintenance works is necessary.
inform
mer
Also, it is possible to perform additional works, by considering the
atio
records in the service plan (or on the adhesive tag: Your next
om
service), out of the regular maintenance intervals. n

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At every 30,000 km
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Supplementary services Page

en
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– Dust and pollen filter: clean case and change filter element ⇒ page 84
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cted AG.
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– Headlights: adjust the beams ⇒ page 94

♦ for Europe on vehicles model ▸2007 and except Europe on vehicles model ▸2008
– Sunroof: check operation, clean the guide rails and lubricate them with Special ⇒ page 46
grease -G 000 450 02-
– Mechanical transmission: check oil level. ⇒ page 66

– Fuel filter: replace (vehicles with engine AQZ, BAH, BLH, and CFZA only) ⇒ page 87
♦ 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 ➤

♦ Identification lettersnCFZA.
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– Fuelau filter: drain the water
th or
a ⇒ page 89
♦ Only
ss for diesel engine vehicles according to DIN EN c590 (only for ASY engines).
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♦ at 30,000 km and after every 60,000 km
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– Fuel filter: replace ⇒ page 88
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♦ Only for biodiesel vehicles in compliance with DIN E 51606 and for diesel vehicles
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not covered by standard DIN EN 590.
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spec
es, in part or in w
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At every 37,282.27 mi
rrectness of i
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♦ for vehicles with kilometers traveled over 60,000 km, within a 3-year period and, then,
every 2 years.
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every 2 years.
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– Air cleaner: replace the filtering element and clean the filter case.
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⇒ page 86
♦ identification letters BAH and BLH.
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♦ for vehicles with kilometers traveled over 37,282.27 mi, within a 4-year period
AG.
♦ for vehicles with kilometers traveled over 60,000 km, within a 4-year period.
– Spark plugs: replace ⇒ page 79

♦ for vehicles with kilometers traveled over 37,282.27 mi, within a 4-year period
♦ Checking data, spark plugs ⇒ Ignition system; Rep. Gr. 28 ; Ignition system
– Fuel filter: replace ⇒ page 88

♦ (only for diesel engine vehicles according to DIN EN 590).
– Fuel filter: drain the water ⇒ page 89

♦ Only for diesel engine vehicles according to DIN EN 590 (only for ASY engines).
– Poly-V belt: check condition: In vehicles without automatic tensioning element, adjust ⇒ page 65
tension.
every 2 years.
– Power steering: check the oil level. ⇒ page 82
2. Service plans 19
FOX 2004 ➤

grease -G 000 450 02-
every 2 years.

every 2 years.
At every 55,923.41 mi
– Timing belt for camshaft drive: check state ⇒ page 85
♦ for Europe on vehicles model ▸2007
At 90,000 km and, then, at every 30,000 km)

♦ 4-cylinder petrol engines: Identification letters AQZ, BAH, BLH, BKR, and CFZA
AG. Volkswagen AG d
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At every 93,205.68 mi aut
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nl
pt
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an
– Timing belt and tensioning roll for camshaft drive: replace ⇒ page 85
itte
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erm
♦ Diesel engine: Identification letters ASY

ab
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♦ extra work to be billed separately!

wit
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hole

spec

es, in part or in w
t to the co

rrectness of i
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At every 2 years
nf
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– Dust and pollen filter: clean case and change filter element ⇒ page 84
atio
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♦ identification letters AQZ and BKR.

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♦ Identification letters CFZA. by c lksw
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20 2. Service plans
FOX 2004 ➤

– Brake fluid: replace ⇒ page 90
♦ for Europe on vehicles model
age▸2007
n AG. Voand
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gen AG Europe on vehicles model ▸2008
doe
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3 years after thessdelivery inspection; then, every 2 years
ce
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un
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an
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itte
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erm
ab
ility
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wit
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h re
ole,
– Poly-V belt: check condition: In vehicles without automatic tensioning element, adjust ⇒ page 65
spec
tension.
t to the co
rrectne
– Brake fluid: replace ⇒ page 90
ss
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
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n
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thi
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sd
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grease -G 000 450 02-

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♦ for vehicles with kilometers traveled over 60,000 km, within a 3-year period and, then, cum
r
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every 2 years.
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t.
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♦ for Europe in model 2008▸ vehicle and in model 2009▸ vehicles elsewhere t. C rig
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AG.
every 2 years.
At every 4 years
♦ identification letters BAH and BLH
– Spark plugs: replace ⇒ page 79

♦ Checking data, spark plugs ⇒ Ignition system; Rep. Gr. 28 ; Ignition system
2. Service plans 21
FOX 2004 ➤
3 General remarks
3.1 Rear license plate (only CrossFox Eu‐

rope) - install
Note
For the “CrossFox”Europe versions, position the license plate

aligned with the line -1- in the rear protector and fasten the plate
-2- to this position
3.2 Lifting the vehicle with a workshop lift

and jack
WARNING
♦ Before positioning the vehicle onto a lift, it is necessary to

make sure that there is enough space between the lift and
the lower body parts.
♦ The vehicle may only be lifted in the support points indi‐
cated in illustration, in order to avoid damaging the vehicle
floor and prevent the vehicle from tipping.
♦ Never start the engine and engage a gear with the vehicle
lifted, even if only one drive wheel is on the floor. If these
AG. Volkswagen AG d
guidelines are not followed, there will be kswrisk
agenof an acci‐ oes
not
dent! by Vol gu
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♦ When it is necessary to workuunder
tho
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the vehicle, it must be tee
or
supported onto appropriatess stands.
a ac
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♦ Before placing a vehicle on an lift, make sure that the ve‐

un
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an
d
hicle weight does not exceed the authorized load capacity

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♦ To prevent damage, always use a suitable rubber or

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wooden support.
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spec
♦ Under no circumstances must the vehicle be lifted by the

oil crankcase, transmission, front or rear axles.

t to the co
♦ The vehicle must not be lifted by the vertical reinforcement

of the longitudinal member.
rrectness o
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mer
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c by lksw
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3. General remarks Prote AG.
FOX 2004 ➤
3.2.1 Support points for workshop lift and jack

Front section: In the longitudinal reinforcement of the central lon‐
gitudinal member.
Rear section: In the welded flange reinforcement of the lower lon‐

gitudinal member.
Note
To anchor the CrossFox, using electrical-hydraulic lifts, refer to

the Tools and EquipmentenManual.
AG. Volkswagen AG
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3.3 Service tag

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3.3.1 Stick the tag “Next service” (upon Deliv‐

hole
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
(internal side) of the Windscreen, with the “FRONT” facing outside

the vehicle (check instructions in the Service Organization Man‐
nf
ercia
ual).
orm
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n in
or c
thi
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gh ht
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co lksw
by
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Prote AG.
3.3.2 Stick the tag “Next service” (upon Oil

Change Service or Inspection Service)
– On the service tag “Next service”: Mark the Oil Change Service
or Inspection Service (whichever occurs first) and write down
the date and mileage traveled.
3. General remarks 23
FOX 2004 ➤
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
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the vehicle (check instructions in the Service Organization Man‐
erm
ab
ual).
ility
ot p
wit
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spec
t to the co
rrectness o
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f inform
mer
atio
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n
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3.3.3 Paste the “data holder” on the customer

t
sd
iva
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service plan (in the delivery inspection):
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t.
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– Please paste the upper data holder on both -arrow-. t. Cop py
rig
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1 - planning week. p by
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2 - PR number. Prote AG.
3.4 Self-diagnosis - refer to the fault memo‐

ry of all systems
3.4.1 Refer to the fault memory of all systems
with the Diagnosis, Measurement and
Information System
Special tools and workshop equipment required

♦ Diagnosis, Measurement and Information System
♦ Diagnosis cable -VAS 5051/3- or - VAS 5051/6-
24 3. General remarks
FOX 2004 ➤
3.4.2 Connect the Diagnosis, Measurement

and Information System
– Operate the parking brake.
– Mechanical transmission: Selector lever in neutral gear posi‐
tion.
Connect the Diagnosis, Measurement and Information System to
the Diagnosis cable -VAS 5051/3- or -VAS 5051/6- with the igni‐
tion turned off as follows:
– Turn the ignition on.
AG. Volkswagen AG d
agen oes
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aut ra
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Indicated on display:
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es, in part or in w
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rrectness of i
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nform
3.4.3 Select the operation mode:
mercia
at
– On the display, press the key for “Vehicle self-diagnosis”
om
ion
-arrow-.
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Note
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If the messages indicated with the operation sequence in the dis‐ C py
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play do not appear on display: ⇒ Vehicle diagnosis, testing and
gh ht
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information system VAS 5051.
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3.4.4 Select the vehicle system:

– On the display, press “Entire system” -arrow-
FOX 2004 ➤
– The Diagnosis, Measurement and Information System sends

all known keywords in sequence.
If a command unit replies with its identification, the display informs
the number of faults or “No fault detected”.
Any faults stored in a system will be listed. Then, the Diagnosis,
Measurement and Information System -VAS 5051A/52- sends
the next keyword.
The automatic verification process is completed when the follow‐
ing indication is displayed:
– On display, press the “Print” key -1- and, in the print menu,
press “Screen”.
The Diagnosis, Measurement and Information System prints all
faults or “0 fault(s) detected”. If there are faults stored in the sys‐
tem, repair measures are required. The fault protocol must be
sent together for repair.
– On the display press the “Skip” key -2-.
– On the display press the “End” key -arrow-. AG. Volkswagen AG d
agen oes
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– Press the “End” key on the conclusion menu. sed b ara
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– Switch the ignition off and disconnect the diagnosis
aut connector. ra
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3.5 Vehicle identification data
t to the co
3.5.1 Vehicle identification number“VIN”- lo‐ rrectness of i
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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
fuel pump access cover.

a
com
tion in
r
te o
thi
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iva
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rig ht
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3.5.2 VIS tag - location

Destructive label with partial chassis number (VIS).
AG. Volkswagen AG d
agen oes
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ara
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ris nte
ho eFOX 2004 ➤
aut or
ac
ss Maintenance - Edition 07.2010
ce
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nl
pt
du
The first VIS tag -arrow- is on the right side suspension housing.
an
itte
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erm
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ility
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wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
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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
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thi
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f
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t.
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rig ht
py by
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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
On four-door vehicles, the tag is on the right pillar B between the

doors. It becomes visible with the right front door opened.
3.5.3 Identification plate

Refer to the body manual ⇒ Body Repairs; Rep. Gr. 00 ; Technical
data .
3.5.4 Vehicle identification tag - location

The vehicle identification tag -arrow- is in the rear section, inside
the spare wheel housing, on the left side in the vehicle motion
direction.
Includes:
FOX 2004 ➤
3.5.5 Meaning of vehicle identification number:

9BW CA0 5z 9 4 T 000 001
Manufacturer Complemen‐ Type Complemen‐ 2004 year Manufactur‐ Sequential
brand tary tary model ing number
digit digit locations
3.6 Service intervals
3.6.1 (The PR number is QG0)
Note

ifications VW 502 00 (petrol) and VW 505 01 (SDI), (diesel PD)
and (TDI).
with higher sulfur percentage ⇒ page 28
Notes for performing works:

– The individual service position sequence is tested and opti‐
mized. It should be observed to prevent unnecessary work
interruptions.
– If faults are found in the Inspection Service scope that
gen AG
. Vorequire
lkswagen AG
does
repairs, the customer must be informed.Volkswa not
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db ara
Intervals rise Service nte
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– Oil change service performedssat every 15,000 ⇒ page 7 c
km or 1 year.
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nl
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– Intermediate service every 30,000 km or 2 ⇒ page 8

itte
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years Models ▸ 2010 (Europe) and Models

erm
ab
ility
2009▸ (except Europe) .

ot p
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– Inspection services every 30,000 km or 2 ⇒ page 13

h re
years (for Europe on vehicles model ▸2007).

hole
spec
– Inspection services every 60,000 km or 3 ⇒ page 13

es, in part or in w
t to the co
years and, then, every 2 years (for Europe on

vehicles model 2008▸ and except Europe on
vehicles model 2009▸).
rrectness of i
– Inflexible inspection services every 1 year, ⇒ page 13

30,000 km, and 60,000 km (except Europe on
l purpos
vehicles model ▸2008 ).

– Brake fluid change every 2 years. ⇒ page 90
nform
ercia
♦ at 3 years and, then, every 2 years (for Europe

m
on vehicles model 2008▸ and except Europe

at
om
io
on vehicles model 2009▸).

n
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3.7 Countries with high sulfur content in diesel

p
cum
for
en
ng
t.
Egypt Indonesia New Zealand Taiwan
yi Co
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Argentina Jamaica Oman Trinidad Tobago
rig
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Armenia Yugoslavia10) Pakistan Turkey
c by lksw
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Prote AG.
Australia Kazakhstan Panama Tunisia
Bolivia Qatar Papua-New Guinea Ukraine
FOX 2004 ➤
Bulgaria Kyrgyzstan Peru Uruguay

Mainland China Colombia Philippines Uzbekistan
Costa Rica Croatia Poland United Arab Emirates
Dominican Republic Kuwait Russia (Eastern & West‐ Vietnam
ern)
El Salvador Malaysia Saudi Arabia Zimbabwe
Ecuador Morocco Singapore
Guatemala Moldavia South Africa
India Myanmar Suriname
10) Yugoslavia = Serbia, Montenegro, Vojvodina, Kosovo
3.8 Engine oils
3.8.1 Approved standards for automotive engine oils

Petrol engines with identification letters AQZ, BAH, BLH, BKR,
BMD, and CFZA
vehicles with PR number (QG0)
Petrol engines VW standards
3 and 4 cylinders 502 00
Diesel engines with identification letters ASY

AG. Volkswagen A
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or VW standards
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pt
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ab
Diesel engines with identification letters BNM

ility
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vehicles with PR number (QG0)

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spec
Diesel engines VW standards

es, in part or in w
TDI
t to the co
505 01
rrectness of i
3.8.2 Oil properties

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Multipurpose oils according to VW 505 00 standard:

nf
ercia
♦ It can be used throughout the year in mild climate zones.

