1974 Karmann Ghia Owner`s Manual

1974 Karmann Ghia Owner`s Manual
Volkswagen Owner's Manual:
Operation and Maintenance
Type 14
-irst Owner
LEG Date
Dealer's Name
Second Owner
Tel, No.
Purchase Date Mileage
WI =
Vehicle Identification
Model Year a =
Chassis Number Jig
License Plate No.
Customer Identification Card
This is another feature of Volkswagen Service that adds
to your convenience. Just present this booklet whenever
you stop for service at your Authorized Volkswagen
Dealer. Your Idenfication Card will quickly furnish the
Service Adviser with your name and address and all
nertinent vehicie data.
Transmission oil
For transmission and final drive use
hypoid oil Mil-L-2105, SAE 80 or SAE
80/90 (multi-grade) all year.
ATF (Automatic Stick Shift)
Check ATF level with engine off. ATF
tank cap has dipstick attached.
Use ATF "Dexron®" with 5-digit number
preceded by B.
E - Filler cap H - Dip stick
F - Dip stick J - Bottom mark
G- Fluid tank K - Top mark
Hood release, front
Pull lever inside glove compartment.
To lock hood, lower hood, press down
firmly at front near safety catch until hood
locks securely.
Brake fluid reservoir (1)
Under front hood. Brake fluid level should
be above seam edge near top.
Only use new brake fluid SAE J 1703, con-
forming to Mot. Veh. Safety Std. 116.
Automatic Transmission Fluid
Battery — in engine compartment
Check each cell. Top up with distilled
Windshield washer container (2)
Unscrew cap, add water and cleaning
solution. Follow mixture instructions on
Spare wheel supplies pressure to operate
washer. Maintain at 42 psi (3 kg/cm?).
opare tire pressure
Spare tire supplies pressure to operate
washer. Maintain at 42 psi (3 kg/cm?).
Disconnect hose from valve (arrow).
Pressurize spare tire by this valve.
Spare tire removal
Disconnect windshield washer hose from
tire valve — M,
Under rear
Jack ports — one on each side
Raises entire side for front and rear whee
according to Federal Motor Vehicle Safety Standard No. 208, Section 7.4
Safety Belt Interlock.
What is
в the Interlock?
Engine ignition and safety
belt system for the front
seats are interconnected.
To start the engine,
follow these steps:
Otherwise the engine
cannot be started.
2 What happens if
« the engine stalls?
Keep belts on!
Turn the key back to the
“off” position and restart
the engine.
What happens if
« driver or front
passenger take
off belts while
driving ?
Engine will not stop.
Warning light and buzzer
will remind driver and
passenger to buckle up
How sensitive is
s the seat switch?
Shopping bags, heavy
packages or pets on the
seat will actuate the
warning system.
Engine cannot be started
until seat is cleared.
4 model is equipped with an Ignition Switch/
What about
« parking
lot attendants ?
The car can be started,
without buckling up,
within 3 minutes after the
engine has been shut off.
However, the warning
system will be actuated.
NEVER attempt to
defeat the Interlock!
If you tamper with the
Interlock, you may not be
able to start the engine, or
the car may become
Volkswagen Owner's Manual:
Operation and Maintenance
1974 Models
Karmann Ghia Coupé and Convertible
Volkswagenwerk Aktiengesellschaft
pc dd ——————
C 1973 Volkewagenwerk Aktiengesellschaft
All rights reserved.
May not be reproduced or translated in whole or in part without the written consent of Volkswagenwerk AG
Specification subject to alteration without notice.
a AA ET RAT A Леандро а ща |
The VOLKSWAGEN OWNER'S MANUAL consists of two major parts: operation
description and Computer Analysis & Maintenance record.
The first part acquaints you with your Volkswagen Warranty and the operation of your
car. It also gives you information on fuel, oil, lubrication, plus technical data.
The second part deals with the maintenance of your Volkswagen. It explains what
how to keep your Volkswagen in top driving condition. Check the mileage chart at
the end of this manual. It will tell you when to bring your car to your Authorized
Volkswagen Dealer for periodic oil change, computer analysis and maintenance
There is no extra charge for the first maintenance
service at 600 miles (you only pay for lubricants).
You are further entitled to a computer analysis at no
extra charge at 6,000, 12,000, 18,000 and 24,000 miles.
Always have your Volkswagen Owner's Manual with you when you take your car to
an Authorized Volkswagen Dealer for service... it provides your Service Adviser
with the information he needs and enables him to make the necessary entries for you.
Please read this manual before you drive your new Volkswagen. Acquaint yourself
with the features, and know how to operate it more safely... because the more you
know about it, the more you will enjoy driving your Volkswagen.
Pictures and text in this manual are based
on the 1974 Volkswagen Karmann Ghia
Coupé with Manual Transmission. Where
the controls, equipment and technical data
of the Automatic Stick Shift and the Con-
vertible differ considerably, we will point
this out in the text.
Various items shown or described in the
manual may be options on certain models.
Check with your Authorized VW Dealer
an available antions or accessories.
It has always been Volkswagen's policy
to continuously make technical improve-
ments; therefore, the right is reserved to
make changes at any time during the
model year without notice.
We're in this together.
We made the car. You own the car.
So we're in this together. As long as
you maintain your new Volkswagen
properly we'll do most of the worrying Owner's
for you. Security
That's what Volkwagen’'s Owner's. Blanket
Wirh Computer Analysis
Security Blanket is all about.
The VW Owner’s Security Blanket
It covers a lot.
amphlets describing details of the Volkswagen Owner's Security Blanket are available at your authorized VW dealer
Address change cards .........- D 13 Emergency flasher ................ 9 Oil pressure warning light .......... 11
Air cleaner .........eeeereeeoroo 44 Engine compartment .............. 20 :
Air Conditioner ...........e..me.e> 23 Engine cilgrades ................. 46 co a mm men! Eve 6 13
Alternator warning light ..........-. 11 Fan belt: adjusting or replacing ..... 40 "ear window Gelogger ............. 13
ASIE <i wv ca cui a e mea OEA 14 Fuel gauge ...........rreevereno 11 Safety belts ...................... 6
Automatic Stick Shift .............. 17 Fuel supply :....:.....erevesemers 35 Seats .............eoorewe.ereceooo 5
Automatic Transmission Fluid .... 43,47 Fuses ..........eeeeerrrrevecree 34 Sparewheel ............— reee... 29
Auxiliary Heater .......e..—ee=.—-- 25 Spark plugs: cleaning and replacing .. 41
Gas Station Information ........... D18 Speedometer dial ................. 10
Battery... meva «wwe visi eo 35 Glove compartment .............-- 14 Starting hínts ................... 19
Brake fluid reservoir ............... 33 SU VISOPE nea co tooo eme arios 13
| Brake warning light . ............... 9 Headlightswitch .................. 10 VTT
1 Bulb chart ......0.0.0000 600 38 Heater ......_e._ecmerresrrromecoe 19 Technical data ................ce... 54
| Bulb replacing - :-< 1.5: WR KR K HH 38 Heater lever spot light ............. 20 Tres TT ESS 28
| Chengiig aves! ...... 00... 30 Ignition/steering lock ............-- 9 Towing and trailer hauling .......... 26
Chassis number ..........ee..—..- 3 Instrument illumination ............. 10 Transmission oil grades ............ +
Checking and changing engine oil.... 42 Instrument panel ..............-.-- g Troubleshooting .................. 40
Cleaning your VW ............... . 36 Interior light ...............e..... ‚ 13 Turn signal/headlight
Clock with fuel gauge and dimmer switch lever ............. 12
arnina li Bg mee НЫ 11 ТОК NA AEREA e 30 ;
warning Hgts . ... 14 V-belt: adjusting or replacing ..... ... 40
Coat hooks ........-.....-—..——- Keys ..........enerrreccreroreras 4 Vehicle Identification .............. 3
Computer Analysis and Ventilation 21
Maintenance ........creereeoo- D2 Lanechanger ..........eos=econos Ya STUNDE ES EEE ES
Convertible top: ==... ERROR 22 ОЕ et о, i Warranty 70m meue sance vil
compartments ............
Dear VW Owner .......eo_o_ee.-e.e... 1 Nai ° EE ee cm Aa 9
Defoggina/defrosting ...........-.. 20 Maintenance record .............. D8 Windshield washer fluid container ... 33
Distributor addresses .............. 53 Manual Transmission .............. 15 Windshield wiper/washer lever ...... 12
OD ene wenu ee 4 Manual Transmission oil ........... 43 Winteroperation .................. 27
Volkswagen offers a quality product
Maintain this quality by having your
Volkswagen Karmann Ghia serviced
regularly.- A service schedule that we
recommend is explained in the section
Volkswagen Computer Analysis and
Should you have occasion to make use of
your Volkswagen Warranty, it is always
helpful to have the related service re-
ceipts handy.
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Air Conditioner Installation
| At Mileage
(Stamp of Installing |
VW Dealer) Make, Model
Auxiliary Heater Installation
(Stamp of Installing
vw ler)
At Mileage
Maks, Model
Speedometer Replacement
| Date
At Mileage
{Stamp of Replacing o В
VW Dealer) | Make, Model
Warranty for New Volkswagen Vehicles
This warranty is issued by Volkswagen of America, Inc. (“VWoA"), the authorized United States importer of Volkswagen
Free repair or
replacement in
the United States
and Canada of
defective parts
for 12 months
or 20,000 miles
required to keep
in effect
Items not
covered by
1. VWo warrants that every 1974 Volks-
wagen vehicle imported by VWoA and sold
as a new vehicle to a retail customer will
be free from defects in material and work-
manship for 12 months after the date of
delivery of the vehicle to the original retail
customer or until the vehicle has been
driven 20,000 miles, whichever comes first.
This warranty is limited, however, to the
following: If the vehicle becomes defective
under normal use and service and is
brought during this period to the workshop
of any authorized Volkswagen dealer in
the continental United States, Hawaii or
Canada, the dealer will, without charge,
repair any defective part or replace it with
a new or factory reconditioned part.
2. In order to keep this warranty in effect,
the owner must have the vehicle main-
tained and serviced as prescribed in the
Volkswagen Maintenance Schedule.
3. VWoA is not responsible for: (i) damage
or malfunctions resulting from: (a) accident,
misuse, negligence or alteration; (b) im-
proper repair of the vehicle, (c) use of the
vehicle in competitive events; or (d) failure
to follow recommended maintenance
requirements; and (ii) loss of time, incon-
venience lace of use of the vehicle or
outside the
United States
and Canada
No other
warranties made
other consequential damage.
Maintenance services, and the replace-
ment of service items, such as air and fuel
filters, and lubricants and fluids are also
at the expense of the owner.
4. If the vehicle is brought to an authorized
Volkswagen workshop outside the con-
tinental United States, Hawaii or Canada,
VWoA's warranty will not be applicable
and defective parts will be repaired or
replaced free of charge with new or
factory reconditioned parts only within the
terms and limitations of the warranty for
new Volkswagen vehicles in effect in the
country where such authorized Volks:
wagen workshop is located.
Volkswagen parts, accessories and exchange units are identified by these trademarks
All meet the same exacting quality control standards as the original equipment on the
car, and comply with all applicable Government safety regulations.
They are guaranteed to be free from defects in material and workmanship for a period
of 6 months or 6,000 miles, whichever comes first.
All Volkswagen parts and accessories are avallable at your Authorized Volkswagen
Also, ask him about rebuilt parts under the Volkswagen Exchange Service they
cost legs than new parts bul carry the same warranty.
“Dear VW Owner
A lot has gone into the manufacture of
your Volkswagen Karmann Ghia. Includ-
ing advanced engineering techniques,
rigid quality control and demanding
inspections. The engineering and safety
features that have gone into your VW will
be enhanced by . . . you,
the safe driver
— who knows his vehicle and all the con-
— who maintains his vehicle properly,
— who uses his driving skills wisely.
Because safe driving is important to you,
we urge you to read this manual care-
fully, to maintain your VW properly and to
follow the check list shown on this page
whenever you use your VW.
Before getting behind the wheel
1 - Make sure that the tires are inflated
2 - Watch the tread depth indicator on
the tires. Look for bruises and wear.
3 - See that all windows are clean and
4 - Check that headlight and tail light
lenses are clean,
5 - Check that all lights are functioning
G - Check turn signal lamps and indicator
light (ignition on).
In the driver's seat
1 - Position seat properly for easy reach
of controls.
2 - Adjust inside and outside mirrors for
unobstructed rear view,
3 - Fasten safety belts.
4 - Check brake warning light when start-
ing the engine.
5 - Check brake operation.
6 - Make sure that all doors are closed
securely and locked.
And when you are on the highway
1 - Always drive defensively. Expect the
2 - Use signals to indicate turns and lane
3 - Turn on headlights at dusk.
4 - Follow at a safe distance. A good rule
of thumb is to allow a minimum of one
car length for each 10 mph of speed
5 - Reduce speed during night hours and
inclement weather.
6 - Observe speed limits and obey high-
way signs.
7 - When tired, get off the highway, stop
and take a rest.
8 - When stopped or parked, always set
the parking brake.
9 - When stalled or stopped for repairs,
move the car well off the road. Set
the emergency flasher and use road
flares or other warning devices to
warn other motorists.
Г ши
GVWR LB.[....) (chassis number)
GAWR LB. FRONT (....)/REAR(....) 1
Le o
This sticker is your assurance that your
1974 Volkswagen Karmann Ghia complies
with all applicable Federal Motor Vehicle
Safety Standards which were in effect at
the time the vehicle was manufactured.
You can find this sticker on the left door-
The sticker also shows the month and year
of production and the chassis number of
your car (perforation) as well as the Gross
Vehicle Weight Rating and the Gross Axle
Weight Rating,
vehicle identification
The identification plate The chassis number The engine number
is the "birth certificate’ of your Volks- is also located on the instrument panel on is stamped on the alternator support
wagen, It is located under the front hood the driver's side so that it is visible from flange.
beside the spare wheel the outside through the windshield. This
is for your protection ... to aid in the
apprehension of car thieves and the re-
covery of stolen vehicles.
Ten elfo! e 1-2
The plate shows such information as The chassis number is also stamped on
manufacturer's name, place of origin, the frame tunnel under the rear luggage
model, weights and ’Fahrgest.-Nr’, which panel.
is the chassis number of your car.
