VOLKSWAGEN FOX 2004 (01) PDF Document

The engine specifications for the VOLKSWAGEN FOX 2004 are as follows:

When working on the fuel supply system of the VOLKSWAGEN FOX 2004, observe the following:

The fuel and hoses in the fuel system may be very hot, creating a burn risk.

The fuel system is under pressure.

Use protective gloves and eyewear when performing any repairs on the fuel system.

Place a gas exhaust hose near the fuel tank opening to absorb gases if exhaust equipment is unavailable, use a radial fan (the motor must be out of the air flow) with an air movement rate higher than 15 m3/hour.

Avoid skin contact with fuel and use fuel resistant gloves.

For jobs on the fuel or injection system of the VOLKSWAGEN FOX 2004, strictly observe the following 6 cleaning rules:

Carefully clean all connections and surrounding areas before disconnecting them.

Place all removed parts on a clean surface and cover them, do not use cloth that releases lint.

If repair work is not to be carried out immediately, open components must be covered or carefully preserved.

Install only clean components and only remove spare parts from their packaging just prior to installation.

If the system is open, avoid using compressed air if possible and do not move the vehicle.

Ensure that no diesel runs onto the cooling system hoses; hoses that come into contact with fuel must be cleaned immediately and damaged hoses should be replaced.

To check compression on the VOLKSWAGEN FOX 2004, the engine oil temperature must be at least 30 degrees Celsius. The test sequence is as follows:

Remove the central connector from the unit injectors.

Remove all glow plugs using a 10 mm U/J extension and socket.

Install the compression meter adapter in place of the glow plugs.

Connect the compression meter.

Operate the starter motor until the meter does not indicate any further increase in pressure.

The new compression pressure is 25 to 31 bar, with a wear limit of 19 bar and a permissible difference between cylinders of 5 bar.

After testing, install the glow plugs to 15 Nm and check/erase the fault memory.

To drain the cooling system on the VOLKSWAGEN FOX 2004:

Remove the coolant reservoir cover, noting that steam may be released and the cover should be opened carefully with a cloth.

Remove the lower noise insulation.

Remove the plug to drain the cooling system.

Disconnect the oil radiator hose.

Follow the recommendations for coolant disposal.

To replenish the cooling system on the VOLKSWAGEN FOX 2004:

Use only purple-colour Additive G12 in compliance with TL VW 774 F.

Recommended mixture proportions for a -25 degrees Celsius protection level are 40% antifreeze (2.0 l G12) and 3.0 l water. For -35 degrees Celsius, use 50% antifreeze (2.5 l G12) and 2.5 l water.

Close the cooling system drainage plug and connect the cooling fluid hose to the oil radiator.

Install the engine noise insulation.

Fill the cooling system circuit, either using a cooling system supply unit or manually by filling the expansion reservoir to the maximum mark, turning off the heating, running the engine at 2000 rpm for approximately 3 minutes until the fan starts, then checking and replenishing as necessary.

To check the heating plugs on the VOLKSWAGEN FOX 2004:

Remove the heating plug connectors.

Connect a test probe wire to the battery positive terminal.

Position the test probe on each heating plug one-by-one. If the diode lights up, the heating plug is OK. If the diode does not light up, replace the heating plug.

Remove and install heating plugs using a spanner (3320) and tighten to 15 Nm.