Volkswagen Fox (2006) Self Study Program

Service Training

Self-study Programme 349

Fox 2006

We chose the English word Fox for this car
because of its intelligent mixture of proven techno­logy, flexibility and dynamism.

- The Fox is manoeuvrable and easy to steer
through city traffic.

- Combining compact dimensions with a large
interior, it has plenty space even for taller
people.

- The Fox gives a functional and harmonious
impression.

You will find further information in the
self-study programmes:

- SSP 259 – EPHS Electrically powered hydraulic
steering

- SSP 237 – Manual gearbox O2T

- SSP 223 – The 1.2 l and 1.4 l TDI engines

- SSP 260 – The 1.2 l 3-cylinder petrol engines

The self-study programme shows the design and
function of new developments.
The contents will not be updated.

S349_002

NEW Important

Note

For current testing, adjustment and repair instruc­tions, refer to the relevant service literature.

2

Contents

In Brief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Occupant Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Convenience and Safety Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Heating and Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

3

In Brief

Marketing

Fox is an ideal name for this car. The low front
section and high tail make the Fox look aggressive
and nimble.

Thanks to its compact dimensions and large interior,
it really has no limitations in terms of usage.

The Fox is a reasonably priced, complete car — a real
Volksw agen .

The intelligence and sportiness suggested by the name
Fox lift the car above the competition in its class.

S349_003

The pie chart shows the Fox’ rivals.

Smart Fortwo

Ford (EU) Ka

11%

Fiat Seicento

10%

12%

8%

Daewoo
Matiz

6%

6%

23%

Opel Agila

4%

3%

Hyundai Atos

Suzuki Alto

S349_004

Renault Twingo

Fiat Panda

4

Production

The Fox is a sporty compact that was created in a suc­cessful joint project between Volkswagen do Brasil
and the parent company. Developed on the basis of
the Polo, the Fox has inherited the best that Volkswa­gen can offer in terms of safety, comfort and techno­logy for compact automobiles.

São Bernado do Campo plant, Anchieta

The world’s second largest Volkswagen plant (the lar­gest is in Wolfsburg, Germany) was opened on 18
November 1959. It has a total floor space of 1,984,811

2

and the buildings cover an area of 1,123,948 m2.

m
The daily production capacity is 1,400 cars.
The main activities at the plant are press moulding,
frame and body assembly, painting, final assembly
and the production of engines as well as research,
product planning and development.

S349_208

São José dos Pinhais plant, Curitiba

The São José dos Pinhais plant features a new kind of
layout for the group:

The areas of frame construction, painting and final

assembly run together into a communication centre.
The building where the administration offices are
located is triangular. The flow of information is
therefore faster and constant quality improvement
is supported.

The Fox 2006 is built at both Brazilian plants.

S349_005

S349_209

S349_007

S349_006

5

In Brief

Fox 2006

The Fox 2006 is based on the Polo 2002 platform, alt­hough the Fox is 15mm taller than the Polo.
The Fox will only be available as a 2-door.

Convenience system with

- power windows

- electrically adjusted mirrors

- central locking with remote control

- anti-theft alarm

- interior monitoring

The chassis number is s
ped onto the underbod
under the rear seat ben

tam­y

ch.

Belt tensioners

Optional driver and front passenger airbag, side airbag

Optional semi-automatic “Climatic” air conditioning

Optional rear vent wings

Optional easy-entry seats

Optional electro/hydraulic power steering

Optional reach and height-adjusted

steering wheel

Drawer under driver’s seat

S349_009

6

ID label in spare wheel well

ID label on front left
strut tower

Diagnostic connector
under steering column

ABS standard in Europe
ESP optional

Chassis number

The 11th digit in the chassis number indicates the pro­duction site. 4 stands for Curitiba, 0 for Anchieta.

S349_011

7

In Brief

Technical data

1544mm

S349_010

1660mm

Length 3828mm Track width at rear 1424mm

Width 1660mm Tank capacity 50l

Height 1544mm Curb weight

Wheelbase 2464mm Maximum weight

Turning circle

Track width at front 1428mm Drag coefficient (Cd) 0.32

1

applies for vehicles with power steering

2

applies for cars with 1.2l engine without power steering

1

2464mm

3828mm

2

1

10.6m Maximum roof load 50kg

978kg

1480kg

8

1016l

260l

353l

S349_211

Front headroom* From 994mm Boot volume 260l

Rear bench headroom* From 963mm With rear bench

pushed forward

Interior length 1691mm With rear bench

folded down

Front shoulder width * From 1348mm Rear shoulder width From 1355mm

Front elbowroom* From 1401mm Rear elbowroom From 1423mm

* Varies depending on model

353l

1016 l

9

Body

Body structure

The Fox has a torsionally stiff body. The design and
structure ensure good crash safety. The body is partly
galvanised and has a 12-year guarantee against
internal corrosion.