Your Volkswagen Karmann Ghia comes
with two sets of keys:
The key with the elongated head is for
the doors and the ignition/steering lock
The key with the round head is for the
glove compartment only
Do not invite car theft
by leaving your car unattended with the
key in the ignition lock. Take the key with
you and lock the doors
A buzzer will remind you when you open
the driver's door and the key is still in the
ignition lock.
It is a good idea to keep a record of your
key numbers in your wallet together with
your license. If you should lose a key,
your Authorized VW Dealer will thus be
able to quickly secure a replacement key
for you
Always drive with locked doors to prevent
inadvertent opening of a door from the
inside, especially with smaller children in
the car.
Since your Volkswagen is almost air tight
it will be easier to close the door if you
open a window slightly.
To lock and unlock doors
from the outside
You can lock and unlock your car with a
key, of course.
But you can also lock it without a key.
First depress the locking lever in the in-
side door handle.
Then squeeze the trigger in the outside
door handle as you close the door.
if the door, with the locking lever de-
pressed, closes by itself, the locking
device will disengage automatically. We
provided this additional safety feature so
you won't be locked out if the door should
slam shut while the key is still inside the
To lock and unlock doors
from the inside —
depress or pull out the locking device
inside door handle
(pull to open)
We recommend you do not put decals or
other signs on the windows of your car
that will interfere with the driver's vision.
You can lower and raise the windows in
the doors by means of winders. We
cushioned the knobs for your safety
The hinged rear side windows can be
opened as required after releasing the
fastener. We recommend that you make
full use of these windows, particularly
under unfavorable weather conditions.
They assure ventilation of the vehicle
interior and, therefore, prevent the win-
dows from fogging.
We recommend you do not adjust the
driver's seat while driving. Your seat may
suddenly jerk forward or backward, which
could result in loss of control.
Your Volkswagen Karmann Ghia has
adjustable seats with built-in headrests.
Seat adjustment
To move the seat forward and backward
pull the lever at the front right-hand side
of the seat. Now slide the seat to the
desired position. Let the lever go. and
move the seat slightly back and forth tc
make sure it is securely engaged
Backrest adjustment
You can adjust the backrest to four diffe-
rent angles.
Take the weight off the backrest and turn
the lever on the outboard side of the seat.
We have installed a lock on the side of
the backrest.
You can disengage this lock by pulling up
the lever. Tilt the backrest forward and
out of the way for easy access to the rear
luggage panel.
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Safety belts
Both seats in your Volkswagen Karmann
Ghia are equipped with lap/shoulder belts
with an automatic locking retractor. The
belt adjusts automatically to your size
and movements as long as the pull on the
belt is slow. A sudden motion locks the
belt. The automatic locking mechanism in
the retractor will also lock the belt when
driving down a steep hill or in a curve,
and when the car's speed is reduced.
For your protection, fasten your safety
belt before driving off and wear it at all
times while the car is in motion.
Do not strap in more than one person in
each belt.
A shoulder belt should not be worn by a
person less than 4’ 7” in height, because
t would not be in its most protective
position, and therefore may increase the
possibility of injury in a collision.
Safety belts that were subjected to ex-
cessive stretch forces during an accident
should be replaced.
Engine ignition and safety belts for both
seats are interconnected. To remind youto
wear your safety belts, the engine cannot
be started before the seat is occupied
and the safety belts are fastened. This
applies to both seats.
The sequence: sitting in your seat, buck-
ling up and starting the engine is im-
Unfastening the belts once the engine is
started does not stop the engine.
Unfastening the belts while driving also
does not stop the engine; however, the
buzzer and FASTEN BELT warning light
will remind you to buckle up again.
Your engine can be restarted, without
wearing safety belts, within approx. 3 mi-
nutes after you shut off the engine, or if
the engine should happen to stall.
This applies regardless of whether you
remain seated or leave the car. This
feature was added to make it possible to
move the car readily, e.g. by a parking
There is a small flow of current from the
battery to the weight sensor in the seat
switch if heavy objects are left on the
seats. Therefore keep the seats free when
parking your car for an extended period
of time.
To fasten your lap/shoulder belt, grasp the
belt tongue and pull the belt in a contin-
uous slow motion across your chest and
lap. Insert the belt tongue into the cor-
responding anchor housing on the center
tunnel and push down until it is securely
locked with an audible click. Belts should
not be worn twisted.
To unfasten the belt, push in the release
marked PRESS on the corresponding
anchor housing. The belt tongue will
spring out of the anchor housing.
To store the lap/shoulder belt, guide the
belt tongue to its stowed position above
the door post. For the passenger's com-
fort, the retracting forces of the belt are
relatively low and winding up of the belt
may be slow. Make sure the belt is fully
wound up on the retractor.
Make sure the belt of the unoccupied
passenger seat is fully wound up on its
retractor so that the belt tongue is in its
stowed position above the doorpost. This
reduces the possibility of its becoming a
striking object in case of a sudden stop.
belt care
Keep safety belts clean. If cleaning is
necessary, wash them with a mild soap
solution, without removing them from the
Do not allow the belts to retract until they
are completely dry.
Do not bleach or dye safety belts. Do not
use any other cleaning agents. They may
weaken the webbing.
Check buckles and retractors for proper
function. Check belt webbing and bind-
ings for damage.
Instrument panel
1 - Vents for defrosting and fresh air ventilation 12 - Horn
Sra) a axvenies cia Za De a sobs Seis Sale 21 13-Fusebox .............. mi erre er >
=- puden are 14 - Control knob for Auxiliary Heater (optional equipment). 25
3 - Speedometer dial See A are as VANE BE 10 15 -Frashairinaha >) ms o bas =
4 - Clock with fuel gauge and warning lights ............ 11 16 - Safety belt warning light/brake warning light ........ aña
5 - Assist handle ;
6 - Emergency flasher switch ...,..................... g —17-Plate over radio aperture
7 - Headlight switch ................... 10 18 - Switch for rear window defogger ................... 13
8 - Turn signal and headlight dimmer switch lever ........ 12 19 - Glove compartment, lockable ............ OCTO TIRE
9 - Windshield wiper/washer lever .................... 12 ABRIO E read: e Bari anio o: 14
10 - ATF warning light 21 - Release for fuel tank flap ..................... дуже 30
(Trailer hauling-Automatic Stick Shift only) .......... 26 22 - Spot light to illuminate the heater levers between
11 -Ignition/steering lock .........................r.e... 9 Не 9088 era aias estes ais see 20
Ignition/steering lock
The steering is equipped with an anti-theft
ignition lock.
Fasten safety belts. Otherwise the engine
cannot be started (see also pages 6 and
19). Make sure the gearshift lever is in
Neutral before turning the ignition key.
1 - Ignition off/steering locked.
Insert the key. If it is difficult to turn
the key, gently move the steering
wheel until the key turns freely.
2 - Ignition on/steering free (for towing).
3 - Starter engages.
The key returns to position 2 as soon
as it is released. Never operate the
starter longer than a few seconds. If
the engine should fail to start, turn the
key back to position 1 and repeat the
starting procedure. More on starting
on page 19.
To remove the key and to lock the steer-
ing, turn the key back to position 1 and
pull it out. Turn the steering wheel until
it locks.
The steering column will lock when you
remove the key. Therefore DO NOT
REMOVE the key while you are driving
or as the car is rolling to a stop.
If you leave the key in the ignition/steer-
ing lock, the buzzer will sound when the
driver's door is opened. This is your
reminder to remove the key.
Emergency flasher switch (7A°)
If your car is disabled or parked under
emergency conditions, pull the switch to
make all four turn signals flash simul-
taneously. The warning light in the switch
knob flashes, too.
When the headlight switch is operated,
the emergency flasher knob glows with
reduced brightness for easy recognition
in the dark. When the emergency flasher
is not in operation, the brightness of the
light can be regulated together with the
instrument panel lights (see instrument
illumination). The light has full brightness
when the emergency flasher system is in
Move the car well off the road when
stalled or stopped for repairs.
Brake warning light
Your Volkswagen is equipped with a dual
circuit brake system. Both circuits, one
for the front brakes and one for the rear
brakes, can function independently.
If the brake warning light lights up when
you apply the brakes while driving, one of
the two brake circuits may have failed.
First make sure the parking brake is fully
Note: If one brake circuit may have failed,
the other brake circuit will still operate,
put a longer distance and greater pedal
pressure are required to bring the car to
a halt.
Pull off the road and stop.
Try out the effectiveness of the brakes
by carefully starting and stopping on the
road shoulder.
If you judge that the brakes operate safely
enough to take you to the nearest dealer,
proceed cautiously and at low speed. If
you do not feel it is safe to continue,
have your car towed to the nearest dealer
for repair
Proper functioning of brake warning light
The brake warning light will light up when
the ignition is turned on. It will go out after
the engine has been started and the park-
ing brake released. This is your assurance
that the brake warning light functions
If the brake warning light does not light
up when turning on the ignition, or if it
does not go out after starting the engine
and releasing the parking brake, there
may be a defect in the electrical system.
If this is the case, contact your Authorized
VW Dealer.
Headlight switch |.)
Pull the knob to the first stop to turn on
the parking and side marker, license
plate, tail and instrument lights, emer-
gency flasher light, spot light for the
heater levers and the light in the TEMP-
switch for the optional Auxiliary Heater.
Pull the knob to the second stop to turn
on the headlights. The headlights only
work with the ignition on.
To preserve the battery, the headlights
will go out automatically when the ignition
is turned off or wher the engine is started
Instrument illumination
Adjust the brightness of the instrument
lights and the heater lever spot light by
turning the light switch knob.
Speedometer dial
The speedometer dial indicates vehicle
The 5-digit odometer records the miles
The 4-digit trip odometer can be reset to
zero by depressing the knob in the dial
to record a driven distance. The last digit
in red indicates '/10 of a mile.
Clock with fuel gauge
and warning lights
The clock is electric. To set the clock, de-
press the knob in the dial center and turn.
Fuel gauge
It is located in the clock dial and only
indicates the fuel level when the ignition
is turned on.
When the needle is on "R", there is a
reserve of about 1.3 US gallons (1.1 Imp.
gal./5 liters) of fuel left in the tank . . . time
to refuel at the next gas station.
The following indicator or warning lights
are in the clock dial:
a - red oil pressure
b - blue high beam
C - green turn signals
d - red alternator
The red warning lights for alternator and
oil pressure in the clock dial will light up
when the ignition is turned on. They
should go out after you have started the
d - Alternator warning light
Stop at once...
if the alternator warning light comes on
while you are driving.
Turn the engine off!
Check first whether the V-belt is slipping
or broken. The V-belt not only drives the
a b с а
| _—
alternator but also the fan that cools the
Tighten or replace the belt (see also page
50 "Trouble shooting , item 18).
a - Oil pressure warning light
if the oil pressure warning light comes on
while you are driving.
Turn the engine off!
Check the oil level to make sure you have
enough oil. If the cause is somewhere
else, do not drive on but contact your
nearest Authorized VW Dealer.
An occasional flickering of the oil pres-
sure warning light when the engine is
idling after a long high-speed trip is no
cause for concern if the light goes out
upon acceleration.
Whenever stalled or stopped for repair,
move the car well off the road. Turn on
the emergency flasher and mark the car
with road flares or other warning devices.
Before working on any part in the engine
compartment, turn the engine off and
wait until the engine has cooled down
Turn signal/headlight dimmer switch lever
and windshield wiper/washer lever
There are two levers just behind the
steering wheel:
The lever on the left side is for the turn
signal/headlight dimmer switch.
The lever on the right side is for the
windshield wiper/washer system.
The turn signals and the windshield wipers
only work with the ignition on
Turn signals Co
Leverup — right turn signal
Lever down — left turn signal
The green turn signal indicator light
comes on in the clock dial when you
operate the lever.
Theturn signals are cancelled automatical-
ly when you have completed a turn (like
driving around a corner), and the steering
wheel returns to the straight-ahead po-
If a turn signal is defective, the control
light flashes at about twice the normal
frequency. Have your Authorized VW
Dealer check and repair it for you.
Lane changer
To indicate your intention when changing
lanes on expressways, slightly lift or de-
press the leverto an intermediate position
The lever will return to the OFF position
when released.
Headlight dimmer (=
Dim the headlights by pulling the lever
toward the steering wheel. The blue indi-
cator light in the clock dial will light up
when the high beams are on.
Windshield wipers WIPE <>
The windshield wiping system operates at
two speeds: low and high.
Lifting lever to first stop — low speed
Lifting lever to second stop — high speed
If you just slightly lift the lever before
reaching the first stop, the wipers will
wipe as long as the lever is held in this
position and come to a stop when re-
He light pre changer |
ol i ——— — |
To give you full battery power while start-
ing the engine, operating windshield
wipers will stop automatically at this
Windshield washer <> WASH
To spray washer fluid on the windshield,
pull the lever toward the steering wheel.
You can operate the washer from any
selected wiping position.
Avoid running the wiper blades over a dry
windshield . . . you may scratch the glass.
Spray washer fluid on it first.
Rear window defogger (550)
The rear window defogger will help to
keep the inside of the rear window clear
of condensation and frost in the winter.
Turn the ignition on first before you
switch on the rear window defogger.
The rocker switch (arrow) for the rear
window defogger is located on the instru-
ment panel on the left side of the glove
A red dot on the rocker switch will
appear when the defogger is switched on.
After the rear window has been cleared,
switch off the rear window defogger to
avoid an unnecessary drain onthe battery.
The filler panel below the rear window
should not be used for storage, even for
small and light items. During sudden stops,
these articles may cause injury when dis-
lodged. Larger items may also reduce
vision to the rear.
Objects with sharp edges may damage
the defogger in the rear window.
Interior light
The light and light switch are on the mirror
The switch positions are:
Left — ON (with doors open)
Center — OFF
Right — ON (with doors closed)
un visors
You can lift the sun visors out of the
center mounting and move them toward
the door windows to prevent glare from
the side.
Rear view mirrors
Adjust the outside and inside mirrors
before driving off. It is important for safe
driving that you have good vision to the
Qutside mirror
The outside mirror is hinged and folds flat
against the car when struck from either
Inside day-night mirror
You can move the day-night mirror from
clear daylight visibility to non-glare visi-
bility at night by adjusting the lever up-
ward or downward at the bottom of the
=— >.
