Volkswagen FOX 2004 Service Manual Download Page 72

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♦ Torque wrench - 40 to 200 Nm (enc. 1/2") -VAG 1332-

♦ Torque wrench - 5 to 50Nm (fit. 1/2") -VAG 1331-

4.25.1

Brake cylinder

Carry out work sequence as follows:
– For better evaluation of the remaining pad thickness, remove

the driver side wheel (the wear is more intense than on the

passenger side).

– Remove the hub cap/super hub cap.
The hook for removing the hub cap is in the tool kit.
– Loosen the wheel fastening screws and remove the wheel.
– For vehicles with brake pad wear indicator, disconnect the

connector -1-.

FOX 2004 ➤

Maintenance - Edition 07.2010

4. Service descriptions

Summary of Contents for FOX 2004

Page 1: ... e r m i t t e d u n l e ssauthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Maintenance FOX 2004 Edition 07 2010 Service Service Department Technical Information ...

Page 2: ...k s w a g e n A G Maintenance Heading 1 Engine overview 2 Service plans 3 General remarks 4 Service descriptions 5 Additional tasks due to country legislation 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 prec...

Page 3: ...6 4 6 Radio activate the anti theft code 36 4 7 Reading radio code using Diagnosis measurement and information system 38 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 ...

Page 4: ...oir 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 4 37 Fuel filter replace 87 4 38 Fuel filter drain 89 4 39 Brake fluid replace 90 4 40 Brake fluid level depe...

Page 5: ...er mm 67 11 76 5 76 5 76 5 Stroke mm 70 6 87 0 87 0 87 0 Compression rate 10 8 1 10 8 1 10 8 1 10 8 1 Injection ignition 4BV1 ME 7 5 102 ME 7 5 102 ME 07 05 30 Octane rating ROZ min 95 lead free 95 lead free 95 lead free 95 lead free Electronic accelerator yes yes yes yes Self diagnosis yes yes yes yes Catalytic converter yes yes yes yes Lambda adjustment 1 Lambda probe 1 Lambda probe 2 Lambda pro...

Page 6: ...Production from 11 22 04 from 11 22 04 from 03 09 Limit value for exhaust gases accord ing to EURO 4 EURO 4 EURO 4 Number of cylinders Valves per cylin der 4 2 3 2 3 2 Cylinder volume l 1 4 1 2 1 2 Max output kW rpm 55 0 5600 40 0 4750 40 0 4750 Engine torque Nm rpm 110 0 4000 106 0 3000 106 0 3000 Diameter mm 76 5 76 5 76 5 Stroke mm 75 6 86 9 86 9 Compression rate 10 5 10 3 10 3 Injection igniti...

Page 7: ...pection 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 interval...

Page 8: ...R at every 30 000 km DUST AND POLLEN FILTER All engines 2007 for Europe and except Europe 2008 at every 30 000 km All engines 2008 for Europe and 2009 except Europe every 18 641 14 mi or 2 years 2 1 3 Replacement intervals for the timing belt Replacement intervals for the timing belt Diesel engines En gine type MKB Time period Replacement interval Tensioning roller 1 9 l SDI ASY at every 93 205 68...

Page 9: ...y 30 000 km or every 2 years whichever occurs first 8 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 7 Models 2008 Europe and Models 2009 except Europe Intervals according to the maintenance in terval indicator not flexible Service Oil change service according to the maintenance interval indicator...

Page 10: ... 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 tection identification letters AQZ and BAH page 35 Radio tag part of the radio s Instruction Manual get the sticker with the serial number and the fixed code Windshield r...

Page 11: ...ol 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 ...

Page 12: ...oil filter replace page 58 Battery fill the electrolyte up to the level except for maintenance free bat teries and Europe Fuel filter drain the water Vehicles with diesel engine using bio diesel ac cording to the DIN E 51 606 or diesel vehicles that do not comply with the DIN EN 590 page 89 Spare wheel support stop lubricate CrossFox only page 35 Vehicle on raised platform Engine oil drain or aspi...

Page 13: ...Windshield rear window wiper system Application Windshield rear window washer additive Proportion EUROPE only G 052 164 A1 or G 052 164 A2 300 ml additive to 700 ml water Tropical climate countries G 052 131 A1 until 07 2005 1 69 fl oz additive for 32 12 fl oz wa ter G 052 184 A2 from 08 2005 100 ml additive for 990 ml water Note Use oils with high lubrication performance according to spec ificati...

