Repair 7

Volkswagen uses a camshaft position sensor on the 2002 Passat sedan to relay information about the camshaft position and engine speed to the electronic control module to determine ignition timing and fuel injection synchronization. Located on the cylinder head behind the upper timing belt cover on the 1.8-liter engine, the sensor is accessible for removal and replacement. Replace the sensor using basic hand tools.

Instructions

1

Locate the cam position sensor electrical connector on the timing belt cover just to the left of center of the engine. Unlock the connector retaining tab and pull the connector off the sensor.

2

Unlock the upper timing belt cover retainer clip at the top-right corner of the cover. Pull the top of the cover away from the engine slightly and disengage the upper cover from the tab in the lower cover. Lift the upper cover straight up and out of the engine compartment.

3

Remove the two camshaft sensor retaining bolts using a ratchet and socket. Pull the old sensor off the engine.

4

Make certain the tab on the faceplate on the end of the camshaft is properly indexed in its detent. Install the new sensor on the engine. Install the two sensor retaining bolts and torque them to 88 inch-pounds using an inch-pound torque wrench and socket.

5

Position the upper timing belt cover on the engine. Engage the tab in the lower timing belt cover with the slot in the upper timing belt cover. Snap the upper cover into place. Install the camshaft sensor electrical connector and ensure the retainer locks in place.

The use of paint codes, whether you have a scratch or huge dent, ensures that in painting, restoring or repairing the exterior of your Volkswagen, you will get a precise match of your autos original color.

Location

The location of the paint codes varies depending on the make, model and year of your VW. The two-to-four number/letter digit code is usually under the rear trunk, under the trunk mat or in the spare tire wheel well.

Other Paint Code Sources

If you are unable to locate your paint code anywhere on your vehicle, check your owners manual. If the information is not available from that source, call a VW dealership, give your Vehicle Identification Number (VIN) and have the dealer look it up for you.

Benefits of Paint Codes

Paint codes will ensure that you are using the correct color. Do not try to match your paint without these codes; even experts will be unable to do an effective match without the correct information. Even if you try to match colors on the Internet, the quality and shade of the color shown will depend on your computer.

The Volkswagen New Beetle, like many other vehicles made in recent years, is equipped with a radio that requires a code to properly function after being disconnected from its power source. This feature is designed to make the radio as useful as a paperweight in the event of theft. The need for a radio code has served to reduce the theft of original equipment manufacturer (OEM) radios, but it also makes it annoying for owners who have removed their radios for various reasons, including replacement and service.

Instructions

Instructions

1

Find the VW owners manual in the glove box. Find the card inside the owners manual that contains the radio code. This code is provided when the car is first purchased from the dealership. In some cases, the card may be misplaced before or after the vehicle is sold to another person.

2

Look for the Vehicle Identification Number (VIN) of the New Beetle if the VW owners manual does not contain the radio code. You can find the VIN near the bottom of the windshield on the drivers side of the vehicle. Write this information down on a piece of paper.

3

Remove the radio from the dashboard. You will need a set of radio removal keys, available for purchase at most car audio outlets. Insert the radio removal keys firmly into the two slots along the bottom edge of the radio then pull the radio out of the slot. Look for the radio serial number located on the back of the unit. This number will start with "vw4z7" or a similar identifier. Write this serial number down on the same piece of paper as the VIN for safekeeping.

4

Take the information written down to the nearest VW dealership and request that they find your radio code with the information provided. Both the VIN and radio serial number are required for the dealership to successfully find your radio code. Upon finding the radio code, write it down in the owners manual or someplace else where you can safely store it.

Volkswagen diesel engines made since 1991 use Turbocharged Direct Injection, or TDI. The 1.9-liter version of this engine appears in various Volkswagen models made since 1995, including the Golf, Jetta, Passat and New Beetle. TDI engines have a turbocharger and inject fuel directly into the cylinder. This is a mechanical method of fuel injection, which does not use an electronic controller to determine when the injector sends fuel to the cylinder.

Instructions

1

Remove the fuel pump fuse from the fuse box under the dashboard. Start the engine, and allow it to idle until it stalls. This will relieve the pressure in the fuel system. Turn the engine off, and replace the fuel pump fuse in the fuse box.

2

Disconnect the negative battery cable with a socket wrench. Wrap a clean shop cloth around the fitting on the fuel line to the fuel rail. Remove the union nuts from the fuel line, and disconnect the fuel line from the fuel rail.

3

Remove the mounting bolts for the fuel rail with a socket wrench, and disconnect the fuel rail from the engine as an assembly. Turn the fuel injectors counterclockwise and remove them from the injector hole on the cylinder head. Remove and discard the heat shields from the injector hole.

4

Install new heat shields to the injector hole, and screw the new fuel injector into its hole. Tighten the fuel injector with a socket wrench, and install the fuel rail to the engine.

5

Connect the fuel line fuel rail, and fasten the union nuts for the fuel line with a socket wrench. Connect the negative battery cable.

All 1974 VW camper models have a sink, ice box, couch/bed and the option for a pop-top. The camper also has storage cabinets and individual front and passenger seats that swivel to face the couch. The design maximizes the space available and can be used for short or long camping trips. Before you begin restoring the camper portion of the vehicle, do all of the work required to restore the body and engine.

Instructions

1

Raise the pop-top and inspect the interior of the camper for water damage and mold. Remove all infested wood, carpet, upholstery and tent fabric. Use a blade to cut out material and a hammer to remove wood panels.

2

Inspect the plumbing for damage and fill the water reservoir. Test the sink to check the water pump operation. Inspect the propane tank and hose for a seal of approval with a service date. Outdated propane tanks must be serviced or replaced.

3

Replace any damaged plumbing with PVC. Use PVC joints and PVC glue to make new connections. Replace the water pump and reservoir then fill the reservoir and test the sink.

4

Remove any damaged wood panels on the sink, bed and cabinets. Replace them with matching panels that can be special-ordered or use 1/4-inch plywood with a varnish finish.

5

Replace the tent material used in the pop-top. The tent must be special-ordered for the correct dimensions. Order new tent material with pre-installed windows to add value to your camper.

6

Use a sander to remove all of the glue from the interior floor. Sweep out the interior of the van. Place new carpet glue on the floor and lay down new carpet. Use a blade to trim the edges for a clean finish.

7

Replace the cushions on the couch/bed or re-cover them with new upholstery.