Longitudinal
member

Longitudinal member

The underbody features a frame structure.
The longitudinal member is made from sheet metal

with increasing thickness. The increased capability to
absorb bumps provided by this system is called pro­gressive absorption. The protection of occupants in
the cockpit is thus maximised.

S349_013

Bumper covers front and rear

The bumper covers at the front and rear can absorb
an impact energy at up to 4 km/h without damage.

Higher collision speeds up to around 15 km/h are
absorbed by impact members without the longitudinal
members being deformed.

10

The longitudinal members are only deformed in
severe collisions.

Front impact member

S349_215

B-pillar reinforcement

S349_017

S349_212

Seat cross member

Rear impact member

Sill
reinforcement

S349_214

Side impact member

Side impact protection

In a side collision, the reinforced B-pillars, the sturdy
sills and the inside door panel, which is almost closed,
minimise deformation of the passenger cell.

The side impact member, the door gutter reinforce­ment and the padding between them provide an ideal
barrier against the impact force. The padding is the
side protection cushioning in the doors.

11

Body

Seats

The Fox has been designed as a 4-seater.
The front seats can be optionally equipped with the
easy-entry system, the rear seat comes as a single
bench as standard or optionally split and folding.

Rear seat bench

The rear bench is made up of two seats with a storage
bin and cup holder in the middle.

Front seats

The front seats in the Fox are available with easy-entry and manual memory function upon request.

S349_216

Driver’s seat

Lever for easy-entry and for
folding the backrest forwards

Backrest tilt adjustment

12

Seat length adjustment

Seat height adjustment

S349_019

Drawer under driver’s seat

Easy-entry

The easy-entry system makes it easier to access the rear seats. When you want to climb into the back seat, the
backrest of the front seat is unlocked as usual and folded forward. At the same time, the front seat can be pushed
forward. This creates more space so you can climb into the car easily.

Function

Folding the front seat backrest forward activates the
memory module on the seat rail.

S349_341

The activated memory module unlocks the length
adjustment of the front seat allowing the front seat to
be pushed forward. At the same time, the memory
function is triggered. Using this function, the memory
module mechanically records a change to the position
of the front seat so that the starting position of the

S349_342

front seat is stored mechanically in the memory
module.

S349_343

S349_344

If the backrest is folded back before it reaches the initial position, only the length adjustment is locked.
The memory function is kept until the initial position is reached.

To return the front seat to its initial position, the front
seat needs to be pushed back with the backrest folded
forward.

Once the front seat has returned to its initial position,
the memory module triggers the memory function and
the length adjustment is locked. Once the backrest
has been folded back, the memory module locks the
length adjustment of the front seat.

13

Body

Rear bench

The rear bench is made up of two seats with a storage
facility and cup holder in the middle.
The rear seat bench can be moved completely (optio­nal) and folded up against the front seats (tipped) to
make the boot larger. The seat backrests can be fol­ded down separately.

Securing hooks

The red hook on the back of the rear seat bench hooks
into the front seat head restraint. It prevents the rear
seat bench falling back.

Moving the rear seat bench
lengthways (optional)

The rear seat bench slides lengthways. A toothed rail
with a catch locks the rear bench so it cannot be
moved back and forth. You release the lock by
lowering it with the lever at the front of the seat base.

Another handle can be accessed from the boot.

Securing hooks

Handle for lengthways adjustment

Lock

14

S349_225

A full-width, one-piece rear seat bench is also available. Both rear bench systems
have Isofix anchor points for securing child seats as standard.

Folding down the back rest

Both rear seats can be unlocked and folded down
separately. Two loop handles have been provided at
the front to help you fold the seat.

Handle for folding down
the backrest and rear
bench

Lever for moving the rear
bench lengthways

Loop

handles

S349_297

The backrests can be released using the lever for fol­ding down the backrest and rear bench in the boot.