Page 14: ...g to the DIN E 51 606 or diesel vehicles that do not comply with the DIN EN 590 page 89 Vehicle on raised platform Engine oil drain or aspirate page 58 Brake system perform a visual check for leaks and damage page 67 Rear pads and linings check the thickness page 67 Brake discs check the level of wear and corrosion page 69 Shock absorbers verify for leaks except Europe Concluding tasks Maintenance...

Page 15: ...ve for 990 ml water Note 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 Intermediate service Models 2011 Europe Service Battery check wi...

Page 16: ...apacity 2 85 l standard 502 00 VW Petrol engine Identification letter BKR filling capacity 3 3 l standard 502 00 VW page 58 Engine and components in engine compartment from above check visu ally for damage and leakage page 65 Engine cooling system fluid correct the proportion of antifreeze and fill up to the level Theoretical value 25 C in Arctic climate countries 35 C actual value value measured ...

Page 17: ...0 000 km or 60 000 km A tolerance of up to 1 000 km is acceptable above or below the indicated kilometer traveled in services based on kilometers trav eled and one month after or before the indicated time for services based on time Note Inform the customer in case of problems within a service scope that require a Repair action Use oils with high lubrication performance according to spec ifications...

Page 18: ...indi cator lights and warning lights Driver and passenger airbag make a visual inspection in relation to external damages for Europe on vehicles model 2007 and except Europe on vehicles model 2008 page 48 Self diagnosis Refer to the failure memory of every system with the Diag nosis Measurement and Information System for Europe on vehicles model 2007 and except Europe on vehicles model 2008 page 2...

Page 19: ...k the state of tread sides and depth of grooves _____ mm page 53 Tyres calibrate including the spare wheel page 53 Underside of the vehicle Engine oil drain or aspirate page 58 Engine and components in engine compartment from below perform a visual check for leaks and damage page 65 Poly V belt check state at every 37 282 27 mi for Europe on vehicles model 2007 and except Europe on vehicles model ...

Page 20: ... l standard 505 01 VW Diesel engine Identification letters ASY 4 3 l filling volume standard 505 00 VW or 505 01 VW Petrol engines Identification letters AQZ filling capacity 3 3 l standard 502 00 VW Petrol engines Identification letters BAH BLH and CFZA filling capacity 4 0 l standard 502 00 VW Petrol engine Identification letter BMD filling capacity 2 85 l standard 502 00 VW Petrol engine Identi...

Page 21: ...m or every 2 years whichever occurs first page 87 Air cleaner replace the filtering element and clean the filter case identification letters AQZ and BKR at every 30 000 km or every 2 years whichever occurs first page 86 Air cleaner replace the filtering element and clean the filter case Engine identification letters ASY BKR BNM and BMD at every 37 282 27 mi or every 4 years whichever occurs first ...

Page 22: ... Perform a test run page 98 2 7 Supplementary services based on time elapsed and or kilometers traveled Besides the oil change or inspection service which depends on the conditions of usage and optional equipments in the vehicle performing supplementary maintenance works is necessary Also it is possible to perform additional works by considering the records in the service plan or on the adhesive t...

Page 23: ...ission check oil level for vehicles with kilometers traveled over 60 000 km within a 3 year period and then every 2 years for Europe in model 2008 vehicle and in model 2009 vehicles elsewhere page 66 Air cleaner replace the filtering element and clean the filter case identification letters BAH and BLH for vehicles with kilometers traveled over 37 282 27 mi within a 4 year period page 86 Air cleane...

Page 24: ...e check state Diesel engine identification letters BNM for Europe on vehicles model 2007 page 85 At 90 000 km and then at every 30 000 km Supplementary services Page Timing belt for camshaft drive check state 4 cylinder petrol engines Identification letters AQZ BAH BLH BKR and CFZA page 85 At every 93 205 68 mi Supplementary services Page Timing belt and tensioning roll for camshaft drive replace ...

Page 25: ...del 2009 vehicles elsewhere page 90 Carry out an exhaust gas inspection additional work with separate payment in function of the country s legislation page 99 Sunroof check operation clean the guide rails and lubricate them with Special grease G 000 450 02 for vehicles with kilometers traveled over 60 000 km within a 3 year period and then every 2 years for Europe in model 2008 vehicle and in mode...

Page 26: ...ssary 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 guidelines are not followed the...