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♦ Excellent cleaning capability.

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♦ Lubricating power ensured in every temperature range and

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engine load.
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♦ High resistance to aging.

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Multipurpose oils according to VW 502 00 standard:
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♦ It is particularly suitable for use in severe operating conditions, yri
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conditions and towing, constant traveling in mountain areas
Prote AG.
and hot climate zones.
FOX 2004 ➤
Multi-purpose oil, according to standards VW 505 01 and
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01 db
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♦ Engine protection between long maintenance
ut
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ss
♦ Protection against residue build-up.
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♦ High viscosity for constant fuel saving in all conditions of use.
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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
3.9 Identification letters and engine number
nform
mercia
a
com
tio
3.9.1 ASY engine
n in
r
te o
thi
s
iva
The engine identification letters and engine number are engraved
do
r
rp
c
on the engine block -arrow- in the engine/gearbox separation
um
fo
area. Additionally, the upper mechanical distribution cover has a
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.
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Prote AG.
3.9.2 BNM engine

The engine identification letters and engine number -arrow- are
engraved on the engine block. Additionally, the upper mechanical
distribution cover has a sticker with the engine identification let‐
ters and serial number. The engine identification letters are also
indicated on the vehicle identification tag.
FOX 2004 ➤
3.9.3 BMD engine

The engine identification letters and engine number are engraved
on the engine block in the area between the engine and the gear‐
box. Additionally, there is on the right engine support side
-arrow- a sticker with the engine identification letters and serial
number. The engine identification letters are also indicated on the
vehicle identification tag.
3.9.4 AQZ, BAH, BLH, BKR, and CFZA en‐

gines
The engine identification letters and serial number are engraved
on the engine block, below the thermo valve case. Additionally,
G. Volkswagen AG d
the upper mechanical distribution cover en Aa
waghas sticker with theoeen‐
lks s no
gine identification letters and serial
d by V number. The engine identifi‐ t gua
o
cation letters are also indicated
or
ise on the vehicle identification tag.
ran
te
th eo
au 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
3.10 Push starting (pushing the vehicle to t to the co
start)/towing
rrectness of i
Push starting and towing are carried out in different ways de‐
pending on the legislation of each country.
l purpos
If the vehicle is provided with a towing hook, then a tow cable or

tow bar should be attached to the front or rear hook.
nform
mercia
a
com
tio
Note
n in
r
te o
thi
s
iva
♦ The tow cable should be elastic, so both vehicles are protec‐

do
r
rp
ted. Thus, only synthetic cables or made of similar elastic

um
fo
materials can be used. Yet, the safest procedure is to use a

en
ng
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.
If the vehicle is push started or towed, please note the following:

Whenever possible, it is recommended that the vehicle is not
pushed for a push start. Instead, use the auxiliary starting cables.
♦ The legal requirements for towing vehicles must be complied
with.
FOX 2004 ➤
♦ Both drivers must be experienced in towing vehicles. Inexper‐

ienced people should not try push starting or towing a vehicle.
♦ When using a tow cable, the driver of the towed vehicle must
carefully release the clutch when starting to move and when
shifting gears. n AG. Volkswagen A ge G do
swa es n
♦ The driver of the towed vehicle must ensure the by
cable
Vol
k
is al‐ ot g
ua
ways taut. ir se
d ran
tee
tho or
♦ The warning lights of both vehicles must
ss
aube turned on, and ac
other legal requirements must also be observed, if necessary.
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
3.10.1 If the jump starting has to be carried out
nform
against our recommendation, please
ercia
note the following points for vehicles

m
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
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
In vehicles equipped with catalytic converter, the engine should

not be started by pushing the vehicle for more than 50 meters if
the catalytic converter is hot. The unused fuel may get into the
catalytic converter and damage it.
Over greater distances, the front vehicle section must be lifted.

With a tow car, the vehicle may only be towed with the front
wheels lifted.
Reason: With the vehicle suspended by the rear wheels, the drive
shafts turn backwards. This causes the planetary gears to turn at
rotation rates so high that the transmission is severely damaged
in a short period of time.
FOX 2004 ➤
4 Service descriptions
4.1 Clock - set olksw

agen
AG. Volkswagen AG d
oes
not
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by ara
Set the clock as follows: rised
nte
ho eo
ut
Set the hours (2-line display): ss a ra
c
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
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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
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nform
mercia
at
om
ion
New Fox
c
in t
or
his
te
Set the minutes:

a
do
priv
cum
or
– To activate the minute set function, keep the button -arrow-

f
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
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by c lksw
cted agen
Prote AG.
– Press the button -arrow- for more than 2 seconds to go back

to partial odometer function.
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
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erm
ab
– There will be a clock symbol beside the hour.
ility
ot p
wit
is n
h re
ole,
spec
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
terclockwise. To set the minutes, turn the button -arrow-
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
– To set the minutes correctly based on another clock, move the

t.
yi Co
op
button -arrow- until it reaches one unit before the exact minute. C py
t. rig
At the moment the other clock reaches the full minute, turn the gh ht
yri by
button again to the right.
op Vo
by c lksw
cted agen
Prote AG.
4.2 Maintenance interval indicator (if avail‐

able) : reset with the Vehicle Diagnosis,
Measurement and Information System
♦ with the Vehicle Diagnosis, Measurement and Information
System
4.2.1 Reset the service interval indicator

through the partial odometer return but‐
ton (vehicles 2010▸)
The service interval indicator must be
♦ reset at the delivery inspection, at every oil change service,
and at every inspection service!
Reset the indicator as follows:
– Turn the ignition off.
– Press and hold the button -arrow- next to the speedometer.
34 4. Service descriptions
FOX 2004 ➤
New Fox
– 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
4.3 Spare wheel support stop: lubricate -
pt
an
d
itte
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(CrossFox)
erm
ab
ility
ot p
– Any grease residue (contaminated grease) must be removed
wit
is n
from the stop.
h re
ole,
spec
– Lubricate the stop inside -2- with Silicone grease -G000 405
A2-
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
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r
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
4.4 Fire extinguisher - check the charge
4.4.1 Engine identification letters AQZ, BAH,

CFZA
Location: fastened to a support on the lower front section of the
passenger's seat
The pressure gauge indicator must be on the green range -2-,
check the indicator and pressure scale:
FOX 2004 ➤
♦ Green range -2-= the extinguisher is charged.

♦ Red range -1-= the extinguisher is discharged.
♦ Inviolability seal -arrow-.
Note
♦ Check for possible oxidation and for fastening of components.

♦ The vehicle fire extinguisher is designed to be used only once,
and the expiration date is defined by law!
♦ Check the expiration date printed on the extinguisher's
agen cylin‐
AG. Volkswagen AG d
o
der. Vol
ksw es n
ot g
d by ua
ran
♦ The inviolability seal -arrow- ensureshthatris the fire extinguisher
e
tee
t o
has not been used. au or
ac
ss
♦ Whenever used, the extinguisher must be immediately re‐
ce
e
nl
pt
du
charged.
an
itte
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erm
♦ Driving vehicles with extinguishers which are out-of-date or in
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
power window drive will not be completely operational. The win‐

dow drives must be reprogrammed before the vehicle's delivery.
nf
ercia
The vehicle battery cannot be disconnected after reprogramming.
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
ed for a few more seconds.

o
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.
is not activated in the plant.

On “alpha” radios, the fixed code is activated as follows:
The security coding of the ready-to-play radio will only be activa‐
ted when the fixed code is specified. The fixed code must be
activated as follows:
– Turn the radio on.
– The digital display will exhibit “SAFE” and the number “1000”.
FOX 2004 ➤
– Press the keys TP and TA -1- simultaneouslywage

n Auntil
G. Vo“1000”
lkswagenap‐
AG do
es n
pears on the digital display. Release
y Vthe
o keys!
lks ot g
u b ara
ed
– Enter the code number attached risto the radio card with the help nte
tho e
of the tuning buttons -1-. Thea first digit of the code number is
u or
ac
ss
entered with key 1, the second digit with key 2, and so forth.
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
– Turn the radio on.
thi
te
sd
iva
o
– The digital display will exhibit “SAFE”.
r
rp
cu
o
m
f
en
ng
– After approximately 3 seconds “1000” will appear on display.

t.
yi Co
Cop py
t. rig
gh ht
– Enter the code number attached to the radio card with the tun‐ yri
p by
co Vo
ing buttons 1 to 4. The first digit of the code number is entered
by lksw
cted agen
with the button 1, the second digit with the button 2, and so
Prote AG.
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.
FOX 2004 ➤
– 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
This procedure can be repeated just once.
If an incorrect code number is entered once again, the unit will

remain inactive for approximately 1 hour.
– Leave the unit on and the ignition key in the switch for one
hour. agen
AG. Volkswagen AG d
o w es n
olks ot g
– After 1 hour, enter the code number again.
ed
by
V ua
ran
ris tee
ho
ut or
4.7 Reading radio code using Diagnosis, ss
a ac
ce
e
measurement and information system

nl
pt
du
an
itte
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Authorization prerequisites for the diagnostic tester
erm
ab
ility
ot p
• The vehicle diagnostic tester is connected via the Central

wit
, is n
Partner Network (CPN) with the central database (Carport,

h re
hole
Fazit). spec
es, in part or in w
• Available access for the user of the system “GeKo” (secrecy

t to the co
and component protection)

rrectness of i
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
tons, as previously ⇒ page 36 .

om
ion
c
in t
or
his
e
Procedure
at
do
priv
cum
– Connect Diagnosis, measurement and information system

for
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.
– Confirm with > button.

– Select one after the other:
♦ Brand
♦ Type
♦ Model year
♦ Engine code
FOX 2004 ➤
AG. Volkswagen AG d
ksw
agen oes
not
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
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♦ “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
– Switch off ignition and separate diagnostic connections.
4.8 Wheel fastening screws - tighten to cor‐
nform
ercia
rect torque
m
a
com
tion in
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.
4.8.1 Hub cap/Super hub cap

The hook for removing the hub cap/ super hub cap is in the vehicle
tool kit
4.8.2 Wheel bolts
Note
Make sure that the wheel screws are tightened in a cross pattern
with the following tightening torque:
Tightening torque: 120 Nm.

– After the works are concluded, place the hook for removing
the hub caps/super hub caps on the vehicle's tools.
FOX 2004 ➤
4.8.3 Super hub cap assembly (if available)

– Install the super hub cap so that the tire inflation valve is posi‐
tioned in the notch -arrow-.
4.9 Battery - check terminals for proper

seating and fastening
4.9.1 Battery - check fastening
Note
Due to manufacturing reasons, different types of batteries are in‐

stalled. Specific work deviations agen
Aand
G. Voinstructions
lkswagen AG must be ob‐
does
served for each battery Votype
lksw ⇒ Electrical equipment; noRep.
t gu Gr.
27 ; Starter, generator,
ised b battery
y ara
n
r tee
ho
aut or
ac
Visual inspection
ss
ce
e
nl
Carry out work sequence as follows:

pt
du
an
itte
y li
– Check the battery case for damage. If the case is damaged,

erm
ab
battery electrolyte may leak.

ility
ot p
wit
, is n
– Check the battery poles (Battery cable connections) for dam‐

h re
hole
age. If the battery poles are damaged, this will compromise

spec
the contact with the cable connections. This may cause a fire
es, in part or in w
and there may be electrical system failures.

t to the co
– Check the battery fastening -arrow- and, if necessary, tighten

the fastening screw to 25 Nm.
rrectness of i
If the battery is not firmly fastened, the following may happen:

l purpos
• The battery life may be reduced because of vibration.

nform
ercia
• Damage to the battery case.

m
at
• Safety problems in case of collision.

om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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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.
FOX 2004 ➤
♦ Torque wrench - 5 to 50 Nm (fit. 1/2") -VAG 1331-

– Press the locks and tilt the positive battery pole cover
-arrow-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
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wit
is n
h re
ole,
spec
– With alternate movements of the positive and negative battery
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
pole to avoid risk of accidents.
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.
FOX 2004 ➤
– Tighten the terminal screws in the battery poles to a torque of

5 Nm -arrow-.
Note
♦ The tightening torque for the additional battery terminals is 6

Nm.
♦ The battery poles cannot be lubricated.
♦ The battery pole terminals can only be connected manually
and should not be forced, thus avoiding damage to the battery
case.
♦ After reconnecting the battery, make an inspection of the ve‐
hicle equipment (radio, clock, electric convenience system,
power window drive, etc.) as per the repair manual and/or in‐
struction manual.
♦ It is essential that you make a visual inspection of the external
condition and the battery connections before any measure‐
ments.
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
2 - Please wear protective goggles.
ab
pe
ility
ot
3 - Keep children away from acid and batteries.
wit
, is n
h re
4 - Recycling:
hole
spec
es, in part or in w
– Dispose of old batteries at a battery collection center (suppli‐

t to the co
er).
5 - Never discard old batteries in domestic waste!
rrectness of i
6 - Risk of explosion:
l purpos
– A highly explosive mix of oxy-hydrogen gas is produced when

charging batteries.
nform
ercia
7 - Follow the instructions mentioned on the battery, in the elec‐

m
trical system repair manual and in the operation manual.

a
com
tion in
8 - Danger of chemical corrosion.

r
te o
thi
s
iva
– The battery acid is highly corrosive, therefore wear protection

do
r
rp
goggles and gloves;

um
fo
en
ng
t.
yi
– Do not tilt the battery. Acid can leak from the degassing open‐
Co
op py
ings. t. C rig
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pyri by
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co lksw
by
cted agen
Prote AG.
FOX 2004 ➤
4.10 Battery - check the charge capacity
Note
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
Carry out a visual inspection on the charge indicator “inspection
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
♦ Since the inspection glass is located on a single battery cell,
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
the battery charge capacity ⇒ page 43 .
nf
ercia
♦ Specially when a battery is recharged, that is, even when the
o
battery is charged during driving, air bubbles can form under
rm
m
atio
the inspection viewing glass. These bubbles change the color
om
indication in the inspection viewing glass.
n in
or c
thi
e
♦ The inspection viewing glass may be located at various posi‐

t
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
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This way, any air bubbles that could influence the indicator are
Prote AG.
eliminated and dissipate.