Folding down the rear seat bench

Lever

Release pin

S349_224

S349_226

The backrest is locked by four teeth at the same time
to distribute the force.

The rear seat bench can only be folded down
completely once it has been pushed back as far as
possible.

In this position, the lever presses against the release
pin when the handle for folding down the backrest
and rear seat bench is moved. This opens the catch in
the floor lock. The backrests are unlocked at the same
time and the rear seat bench can be folded over.

15

Occupant Protection

Airbag system

The Fox is equipped with the proven occupant protection systems, the airbag system and the restraint system.

The complete airbag system includes:

- Driver airbag

- Front passenger airbag

- Optional side airbags in front

Side airbag crash sensor in cockpit

under driver’s and front passenger seat.

Optional front

passenger side airbag

Front passenger

front airbag module

16

Airbag control unit with crash sensor

Restraint system

The belt system includes:

- Three-point seat belts with pyrotechnic belt tensioners for driver and front passenger

- Three-point seat belts without belt tensioners on the rear seat bench

Three-point seat belts without belt tensioners
for the rear seat bench

Driver front airbag module

Optional driver side airbag

S349_231

The restraint system is uses three-point seat belts
with pyrotechnic belt tensioners and belt pressure
limiters for the driver’s and front passenger seat.

17

Engines

Overview of engines and gearbox

1.2l 40kW petrol engine

S349_033

1.4l 55kW petrol engine

1.4l 51kW diesel engine

S349_034

O2T 5-speed manual gearbox

S349_038

18

S349_036

02T 5-speed manual gearbox

The 02T gearbox used in the 2002 model year Polo is
installed in the Fox. The maximum torque to be trans­ferred by this gearbox is 200Nm.

The complete gearbox transmission is configured for
the respective engine version using different gear
ratios and different transmission ratios for the axle
drives. The gearbox is assigned to the engine via the
gearbox code.

S349_038

S349_239

Gear changes

The gears are changed via a selector cable and a shift cable. Thanks to these cables, the rocking movement of the
engine acts only slightly on the gearstick. This allows you to select gears more precisely.

Further information can be found in self-study programme no. 237, which contains details on the
design and operation of this gearbox.

19

Engines

1.2l/-40 kW petrol engine

The 1.2l 40kW petrol has been taken from the 2002
model year Polo without any modifications.

Tech nical featur es

- 2-valve technology

- Chain-driven valve control

- Crankshaft drive with balancer shaft

- Oil filter arranged standing

- Single-spark ignition coils with
integrated output stages

S349_370

You will find further information on this
engine in self-study programme no. 260
The 1.2l 3-cylinder petrol engines.

Technical data

Engine code BMD

Type 3-cylinder in-line engine

3

Capacity [cm

Bore [mm] 76.5

Stroke [mm] 86.9

Valves per cylinder 2

Compression ratio 10.3 : 1

Maximum output 4kW at 4750rpm

Maximum torque 108Nm at 3000rpm

Engine management Simos 3PG

Fuel Super unleaded RON 95

Exhaust gas treatment Catalytic converter,

Emissions standard EU4

]1198

(normal unleaded at RON
91 with reduction in perfor­mance)

Lambda control with two
probes

Power and
torque development graph

Nm

170

160

150

140

130

120

110

100

90

80

kW

60

55

50

45

40

35

30

25

20

15

20

70

1000 3000 4000 5000

2000

Power [kW]
Torque [ N m ]

10

rpm

S349_032

1.4l/55 kW petrol engine

The 1.4l 55kW petrol engine featured in the Fox is an
all-new engine. The EA111 engine series forms the
basis for the basic engine.

Technical features

- 2-valve technology

- Roller rocker arm

- Lightweight crankshaft drive with
lightweight piston and crankshaft

- Grey cast iron cylinder block

- Non-return fuel system

- Air filter integrated in the engine cover

- Electronic distributorless ignition

- Crankshaft flange with duocentric oil pump

S349_371

Technical data

Engine code BKR

Type 4-cylinder in-line engine

3

Capacity [cm

]1390

Bore [mm] 76.5

Stroke [mm] 75.6

Valves per cylinder 2

Compression ratio 10.5 : 1

Maximum output 55kW at 5000rpm

Maximum torque 124Nm at 2750rpm

Engine management Magneti Marelli 4 EV

Fuel Super unleaded RON 95

(normal unleaded at RON
91 with reduction in perfor­mance)