Page 27: ...al member Note To anchor the CrossFox using electrical hydraulic lifts refer to the Tools and Equipment Manual 3 3 Service tag 3 3 1 Stick the tag Next service upon Deliv ery inspection 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 The stamp or tag may also be attached to the ...

Page 28: ...pillar B The stamp or tag may also be attached to the left lower corner internal side of the Windscreen with the FRONT facing outside the vehicle check instructions in the Service Organization Man ual 3 3 3 Paste the data holder on the customer service plan in the delivery inspection Please paste the upper data holder on both arrow 1 planning week 2 PR number 3 4 Self diagnosis refer to the fault ...

Page 29: ...stem 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 Indicated on display 3 4 3 Select the operation mode On the display press the key for Vehicle self diagnosis arrow Note If the messages i...

Page 30: ...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 disp...

Page 31: ...S tag arrow is on the left seat s cross member and is visible from the rear side through an opening in the floor carpet 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...

Page 32: ...al 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 require repairs the customer must be informed Intervals Service Oil change service performed at every 15 000 km or 1 year page 7 Intermediate service every 30 000 km or 2 years Models 2010 Europe and Models 2009 except Europe...

Page 33: ... 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 vehicles with PR number QG0 Diesel engines VW standards SDI 505 00 or 505 01 Diesel engines with identification letters BNM vehicles with PR number QG0...

Page 34: ... loads through long distances Reduced emission of pollutants because of lower fuel con sumption WARNING Follow the rules for disposal 3 9 Identification letters and engine number 3 9 1 ASY engine The engine identification letters and engine number are engraved on the engine block arrow in the engine gearbox separation area Additionally the upper mechanical distribution cover has a sticker with the...

Page 35: ...en gine identification letters and serial number The engine identifi cation letters are also indicated on the vehicle identification tag 3 10 Push starting pushing the vehicle to start towing Push starting and towing are carried out in different ways de pending on the legislation of each country If the vehicle is provided with a towing hook then a tow cable or tow bar should be attached to the fro...

Page 36: ...e engine is turned off Since the power steering does not work with the engine off are much harder to execute when the engine is off If there is no lubricant in the automatic transmission the ve hicle can only be towed with the drive wheels lifted 3 10 1 If the jump starting has to be carried out against our recommendation please note the following points for vehicles with a mechanical transmission...

Page 37: ...ne display With the ignition on select the clock function pressing the button arrow for less than 2 seconds There will be a clock symbol beside the time To activate the hour set function keep the button arrow pressed until the display starts flashing then press the button arrow quickly the numbers will change sequentially in as cending order New Fox Set the minutes To activate the minute set funct...

Page 38: ...changes only one unit at a time If the button is turned and kept pressed the numbers will change sequentially in ascending order To set the minutes correctly based on another clock move the button arrow until it reaches one unit before the exact minute At the moment the other clock reaches the full minute turn the button again to the right 4 2 Maintenance interval indicator if avail able reset wit...

Page 39: ...the ignition on Hold the button at the right of speedometer during approxi mately 10 seconds The display resumes the normal indication 4 3 Spare wheel support stop lubricate CrossFox Any grease residue contaminated grease must be removed from the stop Lubricate the stop inside 2 with Silicone grease G000 405 A2 4 4 Fire extinguisher check the charge 4 4 1 Engine identification letters AQZ BAH CFZA...

Page 40: ...be immediately re charged Driving vehicles with extinguishers which are out of date or in poor condition of use is forbidden by law 4 5 Power window drive reprogram Note When the battery is disconnected and then reconnected the power window drive will not be completely operational The win dow drives must be reprogrammed before the vehicle s delivery The vehicle battery cannot be disconnected after...

Page 41: ...proximately 1 hour Leave the unit on and the ignition key in the switch for one hour After 1 hour enter the code number again On beta and gamma radios the fixed code is activated as fol lows Turn the radio on The digital display will exhibit SAFE After approximately 3 seconds 1000 will appear on display Enter the code number attached to the radio card with the tun ing buttons 1 to 4 The first digi...

Page 42: ...ve 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 After 1 hour enter the code number again 4 7 Reading radio code using Diagnosis m...

Page 43: ...UIDED FUNC TIONS Finish code reading as follows Press GoTo button on display Press the End button on display Press End button in End menu Switch off ignition and separate diagnostic connections 4 8 Wheel fastening screws tighten to cor rect torque Special tools and workshop equipment required Torque wrench 40 to 200 Nm enc 1 2 VAG 1332 4 8 1 Hub cap Super hub cap The hook for removing the hub cap ...

