Volkswagen Fox (2004 year). Manual — part 50
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
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 for damage
During a visual inspection, you must check the floor, the wheel
housing and the lower longitudinal members!
Note
The existing faults must be eliminated (repair measure). This may
prevent oxidation and perforating corrosion.
4.27
Steering bar tips - check clearance, fas‐
tening and sealing bellows
Carry out work sequence as follows:
– With the vehicle lifted (with wheels hanging freely), check the
bars' side movements for clearances -arrow-.
– Check the fastening.
– Check the sealing bellows for damage and proper adjustment.
FOX 2004 ➤
4. Service descriptions
73
Rear wheels: adjust the roller bearing
clearance (only for vehicles without ABS
and equipped with the engines: AQZ,
BAH, ASY, BLH, and CFZA from
07/01/2007.
Special tools and workshop equipment required
♦ Supporting tube -40-21-
♦ 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 wheel hub protector -2-, with the extractor of the hub
nut protectors -VW 637/2- .
– Remove cotter pin -3- and ring gear -1-.
Caution
It is necessary that the washer presents a radial motion exactly
according to the following procedure.
FOX 2004 ➤
74
4. Service descriptions
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.
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 bearings).
– Install the ring gear in order to allow assembling the cotter pin.
– Check the regulation again.
– The washer must move radially with a slight pressure of your
index applied on a screwdriver.
Note
After removed, the cotter pin must be replaced.
– Install wheel hub protector with the Support tube -40-21-
Note
The wheel hub cover must be replaced with every removal
FOX 2004 ➤
4. Service descriptions
75
Suspension arm joints - visual inspec‐
tion
– Check the sealing bellows in the suspension arm joints
-arrow- for damage and leaks.
4.30
Cooling system - check the antifreeze
additive and the coolant level
Note
♦
All engines are supplied with radiator antifreeze additive and
anti-corrosion G 12 - according to TL VW 774 F (lilac color).
Make sure that only G 12 is replenished.
♦
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, 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
Special tools and workshop equipment required
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4. Service descriptions
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