The color indication of the “inspection glass” becomes more ac‐
curate. There are three possible indications:
– Green → the battery is sufficiently charged.
– Black → no charge or insufficient charge, the battery must be
charged (repair measure). For battery recharging procedures
⇒ Electrical system; Rep. Gr. 27 ; Starter, generator, battery .
– Colorless or yellow → the battery must be replaced (repair
measure).
4.10.2 Test for checking the battery charge ca‐

pacity
♦ Battery test device, with printer -VAS 5097A- or
FOX 2004 ➤
♦ -VAS 5097- Battery test with printer, converted (modification-

software recognized by logo -1-)
AG. Volkswagen AG d
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When using the Battery test device, with printer -VAS 5097A- or
an
itte
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-VAS 5097- , it is not necessary to remove the battery. Also, it is
erm
ab
not necessary to disconnect the battery.
ility
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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
– The charge current varies and the battery capacity must be

adjusted on the test device. ⇒ Battery test device operation
instructions.
nform
mercia
at
om
ion
c
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or
his
ate
do
priv
cum
for
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FOX 2004 ➤
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– Carry out the battery charge test according yV
oto
lksthe instructions ot g
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of use for the battery test device and compare
ise
d b the test printout ran
-arrow- with the following table. uthor tee
or
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Clarifications concerning the test printout:
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1 - measurement range adjusted on the test device.
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2 - diagram (the arrow indicates the battery state).
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3 - test result.
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4 - battery voltage during the charge test.
spec
es, in part or in w
5 - vehicle data and date (to be written by the person in charge of
t to the co
the test).
rrectness of i
Note
l purpos
The test printout is required for filling out the guarantee.
nform
ercia
Battery test device printout Measures to be taken

m
at
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Very good starting power Battery OK
n
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or
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Good starting power Battery OK
ate
do
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Insufficient starting power Recharge the battery11)

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cum
for
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Weak starting power Recharge the battery11)

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Very poor starting power Recharge the battery11)
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Unsuitable for tests Recharge the battery11)
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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.
Clarification for the battery charge test:

During this test, the battery voltage is reduced through excessive
charge (a high current flows).
If the battery is OK, the voltage value lowers to the minimum volt‐
age.
If the battery is damaged or has low charge, then the battery volt‐
age will quickly drop below the minimum voltage.
After the test, this low voltage value will remain for a while; then,
the voltage will slowly increase.
For battery recharging procedures ⇒ Electrical system; Rep. Gr.
27 ; Starter, generator, battery .
4.11 Engine oil level - check and replenish if

necessary
Please note the following:
After turning the engine off, you must wait for at least 3 minutes
so that the oil flows back to the crankcase.
– Pull the oil dipstick out, clean it with a clean cloth and push the
oil dipstick in again up to the seat (stop).
FOX 2004 ➤
– 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
♦ There is danger of damaging the catalytic converter when oil

level is above area -c-
♦ The oil level must be between the minimum and maximum
markings. Make sure that the oil level does not exceed the
maximum marking.
– Pull the oil dipstick out again and check the oil level.
Condition 2 lkswage es n
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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
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Arrow -1- Maximum marking
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Arrow -2- Minimum marking
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Condition 3
Area -a- Replenish the oil level. It is sufficient for the oil rrectne
level to be anywhere within area -b-.
ss o

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Area -c- The oil level cannot be replenished.

form
mer
atio
om
n
c
Note
or
n thi
te
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♦ With the oil level below the minimum marking (area -a-), re‐
p
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fo
plenish the oil until it reaches (area -b-) according to the oil
en
ng
t.
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specification. ⇒ page 58 .
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Cop py
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♦ With the oil level above area -c- there is the risk of damaging
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the catalytic converter.
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Prote AG.
♦ During oil changes, you must add oil until the maximum mark‐
ing.
4.12 Sunroof: check operation, clean and lu‐

bricate the guide rails
Carry out the following work procedures:
– Check operation of sunroof.
FOX 2004 ➤
– Clean the guide rails -arrows- and lubricate with Special

grease -G 000 450 02- .
4.13 Transport safety devices - remove
4.13.1 Engine identification letters ASY, BLH,

BNM, BKR, BMD, and CFZA
– Some vehicle versions include front suspension blocking de‐
vices. These vehicles can be identified by a tag attached to
the internal rearview mirror -arrow-.
WARNING
♦ The blocking devices must be mandatorily removed dur‐

ing the vehicle delivery inspection!
wage es n
Carry out the following tasks: yV
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ir se tee
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u or
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It is not necessary to remove the wheels.

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erm
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– Relieve the load form the coil springs by lifting the vehicle with
ot p
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the workshop lift.

, is n
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hole
– Remove the safety devices (blocking devices) from the sus‐

spec
pension column.
es, in part or in w
t to the co
– Move the shock absorber rod protection bellows -arrow- up‐

wards.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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Prote AG.
FOX 2004 ➤
– Remove the blocking device -arrow- from the shock absorber

rod.
– Move the shock absorber rod protection bellow downwards.
4.14 Driver and passenger airbags - visual

inspection of Airbag units
4.14.1 Driver's airbag

The identification feature of the Airbag is the “AIRBAG” inscription
-arrow- on the steering wheel padded plate.
– Carry out visual inspection of the padded surface for external
damage.
agen WARNING
AG. Volkswagen AG d
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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.
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an
itte
♦ The steering wheel's padded plate must only be cleaned

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with a dry cloth or a cloth moistened with water.

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4.14.2 Passenger's airbag

es, in part or in w
t to the co
The identification feature of the Airbag is the “AIRBAG” inscription

-arrow- on the right side of the instrument panel.
rrectness of i
– Carry out the visual inspection of the instrument panel surface

for external damage.
l purpos
WARNING
nform
mercia
♦ The plate that covers the passenger's Airbag module must

at
om
io
never be glued, coated, or undergo any type of rework.

n
c
in t
r
The customer must be guided about this information to

o
his
te
ensure the future Airbag operation.

a
do
priv
cum
or
♦ The plate that covers the Airbag module must only be

f
en
ng
cleaned with a dry cloth or a cloth moistened with water.

t.
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FOX 2004 ➤
4.15 Windshield and rear window wiper and

washer - check the operation
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 .
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4.15.1 Replenish the reservoir level
s
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pt
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pe
ility
♦ Refractometer for cooling system liquid analysis -EQ 7093
ot
(VWB) - ou - T 10007-
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
a
com
tion in
The exact value for the following checks may be read in the light-
r
te o
dark limit. To better see the light-dark limit, use a dropper/pipette
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.
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– 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
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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 .
4.15.2 Windshield/rear window washer additive applications

Application Windshield/rear window washer additive
EUROPE only -G 052 164 A1- or -G 052 164 A2-
Tropical climate countries -G 052 131 A2- until 07/2005
-G 052 184 A2- from 08/2005
FOX 2004 ➤
4.15.3 Mix ratio in arctic climate countries

Antifreeze protec‐ Windshield/rear Water
tion up to window washer ad‐
ditive
3.20 ? 1 part 2 parts
-22.00 ? 1 part 1 part
-40.00 ? 2 parts 1 part
4.15.4 Mix ratio in tropical countries

Until 07/2005
ditive AG. Volkswagen
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From 08/2005 oris e
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- 1 part 99 parts
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Complete:
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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
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♦ The original Volkswagen product Windscreen/rear window

washer additive -G 052 164 A1- or the -G 052 164 A2- have
cleaning properties that protect the ejectors, the reservoir and
nform
ercia
connection hoses against freezing.

m
♦ In warm seasons of the year, it is also possible to use original

com
tion in
Volkswagen product Windshield/rear window washer additive

r
te o
-G 052 131 A2- until 07/2005 and Windshield/rear window

thi
s
iva
washer additive -G 052 184 A2- from 08/2005, which does not
do
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rp
have antifreeze protection, but has cleaning properties.

um
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♦ The antifreeze protection for the Windshield washer should be
Co
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guaranteed at approximately -15 °C (for Arctic climate coun‐ t. C rig
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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 .
FOX 2004 ➤
Note
♦ If the ejector does not enable adjustment, due to impurities,

remove the ejector, ⇒ Electrical system; Rep. Gr. 92 ; Wind‐
shield, rear window and headlight wiper and washer and wash
with water in the opposite direction of the nozzle jet direction.
♦ Under no circumstances should needles or similar objects be
used, since this might damage the nozzle's water passage.
♦ Then, you can blow compressed air in the opposite direction
of the nozzle jet direction.
♦ The spray ejectors are pre-adjusted. However, some minor
height differences can be adjusted.
Nozzle jet position:

-a-: 18.90 in
-b-: 6.50 in
If the two action surfaces of the ejector jet are not according to
the dimensions -a - and -b-, the jet height must be adjusted as
explained below:
AG. Volkswagen AG d
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– Adjust the jet through the nozzle tab-1-, by moving it slightly ss c
ce
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with your hand, upward or downward, with the front bonnet

nl
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closed.
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ility
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To perform the adjustment, support the ejector with your hand to
spec
es, in part or in w
prevent it from moving from the housing.
t to the co
rrectness of i
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4.15.6 Rear window washer - check the ejector

nf
ercia
orm
m
atio
Note
om
n in
or c
thi
♦ If the ejector jet is irregular, replace the ejector (repair meas‐

te
sd
a
ure).
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o
r
rp
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o
m
f
♦ Under no circumstances should needles or similar objects be

en
ng
t.
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used, since this might damage the ejector water passage.
Co
Cop py
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– Check the ejector projection.
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Prote AG.
The ejector jet must fall on the centre of the washer area.
4.16 Windscreen and rear window wiper

blades - check the resting position
FOX 2004 ➤
4.16.1 Windscreen wiper blades - adjust the

resting position
Driver side
– -a- = 30 ± 5 mm (measured in the wiper blade). The adjustment
can also be made by using the round marking on the glass,
which corresponds to the blade installation position (only Eu‐
rope)-arrow-.
– Assembly reference: wiper blade edge.
– Tightening torque of the wiper arm and blade set 15.5 Nm.
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
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d by ara
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4.16.2 Rear window wiper blade - adjust the
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ility
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resting position wit

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– The distance -a- between rear window wiper rubber and the
spec
lower edge of the window must be 36 to 46 mm.

es, in part or in w
t to the co
– To adjust the final rear window wiper position, move the wiper
rod.
rrectness of i
– Wiper rod tightening torque 12 Nm.

l purpos
nform
mercia
4.17 Wiper blade - check the incidence angle

a
com
tion in
r
te o
thi
s
iva
do
Note
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rp
cum
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en
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Check the incidence angle only when the wipers are vibrating or
t.
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noisy. C py
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Prote AG.
FOX 2004 ➤

♦ Adjustment device -3358B-
olkswagen AG
wag en AG. V
Carry out work sequence asVfollows:
olks
does
not
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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
– Place the wiper arm -2- on Adjustment device -3358B- and

un
pt
an
d
fasten with the screw -3-.

itte
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rm
ab
– Check the incidence angle according to the following table:
pe
ility
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Incidence angle (nominal values)
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
– Place the Wrench -1- on the Adjustment device -3358B- and

nform
ercia
move -arrows- the wiper arm -2- to the nominal value.

m
a
com
– Compare the adjusted value, as per the table. If necessary,

ion in
repeat the adjustment and control processes until reaching the

r
te o
thi
nominal value.
s
iva
do
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rp
– Remove the Adjusting device -3358B- and install the wiper

um
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blade.
en
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t.
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– Check the wiper for smooth operation. t. C rig
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Prote AG.
4.18 Tire pressure (including spare wheel),

condition, tread, sides and groove depth
- check
Note
For driving safety reasons, only tyres of the same type and profile
version must be installed on a vehicle!
4.18.1 Check the condition (including spare

wheel)
FOX 2004 ➤
Delivery inspection:
– Check the tread and sides for damage and, if necessary, re‐
move foreign bodies, such as nails and pieces of glass, for
example.
Note
In case of faults, please check if it is necessary to install a new

tire.
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
The faults verified must be reported to the customer.
4.18.2 Check the treads (including spare

wheel)
From the front tire treads it is possible to evaluate, for example, if AG. Volkswagen AG d
agen oes
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there is the need to check the camber and convergence: by
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♦ The existence of burrs on the tire profile may be caused bythor eo
convergence failure. ss au ra
c
ce
le
♦ Tread wear on only one side can be mostly caused by camber

un
pt
an
fault.
d
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ab
If there is such type of wearing, the cause must be determined by
pe
ility
measuring the axle geometry (repair measure).
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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
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mercia
a
com
tion in
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Prote AG.
FOX 2004 ➤
B - Tread wear indicators -arrows-.