Exhaust gas treatment Catalytic converter,

Lambda control with two
probes

Emissions standard EU4

Power and
torque development graph

Nm

170

160

150

140

130

120

110

100

90

80

kW

60

55

50

45

40

35

30

25

20

15

70

1000 3000 4000 5000

2000

Pow er [kW ]
Torque [ N m ]

rpm

10

S349_035

21

Engines

1.4l/51kW TDI engine with unit injector system

The 1.4l 51kW TDI engine is derived from the 1.4l
55kW TDI engine (BAY) used in the 2002 model year
Polo. The engine control unit software has been adap­ted to the reduced output.

Tech nical featur es

- Combination valve for fuel preheating and for
cooling the fuel return

- Balancer shaft for reduction of the
engine vibrations

- Tandem pump, driven directly
by camshaft

- Duocentric oil pump, driven by the
crankshaft via a chain

- Standing oil filter housing

- Coolant pump integrated in cylinder block

S349_372

The design and operation of the 1.4l
55kW 3-cylinder TDI engine is explai­ned in self-study programme no. 223.

Technical data

Engine code BNM

Type 3-cylinder in-line engine

3

Capacity [cm

Bore [mm] 79.5

Stroke [mm] 95.5

Compression ratio 19.5 : 1

Maximum output 51kW at 4000rpm

Maximum torque 155Nm at 1600rpm

Engine management Electronic Diesel Control

Fuel Min. CN 51 in accordance

Exhaust gas treatment Exhaust gas recirculation

Emissions standard EU4

]1422

up to 2800rpm

Bosch EDC 15P

with DIN EN 590

and oxidation catalytic
converter

Power and
torque development graph

Nm

250

225

200

175

150

125

100

75

50

25

kW

60

55

50

45

40

35

30

25

20

15

22

0

1000 3000 4000 50002000

Power [kW]
Torque [ N m ]

rpm

10

S349_037

Fuel supply

The Fox fuel tank is located in the crash-protected
area in front of the rear axle. It has a volume of 50l.

Quick-fastening couplings are used for easier
assembly of the fuel lines.

Activated charcoal

filter

The Fox has a galvanised steel sheet tank. Galvani­sing the steel sheet improves the corrosion resistance
compared with conventional metal tanks.

Quick-fastening
coupling

S349_293

Fuel tank

Reservoir

The activated charcoal filter is located in the rear
right wheel housing.

All petrol fuel systems are equipped with an activated
charcoal filter to meet the environmental legislation.
The activated charcoal container collects the fuel
vapours produced during operation and then delivers
them to the engine for combustion later on.

S349_290

Fuel pump

The fuel pump is secured
with a bayonet ring.

S349_292

23

Engines

Combination valve

The combination valve has the task of preheating and cooling the fuel. It splits the fuel system into a vehicle circu­lation system and an engine circulation system. The combination valve is mounted on the coolant expansion tank in
the engine compartment.

Fuel preheating prevents the fuel filter being blocked in the winter by paraffin that separates from the diesel
fuel at low temperatures.

Fuel cooling protects the fuel tank as well as the fuel gauge sender by preventing a return of high-temperature
fuel. The fuel is warmed due to the high pressure that is built up in the unit injectors.

Vehicle circulation system

The vehicle circulation system is made up
of the fuel tank with the fuel pump and
pressure control valve as well as the fuel
return.

Pressure con­trol valve

Fuel pump

Engine circulation system

The engine circulation system includes the fuel temperature sender,
the injection system, the tandem pump, the fuel filter and the fuel
supply line.

Combination valve

Fuel filter

Fuel temperature sender

Tandem pump

24

S349_364

Injection system

Tank

Mixing the cold and warm fuel in the combination valve increases the temperature of the returned
fuel. This also increases the temperature and pressure in the fuel tank. The threshold value for ope­ning the pressure control valve in the fuel tank has therefore been raised from 0.5 bar to 0.8 bar.

Function

Combination valve closed

Plunger

The vehicle return is closed by the plunger in the com­bination valve during a cold start.
Warm fuel flowing back from the engine return is
mixed in the combination valve with cold fuel from the
vehicle supply line and is returned to the engine. Pre­heating the fuel in this way prevents the separation of
paraffin and thus fuel filter blockages.