Coat hooks
There is one coat hook on each side
above the door post
Hang clothes in such a way that they do
not impair the driver's vision
You will find an ashtray in the center just
beneath the instrument panel
Pull to open it. To remove the tray de-
press the leaf spring which you see on
the right just beneath the top cover. Now
pull out the tray
To put it back in, fold the top cover down,
insert the tray in the guide rails and push
in with the heel of your hand.
ió may
——— —
Glove compartment
The glove compartment is lockable.
To open — Turn knob to the left
To close — Press door; lock
To lock or uniock — Turn key to right
or left
Inside the glove compartment is the
release lever for the front hood. A locked
glove compartment prevents access to
the luggage compartment and the spare
Controls for Manual Iransmıiıssion
1 - Clutch pedal
Always depress the clutch pedal fully
when changing gears. Do not hold the
car on a steep hill with the clutch pedal
partially depressed. This may cause pre-
mature wear or damage.
2 - Brake pedal
Make it a habit to check the operation of
your brakes. You will remember from
page 9 that the brake warning light will
alert you if one brake circuit may have
Make sure that the movement of the brake
pedal is not obstructed by a floor mat or
any other object.
Volkswagen automobiles have excellent
brakes, but they are still subject to wear
. depending on how the brakes are
used. If you find that the brake pedal
travel has increased, have the brakes
adjusted; if necessary, between the spe-
cified maintenance intervals.
Keep in mind that the braking distance
increases very rapidly as the speed in-
creases. At 60 mph, for example, it is not
twice but four times longer than at 30 mph.
Tire traction is also less effective when
the roads are wet and slippery. Therefore,
always maintain a safe distance.
Driving through deep water may reduce
tire traction. Moisture on the brakes may
also affect braking efficiency. Cautiously
apply the brakes for a test. If you notice
a lag in the braking action, the brakes
may be wet. They will dry after you have
applied the brakes a few times, but do it
very cautiously.
Brake pads or linings may not have the
highest possible braking efficiency when
new. Therefore allow for longer braking
distance during the initial 100 to 150 miles.
This also applies when-brake pads or
shoes are renewed.
3 - Accelerator pedal
For good fuel economy we recommend
smooth and even acceleration. Very fast,
racy driving, alternating between full
throttle and hard braking, raises the fuel
consumption considerably. Also, tires
and brake pads or linings wear faster.
You can drive most economically be-
12 and 31 mph in 2nd gear
22 and 50 mph in 3rd gear
31 and 62 mph in 4th gear
4 - Gearshift lever
The Manual Transmission is fully synchro-
nized. The four forward gears and a
reverse gear are arranged as Illustrated.
The shift pattern is also shown on the
Resting your hand on the shift lever knob
while driving will cause premature wear
to the transmission.
Speed ranges
You can drive your Volkswagen at full
speed from the first day. You do not have
a break-in schedule. There are, however,
certain recommended speed ranges for
the various gears:
1st gear 0—19 mph
2nd gear 12—37 mph
3rd gear 22—59 mph
4thgear from 31 mph up
IF you have a traffic situation where it is
necessary for you to overtake rapidly, you
can accelerate, for a brief period only,
up to
43 mph in 2nd gear
68 mph in 3rd gear
Only shift into Reverse when the car is
not moving. To engage reverse gear,
press the lever down, move it to the left
and pull back.
The back-up lights go on automatically
when you engage reverse gear (with the
ignition on).
5 - Parking brake lever
To set the parking brake, press in the
release button at the end of the lever as
vou pull up the lever. The parking brake
is engaged as soon as you release the
button on the raised lever.
With the ignition switched on, the brake
warning light on the instrument panel
lights up and goes out as soon as the
parking brake is released (see page 10).
To release the parking brake, pull the
lever up slightly as you depress the
release button. Then push the lever all
the way down.
Be sure it is fully released because a par-
tially engaged parking brake promotes
wear of the brake linings.
Do not remove the key from the steering
lock while the car is rolling to a stop. The
steering column is locked as soon as you
remove the key. Take out the key only
after the car is parked.
Always set the parking brake when park-
ing your car. On steep hills also turn the
wheels toward the curb.
VW Automatic Stick Shirt
At first glance
you will notice the lack of a clutch pedal.
Driving with the Automatic Stick Shift is
simpler and shifting is easier. We suggest
you carefully read the following instruc-
tions to familiarize yourself with the ope-
ration of the transmission.
For details on the operation of the brake
pedal, the accelerator pedal and the park-
ing brake lever, see pages 15 and 16.
The Automatic Stick Shift
transmission consists of a torque con-
verter. a power-operated clutch for shift-
ing, and a mechanical three speed trans-
mission. The torque converter multiplies
the torque produced by the engine and
allows the vehicle to be driven with very
little shifting — usually two driving ranges
will be used. It automatically changes the
torque from the engine in an infinitely
variable ratio according to driving con-
ditions. Since the torque converter is a
fluid coupling, it also permits stopping the
vehicle with an engaged gear while the
engine is running. The clutch interrupts
the flow of power from the engine to per-
mit the gears in the transmission to be
shifted. Because the power-operated
clutch is actuated by the first slight move-
ment of the gearshift lever, there is no
need for a clutch pedal.
Driving ranges
With the lever mounted on the frame
tunnel you can select three forward drive
ranges and one reverse. The neutral
position "N" is between all gears in the
Neutral (N)
is the only range in which you can start
the engine. In this position, the power
flow to the rear wheels is interrupted. It
should be used when the car is standing
at idle, with the parking brake engaged.
From the Neutral position you select the
desired drive range.
Driving Range 1
is for starting off and accelerating. It
covers the speed range from 0—56 mph.
Always use this range first before shifting
into Range 2. Range 1 is also recom-
mended for use in city traffic, slow mov-
ing lines of vehicles, and whenever maxi-
mum acceleration is required for passing.
If the lever is in Range 2, you may down-
shift into Range 1 at any speed under
56 mph.
Driving Range 2
Always use Range 1 first before shifting
into Range 2. Range 2 should normally be
used for highway driving. It is the only
range that can be used for speeds above
56 mph. You may shift into Range 1 at any
speed under 56 mph.
Low Range (L)
Shift into Low when you want to get the
car moving up steep hills, especially when
carrying a heavy load or when towing,
and when driving down a steep hill or
parking in tight spaces.
Reverse (R)
Engage the reverse gear only when the
car is not moving. The back-up lights go
on automatically when the reverse gear
s engaged (with the ignition on),
Park (P)
The Park position may only be engaged
when the car is stationary.
To shift into Park, depress the selector
lever first to overcome a safety catch.
In Park, the transmission is locked, pre-
venting the car from moving.
Neutral is the only position in which you
can start the engine.
Moving off
With the parking brake set, move the
selector lever to Neutral and start the
engine. Shift into the range you wish to
use, normally Range 1. After shifting be
sure to remove your hand from the lever
to allow the clutch to engage. To move
off, release the brake and accelerate.
Do not release the brake before you are
prepared to move, because power is
transmitted to the wheels as soon as a
gear is engaged.
is easy. Simply release the accelerator
pedal and move the gearshift lever from
the range you are in to the range you
want, remove your hand from the gear-
shift lever, and again step on the accele-
For easier selection of the driving ranges
1 and 2, which are used most, the gear-
shift lever always stays on the right side
when in Neutral, as shown in the ¡llustra-
tion, on the previous page.
Release the accelerator and apply the
foot brake. If you are going to start off
again in another range, you may shift
into the new range while the vehicle is
standing still, but if you remain in a driv-
ing range apply the foot or parking brake
to prevent the vehicle from creeping.
Do not remove the key from the ignition/
steering lock until you have parked the
car, because removal of the key locks
the steering.
When parking your car, apply the parking
brake first, then move the selector lever
to position P. To do this, move the lever
to the left, depress it, move it further to
the left and pull back into Park. The
transmission is then mechanically locked.
Shift out of the Park position before
releasing the parking brake.
When the car is parked on a steep hill,
shifting out of Park may be a little harder.
This is due to the weight the car exerts
on the transmission.
If you like quiet, smooth driving,
which saves fuel, we recommend that you
shift to Range 2 at about 20 to 25 mph.
For normal driving
We recommend that you shift from driving
range 1 to the driving range 2 at 40 miles
per hour.
If you want maximum acceleration
you can stay in Range 1 right up to 53
mph and then shiftinto Range 2. Naturally,
this will use more fuel.
Keep in mind... -
1 - When starting off, shift into a driving
range before releasing the parking
2 - After shifting, remove your hand from
the selector lever.
3- When idling for an extended period
of time, shift into Neutral and apply
the parking brake. When stopped in
traffic, apply either the parking or foot
brake to prevent creeping.
4- When parking, apply the parking brake
and shift into Park position. On hills,
also turn the wheels toward the curb.
Starting hints
Never start or let the engine run in an
enclosed unventilated area. Exhaust
fumes from the engine contain carbon
monoxide which is colorless and odorless.
Carbon monoxide, however, is a very
harmful gas, and can be fatal if inhaled.
Fasten safety belts, otherwise the engine
cannot be started (see also page 6).
Before turning the ignition key, make
sure the gearshift lever is in Neutral. The
Automatic Stick Shift can be started in
Neutral only.
As soon as the engine starts, release the
ignition key.
If the engine does not start the first time
or stalls, turn the ignition key all the way
to the left and restart.
Operate the starter for a few seconds
Summer starting
Operate the starter while slowly depres-
sing the accelerator pedal.
Winter starting
First depress the accelerator pedal fully
and release slowly to activate the auto-
matic choke. Then start the engine.
On the Manual Transmission, also depress
the clutch pedal when starting so that the
starter only has to crank the engine.
Do not try to warm up the engine by letting
it idle with the car stationary . .. drive off
immediately and maintain moderate speed
until the engine is warm.
Starting a hot engine
A hot engine may not start right away
when the outside temperature is above
86 °F. It may be necessary to operate the
starter a few times.
When you operate the starter, keep the
accelerator pedal fully depressed until
the engine starts. Do not release the
pedal between starting attempts, or you
will flood the engine.
Luggage compartments
Your VW has two luggage compartments,
one under the front hood, and the other
behind the seats.
Since improper weight distribution can
affect the car handling, take advantage of
the two luggage compartments. Load the
front luggage compartment first, using
the heaviest pieces of luggage, if possible
Front luggage compartment
To unlock the front hood, pull the release
lever inside the glove compartment, See
page 14.
fo lock the front hood, lower the hood
and press it down firmly. Always press
down at the front near the lock. Make
sure the hood is securely locked.
Rear luggage compartment
Additional luggage can be stored in the
space behind the seats.
You can expand this luggage area by fold-
ing down the rear panel. To release the
panel, pull up the catch. The panel will
lock in place when you fold it up again.
We recommend you do not place articles
on the filler panel below the rear window.
Such items may become dangerous pro-
jectiles when dislodged during a sudden
stop. They may also reduce the driver's
vision to the rear.
Engine compartment
To unlock the engine compartment, pull
out the knob in the left door pillar. Press
down the lock on the engine lid and lift
the lid.
The lid is held in the open position by
To close and lock the lid, press down on
the license plate housing until you hear
a click.
Te e a ee el
A fresh air heater/defroster is standard
equipment on your Volkswagen Karmann
Ghia. The control levers are located on
the tunnel between the seats.
The heater lever spot light will illuminate
the levers when the parking or headlights
are turned on.
The brightness of the spot light and in-
strument illumination can be adjusted by
turning the light switch knob.
1a - Heater temperature lever (TEMP)
The lever toward the passengers seal
controls the temperature level
Lever up — heat on fully
Lever down — heat off
By setting it at any intermediate position,
you can select the degree of heat that is
most comfortable for you. After a reason-
able warm-up time, which also depends
on the speed of your car, the warm air
will enter the car through the two de-
froster/fresh air vents (1) at the lower
edge of the windshield and outlets in the
front and rear footwells.
1b - Heat distribution lever for front
and rear footwells (DEF-HEAT)
With the lever on the tunnel next to the
driver's seat you can control the dis-
tribution of heat to the front and rear
Lever down —
front and rear footwells closed
Lever up —
front and rear footwells fully open
You can select any intermediate position
to regulate the distribution of heat to the
front and rear footwells,
Hints for defogging and defrosting
Defogging and defrosting your windshield
will be more effective if you direct the
total air flow toward the windshield.
Here is what to do:
Heater temperature lever (1 a) all the way
up (TEMP) — heat is on
Heat distribution lever (1b) all the way
down (DEF) — no heat to the front and
rear footwells
To increase the air flow, turn the fresh air
knobs (2) to the left. Now all air is direct-
ed toward the windshield.
Air enters the car through the grilles in
the front and the inside vents below the
windshield. A water separator prevents
rain from entering.
1 - Fresh air vents
Fresh air comes out through a vent on
each side below the windshield.
2 - Fresh air knobs
You can regulate the volume of fresh air
for each side separately by turning the
Turn left — air flow increases (a)
Turn right — air flow decreases (b)
To stop the air flow completely, turn the
knobs to the right beyond the pressure
Convertible top
The top should never be opened or closed
while the car is in motion.
The top should be dry before you open it
How to open the convertible top
Always open the rear window first (A)
Remove luggage that may be in the way.
Release the locking levers on the sides
(B) above the windshield and disengage
the hooks. While folding the top back, pull
the top material and padding to the rear
and the headliner toward the front so that
the top material does not get caught in
the linkage (C).
Press the top down to engage the locking
catches on both sides (D).
Now take the top cover (a separate cover
that comes with every new Convertible)
and place it over the convertible top.
Fasten all snaps, starting at the back and
hook the two eyes over the hooks as
shown in the picture (E).
How to close the convertible top
The top should be dry before closing it
First take off the top cover. Press the top
down lightly to disengage the locking
catches on both sides. Fold the top up and
toward the front,
wali |
From inside the car, grasp both levers and
pull the top forward. Engage the hooks
into the grasping brackets above the
windshield frame and lock the top tightly
by pushing the levers upward
As a last step, close and lock the rear
VW Air Conditioner (optional equipment)
Operating controls
1 - Air volume switch (“FAN”)
This switch serves two functions. It turns
the air conditioning system on and off and
controls the fan speed.
The sequence of the fan positions is:
2 - Air temperature control (“TEMP”)
By progressively turning the control to the
right, the desired cooling range can be
selected. It is in the coldest position when
turned as far as possible to the right.
3 - Air discharge louvers
These movable louvers can be adjusted
by moving the center vane to direct the
conditioned air flow upward, downward
or sideways.
Starting the Air Conditioner
With the windows and fresh air regulator
closed, turn the air temperature control to
the desired position and select the air
volume speed desired.