Page 44: ...ns must be ob served for each battery type Electrical equipment Rep Gr 27 Starter generator battery Visual inspection Carry out work sequence as follows Check the battery case for damage If the case is damaged battery electrolyte may leak Check the battery poles Battery cable connections for dam age If the battery poles are damaged this will compromise the contact with the cable connections This m...

Page 45: ... o l k s w a g e n A G Torque wrench 5 to 50 Nm fit 1 2 VAG 1331 Carry out work sequence as follows Press the locks and tilt the positive battery pole cover arrow With alternate movements of the positive and negative battery cables check if the terminals arrows are firmly fastened to the battery poles WARNING If the terminal is not firmly fastened to the battery pole first you must disconnect the ...

Page 46: ... 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 1 Fires sparks open flame and smoking are prohibited Avoid sparks and electrostatic discharges when handling ...

Page 47: ...acity page 43 Specially when a battery is recharged that is even when the battery is charged during driving air bubbles can form under the inspection viewing glass These bubbles change the color indication in the inspection viewing glass The inspection viewing glass may be located at various posi tions on the battery Before making the visual inspection tap lightly and carefully with a screwdriver ...

Page 48: ...ery test with printer converted modification software recognized by logo 1 Note When using the Battery test device with printer VAS 5097A or VAS 5097 it is not necessary to remove the battery Also it is not necessary to disconnect the battery Performing battery charge test sequence Turn ignition off Connect the claws to the battery poles Check the battery test device operation instructions The cla...

Page 49: ...ttery11 Weak starting power Recharge the battery11 Very poor starting power Recharge the battery11 Unsuitable for tests Recharge the battery11 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...

Page 50: ...e sure that the oil level does not exceed the maximum marking Pull the oil dipstick out again and check the oil level Condition 2 Area A Oil must not be replenished Area B It is not necessary to replenish the oil Area C Replenish the oil level It is sufficient for the oil level to be anywhere within area B Arrow 1 Maximum marking Arrow 2 Minimum marking Pull the oil dipstick out again and check th...

Page 51: ...3 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 Carry out the following tasks Note It is not nece...

Page 52: ...isual inspection of the padded surface for external damage WARNING The steering wheel padded plate must not be glued coat ed or undergo any type of rework This information must be emphasized to the customer to ensure the future Air bag s operation The steering wheel s padded plate must only be cleaned with a dry cloth or a cloth moistened with water 4 14 2 Passenger s airbag The identification fea...

Page 53: ...10007 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 additive for front rear window wip ers with Refractometer for cooling system liquid analysis EQ 7093 VWB ou T 10007 follow the instru...

Page 54: ... rear window washer ad ditive Water 1 part 99 parts Complete The Windscreen washer fluid reservoir must be replenished to the top Note The original Volkswagen product Windscreen rear window washer additive G 052 164 A1 or the G 052 164 A2 have cleaning properties that protect the ejectors the reservoir and connection hoses against freezing In warm seasons of the year it is also possible to use ori...

Page 55: ...tion 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 Adjust the jet through the nozzle tab 1 by moving it slightly with your hand upward or downward...

Page 56: ...he 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 4 16 2 Rear window...

Page 57: ...e incidence angle according to the following table Incidence angle nominal values Driver s side 5 0 Passenger s side 5 0 Tolerance 2 0 If necessary adjust the incidence angle to the nominal value as follows Place the Wrench 1 on the Adjustment device 3358B and move arrows the wiper arm 2 to the nominal value Compare the adjusted value as per the table If necessary repeat the adjustment and control...

Page 58: ...ides 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 ...

Page 59: ...ad Wear Indicators distributed at every 60 degrees a on tire perimeter In this situation the groove depth is approximately 1 6 mm How ever considering that a worn tire is more likely to skid on wet surfaces we recommend replacing a tire when the groove depth reaches 3 mm Note This value may be different depending on each country s legal requirements The minimum profile depth is reached when the we...

Page 60: ...yre pressure table for all sizes of tyres assembled in the factory Pressure values in PSI pounds sq in Note Values obtained at publishing date half load front and rear full load front and rear Engine identification letters AQZ BJE BNX with mechanical steering 175 65 R14 82T 31 27 33 39 Engine identification letters AQZ BJE BNX 175 65 R14 82T 29 28 31 36 185 60 R14 82H 30 29 33 37 195 55 R15 85H 27...

