Volkswagen Fox (2004 year). Manual — part 55
Sequence Wheel brake cyl‐
inder brake shoes
Amount of brake fluid that must be
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) 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- or on the Brake bleeding device -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 not forget to always correct the brake fluid's level in the
reservoir.
Never let it reach the minimum level, otherwise air may enter
the system.
Do not reuse the (used) aspirated brake fluid!
4.40
Brake fluid level (depending on brake
pad/lining wear) - check
Use only new, original VW brake fluid.
WARNING
♦ 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.
♦ Follow the rules for disposal!
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marking.
Note
In order to prevent the brake fluid from overflowing, the maximum
marking must not be exceeded.
Inspection service:
– The fluid level must always be assessed, based on the brake
pad wear. With the vehicle in operation, the fluid level lowers
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
pad wear limit has almost been reached.
– If the pads are new, or far from their wear limit, the fluid level
must be within the minimum and maximum markings.
– If 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 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
level
Additional weight in kg
1/4
30
1/2
20
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4. Service descriptions
level
Additional weight in kg
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
in position (-).
4.41.2
Check the headlight adjustment (with
the new inspection display without 15º
adjustment line).
Main headlights:
Please check the following:
– Check if, with the low beam on, the horizontal light-dark limit
contacts the separation limit -1- of the test surface.
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part and the right ascending part of the light-dark limit runs
vertically through the central mark -3-. In this case, the light
core of the light beam is at the right of the vertical line.
Note
♦
Line -1- is the measurement from the ground to the centre of
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
the headlight minus 60 mm for a distance of 5 m.
♦
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.
♦
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‐
wards is acceptable.
– For the current checking viewer with an adjustment line of 15º,
the same adjustment as for new checking viewer applies. To
avoid incorrect adjustments, the 15º line will no longer be con‐
sidered.
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.
♦
The light-dark separation mark is the measurement from the
ground to the centre of the headlight minus 100 mm in for 5 m
of distance.
Long reach headlights (CrossFox)
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