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General body repairs, exterior

For FOX / Suran/Spacefox/SportV

Original Volkswagen repair manual


23,43 €7% VAT incl.

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  • English

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Language: English

Digital PDF file

9.556 KB

296 Sites

Detailed technical data

Immediately readable

This repair manual contains: Body - front section, Bulkhead, Engine compartment upper partition panel, Bonnet, Rear lid (Fox), Central locking, Glasses glued with adhesive, Tilting window, Materials used and operational care required, Spoiler, Roof Rack, Side footboard (CrossFox and Fox Sunrise), External rear-view mirror and Crossfox components. Show more
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Repair manual FOX / Suran/Spacefox/SportV General body repairs, exterior PDF download has the following content:

Chapter overview

  • Body - front
    1
  • 1 Body - front section
    1
  • 1.1 Front end with complementary parts - remove and install
    1
  • 1.2 Front end - service position
    2
  • 1.3 Front wing - assembly overview
    4
  • 1.4 Noise insulation (petrol engine) - assembly overview
    6
  • 1.5 Noise insulation (diesel engine) - assembly overview
    7
  • 2 Bulkhead
    9
  • 2.1 Tools
    9
  • 2.2 Auxiliary materials for Brazilian market
    9
  • 2.3 Auxiliary materials for export market
    10
  • 2.4 Matching table
    10
  • 2.5 Engine compartment partition panel - assembly overview
    11
  • 2.6 Minimum adhesive drying time
    11
  • 3 Engine compartment upper partition panel
    12
  • 3.1 Engine compartment upper partition panel - assembly overview
    12
  • Bonnet, rear lid
    13
  • 1 Bonnet
    13
  • 1.1 Bonnet - assembly overview
    13
  • 1.2 Bonnet - adjust
    13
  • 1.3 Latch operation cable - assembly overview
    14
  • 1.4 Latch operating cable - remove and install
    15
  • 1.5 Bonnet hinge - remove and install
    17
  • 1.6 Front bonnet latch - assembly overview
    18
  • 1.7 Bonnet latch - remove and install
    19
  • 2 Rear lid (Fox)
    21
  • 2.1 Assembly overview
    21
  • 2.2 Rear door shock absorber - remove and install
    23
  • 2.3 Rear door shock absorber - replace
    23
  • 2.4 Rear lid trim - remove and install
    23
  • 2.5 Rear lid - remove and install
    25
  • 2.6 Rear lid hinge - remove and install
    26
  • 2.7 Rear lid - adjust
    27
  • 2.8 Rear lid lock (► 12.04) - remove and install
    29
  • 2.9 Rear lid lock (01.05 ►) - remove and install
    32
  • 2.10 Rear lid lock cylinder handle (Push Button - 01.05 ►) - remove and install
    32
  • 2.11 Rear lid release motor V139 (Push Button - 01.05 ►) - remove and install
    33
  • 2.12 Lock cylinder (Push Button - 01.05 ►) - assembly overview
    34
  • 2.13 Lock cylinder (Push Button - 01.05 ►) - remove and install
    36
  • 3 Rear lid (Spacefox)
    37
  • 3.1 Rear lid - assembly overview
    37
  • 3.2 Rear door shock absorber - remove and install
    38
  • 3.3 Rear door shock absorber - replace
    39
  • 3.4 Rear lid trim - remove and install
    39
  • 3.5 Rear lid - remove and install
    40
  • 3.6 Rear lid hinge - remove and install
    41
  • 3.7 Rear lid - adjust
    42
  • 3.8 Rear lid lock - remove and install
    42
  • 3.9 Rear lid lock cylinder handle - remove and install
    43
  • 3.10 Rear lid release motor V139 - remove and install
    43
  • 3.11 Lock cylinder - assembly overview
    43
  • 3.12 Latch cylinder - remove and install
    44
  • 4 Fuel reservoir nozzle compartment and lid set
    45
  • 4.1 Fuel tank nozzle compartment and lid set - remove and install
    45
  • Front doors, door components, central locking
    46
  • 1 Front door
    46
  • 1.1 Front door - assembly overview
    46
  • 1.2 Front door - remove and install
    48
  • 1.3 Front door - adjust
    49
  • 1.4 Front door - disassemble and assemble
    51
  • 1.5 Front door - replace
    51
  • 1.6 Door arrester - adjust
    52
  • 1.7 Door limiter - remove and install
    52
  • 1.8 Internal handle - replace
    53
  • 1.9 Front door external handle and lock - assembly overview
    53
  • 1.10 Lock cylinder housing - remove and install
    55
  • 1.11 Central locking motor for driver / passenger door V56/V57 - replace