On extremely hot days turn the airvolume
to full capacity and open a window. Within
a few minutes, the hot air will be forced
out of the car and the window can be
rolled up as cooling starts.
Adjust the air discharge louvers to the
desired position.
Stopping the Air Conditioner
Turning the air volume switch to the
“OFF” position stops the entire air con-
ditioning system.
When restarting a stalled engine, it is not
necessary to turn off the air conditioner.
The current to the air conditioner is inter-
‘upted during the starting process.
Operational hints
f the car interior becomes too cold after
adjusting the air volume, turn the air
temperature control to the left until the
desired comfort level is reached.
If the windows fog over on the exterior on
warm, humid days, turn the air tempera-
ture control to the left until the windows
clear up, or turn the windshield wipers on.
If the windows fog over on the interior,
they can be quickly cleared by turning on
the air conditioner.
During highway driving, set the air tem-
perature control in approximately the
middie position.
Maintenance hints
During the winter season, it is advisable
to operate your Air Conditioner for a brief
moment every week. This will help to
keep the seals and fittings properly
After the winter months and before ex-
tended summer usage, the air conditioner
should be checked and, if necessary,
serviced by an Authorized VW Dealer.
The condenser should be checked perio-
dically for cleanliness. If clogged in any
area with dirt or insects, the condenser
should be washed down with water.
If the condenser fins are bent, the car
should be taken to an Authorized VW
Dealer for straightening of the condenser
An air-conditioned Volkswagen should
only be raised on a lift that provides ade-
quate clearance to prevent damage to the
refrigerant hoses.
Circuit breaker
An automatic resetting circuit breaker for
the current supply of the air conditioning
system is located under the rear luggage
panel. It is connected directly to the
When a VW Air Conditioner is installed,
the vehicle capacity weight will be reduc-
ed accordingly (see sticker on the inside
of the glove compartment door).
vw Auxiliary Heater (optional equipment)
Do not start or let the engine or heater
run in an enclosed, unventilated area to
warm up the car. Exhaust fumes from the
engine or gasoline heater contain carbon
monoxide, which is colorless and odor-
less. Carbon monoxide, however, is a very
harmful gas, and may be fatal if inhaled.
To switch the heater on, pull the knob
out (arrow). This lights up a green indi-
cator light in the knob.
The indicator light will also glow when the
headlight switch is operated while the
heater is not in operation. This feature has
been provided for easy recognition of the
knob in the dark.
To avoid an unnecessary drain on the
battery switch the heater off after about
25—30 minutes if the engine has not been
started in the meantime.
A heat limit switch will turn the heater off
periodically. The heater will come on
again automatically within 3 minutes.
To switch the heater off, push the knob
in. The indicator light then goes out but
the blower motor continues to run until
the heater has cooled down.
The heater must be switched off when
filling the fuel tank.
When it is very cold, the full battery capa-
City is required to start the engine. To
avoid starting difficulties, it is advisable
not to preheat the vehicle interior under
these conditions, that is, do not switch the
heater on until the engine is running.
The heater normally requires no special
maintenance. It is advisable, however,
to have the heater plug checked once a
year before the cold weather sets in and
a new plug installed if necessary. The
fuel system should also be checked for
cleanliness and the electrical connections
for tightness.
During the winter and when driving over
very poor roads, mud or snow may tend
to accumulate in the exhaust and com-
bustion air intake pipes. Have these pipes
checked for blockage from time to time so
that the heater continues to work properly.
When the heater is not in use for long
periods, for instance during the summer,
the fuel in the heater can evaporate. It is
therefore advisable to operate the heater
briefly once a month when it is not in
regular use.
Heat output: 8,000 BTU/h
Fuel: Gasoline from fuel tank
Fuel consumption:
appr. 0.7 pint/h (0.6 Imp. pint/h
or 0,3 liter/h).
Current consumption: 40 watts
Towing and trailer hauling
A - Towing
Your Volkswagen is equipped with two
towing eyes, one at the front and one at
the rear. They are for emergency towing
over short distances only.
A towing eye is welded to the right-hand
side of the lower axle tube.
A towing eye is attached to the left rear
bumper bracket.
When towing your VW place the gearshift
lever in Neutral. Turn the ignition on to
be able to operate the parking lights, turn
signals and stop lights. Be sure to release
the parking brake.
Always observe local laws and municipal
ordinances governing towing.
Please keep in mind ...
The towing eyes on your Volkswagen
Karmann Ghia are not desgined for
towing by commercial tow trucks. Also,
never have your car towed by the bumper.
The driver of the towing car must be very
careful when driving off and shifting to
avoid sudden and abrupt jerks.
The driver of the towed car must always
<eep the tow rope taut.
B - Trailer hauling
It is possible to tow a trailer with your
Volkswagen Karmann Ghia.
When towing a trailer with the Automatic
Stick Shift, start out in the low driving
range with this extra load.
Always shift to a lower range or gear
when driving up or down steep hills.
The total weight of a trailer (without
brakes) should not exceed 882 Ibs./(400
kg). The total weight of a trailer with
brakes should not exceed 1433 lIbs./
(650 kg). The trailer tongue load should
be 55 to 88 Ibs. 25 to 40 kg.
Distribute load in the trailer evenly. And
remember: the additional trailer weight
affects the braking of your car so that a
longer distance is needed to bring the
car and trailer to a stop. Test the brakes
before starting out on a trip with a trailer.
VW Automatic Stick Shift
If you plan to tow a trailer with the VW
Automatic Stick Shift, have an ATF warn-
ing light installed on the dashboard by
your Authorized VW Dealer (see item 10
on page 8).
When towing a trailer, start out in the low
driving range. Always shift to a lower
range when driving up or down steep hills.
ATF warning light
Stop at once...
if the ATF warning light comes on. It indi-
cates that the Automatic Transmission
Fluid may have reached too high a tempe-
rature. This may be caused by stop-and-go
traffic, mountain driving, etc.
Stop the engine and check the ATF level.
If it is not as required, do not continue
driving. Contact your nearest Authorized
VW Dealer.
If you have enough ATF, you may con-
tinue driving, but only in a lower driving
range. The ATF warning light should go
out after a while when the ATF has suffi- .
ciently cooled down.
If the ATF warning light has come on
while driving in Low range, stop the
engine to permit the ATF to cool down.
You may continue driving after the ATF
warning light has gone out.
Winter operation
Your VW has an air-cooled engine. Do
not, under any circumstances, try to in-
fluence the engine temperature by cover-
ing the louvers in the rear hood. These
louvers must always be kept open so that
air can flow to the carburetor and the
engine cooling fan.
During the winter months, the battery is
subjected to greater use than in the
summer months. More current is con-
sumed when starting at very low tempe-
ratures. Lights and the rear window de-
fogger are used more often. Besides, the
battery tends to decrease in capacity as
the temperature drops.
Therefore, it is very important to keep
your battery in the best possible con-
dition. See also "Battery" on page 35.
Do not expose battery to open flame or
electric spark as hydrogen gas generated
by the battery is explosive. Do not let
battery acid come in contact with skin,
eyes, fabric or painted surfaces.
À really cold battery may not have the
same capacity as a battery at normal
temperature. If you mainly drive short
distances or in city traffic, have the
battery checked and, if necessary, charged
between regular inspections.
Door locks
can freeze in the winter if water gets into
them. When washing your car in the
winter, do not aim the water jet directly
at the locks. It is a good idea to put tape
over the keyholes to prevent water from
seeping in. Water in the locks must
be removed with compressed air after-
wards. Squirt lock de-icer, anti-freeze or
glycerine into the lock cylinders to pre-
vent the locks from freezing.
To open a frozen lock, warm up the key
before inserting it. It might also help to
warm the lock. Do not use hot water as it
will later freeze in the lock.
Emergency equipment
It is good planning to carry emergency
equipment in your car. Some of the things
you should have are: window scraper,
snow brush, container or bag of sand or
salt, flares, small shovel, first-aid kit, etc.
Engine oil
To make starting easier during the cold
winter months, we suggest you choose a
thinner grade motor oil. Turn to page 46
for the recommended oil grades.
If you drive mostly short distances and in
city traffic, we recommend you have your
engine oil changed at 1500-mile intervals
in the winter.
Transmission oil
SAE 80W or SAE 80W/90 (multi-grade)
hypoid oil can generally be used all year.
In arctic climate and areas with tempera-
tures consistently below —13"F, use
Automatic Transmission Fluid (ATF) for
the manuel transmission and final drive.
When the temperature rises, replace the
ATF with SAE 80W or 80W/90 (multi-
grade) hypoid oil. See also page 47.
Windshield washer
Add anti-freeze to the washer fluid, such
as Volkswagen's Windshield Washer
Anti-Freeze & Solvent, to prevent it from
freezing. Follow the instructions on the
can for the right amount to be used.
Spark plugs
Make sure the spark plugs are not worn
or have a gap larger than 0.028 in. or
0.7 mm. For further details on spark plugs
see page 41.
BA) Ant
Your Volkswagen Karmann Ghia is
aquipped with tubeless bias ply tires,
Volkswagen tires comply with all appli-
-able Federal Motor Vehicle “Safety
Tire pressures
For good car handling and long tire ser-
vice life, it is important to maintain re-
commended tire pressures. Tires which
are inflated above or below specifications
can cause increased tire wear, increased
gas consumption and affect the road
holding of the car.
VW-recommended cold tire inflation
pressures are listed on a sticker on the
lock pillar of the right door.
In the interest of safety, check the tire
pressure of all tires, including the spare
tire. at least once a week, and always be-
fare going on a long trip.
For road use do not exceed the maximum
tire inflation pressure listed on the tire
side wall.
Spare tire pressure
Since the spare tire supplies the pres-
sure to operate the windshield washer,
the pressure of the spare tire should be
between 29—42 psi (2.0—3.0 kg/cm?).
This pressure level is only to be main-
tained for the operation of the windshield
washer system,
For road use, the pressure in the spare
tire should be adjusted as specified on
the sticker on the lock pillar of the right
door. See also next page.
Tire rotation
If eneven tire wear should occur, we re-
commend that the tires be rotated as
shown in the sketch below. Afterwards,
the tire pressure must be corrected. The
wheel bolts should be torqued diagonally
to 94 ft. Ibs. (13 mkg). Also see page 32.
an. +
Wheel balancing
A wheel should always be balanced after
a tire repair. Also, since regular use can
cause tire imbalance, the wheeis should
be balanced from time to time. Unbatan-
ced wheels may affect car handiing and
tire life.
Tire wear
The original equipment tires on your VW
have built-in tread wear indicators. They
are molded into the bottom of the tread
grooves and will appear as approximately
1» inch bands when the tire tread depth
becomes 1/1 of an inch. When the indi-
cators appear in two or more adjacent
grooves, it is time to replace the tires.
We recommend, however, that you do not
let the tires wear down to this extent
Worn tires cannat grip the road surface
properly, and are even less effective on
wet roads.
Indicator visible — tread worn
If you notice that tires are wearing
unevenly, consult your Authorized VW
Dealer. Uneven wear may not always be
due to improper wheel alignment. It can
be the result of individual driving habits
such as cornering at high speeds. If the
tire pressure is not checked and adjusted
regularly, abnormal tire wear can also
Do not drive with worn tires or tires
showing cuts or bruises as they may lead
to sudden deflation.
Tire replacement
In the interest of maximum safety and best
all-around car handling, always buy re-
placement tires that show the same spe-
cifications with regard to tire size, design,
load carrying capacity, tread pattern, etc.
This also applies to VW-recommended
alternate replacement tires.
Tire specifications are imprinted on the
sidewall of the tires. If in doubt, check
with your Authorized VW Dealer.
Replace all 4 tires at the same time. If this
is not possible, replace tires in pairs,
either front or rear.
New tires do not possess maximum trac-
tion. They tend to be slippery. Break new
tires in by driving at moderate speed for
the first 60—100 miles.
Winter tires
Winter tires give good traction in snow or
For a better grip on hard snow or ice, you
can use winter tires with studs, but check
with your local Motor Vehicle Bureau for
possible restrictions. Winter tires with
studs should be run at moderate speed
when new to give the studs time to settle.
Winter tires should preferably be mount-
ed on all four wheels. They should also
conform to the same load requirements
as original equipment tires.
Winter tires do not fulfill their purpose if
the tread depth is less than 5/4,” (4 mm).
For safety reasons, it is not advisable to
drive with winter tires at top speeds.
Winter tires do not have the same degree
of traction on dry, wet or snow-free roads
as regular tires.
Inflation pressures for winter tires are
listed on the sticker on the lock pillar of
the right door. Do not exceed the maxi-
mum tire inflation pressure listed on the
tire side wall.
The driving direction should be clearly
marked on all tires before removing them
for storage: This is to make sure that they
are mounted and run in the same direction
as before.
Tire care
1 - Frequently check tires for damage.
Remove imbedded material.
2 - Keep oil and gasoline away from tires.
3 - Replace worn tires in time.
4 - Replace missing valve dust caps as
soon as possible.
Spare wheel
The spare wheel is under the front hood.
To unlock the hood, pull the lever inside
the glove compartment. See page 14,
The spare wheel is connected to the
windshield washer container and supplies
the pressure to operate the washer. The
air supply to the windshield washer will
be interrupted automatically by a cut-off
valve if the tire pressure drops to 26 psi
(1.8 kg/cm?). This prevents the spare tire
from being deflated below the required
Check the tire pressure from time to time
and maintain it up to a maximum of 42 psi
(3.0 kg/cm”). This pressure level is only
required for the operation of the wind-
shield washer system. For road use, ad-
just the spare tire pressure as specified
on the sticker on the lock pillar of the right
a с
To check or correct the pressure, first
disconnect the windshield washer hose
from the valve of the spare tire (arrow).
Reconnect the hose to the valve after in-
flating or checking.
The jack is only to be used for changing
a wheel. Do not use it as a support to
work underneath the car.
The jack is located under the rear luggage
panel. It is held in stowage position by a
clamp. To take out the jack, lift the clamp.
Before putting the jack back in again,
wind it down sufficiently. Tighten the
Changing a wheel
If you have a flat tire, move off the road.
Turn on the emergency flasher. In addition,
mark the position of your car with flares
or other warning devices to alert other
Before you change a wheel, be sure the
ground is level and firm, especially near
the rear wheels where the jack ports are.
Set the parking brake and block the
wheels opposite the defective wheel on
the other side of the car.