As the engine temperature increases, the fuel tempe­rature in the engine return also increases. This heats
the plunger with the wax element in the combination
valve. The wax element then expands and pushes the
piston upwards against the spring.

Engine

return

Engine

supply

Housing

Engine

return

Veh ic le
return

Veh ic le
supply

S349_361

Once the operating temperature has been reached,
the combination valve opens the engine circulation
system to the vehicle circulation system. The warm fuel
from the engine supply line mixed with cold fuel from
the vehicle supply can then flow back to the fuel tank.

Mixing with cold fuel in the combination valve pre­vents the fuel in the fuel tank being heated above a
limit temperature.

Wax element

Combination valve open

Spring

S349_362

Vehi cl e
return

S349_363

25

Chassis

Axles

Front axle

The front axle of the Fox is the same as the one used in
the 2002 model year Polo. McPherson struts are used
as on the Polo.

Rear axle

The Fox has either a rear axle with tube profiles like
the 2002 model year Polo and a rear axle with a V­profile cross member. The tube profile is used in the
versions of the Fox with 1.4l 55 kW petrol engine and

1.4l 51 kW TDI engine. The V-profile is used in the Fox

with 1.2l 40 kW petrol engine.

Steering

Rear axle
with tube profile

S349_300

26

S349_044

The hydraulic pump for the electro-hydraulic
power steering is driven by an electric motor. The
power steering is thus not dependent on the opera­ting state of the vehicle engine and the energy supp­lied for steering assistance is adjusted to
requirements. This ensures an improvement in comfort
when manoeuvring and helps save fuel.

Further information on the ESP electronic
stabilisation programme can be found in
self-study programme 204.

Brakes

The brake system used in the Fox is split diagonally
into two circuits. Two different brake systems are
available. ABS (anti-lock brake system) is fitted in the
European version of the Fox as standard and ESP
(electronic stabilisation programme) is available as an
option.

S349_043

Anti-lock brake system

The brake servo with brake master cylinder is
located separately from the ABS/ESP hydraulic unit in
both systems. The hydraulic unit is located on the left
next to the strut tower.

The Fox uses the anti-lock brake system 8.0 from
Bosch. It is the same system as used in the 2006
model year Polo.

S349_042

Rear wheel drum brakes

Drum brakes are used on the rear axle. The brakes
have a diameter of 200 mm and are 40 mm wide.

S349_046

Front wheel disc brakes

Disc brakes are used on the front axle. The ventilated
brake discs are 22mm thick and 256mm in diameter.

On cars without power steering, the brake discs are
18 mm thick and 239 mm in diameter.

S349_045

27

Electrical System

Onboard supply

The onboard supply is decentralised. The most
important components are shown here.

Compact connector

The compact connector is a coupling station on the
bulkhead for connecting/disconnecting the onboard
supply components in the engine compartment and
passenger compartment.

A-pillar coupling station

The coupling station on the A-pillar is used to
connect or disconnect electrical components in the
doors from the rest of the onboard supply system.

Main fuse carrier

The main fuses are all
located in the main fuse
carrier on the battery

lid and are easy to
access.

Onboard supply control unit

This unit takes care of functions that were previously
performed using separate relays (e.g. turn signal
relay). It monitors the supply of power to consumers
and vehicle components outside the CAN systems
(e.g. switches/fuses).

S349_087

Fuse holder

The fuse holder is made
up of two holders.

Relay carrier

The relay carrier is used to hold the relay for basic
and special equipment.

28

Exterior Lights

Headlights

The headlights have clear covers made from plastic.
The headlight unit has a combined reflector for
dipped beam and main beam lights (H4 bulb). The
side lights (W5W) and the turn signal (PY21W).

Fog light

The fog lights are integrated in the bumper. An H3
bulb is used for the fog lights.

Turn signals

S349_047

Dipped beam and
main beam (H4)

Side light

Taillight

One screw, accessed in the boot, needs to be remo­ved when you change the bulbs in the taillight.

A two-filament bulb (P21/5W) is used in the taillight/
brake light. The bulb for the turn signal is a PY21W,
which has been coloured yellow. The rear fog light
(P21W) is only installed on the left-hand side. The
reversing lights also use P21W bulbs.

S349_049

Adjusting screw

Taillight/

brake light

Reversing light

Turn signal

Rear fog light

S349_048

29

Electrical System

Overview of control units

The following diagram shows the
positions of the control units in the Fox.