Page 61: ...values in bar Note Values obtained at publishing date half load front and rear full load front and rear Engine identification letters AQZ BJE BNX with mechanical steering 175 65 R14 82T 2 1 1 9 2 3 2 7 Engine identification letters AQZ BJE BNX 175 65 R14 82T 2 0 1 9 2 1 2 5 185 60 R14 82H 2 1 2 0 2 3 2 6 195 55 R15 85H 1 9 1 9 1 9 2 3 Engine identification letters BAH BJA BPA 175 65 R14 82T 2 1 2 ...

Page 62: ... g e n A G half load front and rear full load front and rear Engine identification letters BNM 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 Engine identification letters BKR 205 60 R15 91V 2 0 2 2 2 0 2 6 Engine identification letters BNM 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 ...

Page 63: ...BLH and CFZA Aspirate the engine oil with the Oil aspirator VAG 1307 A or Oil aspirator VAG 1358 A Remove the oil draining plug arrow Remove the sealing ring from the oil draining plug and cut if necessary Drain the engine oil Tightening torque for the draining plug seta 4 cylinder engines 30 Nm Note Please note that the tightening torque must not be exceeded A very high tightening torque may lead...

Page 64: ...ssary Drain the engine oil Tightening torque for the draining plug 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 Please note that the tightening torque must not be exceeded A very high tightening torque may le...

Page 65: ... lead to damage or even leaks in the oil draining plug area Install a new sealing ring in the oil drainage plug WARNING Follow the rules for disposal Engine identification letters BNM Aspirate the engine oil with the Oil aspirator VAG 1307 A or Oil aspirator VAG 1358 A Remove the oil draining plug arrow Remove the sealing ring from the oil draining plug and cut if necessary Drain the engine oil Ti...

Page 66: ...posal 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 Engine identification letters ASY Carry out work sequence as follows Unscrew the sealing cover 1 with the Wrench SW 36 and remove the cover with the filter Remove the old filter from the faste...

Page 67: ...Loosen the cover 5 with a Wrench SW 36 and remove the cover with the filter Remove the filter 1 Replace the cover sealing ring 4 Replace the sealing rings 2 and 3 WARNING Follow the rules for disposal 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 Tightening torque 25 Nm 4 19 2 Replenish...

Page 68: ... 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...

Page 69: ... the oil specification page 58 With the oil level above area c there is the risk of damaging the catalytic converter During oil changes you must add oil until the maximum mark ing 4 20 Engine and components in engine com partment from above and below make a visual inspection for leaks and damage The visual inspection must be carried out as follows Check the engine and components in the engine comp...

Page 70: ...yer 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 ...

Page 71: ...stall the plug and tighten it to 25 Nm 4 24 Brake system visual inspection for damage and leaks Check the following components for damage and leaks Brake cylinder Brake cylinder in anti blocking systems Hydraulic unit Braking force adjustment Brake cylinder Make sure that the brake system hoses are not twisted Additionally you must make sure that the brake system hoses do not touch vehicle compone...

Page 72: ...y r i g h t b y V o l k s w a g e n A G Torque wrench 40 to 200 Nm enc 1 2 VAG 1332 Torque wrench 5 to 50Nm fit 1 2 VAG 1331 4 25 1 Brake cylinder Carry out work sequence as follows For better evaluation of the remaining pad thickness remove the driver side wheel the wear is more intense than on the passenger side Remove the hub cap super hub cap The hook for removing the hub cap is in the tool ki...

Page 73: ...including the rear plate the brake pads have reached their wear limit and must be replaced repair measure The customer must be informed If the disc brake pads are replaced you must also check the brake discs for wear Checking and occasionally replacing the brake discs is a repair measure Installation is performed in the reverse process to the removal The larger brake pad is installed on the outsid...

Page 74: ...c 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 Note The wear indicators on the front brake discs visual check in dicate when the brake discs must be changed This check is made by using the marks on the contact surface of the brake discs Always check both discs...

Page 75: ... disc contact area Wear indicator 2 is located close to the internal edge of the brake disc Note If the front brake disc wear indicator markings visual check cannot be visualized due to wheel design the wheels must be removed If the front wheels must be removed to check the brake discs after reinstalling them tighten the screws to 120 Nm Checking conditions of front brake disc wear 1 Wear indicato...

Page 76: ...e n A G 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 Wear indicator 1 is located on the centre of the brake disc contact are...