    56
  • 1.12 Cylinder housing - disassemble and assemble
    57
  • 1.13 Cylinders and keys (Specific information for Brazil) - request
    59
  • 1.14 External door handle - remove and install
    59
  • 1.15 External door handle - replace
    60
  • 1.16 Door lock - remove and install
    60
  • 1.17 Door lock - replace
    64
  • 1.18 Lock Bowden cable - replace
    64
  • 1.19 Door sealing membrane - remove and install
    66
  • 1.20 Door sealing packings - assembly overview
    68
  • 1.21 External door packing - remove and install
    69
  • 1.22 Internal door trim - remove and install
    71
  • 1.23 Cylinders and keys (Specific information for Brazil) - request
    72
  • 2 Central locking
    73
  • 2.1 Central locking installation location overview - 2-door
    73
  • 2.2 Central locking installation location overview - 4-door
    75
  • 2.3 Central locking installation locations overview
    77
  • 2.4 Central control unit for convenience system J393 - remove
    79
  • 2.5 Remote-command key - assembly overview
    79
  • 2.6 Batteries for remote-command key - remove and install
    80
  • 2.8 Key - synchronize
    83
  • Rear doors, door components
    84
  • 1 Rear passenger doors
    84
  • 1.1 Rear passenger doors - assembly overview
    84
  • 1.2 Rear passenger door - remove and install
    85
  • 1.3 Rear passenger door - adjust
    87
  • 1.4 Rear passenger door - disassemble and assemble
    89
  • 1.5 Rear door - replace
    89
  • 1.6 Door arrester - adjust
    90
  • 1.7 Door limiter - remove and install
    90
  • 1.8 Internal handle - replace
    91
  • 1.9 Rear door external handle and lock - assembly overview
    92
  • 1.10 Cylinder housing without lock cylinder - remove and install
    93
  • 1.11 External door handle - remove and install
    94
  • 1.12 External door handle - replace
    95
  • 1.13 Rear door lock - remove and install
    95
  • 1.14 Rear door lock - replace
    99
  • 1.15 Inversion lever - replace
    99
  • 1.16 Lock operating cable - remove and install
    100
  • 1.17 Rear left/right power latching motor V307/V308 - replace
    101
  • 1.18 Door sealing membrane - remove and install
    102
  • 1.19 Door sealing packings - assembly overview
    104
  • 1.20 External door packing - remove and install
    106
  • 1.21 Internal door trim - remove and install
    107
  • Sunroof
    109
  • 1 Sliding / tilting sunroof (Fox)
    109
  • 1.1 Operation
    109
  • 1.2 Sliding/tilting sunroof with glass lid - Assembly overview
    109
  • 1.3 Sliding/tilting sunroof glass lid - remove
    111
  • 1.4 Glass lid for sliding/tilting sunroof - install
    111
  • 1.5 Glass lid for sliding/tilting sunroof (height adjustment) - adjust
    112
  • 1.6 Lid trim - replace
    113
  • 1.7 Air deflector - remove
    114
  • 1.8 Sunroof lining - remove and install
    114
  • 1.9 Sliding sunroof movement control unit J245 - remove
    115
  • 1.10 Sliding/tilting sunroof selector key - remove
    116
  • 1.11 Sliding sunroof activation motor V1 - remove
    116
  • 1.12 Sliding sunroof motor V1 (zero position) - adjust
    117
  • 1.13 Parallelism - check
    117
  • 1.14 Parallelism - adjust
    117
  • 1.15 Sliding guide - remove
    118
  • 1.16 Sunroof - remove and install
    118
  • 1.17 Guide with steel cable - remove
    121
  • 1.18 Drain hoses - clean
    122
  • Bumpers
    125
  • 1 Front bumper
    125
  • 1.1 Front protector - assembly overview
    125
  • 1.2 Front bumper protector - remove and install
    126
  • 1.3 Front protector support - assembly overview
    131
  • 2 Rear bumper (Fox)
    132
  • 2.1 Rear protector - assembly overview
    132
  • 2.2 Rear protector - remove and install
    132
  • 2.3 Rear protector support - remove and install
    134
  • 3 Rear bumper (Spacefox)
    137
  • 3.1 Rear bumper - assembly overview
    137
  • 3.2 Rear protector - remove and install
    138
  • 3.3 Rear protector support - assembly overview
    139
  • Glazing
    140
  • 1 Glasses glued with adhesive
    140
  • 1.1 Tools
    140
  • 1.2 Auxiliary materials for Brazilian market
    142
  • 1.3 Auxiliary materials for export market
    142
  • 1.4 Matching table
    143
  • 1.5 Stickers for engraving the VIS number on the windows (only for Brazil) - supply
    143