For a more efficient and safe changing
of a flat tire, observe the following 10
Further on, we expand on these steps in
greater detail.
Step 1 - Take out tools, jack and spare
Step 2 - Remove hub cap.
3 - Loosen wheel bolts. Do not
take them out.
4 - Securely insert the jack in jack
port. There is one for each side.
It is under the body toward the
rear, and is used for front or
rear wheel changing.
Never jack the car up by the bumper or
the body.
5 - Jack up car.
6 - Change wheel and handtighten
wheel bolts.
Step 7 - Lower car.
Step 8 - Further tighten the wheel boits.
Step 9 - Replace hub cap.
Step 10 - Torgue and air pressure adjust-
Step |
Take out your tool kit.
Take out the jack from under the rear
luggage panel. Lift the clamp that is hoid-
ing the jack in stowage position.
Before you take out the spare wheel, dis-
connect the hose leading to the wind-
shield washer container.
Step 2
With the wheels still firmly resting on the
ground, remove the hub cap of the defec-
tive wheel.
Insert the puller in the holes at the rim of
the hub cap. Put the breaker bar through
the puller, brace one end of the bar on the
wheel rim and tug lightly on the other end.
When you place the hub cap face down
you can use it as a tray for your wheel
Step 3
Loosen all wheel bolts counterclockwise
about one turn with the socket wrench.
Insert the breaker bar to make full use of
its leverage. Do not yet remove the bolts.
Step 4
Securely insert the jack into the jack port.
There is one on each side under the body
toward the rear and is used for front and
rear wheel changing. Never jack the car
up by the bumper or body.
Provide for a firm base for the jack on
the ground. If necessary, use a board.
Passengers should not remain in the car
when the car is jacked up.
otep 5
Do not raise the car until you are sure the
jack is securely engaged.
To raise the car, turn the handle clock-
to lower
To get the jack as vertical as possible,
push the upper part of the jack toward the
body while you are jacking up the car.
Only raise the car as much as is needed
to change a wheel.
Step 6
Fully unscrew the wheel bolts and place
them into the hub cap. Place the spare
wheel against the wheel hub so that the
boit holes in the wheel are in line with the
threaded holes in the wheel hub. Insert
the wheel bolts and handtighten them
crosswise before jacking the car down.
Step 7
To lower the car, turn the handle counter-
Step 8
Then go crosswise from one bolt to
another tightening them firmly with the
socket wrench and breaker bar
Step 9
To install the hub cap, place it around the
lower part of the wheel center, and with
a firm push on the upper part, the hub cap
will snap into place. Make sure it is
properly seated.
Step 10
Correct tightness of the wheel bolts is
Correctly tightened bolts should have a
torque of 94 ft. Ibs. (13 mka). This torque
can be obtained with socket wrench and
breaker bar by any person of average
strength. If in doubt about the correct
tightness of the wheel bolts, have it
checked with a torque wrench by your
dealer or a service station.
Also, correct the pressure of the tire you
have just put on.
Container for windshield washer fluid (1)
The windshield washer container has a
capacity of 1.8 US quarts. (1.5 Imp.
quarts./1.7 liters). To add washer fluid,
just unscrew the filler cap. The container
can be filled to the top.
As clear water is usually not adequate for
cleaning the windshield, add a cleaning
solution to the water such as Volks-
wagen's Windshield Washer Anti-Freeze
& Solvent. It is a concentrate, so follow
the directions on the can for the correct
amount to be used.
You can use Volkswagen's Windshield
Washer Anti-Freeze & Solvent all year.
It helps to keep your windshield clean,
and prevents freezing of the washer fluid
in the winter.
Since the spare tire supplies the pressure
to operate the washer, it should always
be kept up to a pressure of 42 psi (3.0 kg/
cm*). To pressurize the spare tire, see
page 29.
Brake fluid reservoir (2)
The brake fluid should always be above
the seam edge near the top of the reser-
voir. If it drops below this point, the cause
should be corrected by your Authorized
Volkswagen Dealer.
Every 2 years, the brake fluid has to be
See "Scheduled Maintenance’ on page
D 7 and “Additional Services Record" on
page D 11,
Only new, unused brake fluid that meets
the SAE recommendation J 1703 and con-
forms to Motor Vehicle Safety Standard
116 must be used.
The 12-point fuse box with plug-in arrange-
ment for relays is located under the in-
strument panel on the right of the steering
When a fuse is blown, it is not sufficient
to merely replace it. The cause of the
short circuit or overload must be found.
On no account should fuses be patched
up with tin foil or wire as this may cause
serious damage elsewhere in the electri-
cal circuit. It is advisable to always carry
a few spare Bamp. and 16 amp. fuses in
your car,
To replace a fuse, simply depress a con-
tact on either side of the fuse.
There are ten 8 amp. fuses (white) and
two 16 amp. fuses (red). No. 9 and No. 10
are the two 16 amp. fuses.
To replace a fuse in an inline fuse holder,
pull the holder out of the clip, where
necessary. To open the holder, grasp both
ends of the holder, press lightly together
and twist counterclockwise. Install fuse.
To close the holder, put both ends to-
gether again. press lightly and twist
1 - Parking and side marker lights,
Tail light left
2 - Tall light right
License plate lights
3 - Low beam left
4 - Low beam right
5- High beam left,
High beam indicator light
6 - High beam right
7 - Accessories
8 - Emergency flasher
9 - Safety belt interlock system,
Interior light
10 - Windshield wipers,
Rear window defogger
(switch current)
11 - Safety belt interlock system, Horn,
Stop lights, Automatic Stick Shift
control valve *
and ATF warning light* *
12 - Warning lights for turn signals,
oil pressure and alternator,
Fuel gauge. Turn signals,
Brake and safety belt warning light |
* If thie fuse is defective; the transmission cannot be
** Trailer hauling only
6 7 8 9 10 il 12
EA ES EL | ë
Additional fuses *— 3 Bomp. «=== 1ботр.
Electrical equipment Fuse Location of fuse holder
Back-up lights B amp. on a support (A) in the engine compart-
ment near the ignition coil
Hear window defogger 8 amp. on a support (B) in the engine compart-
(main current) ment near the ignition coil
Auxiliary heater 16 amp. in the front luggage compartment near the
(optional equipment)
Fuel supply
In the interest of cleaner air, the VW
engine is designed to run also on low-
lead or lead-free gasoline.
The engine requires “Regular” gasoline.
The minimum octane rating is shown on
the label on the inside of the fuel tank
flap. If regular fuels with adequate anti-
knock qualities are not available, premium
fuels should be used or mixed with regu-
lar fuel. This might be necessary when
traveling outside the United States or
Canada if regular gasolines have a lower
octane rating than recommended by the
The Auxiliary Heater (optional equipment)
must be turned off when filling the fuel
Never start or let the engine run in an
enclosed unventilated area. Exhaust
fumes from the engine contain carbon
monoxide whichis colorless and odorless.
Carbon monoxide, however, is a very
harmful gas, and can be fatal if inhaled.
The filler neck to the fuel tank is located
behind a flap above the right front fender,
The flap opens if you pull the release on
the right underneath the instrument panel
The fuel tank has a capacity of 10.6 US
gallons (40 liters or 8.8 Imp. gal).
When putting the cap back on. turn the
threaded filler cap until you hear a click.
The battery is secured to the floor plate
of the engine compartment.
The electrical system depends mainly on
the battery. Therefore, the battery should
be checked regularly and kept in good
working condition,
Never drive the car with a disconnected
battery as this may damage the electrical
Do not expose the battery to an open
flame or electric spark. Hydrogen gas
generated by the battery is explosive. Do
not let battery acid come in contact with
skin, eyes, fabric, or painted surfaces.
Each filler plug has to be unscrewed to
check the fluid level in each cell. If it is
below the indicator, top it up with distilled
water. Only fill up to indicator, otherwise
the electrolyte will overflow when the
battery is being charged and cause da-
How often water must be added to the
battery depends mainly on operating con-
ditions and on the time of year. As a gene-
ral rule, the battery electrolyte level must
be checked more often in the summer
than in the winter, and more often when
driving long distances.
The terminals and connections should be
kept clean and greased with silicone
spray or petroleum jelly. Make sure the
ground connection to the body is tight
and free of corrosion.
When working on the battery, be sure not
to short circuit the terminals. This would
cause the battery to heat up very quickly,
which could lead to damage.
Before having a quick-charge performed
on a battery installed in a car, disconnect
both terminals to avoid serious damage
to the electronic components of the elec-
trical equipment.
If you have not used your car for an ex-
tended period of time, have the battery
SZ E ———] e_——
Ente nn
Cleaning your VW
The paint on your VW is very durable,
and so is the upholstery. But a car can
get a lot of abuse from industrial fumes
and corrosive road salt to half-eaten
lollipops and muddy dog feet.
A well-cared-for VW can look like new 10
years later. It all depends on the owner
and the amount of care he is willing to
give to his car.
Here are a few hints on how to keep your
VW looking young and beautiful. We have
also compiled a list of cleaning products.
They are available at any VW Dealer.
Whenever using VW-recommended pro-
ducts or other cleaning agents, follow the
directions on the containers. Be aware of
warning or caution labels.
Washing your VW
The longer the dirt is left on the paint, the
greater the risk of damaging the glossy
finish, either by scratching if the dirt is
rubbed into the paint, or simply by the
chemical effect dirt particles have on the
paint surface.
Therefore dirt should be washed off as
soon as possible. NEVER WASH IN
Use plenty of water, a car-wash soap,
such as VW's Car Wash and Wax, and a
soft sponge or hose brush, Begin by
Volkswagen Product
Car wash and liquid wax
Paint preservative
Paint waxing
Paint polishing and paint waxing
Paint polishing, remove paint oxidation
Preservation of chrome parts
Paint touch-up
Convertible top cleaning,
Upholstery cleaning,
Whitewall tire cleaning
Windshield cleaning and washer
Car Wash and Wax — ZVW 243 201
Paint Preservative and Wax — 000096011
Classic Car Wax — ZVW 246 101
Combination Car Cleaner and Wax —
ZVW 241 108
Paint Polish — 000 096 001
Chrome Preservative — 000 096 067
Touch-Up Paint (all colors)
All Purpose Cleaner — ZVW 243101
Windshield Washer Anti-Freeze
& Solvent — ZVW 241101
spraying water over the dry car to re-
move all loose dirt before applying the
lukewarm soap/water solution.
Use plenty of water to rinse the car off.
Wipe the car dry with a chamois to avoid
water spots.
Waxing is not really needed when you
have washed your car with VW's Car
Wash and Wax. If you do not use a car
wash liquid with wax, apply Paint Preser-
vative and Wax to preserve the natural
shine of the car.
To obtain a long lasting wax finish apply -
hard wax, such as VW's Classic Car Wax,
eight to ten weeks after buying the car.
Wax again when water remains on the
surface in large patches instead of form-
ing beads and rolling off.
Use a polish such as VW's Paint Polish
later in the cars life when the paint
appears dull and loses its shine. Do not
polish the new car.
Always apply wax after polishing.
Cleaning windows
Clean windows with a sponge and warm
water. Dry with a chamois.
To seal properly, weatherstrips around
windows and doors must be pliable. To
retain flexibility of the rubber, spray with
silicone, available from your VW Dealer,
or coat with talcum powder.
Windshield wiper blades
Remove the wiper blades periodically
and scrub with a hard bristle brush and
alcohol or a strong detergent solution.
Chrome care
To protect the car's chrome, apply VW's
Chrome Preservative,
Touch-up paint
Your dealer has touch-up paint for minor
scratches and stone chips. Scratches
should be touched up soon after they
Care of chassis
The underside of the car picks up dirt and
salt and should be sprayed with a power-
ful jet of water. This is easier to do after
the car has been driven in rain.
Removing spots
Do not use gasoline, kerosene, naphtha,
nail polish remover or other volatile
cleaning fluids. They may be toxic or
flammable or hazardous in other ways.
Only use spot removing fluids in weil
ventilated areas. Keep them out of reach
of children.
Do not allow tar to remain on the paint
finish. Remove it as soon as possible with
a cloth soaked with a special paintcleaner,
such as Paint Preservative and Wax. If
you do not have a spot remover, you may
substitute with turpentine. After applying
a cleaning fluid, always wash with a luke-
warm soap/water solution and apply a
new wax coat.
Remove as soon as possible with a luke-
warm soap/water solution or apply insect
Tree sap
Remove with a lukewarm soap/water
solution. Do not allow tree sap to harden
on the paint surface.
Cloth upholstery and carpet
Clean with a vacuum cleaner or a hard
bristle brush. Dirt spots can usually be
removed with a lukewarm soap/water
Use spot remover for grease and oil
spots. Do not pour the liquid on the cloth
material. Dampen a clean cloth and rub
carefully, starting at the edge and work-
ing inward.
Leatherette and interior trim
Use VW's All Purpose Cleaner or a dry
foam cleaner.
Grease or paint spots can be removed by
wiping with a cloth soaked with VW's All
Purpose Cleaner. Leatherette parts of the
headliner and side trim panels can be
cleaned with a soft cloth or brush and All
Purpose Cleaner.
Cleaning the convertible top
The top does not require any special care.
Wash off dirt as soon as possible. Do not
wash in direct sunlight. Use lukewarm
water together with VW's All Purpose
Cleaner. A hard bristle brush will help to
loosen dirt from the grained surface of
the material. Avoid scratching the body of
the car with the bristles.
BEET = ee
To remove spots, use a stronger solution
of VW's All Purpose Cleaner. Never use
paint thinner, nail polish remover or simi-
lar agents as they may have adverse
effects on the top material.
After cleaning and washing the top, rinse
the car well with clear water
Clean the pivoted points of the top linkage
from time to time, and lubricate them
lightly with a few drops of oil. Wipe off
excessive oil to prevent oil from dripping
on the top material.
Bulb chart
Replacing bulbs
Your Volkswagen ls equipped with double
filament seven Inch sealed beam units
Should it become necessary to replace a
unit, loosen screw in the center of the trim
ring below the headlight and take off the
trim ring
Firmly grasp the loose screw (non-remov-
able) and pull trim ring off
U.S. Replace- VW
ment bulbs Part No.