It is necessary to replace the tyres when the tread wearing rea‐
ches the indicators -position 1- at the bottom of the grooves.
The points where tread wearagindicators

en AG. V are
olkswagefound
n AG d are identified
oes
by the acronym TWI (TreadVolkswWear Indicators), distributed
not at every
gu
60 degrees -a- on stire
by
ed perimeter.
ara
n ri tee
ho
In this situation,ut the groove depth is approximately 1.6 mm. How‐
or
ac
sa
ever, considering that a worn tire is more likely to skid on wet
s
ce
e
surfaces, we recommend replacing a tire when the groove depth

nl
pt
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an
reaches 3 mm.
itte
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erm
ab
ility
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Note
wit
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hole
spec
♦ This value may be different depending on each country's legal

es, in part or in w
requirements.
t to the co
♦ The minimum profile depth is reached when the wear indicator

at the tread, adjusted at 1.6 mm of height, no longer displays
rrectness of i
a profile.
l purpos
♦ If the profile depth is close to the legally accepted depth, the

customer must be informed.
nform
ercia
♦ The tires must also be replaced when they are cut, deformed,
or display other damage.
m
at
om
ion
c
in t
or
4.18.4 Tyre pressure (including spare wheel) -

his
ate
do
riv
check and correct if necessary

p
cum
for
en
ng
t.
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Co
Cop py
ht. rig
♦ Tire inflation device -VAS 5216- rig ht
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co Vo
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Prote AG.
FOX 2004 ➤
Note
♦ Please notice that the tire pressure values mentioned in the

table are valid for cold tires. Heated tyres should not be ex‐
cessively deflated.
♦ The pressure values for the respective model can also been AG. Volkswagen AG
found on an adhesive tag located inside the fuel reservoirksw filling
ag does
not
Vol
nozzle compartment cover. ed
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ara
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Note
e
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On the CrossFox, the spare wheel has an anti-theft screw, which
erm
ab
socket is located on the tool bag.
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4.18.5 Tyre pressure table
hole
spec
es, in part or in w
(for all sizes of tyres assembled in the factory)
t to the co
Pressure values in PSI (pounds/sq-in)
rrectness of i
Note
l purpos
Values obtained at publishing date!
nform
mercia
at
half load front and full load front and
om
ion
rear rear
c
in t
or
his
e
Engine identification letters AQZ, BJE, BNX, with mechanical

at
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
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175/65 R14 82T 29 28 31 36
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185/60 R14 82H 30 29 33 37 Prote AG.
195/55 R15 85H 27 27 28 33

Engine identification letters BAH, BJA, BPA
175/65 R14 82T 31 29 34 38
185/60 R14 82H 30 29 33 37
195/55 R15 85H 28 28 30 34
Engine identification letters BLH
185/60 R14 82H 30 29 33 37
Engine identification letters ASY
175/65 R14 82T 32 30 35 39
195/55 R15 85H 30 29 31 35
Engine identification letters BMD with mechanical steering
165/70 R14 81T 35 32 35 41
Engine identification letters BMD
165/70 R14 81T 29 28 32 38
185/60 R14 82T 29 28 32 38
195/55 R15 85V 28 28 30 36
Engine identification letters BKR
165/70 R14 81T 32 29 35 41
175/65 R14 82T 32 30 35 39
FOX 2004 ➤

rear rear
185/60 R14 82T 32 29 35 41
195/55 R15 85V 28 28 30 36
Engine identification letters BNM
185/60 R14 82T 33 30 36 42
195/55 R15 85V 29 28 32 38
CrossFox
205/60 R15 91V 29 32 29 38
205/60 R15 91V 29 32 29 38
Engine identification letters BAH, BJA and BPA
205/60 R15 91V 29 32 29 38
Tyre pressure values in bar.
Note
Values obtained at publishing date!

rear rear
Engine identification letters AQZ, BJE, BNX, with mechanical
steering
175/65 R14 82T 2,1 1,9 2,3 2,7
. Volkswagen AG
gen AG
Engine identification letters AQZ, BJE, BNX olks
wa does
not
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175/65 R14 82T 2,0 r
1,9
ised 2,1 2,5 ara
nte
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185/60 R14 82H 2,1 s aut 2,0 2,3 2,6 ra
c
s
195/55 R15 85H 1,9 1,9 1,9 2,3
ce
e
nl
pt
du
Engine identification letters BAH, BJA, BPA

an
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ab
175/65 R14 82T 2,1 2,0 2,3 2,6

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185/60 R14 82H 2,1 2,0 2,3 2,6

wit
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195/55 R15 85H 1,9 1,9 2,1 2,3

hole
spec
Engine identification letters BLH

es, in part or in w
t to the co
185/60 R14 82H 2,1 2,0 2,3 2,6

rrectness of i
175/65 R14 82T 2,2 2,1 2,4 2,7

l purpos
195/55 R15 85H 2,1 2,0 2,1 2,4

Engine identification letters BMD with mechanical steering
nf
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165/70 R14 81T 2,4 2,2 2,4 2,8

orm
m

atio
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165/70 R14 81T 2,0 1,9 2,2 2,6

or
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185/60 R14 82T 2,0 1,9 2,2 2,6

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195/55 R15 85V 1,9 1,9 2,1 2,5

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Cop py
165/70 R14 81T 2,2
.
2,0 2,4 2,8
ht rig
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185/60 R14 82T 2,2 2,0 2,4 2,8 by c lksw
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195/55 R15 85V 1,9 1,9 2,1 2,5
FOX 2004 ➤

rear rear
165/70 R14 81T 2,3 2,1 2,5 2,9
185/60 R14 82T 2,3 2,1 2,5 2,9
195/55 R15 85V 2,0 1,9 2,2 2,6
CrossFox
205/60 R15 91V 2,0 2,2 2,0 2,6
205/60 R15 91V 2,0 2,2 2,0 2,6
Engine identification letters BAH, BJA and BPA
205/60 R15 91V 2,0 2,2 2,0 2,6
4.19 Engine oil - drain and fill; change the oil

filter
♦ Oil aspirator -VAG 1307 A-
lkswage es n
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t to the co
♦ Oil aspirator -V.A.G 1358 A-

rrectness o
cial p
f inform
mer
atio
om
n
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Cop py
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pyri by
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Prote AG.
FOX 2004 ➤
AG. Volkswagen AG d
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nl
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ab
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es, in part or in w
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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
– Remove the oil draining plug -arrow-.

– Remove the sealing ring from the oil draining plug and cut if
nform
ercia
necessary.
m
– Drain the engine oil.

at
om
ion
c
– Tightening torque for the draining plug:

in t
or
his
ate
seta - 4-cylinder engines 30 Nm.

do
priv
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for
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Note Cop py
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♦ 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
Engine identification letters AQZ, BKR, and BMD

– Aspirate the engine oil with the Oil aspirator - VAG 1307 A- or
FOX 2004 ➤

necessary.
seta - 3- and 4-cylinder engines 30 Nm.
WARNING
• In 3-cylinder petrol engines an oil drain plug with hexag‐

onal interior and a oil drain plug sealing ring are used. With
this type of plug, replace only the oil drain plug sealing
ring⇒ Etka .
Note

♦ Install a new sealing ring in the oil draining plug.
WARNING
♦ 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
un
pt
an
d

itte
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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
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rp
cum
fo
en
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
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FOX 2004 ➤

necessary.
Note

♦ Install a new sealing ring in the oil drainage plug
AG. Volkswagen AG d
agen oes
olksw not
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by
WARNING rised ara
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ho eo
aut ra
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un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
necessary.
rrectness of i
l purpos

nform
mercia
a
com
tio
Note
n in
r
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thi

s
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cum
fo

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t.
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op
♦ Install a new sealing ring in the oil drainage plug
C py
t. rig
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pyri by
Vo
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by c lksw
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Prote
WARNING
AG.
4.19.1 Replace the oil filter

♦ Screwdriver -SW 30-
♦ Screwdriver -SW 36-
FOX 2004 ➤
Engine identification letters AQZ, BAH, BLH, BKR, and CFZA

– Loosen the filter through the hex section -arrow- with a Wrench
-SW 30- and remove it.
WARNING
– Clean the engine sealing surface.

– Lightly lubricate the new filter rubber sealing. With this, the
filter is better seated and ideal sealing condition is achieved.
– Install the filter and tighten it manually.
– 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
Make sure that no foreign object enters the filter case.
WARNING
– Replace the cover sealing ring -2-.

AG. Volkswagen AG d
agen
– Install the new filter. Volksw
oes
not
by gu
d ara
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or eo
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aut ra
s c
– Install the fastening cover -1-. s
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e
nl
pt
du
Tightening torque in the fastening cover: 25 Nm.

an
itte
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erm
ab

ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
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orm
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or c
thi
te
sd
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♦ 36 mm wrench t. Cop py
rig
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4. Service descriptions
AG.
AG. Volkswagen AG d
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d by ara
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h eo
aut ra
c
ss
ce
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nl
– Loosen the filter through the hex section -arrow- with a 36 mm
pt
du
an
Wrench .
itte
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erm
ab
ility
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WARNING
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
– Replace the sealing ring.
l purpos
nf
ercia
Tightening torque for the filter: 25 Nm.
orm
m
atio
om
n in
c
Carry out the following work sequence:

or
thi
te
sd
a
– Loosen the cover -5- with a Wrench -SW 36- and remove the
iv
o
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rp
cu
cover with the filter.
o
m
f
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ng
t.
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– Remove the filter -1-.
Co
Cop py
t. rig
gh
– Replace the cover sealing ring -4-.
ht
pyri by
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by c lksw
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Prote
– Replace the sealing rings -2- and -3-.
AG.
WARNING

4.19.2 Replenish the engine with oil

Based on the oil properties ⇒ page 29 , use only the following
approved engine oils:
4.19.3 Oil specification for engine identification

letters AQZ, BAH, BLH, BKR, BMD
– Vehicles with “service based on time and kilometers
traveled” (QG0): VW 502 00.
4.19.4 Oil specification for diesel engines with

identification letters ASY
traveled” (QG0): VW 505 00 or VW 505 01.
4.19.5 Oil specification for diesel engines with

identification letters BNM
traveled” (QG0): VW 505 01.
FOX 2004 ➤
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
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nl
pt
du
Note
an
itte
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ab
♦ There is danger of damaging the catalytic converter when oil
ility
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level is above area -c-

wit
, is n
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♦ 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
rrectness of i
Condition 2
l purpos
Area -A- Oil must not be replenished.

nf
ercia
Area -B- It is not necessary to replenish the oil.

orm
m
Area -C- Replenish the oil level. It is sufficient for the oil
atio
m
level to be anywhere within area -B-.

o
n in
or c
thi
Arrow -1- Maximum marking

te
sd
iva
Arrow -2- Minimum marking

o
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t.
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Cop py
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Prote AG.
FOX 2004 ➤
Condition 3
Area -a- Replenish the oil level. It is sufficient for the oil
level to be anywhere within area -b-.
AG. Volkswagen AG d
Area -c- The oil cannot be replenished agen oes
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th or
Note au ac
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nl
pt
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♦ 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
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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
partment (from above and below) -

make a visual inspection for leaks and
nf
ercia
damage
orm
m
atio
m
The visual inspection must be carried out as follows:

o
n in
or c
thi
– Check the engine and components in the engine compartment
te
sd
a
for leaks and damage.

iv
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rp
cu
o
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– 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).
4.21 Poly-V belt - check the condition

– Lift the vehicle.
FOX 2004 ➤
– Turn the engine at the belt shock absorber/pulley -arrow- with

a socket wrench.
– Check the Poly-V belt from below for:
♦ Tears in the lower section (internal fractures, section frac‐
tures).
♦ Layer separation (upper layer, cord strands).
♦ Fracture at the lower section.
♦ Unthreaded cord strands.
♦ Worn toothed sides (material wearing, unthreaded toothed
sides, toothed side hardening -glassy toothed sides-, surface
tears).
♦ Oil and grease residues.
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.
4.22 Constant velocity joint bellows - visual

inspection
swa
gen AG
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does
k not
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– Check the external joint bellows
ed
by -arrow- and the internal joint uaran
bellows (not seen in the
orisillustration) for leaks and damage. tee
th o
au 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
rrectness of i
4.23 Gearbox - check the oil level and replen‐

ish if necessary
l purpos

nform
ercia
♦ Multi-teeth socket SW 27 -3357-

m
a
com
tion in
r
te o
thi
s
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t.
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Cop py
t. rig
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pyri by
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co lksw
by
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Prote AG.
FOX 2004 ➤
4.23.1 02T 5-gear transmission