  • 1.6 Windscreen - assembly overview
    143
  • 1.7 Windscreen - remove
    144
  • 1.8 Windscreen - install
    145
  • 1.9 Side glasses (Fox - 2-door) - assembly overview
    145
  • 1.10 Undamaged side glass (Fox - 2-door) - remove
    146
  • 1.11 Damaged side glass (Fox - 2-door) - remove
    147
  • 1.12 Side glass internal trim (Fox - 2-door) - install
    147
  • 1.13 Side glass (Fox - 2-door) - install
    148
  • 1.14 Side glass (Spacefox) - assembly overview
    148
  • 1.15 Undamaged side glass (Spacefox) - remove
    149
  • 1.16 Damaged side glass (Spacefox) - remove
    150
  • 1.17 Side glass (Spacefox) - install
    150
  • 1.18 Rear window (Fox) - assembly overview
    150
  • 1.19 Undamaged rear window (Fox) - remove
    151
  • 1.20 Damaged rear window (Fox) - remove
    152
  • 1.21 Rear window - install
    153
  • 1.22 Rear glass (Spacefox) - assembly overview
    153
  • 1.23 Undamaged rear window (Spacefox) - remove
    153
  • 1.24 Damaged rear window (Spacefox) - remove
    155
  • 1.25 Undamaged glass - prepare for install
    156
  • 1.26 New glass - prepare for install
    157
  • 1.27 Body flange - prepare to install the window
    158
  • 1.28 Assembly instructions
    159
  • 1.29 Minimum adhesive drying time
    160
  • 1.30 Paint damage - repair
    161
  • 1.31 Cleaning in case of resulting adhesive residues
    162
  • 2 Tilting window
    163
  • 2.1 Tilting window (Fox - 2-door) - remove and install
    163
  • 2.2 Glass internal packing - install
    164
  • 2.3 Tilting window - adjust
    164
  • 3 Door window glass
    165
  • 3.1 Front door window glass - assembly overview
    165
  • 3.2 Front door window glass - remove and install
    165
  • 3.4 Window drive mechanism - remove and install
    169
  • 3.5 Window drive motor - remove and install
    171
  • 3.6 Front door window crank - remove and install
    171
  • 3.7 Front door window channel - remove and install
    172
  • 3.8 Front door window internal trim - remove and install
    172
  • 3.9 Front door window external trim - replace
    172
  • 3.10 Rear door window glass - assembly overview
    172
  • 3.11 Rear door window glass - remove and install
    174
  • 3.12 Rear door window power activation mechanism - remove and install
    175
  • 3.13 Rear door window drive motor - remove and install
    176
  • 3.14 Rear door window drive mechanism - remove and install
    177
  • 3.15 Rear door glass rear guide rail - remove and install
    177
  • 3.16 Rear door window channel - remove and install
    178
  • 3.17 Rear door window internal trim - remove and install
    178
  • 3.18 Rear door window external trim - replace
    178
  • 3.19 Rear door fixed glass - replace
    178
  • Exterior equipment
    180
  • 1 Materials used and operational care required
    180
  • 1.1 Auxiliary materials for Brazilian market
    180
  • 1.2 Auxiliary materials for export market
    180
  • 1.3 Matching table
    181
  • 1.4 Paint damage - repair
    181
  • 1.6 Minimum adhesive drying time
    182
  • 2 Spoiler
    183
  • 2.1 Roof spoiler (Fox) - assembly overview
    183
  • 2.2 Spoiler (Spacefox) - remove and install
    190
  • 2.3 Assembly overview
    190
  • 2.5 Remove
    191
  • 2.6 Install
    193
  • 3 Roof Rack
    197
  • 3.1 Roof rack (Crossfox) - remove and install
    197
  • 3.2 Roof rack (Spacefox) - remove and install
    197
  • 3.3 Roof rack fastening support (Spacefox) - replace
    202
  • 4 Inscriptions
    205
  • 4.1 (1.6) version lettering - replace
    205
  • 4.2 Model lettering (Fox) - replace
    206
  • 4.3 “Total Flex” badge - replace
    207
  • 4.4 Plus version badge (side) - replace
    207
  • 4.5 Version and “Total Flex” Badge (CrossFox) - replace
    208
  • 4.6 Wing and front door decorative stripe (Fox Extreme) - replace
    209
  • 4.7 Rear door decorative stripe (Fox Extreme) - replace
    209
  • 4.8 “Fox extreme” (Fox Extreme) Inscription - replace
    210
  • 4.9 “Fox-shape” badge on door (Fox Extreme) - replace
    211
  • 4.10 Side badge - BlackFox version (Fox BlackFox) - replace
    212
  • 4.11 “BlackFox” (Fox BlackFox) Badge on rear door - replace
    212
  • 4.12 Rear side panel “Refresh” (Fox Refresh) Badge - replace
    213
  • 4.13 “Fox Sunrise” (Fox Sunrise) badge on rear door - replace