Sealed beam (headlights) . 6014 ZVP 118114
Front turn signals / parking lights ............... 1034 Z\NP 118034
Side marker lights 57 ZPP 118057
Rear turn signals 1073 ZVP 118073
Stop/tall Note... .... .-<.02=1e-i-6 delo. чоо 1034 ZVP 118034
Back-up lights 1073 ZVP 118073
License plate lights ..... 67 ZVP 118067
Instrument and warning lights ... ADO == N 177512
Spot light for heater levers .................... — N 177512
nemove three short screws (a) in sealed
beam retaining ring and take ring off.
Do not alter the position of the long head-
light adjustment screws (b).
[Positions (a) and (b) see lower picture
on page 38.]
Take sealed beam unit out of support ring
and pull cable connector off.
When installing new sealed beam units,
be sure the three glass lugs engage
properly in the support ring.
Before installing trim ring be sure the
rubber gasket is in place. Loosely insert
the screw for the trim ring and turn for
2 or 3 turns.
Position edge of trim ring over upper lug
Press ring over lug and tighten screw.
If no other headlight part as described
here was removed or its position changed,
it should not be necessary to aim the
headlights. If in doubt have the adjust-
ment checked at your dealer.
Front turn signal/parking light bulb
or side marker light bulb
Remove two Phillips screws.
Take off lens.
Gently press bulb into holder, turn and
take out.
Install new bulb.
Be sure the gasket is properly positioned
when reinstalling the lens.
Tighten screws evenly. Do notovertighten
as this may crack the lens.
Rear turn signal, stop/tail light
or back-up light bulb
Unscrew two Phillips screws and remove
Bulb positions:
Top — turn signal light
Center — stop/tail light
Bottom — back-up light
Gently press bulb into holder, turn and
take out.
Install new bulb.
| he
When inserting the stop/tail light bulb, the
retaining pin nearest to the bulb glass
must be downward.
Be sure the gasket is properly positioned
when reinstalling the lens. Tighten screws
evenly. Do not overtighten as this may
crack the lens.
License plate light bulb
Open rear hood.
Remove screws on each side of lens and
take off lens.
Gently press bulb into holder, turn and
take out.
Install new bulb
When installing, make sure the gasket
fits properly.
Interior light bulb
Insert screwdriver in lens cut-out (arrow)
on the upper side of the lens and carefully
pry out.
Take bulb out.
Install new bulb.
Insert lens at bottom first, then press
it in until it engages.
General services
Before working on any part in the engine
compartment, turn off the engine and let
it cool down sufficiently. If work has to be
done with the engine running, exercise
extreme caution to prevent neckties,
jewelry or long hair from getting caught
in the V-belt.
Incomplete or improper servicing may
cause problems in the operation of the
car. If in doubt about any servicing, have
it done by your Authorized VW Dealer or
any other properly equipped and qualified
Adjusting or replacing
Turn the engine off!
To adjust the belt, remove the rear half of
the pulley on the alternator. When
loosening and tightening the nut, place
a screwdriver through the cut-out in the
front half of pulley and support the screw-
driver as shown in the left picture on the
next page.
To adjust the belt, remove the rear half of
the pulley on the generator. When loosen-
ing and tightening the nut, place a screw-
driver through the cut-out in the front half
of pulley and support the screwdriver at
the generator housing.
Ihe V-belt must not be too tight or too
loose when you are making the following
belt tension check: Depress one side of
the belt at-the center between the two
pulleys. The tension is correct if the belt
can be depressed between 0.43 (7/,,) in.
or 11 mm and 0.55 (?/,;) in. or 14 mm at a
pressure of 16.5 lbs. or 7.5kg (a firm
press with your thumb). This is only a
temporary adjustment. Have final adjust-
ment made by your dealer.
A new belt may stretch slightly at first. To
compensate for this, the belt should be
tightened slightly more when first in-
stalled. The deflection should be between
0.35 ('/,) in. or 9 mm and 0.43 (7/,)) in.
or 11mm at the same pressure. The
correct belt tension will then be reached
after about 30 minutes of operation.
The heavy-duty V-belt has a very low
stretch factor. When properly installed,
the belt tension will remain fairly constant.
Volkswagen-recommended V-belts have
a relatively long service life, however, it
is good planning to always carry a spare
belt in your car.
For the correct designation on the belt,
see page 56.
or replacing spark plugs
The correct spark plug gap is 0.028 inch.
or 0.7 mm. Since the spark plug gap tends
to increase in time during normal
operation, it is advisable to replace spark
plugs periodically (see Maintenance
Removing spark plugs
Turn the engine off!
Grasp the spark plug connector and pull
it off. Do not pull on the ignition wires as
they may separate from the connectors.
Unscrew the spark plugs with a suitable
spark plug wrench.
Cleaning spark plugs
Dirty spark plugs should be cleaned with
a sand blaster, but if not available, the
carbon can be removed with a wooden or
plastic pick. Do not use a wire brush. The
plugs should also be clean and dry on
the outside to avoid shorting and arcing.
The gap can be set by bending the out-
side electrode. The gap should be
0.024 inch. or 0.6 mm.
Installing spark plugs
Insert them by hand and screw them into
the cylinder head as far as they will go
Only then use the spark plug wrench to
tighten them firmly. Do not overtighten
1.024 inch. or 0.6 mm
N nn — EEE
the engine oil level
You should check the oil level from time
to time. To get a true reading, be certain
the car is on level ground.
Wait at least 5 minutes after the engine
has been stopped; give the oil time to
collect in the crankcase.
To check the oil level, take the dipstick
out and wipe it clean first. Now, insert
and pull it out again. You have enough oil
in the engine if the oil level is between the
upper and lower marks on the dipstick.
Only add the amount of oil that is needed.
Always select a well-known brand and the
recommended grade. Details about the
correct oil viscosities are on page 46.
Changing the engine oil
Engine off!
Change the oil in your engine regularly
(see Maintenance Schedule). This is very
important as the lubricating properties of
oil diminish gradually during normal
operation of the car.
Drain the oil when the engine is still warm.
Loosen all six cap nuts. Then, after remov-
ing five of the nuts, pry the oll strainer
cover loose. Allow the oil to drain.
After the oil is drained, remove the oil
strainer to clean it. The cleaning of the
strainer should be done with every oil
change. Use new gaskets and copper
washers when re-installing the strainer
to be sure no oil leak will develop later.
Tighten cap nuts in a crosswise pattern
to a torque of 5 ft.ibs. (0.7 mka).
Fill the engine with 2.6 US quarts (2.2 Imp.
quarts/or 2.5 liters) of oil labeled "For
Service SD" or "SE" (or combination).
For the right oil viscosity, se€ page 46.
Because of detergent additives in the oil
the fresh oil will look dark after the engine
has been running for a short time. This is
to be expected, and there is no reason to
change the oil at intervals shorter than
recommended by the manufacturer.
We recommend more frequent oil changes
(every 1,500 miles) if you drive your car
only short distances during the winter
months. If you drive for only a few
hundred miles a month under these con-
ditions, we advise you change the oil
every 6 to 8 weeks. In areas with arctic
climate where average temperatures are
below —13° F, the oil should be changed
every 750 miles.
Both transmission and final drive are
combined in one housing. The lubricant
used is hypoid oil that is changed by your
dealer only one time at 600 miles as part
of the lubrication service. See page D3.
Should the need arise to add oil, it should
only be done with the necessary work-
shop equipment. Also hypoid oil is gene-
rally not marketed in small quantities.
Automatic Transmission
On vehicles with Automatic Stick Shift,
the ATF in the torque converter does not
have to be changed, but the level should
be checked at specified intervals (see
Maintenance Schedule) with the engine
turned off.
An ATF tank filler with a dipstick attached
to its cover is provided for this purpose
on the right side in the engine compart-
Wipe the dipstick clean first before in-
serting it to take a level reading. The fluid
level should be between the two marks
on the dipstick, and should never fall
below the lower mark. Only add the re-
quired amount of ATF. Check for leaks.
For ATF specifications, see page 47.
Air cleaner
All the dust present in the air drawn in by
the engine is retained by the filter element
in the air cleaner
A dirty filter element not only reduces the
engine output, it can also cause prema-
ture engine wear. If local conditions are
such that the vehicle is often driven on
very dusty roads, the cleaner must be
serviced frequently, even daily if neces-
Under normal conditions it is not neces-
sary to service the filter element more
frequently than is mentioned in the Main-
tenance Schedule.
To check the filter element, the air cleaner
mist be removed. Here is what to do:
Loosen clamp —A— and take intake elbow
Loosen clamp —B— and pull hose off.
For easier reinstallation note the hose
attachments; interchanging of hoses af-
fects the operation of the engine.
Pull off hoses C through E.
Release the two clips —F— and take
cleaner off the bracket. Keep air cleaner
upright to avoid spilling oil. Release the
three clips —G— and take top part of air
cleaner off. The top part must be put down
with the filter element downward
When there is only ¥/,, in. of oil above the
sludge layer in the bottom of the lower air
cleaner part, it must be cleaned and filled
with fresh oil:
Clean bottom of lower part of air cleaner
Fill cleaner to the mark with 0.48 U.S.
quarts (0.40 Imp. quarts/0.45 liter) of fresh
engine oil. SAE 30 oil should be used all
the year except in areas with artic climate
where SAE 10W oil should be used all
The top part does not normally need
cleaning. If the bottom part or the filter
element has become so’ dirty that the: air
inlet holes on the underside are partly
blocked, the encrusted dirt should be
scraped off with a wooden or plastic
Check that the weighted cantrol flap —H—
for the crankcase ventilation is always
free to move.
After assembling the cleaner, secure it
to the bracket in the engine compartment
with the two clips —F—.
Tighten intake elbow clamp —A— care-
fully. Make sure all hoses are properly
Front axle
Lubricate the front axle once a year or
at the specified mileage intervals (see
Maintenance Schedule).
LEN a.
#/ | \\\
Lift the front end of the car to take the
weight off the front wheels. This is neces-
sary to free the bearings to accept the
lubricant. There are 4 grease fittings for
the front axle. For their location, see
arrows in the illustration
Before forcing grease into the fittings, be
sure to wipe them clean with a piece of
cloth. Force lithium-based multi-purpose
grease into the fittings until fresh grease
starts to emerge at the torsion arm seal-
ing rings.
Wipe off any grease or oil that may have
come in contact with tires or brake hoses
because grease and oil have an adverse
effect on rubber.
Door hinges and locks
The door hinges should be lubricated
at specified intervals (see Maintenance
Schedule) by putting a few drops of en-
gine oil into the small oil chamber above
each door hinge pin. The oil chamber is
accessible after lifting the top plastic plug
(arrow). After oiling, reinstall the plug and
wipe off excess oil.
The door locks should also be lubricated
with a few drops of engine oil.
The hood locks and the sliding surfaces
of the striker plates should be lubricated
with dry stick lubricant.
Lubricate the door lock cylinders with
graphite. Dip the key into graphite and
turn it in the lock a few times.
EE ———— ll A —l<—]> — [e]. TTT—o—]oom
Engine oil
Always use a name brand oil labeled "For Service SD" or "SE" (or combination) for
the engine of your Volkswagen.
Engine oils are graded according to their viscosity. The proper grade to be used in
your engine depends on existing climatic or seasonal conditions.
The following table contains the grading for oils to be used in VW engines:
Hot season SAE 40 Temperature ranges of SAE grades
Tropical climate
Cool season oc OF |
SAE 30 wo]
ummer EE "100
At average outside te at Dm -
Moderate climate ried Sor © mperasure SAE 20 W-20 TH 30-
Winter At an 5 ; -80
average outside temperatures + ОРУТ
not lower than — 13° F SAE 10 W de 20- |
(EIT -60
(III il
If outside temperatures are continuously below — 13° Е use SAESW™. a
mm | |||
EAE | оч |
* Avoid high speed long distance driving when using SAE 10W or SAESW if outside tempe- — _20
ratures rise above the indicated limits. Е 10-
exe | 1OW 20-
As temperature ranges of the different oll grades overlap, brief variations In outside =p
temperatures are no cause for alarm. It is also permissible to mix oil of different
viscosities if you find it necessary to add oil.
Transmission oil and Automatic Transmission Fluid (ATF)
Transmission and final drive are both lubricated with hypoid oil according to
Mil-L-2105 specifications (additive basis: sulphur-phosphorus):
or In general all year
SAE 80 W/90 у ,
(multi-grade oil)
ATF In areas with arctic climate and temperatures consistently below —13° Е.
ATF is a special fluid for automatic transmissions, but ATF can also be used in the
Manual Transmission under the above mentioned climatic conditions.
The torque converter of the Automatic Stick Shift requires ATF all year.
All ATF's labeled "Dexron®" with a five-digit number preceded by the letter “B" can
be used.
Lubricant additives
If a VW engine is properly maintained, it is uneconomical to mix any type of additive
with fuel, or lubricating oils and transmission fluids.
I - Multi-purpose greasé with a lithium base should be used for the front axle.
2 - Dry stick lubricant should be used for the hood locks and the sliding surfaces of
the striker plates.
3 - Silicone spray or petroleum jelly should be used for the battery terminals and posts.
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Probable Cause
What To Do
VW will not start:
engine turns over
8. If spark is present at black coil
cable, trouble is in ignition
9. If spark is fairly good at plugs,
trouble is most likely in fuel
A. Caused by improper start-
ing procedure. If the gas
pedal is depressed too
often, the accelerator pump
in the carburator injects too
much gasoline
8. Check in this sequence:
A. Turn ignition off. Remove distributor cap and rotor. Clean distributor con-
tacts with stiff paper (post card). Have someone turn engine over with starter.
Sparks should be visible between contacts.
If no spark, check contact of cable connectors between coil and distributor
cap. Check if contacts open. If there is still no spark, see your nearest
Authorized VW Dealer.
B. If sparks are visible between contacts disconnect high tension cable from
center connection of distributor cap. With starter cranking the engine point
cable to a metal object in the engine leaving a gap of approximately '/”.
Strong arcing sparks should appear. If there are no sparks, contact your
nearest Authorized VW Dealer.
C. If sparks appear at high tension cable, the distributor cap should be cleaned
inside and out. Reconnect high tension cable. Remove all spark plugs. If
plugs are clean and dry, reconnect ignition cables to spark plugs and bring
spark plugs into contact with metal (ground). Hold cable with dry piece of
cloth to avoid shock. Sparks should appear between spark plug electrodes
when the engine is turned over. If not, clean and dry ignition cables and
spark plug connectors and check that ignition cables are tight in distributor
cap and plug connectors. Ask for assistance if the above steps did not
ensure proper ignition.