Page 77: ...pection 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 If the wear limit has been reached replace the linings re placement measure The client should be informed Brake system Rep Gr 46 Brakes Mechanical systems 4 26 Lower body section protection make a visual inspection...

Page 78: ...ly for vehicles without ABS and equipped with the engines AQZ BAH ASY BLH and CFZA from 07 01 2007 Special tools and workshop equipment required Supporting tube 40 21 Hub nut protector puller VW 637 2 Rear wheel hub 1 Ring gear 2 Wheel hub protector must be replaced after removal 3 Cotter pin must be replaced after removal Removal of the wheel is necessary only for vehicles with alloy rims Remove ...

Page 79: ...rows or leverage the screwdriver WARNING The screwdriver should touch only the washer and never the outer roller bearing of the wheel Never rotate or leverage with the screwdriver assuring that the screwdriver does not touch the brake drum hub on no account If the notes above are not strictly followed the adjustment of bearing end clearance will be jeopardized it can lead to noises and breakage of...

Page 80: ...shed Do not mix with the G 11 antifreeze additive blue or green colors WARNING The coolant additive G 12 cannot be mixed with other additives When they are mixed severe damage is caused to the engine If a mix is detected brown color the coolant must be imme diately replaced repair measure Note The G 12 as permanent filling does not require replacement is adequate for cast iron and aluminum engines...

Page 81: ...lysis 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 The antifreeze protection must be guaranteed in approximate ly 13 F in Arctic climate countries in approximately 31 00 Due to climatic reasons a higher antifreeze protection is nec essary so the percentage...

Page 82: ...necessa ry replenish the cooling system Check the coolant level in the reservoir with the cold engine Delivery inspection With cold engine the coolant level must be in the middle area between the maximum and minimum reservoir markings If it is above the middle area remove the excess until it reaches the level in the middle area between the maximum and minimum reservoir markings With the heat ed en...

Page 83: ...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 The concentration of coolant cannot be diluted in water even during hot season...

Page 84: ...ry out work sequence as follows Loosen the spark plug connectors arrows with the Assembly tool T10029 Remove the spark plugs with the Spark plug wrench 3122B Install the new spark plugs with the Spark plug wrench 3122B and the Torque wrench 5 to 50 Nm enc 1 2 VAG 1331 Tightening torque 30 Nm Note The air filter case assembly is initially carried out by fitting the butterfly valve command unit nozz...

Page 85: ...ors arrows with the Assem bly tool T10029 Remove the spark plugs with the Spark plug wrench 3122B Install the new spark plugs with the Spark plug wrench 3122B and the Torque wrench 5 to 50 Nm enc 1 2 VAG 1331 Tightening torque 30 Nm Note The air filter case assembly is initially carried out by fitting the butterfly valve command unit nozzle side supports and then the front supports Apply neutral s...

Page 86: ...connector block carefully and remove the connec tor Remove the spark plugs with the Spark plug wrench 3122B Install the new spark plugs with the Spark plug wrench 3122B and the Torque wrench 5 to 50 Nm enc 1 2 VAG 1331 Tightening torque 30 Nm Install the Extractor T10094 over the ignition coil with final power stage Connect the connector to the ignition coil with final power stage until fitting it...

Page 87: ...evel 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 A you must check the hydraulic system for possible leaks repair measure it is not enough to just replenish the level 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 oi...

Page 88: ...re 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 replace the filter element The filter is in the ventilation case at the right of the in...

Page 89: ... Installation is performed in the reverse sequence to the re moval 4 34 Timing belt replace Semi automatic camshaft tensioning pulley check 4 34 1 Engine identification letters ASY Carry out the work sequence Engine Rep Gr 15 Cylinder head camshaft mechanism 4 34 2 Engine identification letters BNM Carry out the work sequence Engine Rep Gr 15 Cylinder head camshaft mechanism 4 35 Camshaft activati...

Page 90: ... 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 Carry out work sequence as follows 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 ar...

Page 91: ...nd then from the front supports arrow Remove the air filter case fastening screws arrows Remove the filtering element WARNING Follow the rules for disposal Clean the filter s case and install a new filtering element The installation is performed in the reverse order from remov al 4 36 3 Engine identification letters ASY BNM BMD and CFZA Carry out work sequence as follows Loosen the screws arrows a...