– Remove the transmission oil filling plug -arrow-.
– The oil level is correct when the transmission is full up to the
lower edge of the oil filling hole.
– Reinstall the plug and tighten it to 25 Nm.
4.24 Brake system - visual inspection for

damageaand
gen AG
.leaks
Volkswagen AG
do
w es n
olks o
Check the following
db
y V components for damage andt leaks:
gu
ar
e an
ris te
♦ Brake cylinder.
tho eo
s au ra
c
s
♦ Brake cylinder (in anti-blocking systems: Hydraulic unit).
ce
e
nl
pt
du
an
♦ Braking force adjustment.

itte
y li
erm
ab
♦ Brake cylinder.
ility
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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
do not touch vehicle components when the steering wheel is

es, in part or in w
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
– Also check the brake system connections and fastenings for

proper seating, leaks and corrosion.
nform
ercia
WARNING
m
at
om
ion
c
in t
r
The existing faults must be eliminated (repair measure).

o
his
ate
do
priv
cum
for
4.25 Front brake pads - check the thickness

en
ng
t.
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Cop py
t.
rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
FOX 2004 ➤
♦ Torque wrench - 40 to 200 Nm (enc. 1/2") -VAG 1332-
♦ Torque wrench - 5 to 50Nm (fit. 1/2") -VAG 1331-
4.25.1 Brake cylinder

– For better evaluation of the remaining pad thickness,
agen
AG. Volkremove
swagen AG
does
the driver side wheel (the wear is moreVointense
lksw than on the not
gu
passenger side). sed by ara
n i tee
or
– Remove the hub cap/super hub
au cap.
th or
ac
ss
The hook for removing the hub cap is in the tool kit.
ce
le
un
pt
an
d
– Loosen the wheel fastening screws and remove the wheel.

itte
y li
erm
ab
– For vehicles with brake pad wear indicator, disconnect the

ility
ot p
connector -1-.
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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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.
FOX 2004 ➤
– 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
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aut ra
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– Measure the internal and external pad thickness.

un
pt
an
d
itte
y li
– External pad thickness including rear plate-a-.
erm
ab
ility
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– Internal pad thickness including rear plate-b-.
wit
is n
h re
– Wear limit: 7 mm with the rear plate.
ole,
spec
t to the co
Note
♦ For a pad thickness of 7 mm (including the rear plate), the
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
brake discs is a repair measure. atio

om
n
c
– Installation is performed in the reverse process to the removal.

i
or
n thi
te
sd
a
– The larger brake pad is installed on the outside! (FS II brake

iv
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.
– When installing the wheel, screw in the indicated position.

– Install the wheel fastening screws in a cross pattern and tight‐
en them to 120 Nm.
– After completing the tasks, keep the hub cap/super hub cap
removal hook with the tools.
– Install the super hub cap so that the tire inflation valve passes
through the opening -arrow- for this purpose.
4.25.2 Brake disc - check the thickness

Please check the following:
FOX 2004 ➤
• Brake disc thickness: 18 mm for FSII and 22 mm for FSIII-a-.

• Wear limit: 16 mm for FSII and 19 mm for FSIII.
Note
Always replace both discs from the same axle.
4.25.3 Brake disc with visual check - check
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) in‐ntee
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
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♦ Always check both discs on the same axle and, if necessary,
rm
ab
replace them.
pe
ility
ot
wit
, is n
4.25.4 ?Vehicles with light-alloy wheel h re

hole
spec
es, in part or in w
Position the wheel so that the brake disc wear indicators (visual
t to the co
check) can be visualized.

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.
FOX 2004 ➤
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
♦ If the front brake disc wear indicator markings (visual check)

com
tion in
cannot be visualized due to wheel design, the wheels must be

r
te o
removed.
thi
s
iva
do
♦ If the front wheels must be removed to check the brake discs,

r
rp
cum
fo
after reinstalling them, tighten the screws to 120 Nm.

en
ng
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.
FOX 2004 ➤
Replace the brake discs.

Remove and install the front brake discs.
4.25.5 Vehicles with steel wheel
Note
♦ In order to visualize the brake disc wear indicators (visual

check) in vehicles with steel wheels, the front wheels must be
removed.
♦ After checking the brake discs, install the wheels and tighten
fastening screws to 120 Nm.
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
♦ Wear indicator -1- is located on the centre of the brake disc

n
c
in t
or
contact area.
his
ate
do
riv
♦ Wear indicator -2- is located close to the internal edge of the

p
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.
FOX 2004 ➤
The brake discs need not be replaced.

2- Only wear indicator -2- is visible:
The brake discs do not require replacement, but pay attention on
the next change.
3- No brake disc wear indicator is visible.
Replace the brake discs.
Remove and install the front brake discs.
4.25.6 Rear brake lining: check thickness

– Check the brake lining thickness through the inspection eye‐
let-a- or, for clearer verification, remove the rear brake drum⇒
Brake system; Rep. Gr. 46 ; Brakes - Mechanical systems .
Wear limit: 2.5 mm (lining thickness only) or rivet height.
WARNING
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
4.26 Lower body section protection - make a
ab
ility
ot p
visual inspection for damage
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
prevent oxidation and perforating corrosion. nf

ercia
4.27 Steering bar tips - check clearance, fas‐

orm
m
atio
tening and sealing bellows

om
n in
or c

thi
te
sd
iva
o
r
– With the vehicle lifted (with wheels hanging freely), check the
rp
cu
o
bars' side movements for clearances -arrow-.

f
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.
FOX 2004 ➤
4.28 Rear wheels: adjust the roller bearing

clearance (only for vehicles without ABS
and equipped with the engines: AQZ,
BAH, ASY, BLH, and CFZA from
07/01/2007.
♦ Supporting tube -40-21-
♦ Hub nut protector puller -VW 637/2- .
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,
Rear wheel hub

spec
1 - Ring gear.
t to the co
2 - Wheel hub protector, must be replaced after removal.

3 - Cotter pin, must be replaced after removal.
rrectne
Removal of the wheel is necessary only for vehicles with alloy

s
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
nut protectors -VW 637/2- .

um
r
fo
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.
It is necessary that the washer presents a radial motion exactly

according to the following procedure.
FOX 2004 ➤
– Release or tighten nut by applying less or more pressure on

the washer -arrow-, and simultaneously check its radial move‐
ment with light pressure of your index applied on a screwdriv‐
er.
– Never turn -arrows- or leverage the screwdriver.
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
bearing end clearance will be jeopardized (it can lead to noises

nl
pt
du
and breakage of bearings).
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
– Check the regulation again.
spec
es, in part or in w
– The washer must move radially with a slight pressure of your
t to the co
index applied on a screwdriver.
rrectness of i
Note
l purpos
After removed, the cotter pin must be replaced.

nf
ercia
orm
m
– Install wheel hub protector with the Support tube -40-21-

atio
om
n in
or c
thi
te
Note
sd
iva
o
r
rp
cu
o
m
f
The wheel hub cover must be replaced with every removal

en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
FOX 2004 ➤
4.29 Suspension arm joints - visual inspec‐

tion
– Check the sealing bellows in the suspension arm joints
-arrow- for damage and leaks.
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
anti-corrosion G 12 - according to TL VW 774 F (lilac color).

Make sure that only G 12 is replenished.
nform
ercia
♦ Do not mix with the G 11 antifreeze additive, blue or green

m
a
colors.
com
tion in
r
te o
thi
s
iva
WARNING
do
r
rp
cum
fo
en
g
The coolant additive G 12 cannot be mixed with other additives.

n
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
♦ The G 12 as permanent filling (does not require replacement)

is adequate for cast iron and aluminum engines, and protects
the engine against freezing, damage from corrosion, lime‐
stone build-up and overheating.
♦ The G 12 raises the boiling point to 275°F and provides better
heat dissipation.
♦ The coolant ratio must be at least 40% (antifreeze protection
to - 77ºF) and it must not exceed 60% (antifreeze protection
to - 104ºF), otherwise the antifreeze protection is reduced and
also the cooling operation is worsened.
4.30.1 Check the antifreeze protection and re‐

plenish the cooling system, if necessary
FOX 2004 ➤
♦ Refractometer for cooling system liquid analysis -EQ 7093

(VWB) - ou - T 10007-
Note
The exact value for the following checks may be read in the light-
dark limit. To better see the light-dark limit, use a dropper/pipette
to put a water drop on the glass. Now the light-dark limit may be
easily recognized by the “WATERLINE”.
– Check the concentration of antifreeze additive with the Re‐

fractometer for cooling system fluid analysis -EQ 7093 (VWB)
- ou - T 10007- (follow the instruction manual).
The scale -1- of the refractometer is related to coolant additives -
G 12- and -G 11-.
The scale -2- is related to the cooling additive -G 13-.
Note AG. Volkswagen AG d

agen oes
o lksw not
♦ The antifreeze
e d by
V
protection must be guaranteed gu in approximate‐
ara
ly -13horis° F (in Arctic climate countries in approximately
nte
eo
-31.00
s aut ?). ra
c
s
♦ Due to climatic reasons, a higher antifreeze protection is nec‐
ce
e
nl
pt
du
essary, so the percentage of G 12 may be increased, but only

an
itte
y li
up to 60% (antifreeze protection to approximately - 40º F), be‐

erm
ab
cause the antifreeze protection can be reduced again and,

ility
ot p
additionally, the cooling action is worsened.

wit
, is n
h re
hole
– When the antifreeze protection is too weak, drain the differ‐

spec
es, in part or in w
ence volume mentioned in the antifreeze protection table

t to the co
⇒ page 77 and replace with the cooling additive -G 12- ac‐

cording to TL VW 774 F.
rrectness of i
WARNING
l purpos

nform
mercia
at
om
io
4.30.2 Antifreeze table

n
c
in t
or
his
ate
Antifreeze protection up to º F Difference quantity in liters14)

do
priv
cum
or
Actual value12) Nominal value

f
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
FOX 2004 ➤
Antifreeze protection up to º F Difference quantity in liters14)

Actual value12) Nominal value
13)
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
-25 -35 2,0
wit
is n
h re
-30 -35 1,0
ole,
spec
-35 -40 0,5
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
ry, replenish the cooling system

i
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
In case of loss of fluid not caused by consumption, you must de‐

termine and eliminate the cause (repair measure).
4.30.4 Mixture ratio

Antifreeze protec‐ Coolant additive Water
tion up to
-13.00 ? approx. 40% approx. 60 %
-31.00 ? approx. 50 % approx. 50 %
-40.00 ? approx. 60 % approx. 40%
FOX 2004 ➤
Note
♦ The coolant additive -G12- prevents damage from corrosion

and freezing, limestone build-up and also increases the boiling
point. For these reasons, the cooling system must always be
replenished with antifreeze and anti-corrosion agent through‐
out the year.
♦ Specially in tropical countries, the coolant ensures the engine
operation by increasing the boiling point under high engine
charges. n AG. Volkswagen AG do
lkswage es n
ot g
The concentration of coolant cannot be diluted in water, y V even
o
♦ b ua
ed ran
during hot seasons or in hot countries. The coolingor additive
is tee
percentage must be at least 40%. auth or
ac
ss
ce
le
4.31 Spark plugs - replace un
pt
an
d
itte
y li
rm
ab
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.
FOX 2004 ➤
4.31.1 Engine identification

agen
AG. Vletters
olkswagenBAH
AG do and
BLH lksw es n
Vo ot g
by d ua
ran
ise
– Remove the crankcase
ut
ho
r
air vent hose -1- from the air filter case.tee o
ra
sa c
– Remove the air
s filter case from the supports and the butterfly
ce
le
valve command unit -arrows- and remove the air filter case.
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Loosen the spark plug connectors -arrows- with the Assembly

tool -T10029- .
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
and the Torque wrench - 5 to 50 Nm (enc. 1/2") -VAG 1331- .
thi
s
iva
Tightening torque: 30 Nm. do

r
rp
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
– Connect the spark plug connectors.

– Install the air filter case.
4.31.2 Engine identification letters AQZ and

BKR
– Remove the crankcase venting hose -1- from the air filter case.
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
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
– Remove the spark plug connectors -arrows- with the Assem‐
bly tool -T10029- .
ss o
cial p
f inform
mer
atio
om
n
c
i
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
– Connect the spark plug connectors.

– Install the engine cover.
4.31.3 Engine identification letters BMD

– Disengage and pull the engine cover up, when applicable.
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
t to the co
rrectne
s
s o
cial p
f in
form
mer
– Install the Extractor -T10094- over the ignition coil with final
atio
m
power stage.
o
n
c
i
or
n thi
e
– Connect the connector to the ignition coil with final power

t
sd
va
stage until fitting it audibly.

i
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
– Install the engine cover, when applicable.
4.32 ATF oil reservoir for power steering - re‐

plenish the level
Oil in cold condition:
– The engine must be turned off and the front wheels, aligned.
FOX 2004 ➤
– Remove the cover with a screwdriver -arrow-.