D. Dirty or wet spark plugs should be cleaned and dried. Install new plugs if
necessary. Unburned gasoline on plug electrodes indicates excessive fuel
9. Check fuel system in the following sequence:
A. Depress gas pedal completely and operate starter for a prolonged period.
If engine does not start, remove "and dry spark plugs, turn over engine with
plugs removed for approximately 30 seconds. Reinstall plugs and start
EE —————————————————
Probable Cause
What To Do
VW will not start:
engine turns over
B. Carburetor may be flooded,
float or needle valve may
be sticking
B. Tap around outside of carburetor with wooden or plastic tool handle. Wait
a few minutes and try starting again as described at 9 À.
Engine stalls shortly | 10. Poor fuel supply 10. See paragraph 13 through 15.
after starting
11. Automatic choke does not 11. Check whether ckoke valve is in vertical position after ignition has been
open, excessive fuel supply switched on for 2—5 minutes (depending on outside temperatures). Cover for
choke unit must be hot. If choke valve is binding in à closed position, open at
fast idle cam and if necessary, retain with wire. See your Authorized VW Dealer.
Engine stalls while 12. Defect in ignition system 12. See paragraph 6 through 8.
vehicle is driven
13. Fuel supply is exhausted 13. Check whether any gasoline is left in tank.
14. Fuel pump filter may be 14. After removing the upper part of the pump, the fuel filter can be taken out for
clogged cleaning.
15. Gasoline may be contaminated 15. See your VW dealer for cleaning of all components of the fuel system L
by water, dust or dirt
Red warning light for on. the oil pres- 16. Stop at once and check oil level. Add oil as necessary. If the oil level is
oll pressure pa 5 ils Bo ow ° sufficient and light goes on during driving, contact the nearest Authorized VW
cn while vou are Dealer before driving on,
driving 17. Fuse 12 in the fuse box (see 17. Replace fuse. If it blows again, do not drive on, because the turn signals will
page 34) may be blown not work, Ask for assistance.
Red warning light for | 18. If light goes on, V belt may be 18. If belt drives alternator without slipping, switch off all unnecessary electrical
alternator and cool- broken or alternator does not equipment (radio, etc.). Drive to nearest VW dealer as otherwise the battery
ing comes on while charge will soon run down. If belt is broken, replace it before driving on, because
you are driving engine cooling fan is no longer working.
Vehicles with Auto- 19. Control valve fuse burned out | 19. Replace fuse 11 (see page 34), Check cable connections on control valve
matic Stick Shift:
Lever cannot be
located on the left in the engine compartment.
Engine with Manual Transmission
Owner Relations
There are more than 1500 authorized Volkswagen dealers in
North and Central America. Their addresses and telephone
numbers are listed in a booklet which is available at your VW
Any one of these dealers is well equipped to help you with
virtually all VW-related matters; and your dealer should be
your primary source.
Should there be an occasion where you need further assi-
stance, you may want to contact the Volkswagen regional office
in your area. We have listed their addresses and telephone
numbers on the next page.
Should you feel that you require assistance beyond that offered
by your dealer, distributor or regional office, you may want to
contact in the U.S.A. Volkswagen of America, Inc., Englewood
Cliffs, New Jersey 07632. In Canada contact Volkswagen
Canada Ltd., Golden Mile, Toronto 375, Ontario M1L2M2.
However, remember that ultimately your questions will be
resolved in the dealership with dealer personnel and dealer
equipment. We therefore suggest you contact your dealer first.
Authorized Volkswagen Distributors
and Regional Offices in the U.S.
New Hampshire
Rhode Island
North Dakota
South Dakota
Tennessee (West)
Volkswagen of America, Inc
Northeastern Region
Volkswagen Customer Relations
100 Fordham Road
Wilmington, Massachusetts 01887
(617) 658-6700
Volkswagen of America, Inc.
North Central Region
Volkswagen Customer Relations
3737 Lake Cook Hoad
Deerfield, Illinois 60015
(312) 272-5500
Midvo, Incorporated
Volkswagen Customer Relätions
5000 Post Road
Dublin, Ohio 43017
(614) 889-2911
Import Motors Ltd., Inc
Volkswagen Customer Relations
P.O. Box 2008
2660 28th Street, S.E.
Grand Rapids, Michigan 49501
(616) 949-7788
volkswagen Atlantic, Inc
Volkswagen Customer Relations
P.O. Box B30
1001 South Trooper Road
Valley Forge, Pennsylvania 19482
(215) 666-7500
International Auto Sales & Service, Inc.
Volkswagen Customer Relations
P.O. Box 29127 Michoud Station
4200 Michoud Boulevard
New Orleans, Louisiana 70129
(504) 254-1500
New York
Mew lersey
North Carolina
South Carolina
Tennessee (East)
West Virginia
Washington, D. C.
New Mexico
Authorized Volkswagen Zone Offices
World-Wide Volkswagen Cooperation
Volkswagen Customer Relations
Greenbush Road
Orangeburg, New York 10962
(914) 359-5000
Volkswagen of America, Inc.
Southeastern Region
Volkswagen Customer Relations
9300 George Palmer Highway
Lanham, Maryland 20801
(301) 577-2600
Volkswagen of America, Inc.
Western Region
Volkswagen Customer Relations
11300 Playa Street
Culver City, California 80230
(213) 390-8011
Riviera Motors, Inc.
Volkswagen Customer Relations
P.O. Box 2953
Portland, Oregon 97208
(503) 645-5511
Volkswagen Mid-America, Inc.
Volkswagen Customer Relations
8825 Page Boulevard
St. Louis, Missouri 63114
(314) 429-2141
Volkswagen of America, Inc.
South Central Region
Volkswagen Customer Relations
P.O. Box 2207
San Antonio, Texas 7898
(512) 341-8881
in Canada
Eastern Zone
Central Zone
Western Zone
Volkswagen Canada Ltd.
Volkswagen Customer Relations
3500 Trans Canada Highway
Pointe Claire, Quebec
(514) 697-5930
Volkswagen Canada Ltd.
Volkswagen Customer Relations
18920 Eglinton Ave. East
Scarborough, Ontario MIL 2M2
(416) 750-4700
Volkswagen Canada Ltd.
Volkswagen Customer Relations
8081 Lougheed Highway
Burnaby, B.C. V5A 1X1
(604) 299-9321
EE 2222222220
Technical data
Engine Four cylinder, four stroke, horizontally opposed, in rear.
Air cooling by fan, thermostat-controlled. Pressure oil feed with gear-type pump.
Oil cooler. Mechanical fuel pump.
Downdraft carburetor with automatic choke and accelerator pump.
Air cleaner with load and temperature sensitive intake air pre-heating.
Exhaust emission control system. Activated charcoal filter in the fuel system.
Dore rua ua UA Srs ana 3.36 in. (85.5 mm)
DOG ss TT TT EA 2.72 in. (69 mm)
DE SEE 96.6 cu.in. (1584 ce)
Compression ratio: Re fat
Maximum output SAE net ................. 46hp at 4000 rpm,
Maximum torque SAE net ................. T2.0lb.ft. at 2800 rpm.
Valve clearance with engine cold .......... Intake and exhaust 0.006 in. (0.15 mm)
POS FEDER EEE “Regular” gasoline incl. low-lead or
lead-free fuels *
* The correct fuel octane rating for your VW engine le listed ón a sticker on the inside of the fuel tank flan
Transmissions Manual Transmission
Single plate, dry clutch.
Clutch pedal free play: 3%/1—/4 in. (10—20 mm).
Baulk synchronized four-speed transmission and bevel gear differential in one housing.
Drive shafts with two constant velocity joints per shaft.
Automatic Stick Shift
Hydrodynamic torque converter with three speed synchromesh transmission,
combined with final drive in one housing.
Drive shafts with two constant velocity joints per shaft.
General specifications
Platform frame with tunnel-shaped center member.
Front axle bolted to frame head, engine/transmission unit bolted to frame fork.
Independent wheel suspension: torsion arms at front,
trailing arms and diagonal links at rear.
Torsion bar springing, telescopic shock absorbers, stabilizer at front.
Roller steering (energy absorbing) with maintenance free tierods
and hydraulic steering damper.
Foot-brakes: Hydraulic, dual circuit system with discs at front and drums at rear.
Parking brake: Mechanical, effective on rear wheels.
Wheelbase ............... 94.5 in. (2400 mm)
Turning circle diameter ..... 37 ft. (11.25 m)
Track at front ............. 51.7 in. (1314 mm)
Track at rear .............. 53.0 in. (1348 mm)
Wheels .................. 4'/2 1 X15 safety rim wheels
Tires, tubeless ............ Bias Ply Tires
Tire size and pressures .... Tire size and VW-recommended cold tire inflation pres-
sures are listed on a sticker on the lock pillar of the
right door.
ee eee eee —
Electrical system Voltage ..-= «0... eno 12 volts
Battery <.::.e=cc..e.. 005 45 Ah
Starter e. RA TES 0.7 hp, with Automatic Stick Sh ift 0.8 hp
Alvormato? canny ase mn max. 700 watts
Vebelt Size ..—..:2..—e rezo. a5x 900 LA “DA”, 9.5x 905 LA “DA”,
9.5 x 905 LA "XDA” (“DA” = Low stretch factor)
Ignition distributor ......... with combined vacuum and centrifugal spark advance
Firing order ........-.-.- 1—4—3—2
Ignition timing ............. for correct specifications for your engine, ses label in
engine compartment
Contact breaker gap ....... 0.016 in. (0.4 mm)
Spark plugs .............. Bosch W 145T 1, Bosch W175T1* Bi i ый
Beru 145/14, Beru 175/14 * values from other
Champion L88 A OR es
Plug thread ..............- 14 mm
Electrode gap ............. 0.024 in. (0.6 mm)
* To be used In vehicles driven at high speed for long periods in areas, where the average temperature is
above 77° F.
Dimensions and weights LOREEN oo s swe sass memes pene кое тн AT 165.7 in. (4210 mm)
WII os iis esi me a Fae a iawn a 64.3in. (1634 mm) =
Helght nn lade sedis 52.0in. (1320 mm)
Ground elearance ..............0...0..655m 0000... 59in. ( 150 mm)
Unladen weight (ready for use) ............=.....—- 2094 Ibs. ( 950 kg)
Vehicle capacity weight ** ..........-...e===..—.. 550 Ibs. ( 250 kg)
Gross vehicle weight ........... 2645 Ibs. (1200 kg)
Gross axle weight, front ................e..í-e..- 1102 Ibs. ( 500 kg)
FDO Sas ARA oa E 1565 Ibs. ( 710 kg)
Permissible roof weight *** ..........2-eí-=e.e.e- 110165. ( 50kg)
Permissible trailer weights:
Trailer without brakes ......._.eereresesrvevecoo 882 Ibs. ( 400 kg)
Trailer with brakes ........... uN paa 1433 lbs. ( 650 kg)
Trailer tongue load ..................eeeeve... 55—88 Ibs. (25—40 kg)
** Lass, if an VW Air Conditioner is installed (see page 23)
«+ Applies only to roof rack mounted to rain gutters of the Coupe. Distribute load evenly |
Capacities CUENTAN emma DEA 10.6 U.S. gal. (40 liters; 8.8 Imp. gal.)
CRAGIN: acres agian 2.6 U.S. quarts of engine oil (25 liters; 2.2 Imp. quarts)
and final drive .......... 3.2 U.S. quarts of hypoid oil (3 Itters; 2.6 Imp. quarts)
refill with 2.6 U. 8. quarts (2.5 liters; 2.2 Imp. quarts)
On vehicles with Automatic Stick Shift:
Torque converter circuit* approx. 3.8 U.S. quarts ATF (3.6 liters; 3.2 Imp. quarts)
and final drive ........ 3.2 U.S. quarts of hypoid oil (3 liters; 2.6 Imp. quarts)
Oil bath air cleaner ,..... approx. 0.48 U.S. quarts of engine oil (0.45 liter:
0.40 Imp. quarts)
Windshield washer ...... approx. 1.8 U.S. quarts of fluid (1.7 liters; 1.5 Imp. quarts)
operating pressure 42 psi (3 kg/cm?)
* Does not have to be changed
Performance Manual Transmission Automatic Stick Shift
Maximum and cruising
PEGO => RT ANT Ele”: 90 mph 88 mph
Volkswagen offers a quality product. You
can help maintain this quality by having
your car serviced regularly. Your autho-
rized Volkswagen dealers have Volks-
wagen-trained mechanics and the proper
1 workshop equipment for performing all
required maintenance services to help
you maintain your car in top driving con-
À service scnedule that we recommend is
on the following pages. The emission
control maintenance is listed in the
brochure which you received from your
authorized dealer when you bought your
| new Volkswagen.
The Emission Control brochure explains
what emission control is all about, and
what you can do to keep it effective. It
| also contains the Emission Control
System Warranty.
PEEP _m-m-m- m-m -
Authorized VW Dealers use a unique service system
specially developed for the VW.
Lots of service stations say they can repair Volkswagens and
a lot of them really can.
But they cannot offer you VW Computer Analysis.
Instead of giving every VW the same basic maintenance, we
treat each one as an individual.
Specially trained diagnosticians will check your VW directly
using special testing equipment; that means your car gets just
the maintenance it needs. No more, no less.
And you get a test report so you know the exact condition of
your VW,
It tells you a lot about the car you drive
D 1
EE ——————— _———.——]é rfrR
VW Computer Analysis and Maintenance
The VW Computer Analysis and Maintenance Record shows Your VW also needs regular lubrication and maintenance. The
you the mileage intervals at which computer analysis and main- first oil change and maintenance service will be performed at
tenance services should be performed to keep your VW in top 600 miles. There is no extra charge for this service; you only
driving condition. It also tells you which services are provided pay for lubricants. From then on, every 3,000 miles and every
at no extra charge to you, and which are at your expense. 6,000 miles we recommend regular lubrication and main-
tenance, as outlined on the following pages.
VW Computer Analysis establishes the proper amount of
service that your car needs.
At 6,000, 12,000 18,000 and 24,000 miles, the computer ana-
lysis will be performed at no extra charge to you. From then
on, at 6,000-mile intervals, the VW computer analysis 15 atyour Every authorized Volkswagen dealer at home and abroad will
expense. perform all necessary tests and maintenance in accordance
with Volkswagen quality service standards. Your service
adviser will certify on the mileage chart which services have
With each analysis you receive a test report. It will tell you been completed.
everything about your car's “health”. On the basis of this test
report, your service adviser will help you to decide what work
should be done.