Climatic

control unit

Control unit

of ABS Bosch

8.0

Radio

Convenience system

central control unit

Dash panel insert

Onboard supply
gateway

S349_088

30

Location of
engine control units

-Simos 3PD

-Bosch EDC 15P

*

The engine control unit used depends on the engine.

*

*

Airbag control unit

Power steering control unit

Engine control unit
Magneti Marelli 4EV

*

Dash panel insert

The dash panel insert has been newly developed for the Fox and is based on the group dash panel insert.
The gauges are driven electronically via stepper motors.

Coolant tem-

Turn signal

Fuel reserve

Electro-

hydraulic

power steering

Rear window

heating

Anti-lock

brake system

perature

Fog light/rear fog
light

Fuel gauge

Alternator

Main
beam

Brakes
Hand brake

S349_050

Engine oil
pressure

Electronic

stabilisation programme

* Electronic power control with petrol

engine

** Glow system with diesel engine

Seat belt

*

Engine fault

Electronic
immobilizer

**

Airbag system

The fuel gauge is electronically damped against
vibrations in the fuel tank.

When the ignition is switched off and the tank con­tents are increased by at least four litres, the level is
determined and displayed immediately once the igni­tion is switched on again.

If the ignition is switched on and the vehicle is statio­nary, the damping is switched off and the level is dis­played immediately.

Fuel gauge pre­viously when
cornering

Fuel gauge now
when cornering

S349_051

Fuel gauge when
filling up

31

Electrical System

CAN data bus

The Fox has a CAN data bus system that is made up of the drive CAN data bus
and the convenience CAN data bus. They differ in transfer speed and data content.

Drive CAN data bus

The drive CAN data bus works at a transfer speed of 500 kbit/s to achieve a faster data transfer rate in the systems
that are important to safety.

Control unit with dis-

play in dash panel

ABS control unit J104

insert J285

Power steering control unit

Onboard supply control unit
J519

Diagnosis connector

Engine control unit Jxxx

Airbag control unit J234

Steering angle sender G85 –
only present if ESP is instal­led.

J500

S349_052

32

You will find further information on the CAN data bus in self-study programme 186.
The data transfer on the CAN data bus is described in more detail in self-study programmes 238
and 239.

Convenience CAN data bus

The convenience CAN data bus works at a transfer rate of 100 kbit/s.

Onboard supply control unit J519
with data bus diagnostic interface J533

Climatic control

unit J301

Diagnosis connector

Radio

Convenience system
central control unit J393

S349_053

33

Electrical System

Overview of convenience system

The convenience system is responsible for the follo­wing functions:

Optional anti-theft alarm
with interior monitoring sensor

The interior is protected against break-in by
an ultra-sound monitoring system.

Optional remote control

The vehicle can be locked and unlocked using the
door lock cylinder or the remote control. When
you press the unlock button on the remote control,
the whole car is unlocked and the anti-theft alarm
is deactivated. The anti-theft alarm is activated
when you lock the car.

Interior lights

The interior lights are controlled by the convenience
control unit. If the switch on the interior lights is in the
“Open door” position and the doors are opened, the
lights will remain on for 30 seconds after
the doors are closed.

S349_327

S349_320

S349_330

Crash signal

In a collision, the airbag control unit will
issue a signal to unlock the doors.

Optional central locking

Turning the door lock cylinder clockwise locks the car
and activates the anti-theft alarm. Turn the key anti­clockwise to unlock the car.

S349_323

S349_325

S349_326

Interior locking / unlocking

The doors are locked and unlocked using the lock /
unlock switch on the driver’s door.

34

Closing the windows from outside

You can close the windows from the outside by turning
the door lock cylinder clockwise and holding it. The
convenience close function is started after approx. 2
seconds. You need to hold the door lock cylinder until
the windows have closed completely. The convenience
close function will be interrupted if a window switch is
pressed or the EFL roll-back feature is triggered.

Convenience open function for windows

If you turn the key clockwise in the door lock cylinder
and hold it in cars with power windows, the conveni­ence open function will open all windows after 2
seconds. You need to deactivate the anti-theft alarm
with the remote control beforehand.

S349_329

S349_328

Excessive force limitation (EFL)

The excessive force limitation reduces the

S349_324

S349_332

Command Effect

1st upwards run When the window is jammed, the excessive force limitation reacts and the window is reversed. The win-

dow rolls back to create an opening of at least 200mm.