– Clean the oil dipstick with a clean cloth.
– Manually install the cover and remove it again.
Note
The oil level inspection must only be considered in the second

measurement.
– Check oil level: the level must be in region -A-.
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
oil -G 002 000- .

an
d
itte
y li
rm
ab
pe
ility
– Install the cover with a screwdriver.

ot
wit
, is n
h re
Oil at service temperature (from approximately 50°C):

hole
spec
– The engine must be turned off and the front wheels, aligned.
es, in part or in w
t to the co
– Remove the cover with a screwdriver -arrow-.

– Clean the oil dipstick with a clean cloth.
rrectness of i
– Manually install the cover and remove it again.

l purpos
nform
ercia
Note
m
a
com
ti
The oil level inspection must only be considered in the second

on in
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.
FOX 2004 ➤
– 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- .
– Install the cover with a screwdriver.
4.33 Dust and pollen filter

lksw
ag-
enreplace
AG. Volkswagthe filter
en AG
does
not
element Vo gu
y
edb ara
s i n tee
or
The filter is in the ventilation
au
th case, at the right of the instrument or
ac
panel, below the glove scompartment.
s
ce
le
un
pt
4.33.1 Behr box
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
– Join the two sliding locks -arrows- up to the centre.

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
– Remove the dust and pollen filter -arrow- with the filter support.
thi
s
iva
do
– Separate the filter from its support.

r
rp
cum
fo
en
ng
t.
yi Co
op
WARNING C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Installation is performed in the reverse sequence to the re‐

moval.
4.33.2 Denso box

FOX 2004 ➤
– Loosen the filter compartment cover screw-arrow-.
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
– Installation is performed in the reverse sequence to the re‐
t to the co
moval.
rrectness of i
4.34 Timing belt - replace; Semi-automatic
l purpos
camshaft tensioning pulley - check
nform
mercia
at
4.34.1 Engine identification letters ASY
om
ion
c
in t
or
– Carry out the work sequence ⇒ Engine; Rep. Gr. 15 ; Cylinder
his
ate
head, camshaft mechanism .
do
priv
cum
for
4.34.2 Engine identification letters BNM

en
ng
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.

BLH, BKR, BMD, and CFZA
– Remove the upper mechanical distribution cover.
– Check the timing belt condition for:
♦ Tears, section fractures.
♦ Layer separation (timing belt body, cord strands).
♦ Fracture in the timing belt body.
♦ Unthreaded cord strands.
♦ Surface tears (plastic coating).
♦ Oil and grease residues.
FOX 2004 ➤
Note
If there are faults, you must replace the timing belt. This will avoid
failures and faults during operation.
When checking the timing belt condition, pay special attention to

the following damage:
A - Tears (on the cover side).
B - Side wearing.
C - Unthreading.
D - Tears (at the teeth base)
4.36 Air filter - clean the case and replace the

filter element
4.36.1 Engine identification letters BAH and

BLH
– Remove the crankcase air vent hose -1- from the air filter case.
– Remove the air filter case from the supports and the Butterfly
valve command unit from the accelerator -J338- -arrows- and
remove the air filter case.
agen
AG. Volkswagen AG d
o w es n
olks ot g
byV ua
ed ran
ris tee
tho or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
– Remove the air filter case fastening screws -arrow-.

es, in part or in w
t to the co
– Remove the filtering element.

rrectness of i
WARNING
l purpos

nform
mercia
– Clean the filter's case and install a new filtering element.

at
om
ion
c
– The installation is performed in the reverse order from remov‐

in t
or
his
al.
ate
do
priv
cum
or
4.36.2 Engine identification letters AQZ and

f
en
ng
t.
yi Co
BKR Cop py
t. rig
gh ht
pyri by
co Vo
by lksw
cted agen
Prote AG.
FOX 2004 ➤
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-.
– Remove the air filter case fastening screws -arrows-.

– Remove the filtering element.
WARNING
♦ Follow the rules for disposal! n AG. Volkswagen AG do

lkswage es n
o ot g
byV ua
d ran
ir se
– Clean the filter's case and install a new filtering
tho element. tee
or
au ac
ss
ce
le
al.
un
pt
an
d
itte
y li
erm
ab
4.36.3 Engine identification letters ASY, BNM,
ility
ot p
BMD, and CFZA
wit
is n
h re
ole,
spec
– 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
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
4.37 Fuel filter - replace

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
BLH, and CFZA

⇒ Engine - Supply and ignition system; Rep. Gr. 20 ; Supply
system - reservoir, fuel pump
FOX 2004 ➤
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!

Removal
– Remove the fastening clip -3- and remove the regulating valve
-4- with the fuel ducts connected.
– Disconnect the fuel hoses -1- and e-2-.
n AG. Volkswagen AG ag does
lksw not
– Unlock the -arrows- hooks.
by
Vo gu
ara
d
ise nte
– Remove the fuel filter
ut
ho cover upwards.
r eo
a ra
ss c
Installing
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
– Install the new sealing ring to seal the regulating valve.

wit
, is n
– Install the filter. h re

hole
spec
– Lock the -arrows- small hooks.
es, in part or in w
t to the co
– Assemble the regulating valve -4- with the ducts connected.

– Install the fastening hook -3-.
rrectness of i
l purpos
– 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
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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!
FOX 2004 ➤
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-
lkswage es n
o ot g
4.38 Fuel filter - drain ir se
d byV ua
ran
o tee
th or
au ac
ss
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
l purpos
nf
ercia
orm
m
– Remove the fastening clip -3- and remove the regulating valve
atio
m
-4- with the fuel ducts connected.

o
n in
or c
thi
– Install the hose to the draining screw connection coupling
te
sd
iva
-arrow-, open the screw and drain approximately 0.1 liter.

o
r
rp
cu
o
m
f
– Tighten the draining screw -arrow- and remove the hose.

en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Install the new sealing ring to seal the regulating valve.

– Install the regulating valve -4- and put the fastening clip -3-
FOX 2004 ➤
– Check the fuel system tightness (visual inspection).
4.39 Brake fluid - replace

AG. Volkswagen AG d
♦ Brake pedal pressing device -VAG
lksw
agen 1869/2- oes
not
o
yV gu
db ara
ir se 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
♦ Brake filler and bleeder -VAS 5234-

rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
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f
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t.
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Cop py
t. rig
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yri
♦ Brake bleeding device -VAG 1869-
p by
co Vo
by lksw
cted agen
Prote AG.
♦ Brake bleeding device -V.A.G 1869- with Adapter -V.A.G

1869/4-
Use new brake fluid only (which corresponds to the American US
FMVSS 116 DOT 4 standard).
FOX 2004 ➤
Authorized brake fluid specifications in vehicles from model until

year 2005:
♦ Brake fluid corresponds to the USA rule FMVSS 116 DOT 4
(brake fluid used up to the date)
♦ Brake fluid corresponds to the VW rule, VW 501 14 (new brake
fluid).
Authorized brake fluid specification in vehicles from model after
year 2006:
♦ Brake fluid corresponds to the VW rule, VW 501 14 (new brake
fluid).
WARNING
♦ Do not let the brake fluid contact fluids containing mineral

oils (oil, petrol, cleaning materials). Mineral oils damage
the sealing and the brake system hoses.
♦ The brake fluid is toxic. Due to its acidic properties it
should not come into contact with painted surfaces.
♦ The brake fluid is hygroscopic, that is, it absorbs the local
air humidity and, for this reason, it is stored in airtight
packages.
♦ Wash off any brake fluid spillage with plenty of water.

Observe the work instructions for Brake filler and bleeder -VAS
5234- and Brake bleeding device - VAG 1869- .
G. Volkswagen AG d
– Remove the cover -1- from the brake fluid reservoir.
lksw
agen
A
oes
not
o
yV gu
edb ara
ris nte
tho eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
– 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
aspiration bottle with filter, removing as much brake fluid as

possible.
l purpos
nform
ercia
Note
m
at
om
io
Do not reuse the (used) aspired brake fluid.

n
c
in t
or
his
ate
– Install the Brake pedal's tensioning element -VAG 1869/2- be‐

do
priv
tween the driver's seat and the brake pedal, pressing it.
um
for
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.
FOX 2004 ➤
– Connect the adapter -1- to the brake fluid reservoir.

– Connect the hose from the Brake filler and bleeder -VAS 5234-
or the Brake bleeding device - VAG 1869- to the adapter.
– Remove the protection covers in the bleeding screws.
– Position the venting hose -1- of the draining bottle in the rear
section of the bleeding screw, loosen the bleeding screw and
drain a corresponding quantity of brake fluid (check the table
below).
– Tighten the bleeding screw.

For vehicles with steering wheel to the left, start bleeding agenin the
AG. Volkswagen AG d
oes
right rear wheel; with the steering wheel to the right, o lksw bleeding
start not
yV gu
in the left rear wheel, because it is farther from
isedthe
b brake cylinder. ara
n r tee
ho
– Repeat the work procedure on the other
sa
ut rear side of the vehi‐ or
ac
cle. s
ce
e
nl
pt
du
– Install the venting hose -1- of the draining bottle in the rear
an
itte
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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
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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
Vehicles with 5-gear mechanical transmission.

orm
m
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
piston -1-, loosen the bleeding screw and drain approximately

r
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cu
o
0.1 liter.
f
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
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Prote AG.
FOX 2004 ➤

– Press the clutch pedal several times.
Sequence Wheel brake cyl‐ Amount of brake fluid that must be
inder brake shoes drained from the wheel brake cyl‐
inders, that is, from the brake fit‐
tings:
right rear 0.25 litre
left rear 0.25 litre
right front 0.25 litre
left front 0.25 litre
Total quantity: 1 litre 15)
15) of brake fluid drained from the brake fluid reservoir and from quantity changed
in the hydraulic clutch drive.
– Put the protection covers in the bleeding screws.

– Change the position of the passage lever on the Brake filler
and bleeder -VAS 5234- n Aor on
G. Volkthe Brake
swagen AG bleeding device -VAG
1869- to position wage
olks-B- (check the operating sinstructions).
doe
no t gu
V
by ara
– Removerithe
se passage hose from the adapter.
d
nte
ho eo
ut
– Remove
ss
a the brake fluid reservoir adaptor. ra
c
ce
le
– Install the brake fluid reservoir cover.

un
pt
an
d
itte
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– Remove the Brake pedal's tensioning element -VAG 1869/2-

rm
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
clearance 1/3 of the pedal stroke.

hole
spec
es, in part or in w
t to the co
WARNING
Do not forget to always correct the brake fluid's level in the

rrectness of i
reservoir.
l purpos
Never let it reach the minimum level, otherwise air may enter
the system.
nform
ercia
Do not reuse the (used) aspirated brake fluid!

m
a
com
tion in
r
te o
thi
4.40 Brake fluid level (depending on brake

s
iva
do
r
pad/lining wear) - check

rp
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.
♦ Do not let the brake fluid contact fluids containing mineral

oils (oil, petrol, cleaning products). Mineral oils damage
the seals and brake system hoses.
♦ The brake fluid is toxic. Additionally, due to its corrosive
effect, it must not come into contact with painted surfaces.
♦ The brake fluid is hygroscopic, that is, it absorbs the local
air humidity and, for this reason, it is stored in airtight
packages.
♦ Wash off any brake fluid spillage with plenty of water.
FOX 2004 ➤
Please note the following:

Delivery inspection:
Volkswa
In the delivery inspection, the fluid levelswmust
agen be at the maximum
AG. gen AG
does
marking. by
Volk not
gu
a
ed ran
ris tee
tho or
au ac
Note ss
ce
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nl
pt
du
In order to prevent the brake fluid from overflowing, the maximum
an
itte
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marking must not be exceeded.
erm
ab
ility
ot p
wit
Inspection service:
, is n
h re
hole
– The fluid level must always be assessed, based on the brake
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
brake system (repair measure) before replenishing the brake
atio
m
fluid.
o
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or c
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e
4.41 Headlight adjustment - check and adjust

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headlights if necessary cu
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Special tools and workshop equipment required t. Cop py
rig
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♦ 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.
4.41.1 Filling quantities table

Fuel reservoir indicator filling Additional weight in kg
level
1/4 30
1/2 20
FOX 2004 ➤
Fuel reservoir indicator filling Additional weight in kg

level
3/4 10
full 0
Example:
If the fuel reservoir is half full, you must put an additional weight
of 20 kg in the boot.
Note
As additional weight, it is preferable to use fuel containers filled

with water (one fuel container with a 5-liter capacity corresponds
to a weight of approximately 5 kg).
The vehicle should be moved for a few meters and dampened

several times both at the front and at the rear so that the shock
absorbers are properly settled.
♦ The vehicle and the headlight adjusting device must be on a
level surface. ⇒ Instruction manual for the headlight adjusting
device.
♦ The vehicle and the headlight adjusting device must be
aligned.
♦ Tilting must be adjusted.
The frame above the headlight has the tilt values engraved in “%”.
The headlights must be adjusted according to the following data.
The percentage is related to a projection distance of 10 meters.
For instance, a 1.0% tilting value corresponds to 10 cm.
♦ The knurled wheel for adjusting the headlight reach must be
olkswagen AG
in position (-). swagen AG. V does
k not
Vol gu
by
4.41.2 risCheck the headlight adjustment (with
ed ara
nte
tho eo
ss
au the new inspection display without 15º ra
c
adjustment line).
ce
le
un
pt
an
d
itte
Main headlights:
y li
erm
ab
ility
Please check the following:

ot p
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– Check if, with the low beam on, the horizontal light-dark limit
h re
ole,
contacts the separation limit -1- of the test surface.

spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
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fo
en
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t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
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Prote AG.
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
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core of the light beam is at the right of the vertical line.
erm
ab
ility
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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
the right or to the left, 150 mm upwards and 100 mm down‐
thi
te
sd
a
wards is acceptable.
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o
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f
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t.
yi Co
– For the current checking viewer with an adjustment line of 15º, t. Cop py
the same adjustment as for new checking viewer applies. To
rig
gh ht
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avoid incorrect adjustments, the 15º line will no longer be con‐ op Vo
by c lksw
sidered. cted agen
Prote AG.
Fog lights
– Check if the light-dark limit reaches the adjustment line and

runs vertically over the entire measuring device line.
Note
♦ The light-dark separation mark is the measurement from the

ground to the centre of the headlight minus 7.87 in in for 10.94
yd of distance.
ground to the centre of the headlight minus 100 mm in for 5 m
of distance.
Long reach headlights (CrossFox)
FOX 2004 ➤
– Check if the light-dark limit reaches the adjustment line and

runs vertically over the entire measuring device line.
Note

ground to the centre of the headlight minus 5.00 cm in for 10.94
yd of distance.
♦ The light-dark separation mark is the measurement from the G. Volkswage
ground to the centre of the headlight minus 0.98 in in lfor
gen A
ksw
a5 m
n AG d
oes
of distance.
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Vo gu
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Additional headlights: ss c
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un
pt
– Additional headlights from other systems, installed afterwards,
an
d
itte
must be installed according to their instructions.
y li
erm
ab
ility
ot p
4.41.3 Adjust the headlights
wit
is n
h re
ole,
Main headlights
spec
Main right headlight (the left headlight adjustment screws are
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.
FOX 2004 ➤
Long reach headlights (CrossFox)

– Release the screws-1- and -2-only enough to slightly move the
headlight.
– Press the headlight or move it forward -c- to the vertical ad‐
justment (height).
– Press the headlight in -a- or -b- for horizontal adjustment (right
and left).
4.42 Perform a test run

The following items depend on the vehicle equipment and local
conditions (city/country).
During a test run, evaluate the following items:
– Engine: Power, ignition failures, idle speed behavior, acceler‐
ation.
– Clutch: Starting performance, pedal force, smell.
– Transmission: Mobility, position of the selection lever.
– ABS operation: During an ABS-controlled braking, a slight
pulsing on the brake pedal should be noticed.
– Service brake and parking brake: Operation, idle stroke and
action, one-side pulls, trepidations, noises.
G. Volkswagen
– Steering wheel: Operation, steering wwheel
agen play, steering
A AG do
es n
olks
wheel in intermediate positionbwith
y V front wheels in straight po‐ ot gua
d
sition. or
ise
ran
te
h eo
ut ra
– Radio: Reception, interference
ss
a noises. c
ce
le
– Air conditioning: Operation.

un
pt
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– Vehicle: Offsets on a straight run (level road).

erm
ab
ility
ot p
– Balancing: Wheels, drive shafts.

wit
is n
h re
– Wheel roller bearing: Noises.

ole,
spec
– Engine: Hot start behaviour.

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.
FOX 2004 ➤
5 Additional tasks due to country legis‐

lation
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
5.1 Exhaust gas test

nl
pt
du
an
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erm
ab
ility
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Note
wit
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hole
♦ Follow the specific rules for the country.
spec
es, in part or in w
♦ The exhaust gas tests described below were performed in
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
Vehicles with catalytic converter adjusted or vehicles with diesel

engines:
nf
ercia
♦ 3 years after the first approval and, then, every 2 years.

orm
m
♦ Vehicles for commercial transport of people, such as, for ex‐ atio
m
ample, taxis: at every 1 year.

o
n in
or c
thi
e
Exhaust gas test for diesel engines ⇒ page 113 .

t
sd
iva
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cu
Exhaust gas test for petrol engines ⇒ page 99 .

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f
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t.
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5.1.1 Exhaust gas test for petrol engines
Co
Cop py
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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
♦ The description below refers to vehicles equipped with “On-

Board Diagnosis”, OBD, with catalytic converter adjusted.
♦ The OBD checks all components and systems that influence
the quality of the exhaust gases.
5. Additional tasks due to country legislation 99

FOX 2004 ➤
♦ Gas tester - 4 components (CO, CO2, HC and O2) or GAS

TESTER -VAS 6300-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
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nl
pt
du
an
itte
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erm
ab
ility
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♦ OBD adapter cable -VAS 5052/16-
h re
hole
spec
es, in part or in w
t to the co
Note
♦ It is only possible to perform an exhaust gas test when all de‐
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
with one another, according to the operation instructions.

♦ All works to be performed are indicated by the Gas tester - 4
nform
ercia
components (CO, CO2, HC and O2) or GAS TESTER -VAS

6300- .
m
at
om
ion
c
in t
or
Prior conditions for inspection:
his
ate
do
riv
• All conditions for inspection and data necessary for the ex‐
p
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
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pyri by
• The exhaust gas test datasheet must be printed to enable the
o Vo
by c lksw
cted
barcode reading.
agen
Prote AG.
• Automatic gearbox: selector level in position “P” or “N”.

• Mechanical transmission: selector lever in “neutral gear”.
• Handbrake operated.
– Perform the exhaust gas test according to the instructions on
the screen.
Startup screen:
– Select the function-arrow-, “Exhaust gas test”.
100 5. Additional tasks due to country legislation

FOX 2004 ➤
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
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rm
ab
pe
ility
ot
wit
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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
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te o
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s
iva
– Continue the exhaust gas test according to the instructions on

do
r
rp
the screen. cum

fo
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:

FOX 2004 ➤
– Enter in positions -1...7- the vehicle's data included on the ve‐

hicle's documentation.
♦ -1- Vehicle's manufacturer: “for example VOLKSWAGEN —
VW”
♦ -2- Type of vehicle: “for example, 1J”
♦ -3- Code number for 2: “z.B. 0603”
♦ -4- Code number for 3: “for example 358”
♦ -5- Engine identification letters “for example, AQY”
♦ -6- License plate: “for example WOB-HH 1234”
♦ -7- Vehicle identification number: “for example
WVWZZZ9NZYW123456”
– Enter in position- 8 - the kilometers traveled “for example,
32000”.
Note n AG. Volkswagen AG do

lkswage es n
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♦ Other functions can be optioned d b with the Skip key. ua
ran
ir se tee
o
You can interrupt the test
u with the Skip key.
h
♦ a
t or
ac
ss
ce
le
un
pt
an
d
– Select “with OBD”, -arrow-.

itte
y li
erm
ab
Entering nominal data for the exhaust gas test:
ility
ot p
wit
is n
h re
ole,
Note spec
t to the co
♦ If the nominal values do not exist as barcode, they must be

entered manually.
rrectne
♦ 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
– Follow the indications on the screen during the manual data

form
mer
entering.
atio
om
n
c
– With “Inspection values for the exhaust gas test” on the

i
or
n thi
e
screen, enter successively the values displayed on the ex‐

t
sd
va
haust gas test datasheet:

i
o
pr
cum
r
fo
1- Test rotation (idle speed rotation)

en
ng
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-.

FOX 2004 ➤
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
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b ara
– Perform the visual inspections. rise d
nte
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– 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
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When the Not OK button is pushed, you start a new test.
wit
is n
h re
ole,
spec
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.
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– Connect the diagnosis cable to the EOBD socket. Prote
cted AG.
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FOX 2004 ➤

– Perform the visual inspection of the “MI Lamp”.
– When the light is turned on, press on the screen “Light on”
- arrow C -.
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– Follow the indications on ethed b screen, - arrow C - and
y V gu
ara
-arrow A -. horis nte
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a
♦ Start the engine. ss c
ce
le
un
pt
♦ Perform an inspection with the MI lamp.
an
d
itte
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– Insert the exhaust gas probe in the exhaust gas exit tube.
erm
ab
ility
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wit
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Note
ole,
spec
The exhaust gas test process continues if the measuring probe
t to the co
is in the exhaust gas exit tube.
rrectness o
It automatically switches to readiness code.
cial p
f inform
The readiness code checks if all control devices work.

mer
atio
om
n
c
i
or
Note
thi
te
sd
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pr
♦ If all indication values are at zero, no probe inspection test is

cum
r
fo
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.

The measurement starts as soon as the engine rotation reaches
the necessary level.
– Keep the engine rotation on the necessary level.
The remaining time for performing the heating phase is indicated
-arrow A-.

FOX 2004 ➤
Maintenance
AG. Volkswagen - Edition 07.2010
n AG do
wage es n
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Heating period: ed
by
V ua
ran
ris tee
It automatically switches to the engine temperature au
tmeasurement
ho
or
ac
indication. ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
Note
ot
wit
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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
It switches automatically to the high idle speed rotation measure‐

ment indication.
nform
ercia

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a
com
t
ion in
r
te o
thi
s
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Note
fo
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ng
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♦ With the key → — it is possible to cancel the measurement,
C py
t. rig
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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.

The remaining time for performing the measurement is indicated
on the space -arrow A-.

FOX 2004 ➤
Idle speed rotation measurement and content of CO:

It automatically switches to the indication of idle speed rotation
measurement and content of CO.
The remaining time for performing the measurement is indicated
on the space -arrow A-.
Probe inspection test:
Note
The probe inspection test is not performed when all readiness

code values are at zero.
It switches automatically to the probe inspection test indication.
Note
The probe inspection test is performed individually for each Lamb‐

da Probe .

n AG. Volkswagen A ge Gd
wa oes
The remaining time for performingbthe olks
y V measurement is indicated t gua
no
on the space -arrow A-. ris
ed ran
te
tho eo
s au ra
c
Assessment: s
ce
e
nl
pt
du
After the exhaust gas test, the report will be displayed on the
an
itte
y li
screen.
erm
ab
ility
ot p
The test result is indicated.

wit
, is n
h re
In this location, remarks about the exhaust gas test can be en‐
hole
tered -arrow A-. They are included on the test report.

spec
es, in part or in w
– After successfully performing the exhaust gas test, select on

t to the co
the hanging menu - arrow B - “Assigned exhaust gas test plate”

and the date.
rrectness of i
– Confirm with “Yes” - arrow C -.

l purpos
– Then, press it.

nf
ercia
orm
m
atio
om
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or c
thi
te
sd
iva
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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.

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agen oes
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ee 2004 ➤
ho
aut Maintenance - Edition or 07.2010
ac
ss
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e
nl
After the confirmation, two “TEST CERTIFICATES” are automat‐
pt
du
an
ically printed.
itte
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erm
ab
– To get other certificates, press the -arrow A - “Print” button.
ility
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wit
, is n
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
Exhaust gas test for petrol engines without OBD
nf
ercia
orm
Note
m
atio
om
n in
c
♦ All test conditions and data necessary for the exhaust gas test:
or
thi
e
⇒ "Exhaust gas test"

t
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.
♦ The content of CO is adjusted to the theoretical value by the

lambda probe adjustment. The defects in the lambda probe
inspections are processed by the Diagnosis, Measurement
and Information System -VAS 5051A /52- and stored in the
fault memory.
♦ When consulting the fault memory, the faults detected (elec‐
tronic engine system) must be eliminated and deleted from the
fault memory.
♦ To avoid injuries in people and/or destruction of ignition and
injection systems, the ignition system cables (also high volt‐
age cables) must be turned on and off only with the ignition
turned off.
Note
The following description refers to vehicles without OBD with cat‐

alytic converter adjusted.

♦ Gas tester - 4 components (CO, CO2, HC and O2) or GAS
TESTER -VAS 6300-
♦ Adapter for older vehicles -VAS 5051/2-

FOX 2004 ➤
or
♦ Rotation adapter -VAS 5087/ A-
♦ Exhaust gas test requester
Note
♦ It is only possible to perform an exhaust gas test when all de‐

vices from the Gas tester - 4 components (CO, CO2, HC and
O2) or GAS TESTER -VAS 6300- are working and connected
with one another, according to the operation instructions.
♦ All works to be performed are indicated by the Gas tester - 4
components (CO, CO2, HC and O2) or GAS TESTER -VAS
6300- .
Prior conditions for inspection:

• All conditions for inspection and data necessary for the ex‐
haust gas test are available on the exhaust gas test datasheet
for the respective engine⇒ Data sheets for exhaust emission
test.
• The exhaust gas test datasheet must be printed to enable the
barcode reading.
• Automatic gearbox: selector level in position “P” or “N”.
• Mechanical transmission: selector lever in “neutral gear”.
• Handbrake operated.
– Perform the exhaust gas test according to the instructions on
the screen.
Startup screen:
AG. Volkswagen AG d
– Select the function-arrow-, “Exhaust gas test”. lksw
agen oes
not
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by ara
d
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au ra
ss c
ce
e
nl
pt
du
an
itte
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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
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nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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f
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ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
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cted agen
Prote AG.