Of course, you can obtain a VW computer analysis at any
time — outside the regular schedule — at your authorized VW Regular maintenance services are necessary to keep your
dealer. Especially if you drive less than 6,000 miles a year, we warranty in effect. Should you have occasion to make use of
recommend you have a VW computer analysis performed at your Volkswagen warranty, it is always helpful to have the
least once a year. related service receipts handy.
— »cheduled Maintenance at 600 miles
(includes oil change and emission control maintenance)
The first maintenance service will be performed at 600 miles.
There is no extra charge for the service; you only pay for
1 - Engine: Change oil, clean oil strainer.
2 - Manual Transmission: Change oil, clean magnetic drain
3 - V-belt: Check, adjust if necessary.
4 - Valves: Check and adjust clearance.
5 - Clutch pedal free play: Check and adjust.
6 - Rear axle: Check torque of bolts on constant velocity
7 - Tires and wheels: Check tire pressures, including spare
8 - Brake system: Check for damage and leaks. Check brake
| fluid level, add if necessary. Check brakes: adjust foot
and parking brakes if necessary.
9 - Electrical system: Check operation of all components,
adjust headlights if necessary.
10 - Fuel cap, tank and connections: Check visually.
During road test:
Check efficiency of braking, steering, heating and ventilation
systems. Check overall performance.
After road test:
1 - Engine: Check and adjust idle speed.
2 - Cylinder head covers: Check for leaks.
FL —————— 0
Oil Change Service every 3,000 miles VW Computer Analysis every 6,000 miles
(only applicable operations on your vehicle will be performed)
The engine in the Volkswagen requires líttle oil. But for long
engine life, the oil should be changed every 3,000 miles. This The first four computer analysis at 6,000, 12,000, 18,000 and
oil change is at your expense. It includes: 24.000 miles will be done at no extra charge to you. From then
on, at 6,000 mile intervals the VW computer analysis test is
at your expense.
Engine: Change oil, clean oil strainer.
Engine and clutch:
VW Computer Analysis 1 - V-belt: Check tension and condition.
A physical checkup of your VW is extremely important for 2 - Ignition system: Check with electronic equipment,
determining the amount of additional maintenance your
3-C ression: Check.
vehicle may need for continuing peak performance. ompression: Check
4 - Exhaust system: Check for damage.
Listed on the following pages is the VW Computer Analysis
procedure which applies to your vehicle. 5 - Manual transmission Ч
. | f lay.
Chances are, If you have regularly maintained your vehicle, Clutch: Check pedal iree play
it is In good running condition. 6 - Engine: Check oil level.
The VW Computer Analysis Test Report will be given to you
so you will know the exact condition of your VW. Rear axle and transmission:
It is sôgething you should know. 7 - Drive shafts: Check boots for leaks.
Г) 4
Front axie and steering
8 - Front axle: Check dust seals on ball joints and dust seals
on tie rod ends, check tie rods.
9 - Ball joints: Check play.
10 - Steering: Check play.
11 - Front wheels: Check camber and toe.
Brakes, wheels, tires
12 - Brake system: Check for damage and leaks.
13 - Brake pedal: Check pedal travel.
14 - Parking brake: Check adjustment.
15 - Brake fluid: Check level.
16 - Brake linings or pads: Check thickness.
17 - Tires, including spare wheel: Check for wear and damage,
check and correct pressure.
Electrical system
18 - Cranking system: Check with electronic equipment.
19 - Charging system: Check with electronic equipment.
20 - Check operation of headlights, high beam indicator light,
parking lights, side marker lights, license plate light, emer-
gency flasher, stop lights, tail lights, back-up lights, turn
signals, horn, rear window defogger and brake warning
21 - Headlights: Check adjustment.
22 - Windshield wiper: Check operation.
23 - Windshield washer: Check operation and fluid.
24 - Battery: Check electrolyte level, check voltage under load.
Test Drive
Test drive if computer analysis is not followed by maintenance
or repair. If maintenance or repair follows the computer ana-
lysis, test drive after the job is completed.
1 - Check braking, clutch, steering, heating, ventilation system
and overall performance.
2 - Check interior lights and instrument lights.
3 - Check ignition/steering lock and buzzer alarm.
4 - Check warning lights for alternator and oil pressure.
5 - Automatic Stick Shift: Check ATF level.
Scheduled Maintenance
(includes oil change and emission control maintenance —
at your expense)
After your vehicle receives a VW Computer Analysis, your
Authorized Volkswagen Dealer can perform the VW Main-
The maintenance which should be performed at specified
mileage intervals is shown below.
There may be additional maintenance required which will show
up on the VW Computer Analysis Test Report.
Your VW Service Manager or Service Adviser will explain the
results of the VW Computer Analysis in detail.
This will help keep a small maintenance problem from growing
into a big maintenance problem.
So that your VW will keep running like a VW.
Every 6,000 miles — at your expense
| - Engine: Change oil, clean oil strainer.
2 - Valves: Check and adjust clearance.
3 - Door hinges and door check: Lubricate.
4 - Manual Transmission: Check oil level, add if necessary.
5 - Automatic Stick Shift
Fluid pan: Check torque of bolts.
6 - Safety belt warning light and buzzer alarm: Check.
7 - Brakes: Check, adjust if necessary.
8 - Clutch: Check, adjust if necessary.
9 - Heater lever spot light: Check.
EE EE EE EEE eee vv nt]
During Road Test
Check braking, clutch, steering, heating, ventilation and overall
performance. Check operation of Automatic Stick Shift trans-
After Road Test
1 - Cylinder head covers: Check for leaks.
2 - Engine: Check and adjust idle speed.
At 12,000 miles — no extra charge
Spark plugs and ignition points replacement, including adjust-
ment of dwell angle and timing needed at the 12,000-mile
service will be provided by your authorized Volkswagen dealer
at no extra charge, if performed from 11,000 to 14,000 miles.
The necessary replacement at subsequent 12,000-mile inter-
vals thereafter is at your expense.
In addition:
Every 12,000 miles — at your expense
1 - Contact breaker points and spark plugs: Replace
Adjust dwell angle and timing.
2 - Ignition wires, distributor cap and rotor: Check visually,
replace if necessary.
3 - Activated charcoal filter: Check visually.
4 - Timing vacuum hose: Check visually.
Every 18,000 miles — at your expense
1 - Front axle: Lubricate (at least once a year).
2 . Air cleaner: Replace filter element (at least every 2 years).
| Every 24,000 miles — at your expense
1 - Exhaust recirculation valve: Check, replace if necessary.
2 - Filter element for exhaust recirculation: Replace
(at least every 2 years).
3 - Fuel cap, tank and connections: Check visually.
4 - Crankcase ventilation hoses: Check visually.
Every 48,000 miles — at your expense
A ен — ——— —
Activated charcoal filter: Replace.
Every 2 years — at your expense
1 - Brakes: Replace brake fluid.
2 - Brake warning light switch: Check functioning.
| —
| Dealer Stamp)
600 miles
Engine and Maintenance
Transmission Service
Oil Change (No charge *)
(Dealer Stamp)
Valid only between
500 and 1,000 miles
(Dealer Stamp)
Date Date |
Miles Miles | — | * {Lubricants are paid for by the customer)
6,000 miles 6,000 miles 12,000 miles 12,000 miles
Computer Analysis oil Change Service Computer Analysis Oil Change Service
(No charge *) Maintenance (No charge *) Maintenance
Valid only between Valid only between
5,000 and 8,000 miles 11,000 and 14,000 miles
(Dealer Stamp) {Dealer Stamp) (Dealer Stamp) {Dealer Stamp)
Date = Date — Date Date
Miles Miles _ Miles =e Miles
18,000 miles 18,000 miles 24,000 miles 24,000 He
Computer Analysis Oil Change Service Computer Analysis Oil Change Service
(No charge *) Maintenance (No charge *) Maintenance
Valid only between Valid only between
17,000 and 20,000 miles 23,000 and 26,000 miles
(Dealer Stamp) (Dealer Stamp} (Dealer Stamp) {Dealer Stamp)
Date Date Date = Date
Miles Miles Miles Miles
30,000 miles 30,000 miles
oil’ Change Service
Computer Analysis Maintenance
(Dealer Stamp) (Dealer Stamp)
Date Date =
Miles Miles
42,000 miles 42,000 miles
Oil Change ce
Computer Analysis Maintenance
{Dealer Stamp) (Dealer Stamp)
Date Date
Miles NU Miles
54,000 miles 000 miles
Su l'Change Service
Computer Analysis
(Dealer Stamp)
(Dealer Stamp)
36,000 miles 36,000 miles
: Oil Change les ius
Computer Analysis Kian ns
(Dealer Stamp) (Dealer Stamp)
Date Date
Miles Miles
48,000 miles 48,000 miles
oil’ Change Service
Computer Analysis Maintenance
(Dealer Stamp) (Deater Stamp)
Date Bb Date
Miles Miles
60,000 miles 60,000 miles
Oil Change Service
Computer Analysis Maintenance
(Dealer Stamp) (Dealer Stamp)
Date Date
66,000 miles
Computer Analysis
(Dealer Stamp)
66,000 mile
Oil Change
(Dealer Stamp)
Date = Date
Mites Mites: =—
78,000 miles 78,000 miles
“Oil Change Service
Computer Analysis Maintenance
(Dealer Stamp)
{Dealer Stamp
Date Date
Miles Miles —
90,000 miles 90,000 miles
Oil Change Service
Computer Analysis Maintenance
[Dealer Stamp)
(Dealer Stamp)
72,000 miles 72,000 miles:
| Oil Change Service
Computer Analysis Maintenance
(Dealer Stamp) (Dealer Stamp)
Date Dale
Miles Miles
84,000 miles 84,000 miles
Oil Change Service
Computer Analysis Maintenance
(Gealer Stamp) (Dealer Stamp)
Date Date” a
Miles Miles
96,000 miles 96,000 miles
= Oil Change Service
Computer Analysis Maintenance
(Dealer Stamp) (Dealer Stamp)
Date Date
Miles Miles
100,000 miles
Computer Analysis
(Dealer Stamp)
100,000 miles
Oil Change Service
{Dealer Stamp)
Additional Services Record
The boxes to the right indicate a brake service
in addition to the preceding Maintenance sche
that is required
Your Authorized Volkswagen Dealer will perform this service
at the recommended intervals.
It is the best way to keep your VW running. And running. And
Brake Fluid Renewal
and checking of brake warning light switch
after 2 years
of operation
(Dealer Stamp)
after 4 years after 6 years
of operation of operation
(Dealer Stamp) (Dealer Stamp)
Date Date
Miles Miles a.
D 11
The “National Traffic & Motor Vehicle Safety Act of 1966"
requires manufacturers to be in a position to contact vehicle
owners if a correction of a product defect becomes necessary.
Please fill in one of the attached postcards if you change your
address or purchase a Used Volkswagen.
You need not use this card if you purchased your car through
an Authorized Volkswagen Dealer.
Please quote the VW chassis number as it appears on the
identification plate of the vehicle. Its location is shown on
page 3. Do not use an abbreviated serial number.
Additional cards can be obtained from any Authorized Volks-
wagen Dealer.
— = — ="
Headlights, check adjustment
Wheel mounting bolts/nuts, check torque
Cotter pins for rear axle nuts, visually check for
correct instailation (except Type 4)
Tire pressure (incl. spare wheel), check
Engine and transmission, visually check for leaks
Brake system; all brake lines and hoses, visuaily
check for leaks
Steering components lock plates and cotter pins,
visually check for proper setting
Tie rod ends and tie rods, visually check
Hose connections of cooling and heating, check
D. Road test
Foot and parking brakes, check operation
Clutch and gearshifting, check operation
Ventilation and heating (incl. fresh air fan and
heater booster where applicable), check
Speedometer, check operation
Kickdown switch, check operation
(where applicable)
E. After road test
ATF level, check
Engine idle speed, check and adjust
Vehicle In perfect condition:
(Signature of Service Adviser) (Date)
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VW Chassis Number
First Name
Last Name
Zip Code
Please print and give complete information.
New Vehicle Delivery Inspection
Checklist for _
(Chassis Number)
A. Install following items
Windshield wiper arms and blades
Floor mats (where applicable)
Hub caps
Outside mirror(s)
Fuse for heater booster (Type 4)
Interlock system: Connect (where applicable)
B. Preparatory services
Battery electrolyte level, check
Brake fluid level, check
Engine oil level, check and add oil
C. Operation and safety items
Door lock functioning, check
Seat operation and adjustment, check
Safety belts, locking mechanism,
warning light and buzzer alarm, check
Ignition lock, check (where applicable)
Check operation of:
Headlights, dimmer switch, high beam indicator
light, parking lights, stop lights, turn signals
and indicator lights,
tail lights, side marker lights, license plate lights,
back-up lights, horn, windshield wipers and
washer, rear window defogger, emergency
flasher, brake warning light, alternator/generator
and oil pressure warning lights, instrument lights,
incl. heater lever spot light (where applicable)
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Sit on seat, Buckle up. Start engine. This
sequence must be observed by driver
and passenger,
To move car within 3 minutes after engine
shut-off, it is not necessary to buckle
safety belts. For details see page 19
Driving ranges
See shift pattern on dashboard.
Chassis number (Serial No, VIN)
Visible through drivers side of wind-
Seat adjustment
Pull lever at front right side of seat (A).
Backrest release, front
Lift lever on outboard side of backrest(B)
D 18
Gas Station Information
Fuel recommendation
“Regular”, low-lead or lead-free. Min.
octane rating listed on label inside fuel
tank flap
Auxiliary Heater (option) must be off
when filling fuel tank.
Fuel cap
Above right front fender. To close, turn
cap until it clicks.
Tire pressure
See sticker on lock pillar of right door.
Fuse box — under dashboard
Details on page 34
Additional fuses for:
Back-up lights and rear window defogger
(main current) — in engine compartment
on support near ignition coil.
Auxiliary heater (option) — under front
hood near heater
Engine hood release
Pull out knob in door pillar on drivers
Engine oil dipstick
Check oil level 5 min. after engine has
stopped. Level should be between upper
and lower marks on dipstick. Difference
between marks is 1.1 U.S at (09 Imp
gt liter). |
C - Oll dip stick D.- Onl filler cap
Engine oil
Engine oil grades
Use name brand oil labeled "For Service
SD' or ‘SE’ (or combination). See oil
viscosity chart on page 46
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