Page 92: ... fastening clip 3 and remove the regulating valve 4 with the fuel ducts connected Disconnect the fuel hoses 1 and 2 Unlock the arrows hooks Remove the fuel filter cover upwards Installing Fill the new filter with new diesel fuel Thus the engine works faster Install the new sealing ring to seal the regulating valve Install the filter Lock the arrows small hooks Assemble the regulating valve 4 with ...

Page 93: ...s 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 4 38 Fuel filter drain 4 38 1 Engine identification letters ASY Note Make sure that no diesel fuel reaches the coolant hoses If nec essary clean the hoses immediately WARNING Follow the rules for disposal Carry out work sequence as foll...

Page 94: ...f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Check the fuel system tightness visual inspection 4 39 Brake fluid replace Special tools and workshop equipment required Brake pedal pressing device VAG 1869 2 Brake filler and bleeder VAS 5234 Brake bleeding device VAG 1869 Brake bleeding device V A G 1869 with Adapter V A G 1869 4 Use new brake flui...

Page 95: ...ct 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 ple...

Page 96: ...hten the bleeding screw For vehicles with steering wheel to the left start bleeding in the right rear wheel with the steering wheel to the right start bleeding in the left rear wheel because it is farther from the brake cylinder Repeat the work procedure on the other rear side of the vehi cle Install the venting hose 1 of the draining bottle in the rear section of the bleeding screw loosen the ble...

Page 97: ...VAG 1869 to position B check the operating instructions Remove the passage hose from the adapter Remove the brake fluid reservoir adaptor Install the brake fluid reservoir cover Remove the Brake pedal s tensioning element VAG 1869 2 between the driver s seat and the brake pedal by pressing it Check the brake pedal s pressure and its free clearance Max clearance 1 3 of the pedal stroke WARNING Do n...

Page 98: ...the fluid level drops below the minimum marking check the brake system repair measure before replenishing the brake fluid 4 41 Headlight adjustment check and adjust headlights if necessary Special tools and workshop equipment required Headlight aligner VAS 5046 or VAS 5047 In principle the following checking and adjustment description is valid for every country However it is necessary to consider ...

Page 99: ...ould 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 ...

Page 100: ...n 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 After correctly adjusting the low beam the high beam is auto matically adjusted This means that the high beam centre must be on the headlight central mark 3 A 200 mm deviation to the right or to the left 150 mm upwards and 100 mm down war...

Page 101: ... 94 yd of distance The light dark separation mark is the measurement from the ground to the centre of the headlight minus 0 98 in in for 5 m of distance Additional headlights Additional headlights from other systems installed afterwards must be installed according to their instructions 4 41 3 Adjust the headlights Main headlights Main right headlight the left headlight adjustment screws are positi...

Page 102: ...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 b...

Page 103: ...y Intervals for the exhaust gas test in Germany Vehicles with catalytic converter adjusted or vehicles with diesel engines 3 years after the first approval and then every 2 years Vehicles for commercial transport of people such as for ex ample taxis at every 1 year Exhaust gas test for diesel engines page 113 Exhaust gas test for petrol engines page 99 5 1 1 Exhaust gas test for petrol engines Exh...

Page 104: ...S 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 sh...

Page 105: ...e of exhaust gas test is displayed Select Petrol exhaust gas test arrow The indication for the heating period is displayed Continue the exhaust gas test according to the instructions on the screen When the selection of the theoretical value of exhaust gases is displayed select Selection of theoretical value of exhaust gases arrow Select Pre defined value when it is related to the first exhaust gas...

Page 106: ...er functions can be optioned with the Skip key You can interrupt the test with the Skip key Select with OBD arrow Entering nominal data for the exhaust gas test Note If the nominal values do not exist as barcode they must be entered manually All conditions for test and data necessary for the exhaust gas test are included on the exhaust gas test datasheet for the respective engine Follow the indica...

Page 107: ... 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 Follow the indications on the screen Perform the visual inspections If there are no problems press OK on the screen arrow Note When the Not OK button is pushed you start a ...

Page 108: ...xhaust 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 readiness code The readiness code checks if all control devices work Note If all indication values are at zero no probe inspection test is performed If not all indication values are at zero a probe inspection test is further p...

Page 109: ...dication 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 Follow the indications on the screen The measurement starts as soon as the engine rotation reaches the necessary level Note With the key it is p...

Page 110: ... 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 The measurement starts as soon as the engine rotation reaches the necessary level Keep the engine rotation on the necessary level The remaining ti...

Page 111: ...nit J623 and will not be indicated It is not possible to make an adjustment The idle speed rotation and the content of CO cannot be ad justed just checked If there are divergences between the actual and the theoretical values perform a Repair Measure 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 th...