FOX 2004 ➤
The indication for the heating period will be displayed.
lkswage es n
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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
– When the selection of the theoretical value of exhaust gases
y li
erm
ab
is displayed, select the respective “Selection of theoretical val‐
ility
ot p
ue of exhaust gases”, -arrow-.
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
The vehicle's data entering menu will be displayed.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
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o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

FOX 2004 ➤
– Enter in positions -1...7- the vehicle's data included on the ve‐

hicle's documentation.
♦ -1- Vehicle's manufacturer: “for example VOLKSWAGEN —
VW”
♦ -2- Type of vehicle: “for example, 1J”
♦ -3- Code number for 2: “z.B. 0603”
♦ -4- Code number for 3: “for example 358”
♦ -5- Engine identification letters “for example, AQY”
♦ -6- License plate: “for example WOB-HH 1234”
♦ -7- Vehicle identification number: “for example
WVWZZZ1JZYW123456”
– Enter in the space - 8 - the kilometers traveled “for example,
32000”.
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
Entering nominal data for the exhaust gas test:

nl
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
Manually entering nominal data for the exhaust gas test:

l purpos
– Follow the indications on the display during the manual data

entering.
nf
ercia
orm
m
atio
m
– With “Inspection values for the exhaust gas test” on the

o
n in
c
screen, enter successively the values displayed on the ex‐

or
thi
haust gas test datasheet:

te
sd
iva
o
r
1- Test rotation (idle speed rotation)

rp
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
5- Content of CO with high idle speed rotation

6- Lambda with high idle speed rotation
7- Idle speed operation
8- Select the type of probe adjustment: “Enrichment probe” or
“Broad range probe” - 1 -.
9- Lambda probe value
– After entering all data correctly, press the “Continue” key
-arrow-.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
autho eo
ra FOX 2004 ➤
ss c
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
sheet with the reading pencil.
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
ion in
r
te o
– Perform the visual inspections.
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.
– 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
♦ In some engines, it is not possible to connect the inductive

sensor to cylinder 1.
♦ In these engines, you can use the rotation number adapter -
VAS 5087/- .
♦ In some engines, you must use the rotation number adapter -
VAS 5087/- .

– Insert the exhaust gas probe in the exhaust gas exit tube.
Note
The exhaust gas test process continues if the measuring probe

is in the exhaust gas exit tube.
It automatically switches to the readiness code

Condition of the catalytic converter:
It automatically switches to the catalytic converter's heating
phase.

FOX 2004 ➤

The remaining time for performing the heating phase is indicated
-arrow A-.
Heating period:
It automatically switches to the engine temperature measurement
indication.
Note
This indication appears just before the engine temperature rea‐

ches 80 degrees Celsius.
– The engine temperature must reach the necessary level.
Measurement in high idle speed rotation:

It switches automatically to the high idle speed rotation measure‐
ment indication. swa
gen AG
. Volkswagen AG
does
k not
Vol gu
– Follow the indications on the
se
d bscreen.
y ara
nte
i
or eo
The measurement starts aas
ut soon as the engine rotation
h
reaches ra
the necessary level. ss c
ce
le
un
pt
an
d
itte
y li
Note
erm
ab
ility
ot p
wit
♦ With the key, ▸ it is possible to void the measurement, that is,

is n
h re
not perform the exhaust gas test.

ole,
spec
♦ With the key, ← the measurement values are reset and the test
t to the co
can be repeated.

rrectne
The remaining time for performing the measurement is displayed

-arrow A-.
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
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

lkswage es n
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o
FOX
ot g
ua 2004 ➤
ran
ho
ir se Maintenance - Edition 07.2010
tee
ut or
a ac
ss
Idle speed rotation measurement and content of CO:
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
wit
, is n
h re
hole
spec
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 necessary level. l purpos
nf
ercia
orm
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.
– After successfully performing the exhaust gas test, select on

the hanging menu - arrow B - “Assigned exhaust gas test plate”
and the date.
– Confirm with “Yes”, inquire - arrow C -.
After the confirmation, two “TEST CERTIFICATES” are automat‐

ically printed.
– To get other certificates, press the - arrow A - “Print” key.
– Remove the exhaust gas probe from the final exhaust gas
tube.
– Then, press the ▸ key -arrow B-
The exhaust gas test is finished. It is possible to perform a new
exhaust gas test.
5.1.2 Exhaust gas test for diesel engines

The test sequence was prepared for its execution with the com‐
bination of test devices for analyzing exhaust gases.

FOX 2004 ➤
♦ Diesel engine test device -V.A.G 1743-
♦ Rotation adapter -VAS 5087 A-
♦ or
♦ Rotation adapter -VAS 6296-
AG. Volkswagen AG d
agen oes
olksw not
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ility
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spec
♦ Data reading device -V.A.G 1798-

es, in part or in w
t to the co
♦ or
♦ Data reading device -V.A.G 1799-
rrectness of i
♦ ⇒ Data sheets for exhaust emission test

l purpos
Note
nform
mercia
♦ All test conditions and data necessary for the exhaust gas
a
com
tio
test:⇒ Data sheets for exhaust emission test

n in
r
te o
thi
♦ If there is the possibility, the test must be performed after a

s
iva
do
test drive. If, for any reason (atmospheric conditions, inadmis‐

r
rp
cum
sible noise level in residential areas), it is not possible, the test

fo
en
g
can also be performed on the workshop.

n
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.

FOX 2004 ➤
Perform a visual inspection of the components that influence the

exhaust gases
– Perform the visual inspection in relation to:
♦ Existence time
♦ Integrity
♦ Tightness
♦ Damage
Note
When finding defects, they must be eliminated.
Test conditions
• Minimum engine temperature of 80 ºC agen
AG. Volkswagen AG d
oes
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• 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
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erm
Description, measurement process, device operation, start-up
ab
ility
and operation ⇒ Operation instructions V.A.G 1743
ot p
wit
is n
h re
ole,
spec
Note
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
– Connect the Rotation adapter -VAS 5087 A- with the ignition

om
turned off, as follows.

c
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).

FOX 2004 ➤
– With the other Adapter -VAS 5087/1- cable, make a connec‐

tion to the vehicle's battery. For this purpose:
♦ red terminal on positive
♦ black terminal on negative.
Note
♦ When you use the Rotation adapter -VAS 5087 A- , press the
G. Volkswage
“Start” key. The red signaling lamp must ksw
agbe
en Aturned on for ap‐oes 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
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Test sequence
h re
hole
– Start the engine and let it run only in idle speed.
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
Manual inputting with the -

> Key
– Through the data reading device keyboard, enter the following
nform
ercia
vehicle identification data:

m
at
om
♦ License plate ion

c
in t
or
♦ Vehicle manufacturer = “Number 2”

his
ate
do
riv
♦ Code = “for Number 2”

p
cum
for
en
g
♦ Type of vehicle = “Number 3”

n
t.
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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.
Check input with -> Key

Continue with the - Q key
– Confirm the vehicle identification data through the Q key.

Select barcode
Manual inputting with the -> 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.

FOX 2004 ➤

AG. Volkswagen AG d
Check input with -> Key
agen oes
olksw not
V gu
d by ara
ise nte
or eo
– Confirm the vehicle data entered orautread through the Q key.
h
ra
ss c
ce
le
un
pt
an
d
itte
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Visual inspection Ok = j not Ok =
erm
ab
ility
– Enter the visual inspection result. ot p
wit
is n
h re
ole,
spec
F1 temperature measurement with sen-
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
om
n
c
i
or
n thi
e
Idle speed rotation -

t
sd
a
>
iv
o
r
ACTUAL rotation xxxx/

p
cum
r
min THEORETICAL xxxx/min

fo
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.
– If the values are not in the theoretical value field, a Repair

Measure must be performed.
Engine cutting rotation
5 sec.
min THEORETICAL xxxx...xxxx/min
– Press the accelerator pedal up to the end for the time required,
and keep it pressed.
WARNING
If the engine cutting rotation is exceeded, release the acceler‐

ator pedal immediately and perform a Repair measure.

Engine cutting rota-
tion ->
min THEORETICAL xxxx...xxxx/min
– Release the pedal.

FOX 2004 ➤
– 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.
Idle speed rotation 1ª measurement 15 sec
min THEORETICAL xxx...xxxx/min
– The data reading device assumes actual values in 15 sec‐

onds.
AG. Volkswagen AG d
Upon indication on display: agen oes
olksw not
byV gu
ara
ed
Data transmission for the gas oil test de- ris nte
ho eo
ut
vice
Quickly press the pedal a ra
ss c
ce
le
un
– Press the accelerator pedal up to the end and keep it pressed.
pt
an
d
itte
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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
– Keep pressing the accelerator pedal.
t to the co
rrectness of i
l purpos
nform
ercia
The data reading device assumes actual values in 15 seconds.

m
a
com
tion in
r
te o
thi
s
iva
vice do
r
Quickly press the pedal

rp
cum
fo
en
g

n
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
Data transmission for the gas oil test de- cted agen
vice
Prote AG.


vice
Quickly press the pedal

FOX 2004 ➤

vice


vice
wage
Quickly press the
ks
pedal e
s no
Vol t gu
by ara
– Press the accelerator
orised
pedal up to the end and keep it pressed.
nte
th eo
u ra
With the indication
ss a on display: c
ce
le
un
pt
an
d
itte
vice
y li
erm
ab
ility
ot p

wit
is n
h re
ole,
spec
Peak turbidness value - -

t to the co
>
ACTUAL x.xx/
m THEORETICAL x...x.xx/m
rrectne

ss o
cial p

inform
mer
Average turbidness value - -

atio
m
>
o
ACTUAL x.xx/
c
i
or
m THEORETICAL x...x.xx/m
thi
te
sd
va

i
o
pr
cum
r
fo
en
ng

t.
yi Co
Cop py
t. rig
Turbidness range width - gh - ht
> pyri by
Vo
co
ACTUAL x.xx/ by lksw
m THEORETICAL x...x.xx/m cted agen
Prote AG.

Test Ok continue with the Q key
Repeat the test with the F1 key
– Press the key Q .

FOX 2004 ➤
Note
♦ Upon indication on display: n AG. Volkswagen AG do

lkswage es n
♦ Press the F1 key and repeat by V the test or perform a Repair t gua
o o
ed ran
Measure. ris tee
tho or
au
Test not Ok continue with the - Q key ac
ss with the - F1 key
Repeat the test
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
Input of clarifications with -> Taste
wit
is n
h re
ole,
spec
– If necessary, enter clarifications by pressing the key → .
t to the co
– Press the key Q .
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
– Press the Q , wait for the protocol.
atio
om
n
c
i
or
n thi
te
– Finish the test by pressing the F2 key. sd

iva
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
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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 für 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

FOX 2004 ➤
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
♦ Flexible service interval indicator in the combined instrument

♦ Engine oil's level sensor
nform
ercia
♦ Brake pad's wearing indicator

m
at
om
ion
QG2 The LongLife service is not active from the factory. It means that the vehicles have a
c
in t
or
fixed service interval indicator (maintenance intervals dependent on time or kilometers
his
ate
traveled) and are equipped with the following components:
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°

FOX 2004 ➤
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 deter‐ran
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
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ng
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ht. rig
rig ht
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Prote AG.

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Service

Service Department. Technical Information

All rights reserved.

Copyright © 2010 Volkswagen AG, Wolfsburg BRA5R005420

3.1 Rear license plate (only CrossFox Europe) - install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3.8 Engine oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4.1 Clock - set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

and Information System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

4.4 Fire extinguisher - check the charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

4.31 Spark plugs - replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

5.1 Exhaust gas test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Exhaust gas warning light no no yes yes

Octane rating min. 95 lead-free 95 lead-free 95 lead-free 95 lead-free

1) 4BV injection system with immobilizer

2) ME 7.5.10 injection system with immobilizer

3) Argentina from the start.

Identification letters ASY BNM

Identification letters BKR BMD CHFB

Cylinder volume l 1,4 1,2 1,2

Max. output kW/ 55,0/5600 40,0/4750 40,0/4750

Electronic accelerator yes yes yes

Catalytic converter yes yes yes

Recirculation of exhaust gases no no no

2.1 Service table

2.1.1 VW standards on engine oil

Diesel engines VW standards

With injector - pump 505 01

Without injector - pump 505 00

2.1.2 Replacement intervals for the filters

ENGINE OIL FILTER

For all countries: every 15,000 km or 1 year

Europe only every 60,000 km or 4 years

Except Europe every 18,641.14 mi or 2 years

Replacement intervals for the filter

DUST AND POLLEN FILTER

2.1.3 Replacement intervals for the timing belt

2.1.4 Replacement intervals for spark plugs

Replacement interval for spark plugs

All petrol engines every 60,000 km or 4 years

2.1.5 Service intervals - Models ▸ 2008 (ex‐

Petrol engines and diesel engines

Intervals according to the maintenance in‐ Service

terval indicator (not flexible)

– Oil change service according to the 7)

maintenance interval indicator

♦ at every 15,000 km or every 1 year,

whichever occurs first, (for all coun‐

Intervals according to the maintenance in‐ Service

2.1.6 Service intervals - Models ▸ 2007 (Eu‐

maintenance interval indicator

8) In vehicles using diesel withahigh lkswagenthe

Intervals according to the maintenance in‐ Service

terval indicator (not flexible)

– Oil change service according to the 9)

maintenance interval indicator

♦ at every 15,000 km or every 1 year,

whichever occurs first, (for all coun‐

whichever occurs first, (for all coun‐

♦ at every 60,000 km or 3 years and,

then, every 2 years, whichever occurs

first, (for all countries)

– Battery - check the battery terminals for proper seating. ⇒ page 40

– Airbag: check turn on.