2nd upwards
run

When the window is jammed again, it will not reverse. The window stops in that position.

risk of injury from the power windows.

3rd upwards run The upwards movement is carried out without EFL. The full power of the motor is available for the

whole path. The window can be closed even though it may run slowly.

The three commands each have to occur within 10 seconds otherwise the electronics will switch back to
normal window operation.

35

Convenience and Safety Electronics

Anti-theft alarm with interior monitoring sensor

Anti-theft alarm

The anti-theft alarm monitors the areas

-Doors

- Bonnet

- Tailgate

- Ignition

Special features

The system is completely secure against false alarms
caused by:

- Objects hitting the roof or the windows

- Air movement caused by wind or passing vehicles,
temperature fluctuations, for example, when the
car is heated up by direct sunlight and

- noises of all kinds (for example, sirens, horns and
bells).

The anti-theft alarm is activated within 30 seconds
after the doors are locked.
The anti-theft alarm can only be deactivated from the
outside using the remote control.

Convenience system

central control unit

Alarm horn

Alarm horn

The alarm is signalled acoustically via the anti-theft
alarm horn and optically via the turn signals.

If, for example, the bonnet is opened, an alarm is triggered immediately. The alarm is
stopped when the ignition is switched on or the remote control is pressed.

36

Interior monitoring

The interior monitoring works as an ultrasound monitoring system.
It is only used in conjunction with the anti-theft alarm.

Interior light with sensor for
interior monitoring

Interior light

S349_356 S349_357

S349_054

S349_055

Interior light with interior
monitoring without
sunroof

Interior monitoring sensor buttons

On vehicles with a sunroof, the button with which the
interior monitoring system can be temporarily deacti­vated is located on the B-pillar.

On vehicles without a sunroof, the button for tem­porarily deactivating the interior monitoring system is
located on the interior light.

Interior light with interior
monitoring with sunroof

S349_358

37

Convenience and Safety Electronics

Convenience system functional diagram

Positive
Negative
Input signal
Output signal
Communications line

S349_314

CAN data bus

J519

E48 E43

OutIn

S349_315

E43 Mirror adjustment switch
E48 Mirror adjustment change-over switch
J519 Onboard supply control unit
L78 Mirror adjustment switch

illumination bulb

V17 Driver side mirror adjustment motor
V25 Front passenger side mirror adjustment
V149 Driver side mirror adjustment motor
V150 Front passenger side mirror adjustment motor
Z4 Heated exterior mirror on driver side
Z5 Heated exterior mirror on front passenger

side

V17 V149

Z4

L78

Z5

V25 V150

S349_310

38

J519

J533

W

F3F2 E183L118

E183 Interior monitoring switch
F2 Driver door contact switch
F3 Front passenger door contact switch
J393 Convenience system central control unit
J519 Onboard supply control unit
J533 Data bus diagnostic interface
K Communications line for diagnosis
L118 Deactivation of interior monitoring system

switch illumination bulb

W Front interior light

Convenience CAN data bus

K

J393

S349_311

39

Convenience and Safety Electronics

Ter mi na l 30

1

Ter mi na l 30 a

J519

G209 V147 V148

W3

F120

E150

E40 Front left window regulator switch
E81 Front right window regulator switch
E107 Window regulator switch in front

passenger door

E150 Driver side interior locking switch
F120 Anti-theft alarm and vermin repellent system

contact switch

G209 Anti-theft alarm ultrasonic sensor
J393 Convenience system central control unit
J519 Onboard supply control unit
L53 Window regulator switch

illumination bulb

L99 Interior lock switch illumination bulb

J393

E107L99 L53 E81E40 L53

S349_312

V147 Driver side window regulator motor
V148 Front passenger side window regulator motor
W3 Luggage compartment light
1 Te rm i na l 8 6 s

40

H8

F121 V162 V161

Ter min a l 3 0 a

Ter min a l 3 1

V139 F5

J393

M27

F5 Luggage compartment light switch
F121 Driver door exterior handle switch for

anti-theft alarm system

H8 Anti-theft alarm system horn
J393 Convenience system central control unit
M27 Left door warning lamp
V139 Rear lid release motor
V161 Driver door central locking deadlock

function motor

V162 Front passenger door central locking

deadlock function motor

S349_313

41

Heating and Air Conditioning

Heating

The basic version of the Fox has a heating system with
fresh air and recirculation mode.