Page 112: ...ration 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 ...

Page 113: ...dication for the heating period will be displayed Continue the exhaust gas test according to the instructions on the screen When the selection of the theoretical value of exhaust gases is displayed select the respective Selection of theoretical val ue of exhaust gases arrow Select Pre defined value when it is related to the first exhaust gas test Or when it is necessary to perform an exhaust gas t...

Page 114: ...possible to call new functions With the Skip key it is possible to interrupt the test Entering nominal data for the exhaust gas test Note If the nominal values do not exist as barcode they must be entered manually All conditions for test and data necessary for the exhaust gas test are included on the exhaust gas test datasheet for the respective engine Manually entering nominal data for the exhaus...

Page 115: ...re are no problems press the in order key arrow Note When the Not OK key is pressed a test is originated Here you find the indication of visual inspection with the instruc tion to connect the cable to the vehicle Follow the indications on the screen Turn ignition off Connect the adapter for old vehicles VAS 5051 2 or rotation number adapter VAS 5087 or the Diagnosis cable VAS 5051 6A to the vehicl...

Page 116: ...od It automatically switches to the engine temperature measurement indication Follow the indications on the screen Note This indication appears just before the engine temperature rea ches 80 degrees Celsius The engine temperature must reach the necessary level Measurement in high idle speed rotation It switches automatically to the high idle speed rotation measure ment indication Follow the indica...

Page 117: ... rotation on the necessary level The remaining time for performing the measurement is displayed arrow A Assessment After the exhaust gas test the report will be displayed on the screen The test result is indicated In this location remarks about the exhaust gas test can be en tered arrow A They are included on the test report After successfully performing the exhaust gas test select on the hanging ...

Page 118: ...on adapter VAS 5087 A or Rotation adapter VAS 6296 Data reading device V A G 1798 or Data reading device V A G 1799 Data sheets for exhaust emission test Note All test conditions and data necessary for the exhaust gas test Data sheets for exhaust emission test If there is the possibility the test must be performed after a test drive If for any reason atmospheric conditions inadmis sible noise leve...

Page 119: ...ment process device operation start up and operation Operation instructions V A G 1743 Note 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 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 ...

Page 120: ... instructions from VAS 5087 Test sequence Start the engine and let it run only in idle speed Press on the data reading device F2 the key for AU diesel Upon indication on display Insert vehicle identification card Manual inputting with the Key Through the data reading device keyboard enter the following vehicle identification data License plate Vehicle manufacturer Number 2 Code for Number 2 Type o...

Page 121: ...il temperature reaches 80 C remove the sensor and insert the oil dipstick up to the stop Proceed with the test by pressing the Q key Upon indication on display Idle speed rotation ACTUAL rotation xxxx min THEORETICAL xxxx min Press the key Idle speed rotation out of the theoretical value field Note The idle speed rotation and the maximum rotation can be tested but cannot be adjusted If the values ...

Page 122: ...ly press the pedal Press the accelerator pedal up to the end and keep it pressed With the indication on display Data transmission for the gas oil test de vice Free acceleration in movement Keep pressing the accelerator pedal Upon indication on display Idle speed rotation 2ª measurement 15 sec ACTUAL rotation xxxx min THEORETICAL xxx xxxx min Release the pedal The data reading device assumes actual...

Page 123: ...Release the pedal The data reading device assumes actual values in 15 seconds Upon indication on display Data transmission for the gas oil test de vice Quickly press the pedal Press the accelerator pedal up to the end and keep it pressed With the indication on display Data transmission for the gas oil test de vice Free acceleration in movement Keep pressing the accelerator pedal Upon indication on...

Page 124: ...lect the tester or enter the name Press the Q wait for the protocol Press the key Finish the test by pressing the F2 key 5 2 Glossary These explanations refer only to the Maintenance Cares They are not intended to be universal 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 stabilit...

Page 125: ...r in the combined instrument Engine oil s level sensor Brake pad s wearing indicator QG2 The LongLife service is not active from the factory It means that the vehicles have a fixed service interval indicator maintenance intervals dependent on time or kilometers traveled and are equipped with the following components Fixed service interval indicator in the combined instrument Engine oil s level sen...

Page 126: ... 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 Broad range probe Also named LSU probe universal lambda probe The emission of the lambda value is made through a tension curve with an...

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Volkswagen FOX 2004, Service Manual

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