    214
  • 4.14 “Fox Sunrise” (Fox Sunrise) badge on rear side - replace
    215
  • 4.15 “Fox Sunrise” (Fox Sunrise) Badge on external rear-view mirror case - replace
    216
  • 4.16 “Spacefox” lettering on rear lid - replace
    217
  • 4.17 “1.6” lettering on rear lid (Spacefox) - replace
    217
  • 4.18 Decorative stripe on bumper rear protector - replace
    218
  • 4.19 CrossFox (► 2007) side badge - replace
    219
  • 4.20 CrossFox (2008 ►) side badge - replace
    220
  • 5 Side footboard (CrossFox and Fox Sunrise)
    221
  • 5.1 Rear bumper trim - replace
    221
  • 5.2 Rear side panel trim - replace
    222
  • 5.3 Front wing trim - replace
    223
  • 5.4 Side footboard (CrossFox ► 02.06) - assembly overview
    224
  • 5.5 Side footboard (CrossFox ; ► 02.06) - remove and install
    225
  • 5.6 Side footboard rear lining (CrossFox ; ► 02.06) - general overview of assembly
    229
  • 5.7 Side footboard rear lining (CrossFox; ► 02.06) - replace
    230
  • 5.8 Side footboard (CrossFox ; 03.06 ►) - assembly overview
    232
  • 5.9 Side footboard (CrossFox ; 03.06 ►) - assembly overview - continued
    234
  • 5.10 Side footboard (CrossFox ; 03.06 ►) - remove and install
    235
  • 5.11 Side footboard rear lining (CrossFox ; 03.06 ►) - assembly overview
    238
  • 5.12 Side footboard rear lining (Crossfox ; 03.06 ►) - replace
    240
  • 6 External rear-view mirror
    242
  • 6.1 External rear-view mirror - assembly overview
    242
  • 6.2 Exterior rear-view mirror - remove and install
    243
  • 6.3 Mirror glass - remove and install
    244
  • 6.4 Mirror frame - remove and install
    244
  • 6.5 Mirror glass - remove and install
    245
  • 7 Side trims
    247
  • 7.1 Side trims (Fox - 2-door) - replace
    247
  • 7.2 External longitudinal member lower lining (Fox 09.06 ►) - assembly overview
    249
  • 7.3 External longitudinal member lower lining (Fox 09.06 ►) - remove and install
    249
  • 8 Wheel arch protector
    253
  • 8.1 Front wheel arch protector - remove and install
    253
  • 8.2 Rear wheel arch protector - remove and install
    254
  • 8.3 Rear wheel arch protector (Spacefox) - remove and install
    255
  • 9 Central bumper protector - (CrossFox)
    256
  • 9.1 Front bumper centre protector (Crossfox ; ► 2007) - assembly overview
    256
  • 9.2 Front bumper centre protector (CrossFox ; ► 2007) - remove and install
    256
  • 9.3 Front bumper centre protector (CrossFox ; 2008 ►) - remove and install
    258
  • 9.4 Rear bumper central protector (CrossFox) - remove and install
    259
  • 10 External linings
    260
  • 10.1 Lower windscreen covering - assembly overview
    260
  • 10.2 Lower windscreen covering - remove and install
    261
  • 10.3 Floor lower lining - assembly overview
    263
  • 10.4 Lower longitudinal member external lining - replace
    263
  • 10.5 Pillar and door external lining - replace
    265
  • 11 Rear and front spoiler (Fox)
    268
  • 11.1 Front spoiler (Fox 09.06 ►) - remove and install
    268
  • 11.2 Rear spoiler (Fox 09.06 ►) - remove and install
    269
  • 12 Spare wheel support (CrossFox)
    270
  • 12.1 Spare wheel support upper (fixed) hinge - remove and install
    270
  • 12.2 Spare wheel support upper (fixed) hinge - position adjustment
    272
  • 12.3 Spare wheel support lower (fixed) hinge - remove and install
    272
  • 12.4 Spare wheel support lower (fixed) hinge - position adjustment
    275
  • 12.6 Spare wheel support (► 2007) - remove and install
    278
  • 12.7 Spare wheel support (2008 ►) - remove and install
    279
  • 12.8 Spare wheel support external cover (2008 ►) - remove and install
    282
  • 12.9 Spare wheel support internal cover (2008 ►) - remove and install
    283
  • 12.10 Support unlocking lever cover (2008 ►) - remove and install
    284
  • 12.11 Support lock activation cable (2008 ►) - remove and install
    284
  • 12.12 Spare wheel latch buffer - remove and install
    286
  • 13 Crossfox components
    288
  • 13.1 Assembly overview
    288
Manufacturer's designation General body repairs, exterior
Manufacturer Volkswagen
Suitable for FOX (2004 - 2010) / Suran/Spacefox/SportV (2006 - 2007)
Suitable car types 5Z1, 5Z6
Category Reparaturanleitung

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