Fresh-air and recirculation flap

The fresh-air and recirculation flap is adjusted by an
electric motor. Both flaps are adjusted independently
via a common lever mechanism. The flap is automati­cally closed when the car reverses to avoid
unpleasant smells.

In comparison, the design of the housing is very simi­lar. Depending on the equipment version, the housing
is specially adapted for the heating or air-condi­tioning functions.

Fresh-air flap

S349_064

Recircula­tion flap

Dust and
pollen filter

S349_065

Dust and pollen filter

The dust and pollen filter has been integrated in the
housing and is located between the fresh-air intake
and the distribution system housing.
The filter can be accessed from inside the vehicle
and can be pulled downwards after the filter lid has
been removed.

Tem p e r a t u re flap

42

Climatic

In addition to the heating, the Fox has a semi-automa­tic air-conditioning system with automatic temperature
control (Climatic).

S349_062

Temperature control according to your needs

Two new components in the air-conditioning system
allow you to set the temperature according to your
needs:

While the interior temperature is regulated to the
value set on the controller, the air distribution and the
fan level is set manually.

Fresh-air flap

Recircula­tion flap

Dust and
pollen
filter

- Evaporator output temperature sender G263

- Externally controlled compressor with regulating

valve N280 and integrated overload protection

Controlling the temperature to suit your needs allows
the energy consumption to be reduced and contribu­tes to fuel savings.

S349_063

Auxiliary heater ele­ment

Other new features:

- Functional improvements and controls
adapted to the dash panel design

- Flexible shafts for adjusting the flaps

- Separate fresh-air and recirculation flap

- Dust and pollen filter integrated in housing for
the heating and air-conditioning system.

Temperature flap

Heat exchanger

43

Radio system

Radio RCD 200

The Radio RCD 200 has the following functions:

-CD drive

- Four speaker channels each with 20 Watts

- RDS FM/AM Europa radio (AM without LW)

- Control for an external 6-CD changer

- Telephone control (hands free)

- Speed-dependant volume control

- Self-diagnosis including speaker diagnosis

If only front speakers are installed, the FADER
function will be hidden automatically

Radio RCD 200

The aerial system for the RCD200 radio is made up of
a front windscreen aerial and the aerial amplifier in
the aerial cable. The aerial amplifier is supplied with

power (+12 volt) directly from the radio via the aerial
cable. The earth connection is formed via the screw
fastening the aerial amplifier to the body.

S349_059

Aerial amplifier
(impedance transformer)

44

S349_333

Earth

Service

Diagnosis

The Fox uses the VAS 5051 vehicle diagnosis, measuring and information system and the VAS 5052 vehicle
diagnosis and service information system.

The VAS 5051 vehicle diagnosis, measuring and infor­mation system has the familiar operating modes:

- Guided Fault Finding

- Vehicle Self-Diagnosis

- OBD (on-board diagnosis)

-Test Instruments

The “Guided Fault Finding” operating mode
checks all control units installed in the vehicle for fault
entries and automatically compiles a
system test plan from the results.
In conjunction with ELSA information, for example, the
circuit diagrams or repair guides, this mode
guides you directly to the cause of the fault.

In addition, you also have the option of compiling
your own test plan. The function and component sel­ection records the tests you select in the test plan. You
can then work through the tests in any order during
the diagnosis procedure.

The “Vehicle Self-Diagnosis” mode can still be used,
but there is no further ELSA information available.

VAS 5051

S349_067

The VAS 5052 also has the “Guided
Fault Finding” and “Guided Functions”
operating modes.

The “Guided Functions” operating mode is new. In this
way, without a complete vehicle system test, you can
quickly access general service functions, for example,
adapting vehicle keys.

It is used from the basis CD V06.00.00 and the Volks­wagen brand CD V06.42.00.

For more detailed information on the procedure and “Guided Fault Finding”, please refer to chapter
7 of the VAS 5051 operating manual.

45

Notes

46

47

349

© VOLKSWAGEN AG, Wolfsburg
All rights and rights to make technical alterations reserved.

000.2811.63.20 Technical status 05/2005

Vol ksw ag en
Service Training VK-21
Brieffach 1995
38436 Wolfsburg

❀ This paper was manufactured from pulp that was bleached without the use of chlorine.