1974 Karmann Ghia Owner`s Manual

Volkswagen Owner's Manual: Operation and Maintenance Type 14 -irst Owner Л LEG Date Dealer's Name Second Owner Address Tel, No. Purchase Date Mileage WI = Vehicle Identification Model Model Year a = Color 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 water. Windshield washer container (2) Unscrew cap, add water and cleaning solution. Follow mixture instructions on can. 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, lack Under rear luggage panel. Jack ports — one on each side Raises entire side for front and rear whee changing. NEW SAFETY REQUIREMENT according to Federal Motor Vehicle Safety Standard No. 208, Section 7.4 FOR ADDED SAFETY, this 197 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: — SIT DOWN — BUCKLE UP — TURN KEY 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 again. 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. 6 IMPORTANT s REMINDER! 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 inoperative. 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 the VOLKSWAGEN COMPUTER ANALYSIS and MAINTENANCE is all about, and 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 services. 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 Contents 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 V 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 Maintenance Should you have occasion to make use of your Volkswagen Warranty, it is always helpful to have the related service receipts handy. Rv: EDEN НОАК ОК o” Ju Ce gf Artt OO D is LOTUS o NA POR pwc y DOW МОЁ ый у DN BZ EN VW BOOT Da DO J a PO y Y Da q DH Y tor NADO I la A je Ne X \ 2 ee YX QI DDS ох 00 2. EL as m A POR a dt + Selling VE i PCE T ww e Y o VO O HOON i ? b ho De Y 4 AN ww У X 00 CONDE DÍ DOOD OXIDO "a we DO 0 (ODO À GX) " VA © о 0 ul DON | 000000 ху uu ОО) RR | % у bY Dh 0090000 у X 6 КОАО ON AD a NDA XD WR МО № QU o WW OU 694 pW Y 0 ( - Mad == Tr VF WA VV RA RIAA BEN X nu DDD RDI oF he D ЖК не erases % mont sion ve étiod before té Te: Tn Чт ay i : un qu ro oi ba se do ZA DDD DUDA X 0 CODD y DD OA jo eZ 0 GE Se A RO D us N 5 DO 0 п Ta i OW DIS que 4, phat “4 ил AT $: YA — 77 CY DOVE NL N ok LODO Sot BHO DOD Air Conditioner Installation Late | At Mileage (Stamp of Installing | VW Dealer) Make, Model Auxiliary Heater Installation (Stamp of Installing vw ler) Date At Mileage Maks, Model Speedometer Replacement | Date At Mileage {Stamp of Replacing o В VW Dealer) | Make, Model — Vil Warranty for New Volkswagen Vehicles This warranty is issued by Volkswagen of America, Inc. (“VWoA"), the authorized United States importer of Volkswagen vehicles. Free repair or replacement in the United States and Canada of defective parts for 12 months or 20,000 miles Maintenance required to keep warranty in effect Items not covered by warranty 1. VWoÂ 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 workmanship 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 maintained 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) improper 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 Warranty outside the United States and Canada No other warranties made other consequential damage. Maintenance services, and the replacement 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 continental 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. 5. THIS WARRANTY, THE 24,000-MILE OR 24-MONTH ENGINE AND TRANSMISSION POLICY UNDER THE VOLKSWAGEN OWNER'S SECURITY BLANKET AND THE EMISSION CONTROL SYSTEM WARRAN- TY ARE IN LIEU OF ALL OTHER EXPRESS WARRANTIES OF VWoA, THE MANU- FACTURER, THE DISTRIBUTOR AND THE SELLING DEALER. NEITHER VWoA NOR THE MANUFACTURER ASSUMES, OR AUTHORIZES ANY PERSON TO ASSUME, ON ITS BEHALF, ANY OTHER OBL} GATION OR LIABILITY. — GENUINE 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 Dealer 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 controls, — 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 carefully, 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 correctly. 2 - Watch the tread depth indicator on the tires. Look for bruises and wear. 3 - See that all windows are clean and unobstructed. 4 - Check that headlight and tail light lenses are clean, 5 - Check that all lights are functioning properly. 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 starting 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 unexpected. 2 - Use signals to indicate turns and lane changes. 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 highway 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 TYPE PASSENGER CAR MANUFACTURED BY VOLKSWAGENWERK AG (month/year) THIS VEHICLE CONFORMS TO ALL APPLICABLE FEDERAL MOTOR VEHICLE SAFETY STANDARDSIN EFFECT ON THE DATE OF MANU- FACTURE SHOWN ABOVE. 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- jamb. 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. Keys 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 Doors 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 inside door handle. Then squeeze the trigger in the outside door handle as you close the door. if the door, with the locking lever depressed, 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 car. To lock and unlock doors from the inside — depress or pull out the locking device inside door handle (pull to open) windows 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 windows from fogging. Seats 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 different 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. Tr B- | SN Я = == \ = E ' ей РВ, Y = N A 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 excessive 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, buckling up and starting the engine is important. 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 minutes 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 attendant. 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 corresponding 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 comfort, 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 car. 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 5 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 steering, 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/steering 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 operation. 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 released. 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 parking brake released. This is your assurance that the brake warning light functions properly. 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, emergency 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 speed. The 5-digit odometer records the miles driven. 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, depress 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 engine. 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 | _— a alternator but also the fan that cools the engine. Tighten or replace the belt (see also page 50 "Trouble shooting , item 18). a - Oil pressure warning light Stopatonce... 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 pressure 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 sufficiently. 11 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 automatically when you have completed a turn (like driving around a corner), and the steering wheel returns to the straight-ahead position. 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 depress the leverto an intermediate position The lever will return to the OFF position when released. 10 Headlight dimmer (= Dim the headlights by pulling the lever toward the steering wheel. The blue indicator 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 released. 6 He light pre changer | ol i ——— — | To give you full battery power while starting the engine, operating windshield wipers will stop automatically at this moment 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 instrument panel on the left side of the glove compartment. 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 dislodged. 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 bracket. 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 rear. Qutside mirror The outside mirror is hinged and folds flat against the car when struck from either direction. Inside day-night mirror You can move the day-night mirror from clear daylight visibility to non-glare visibility at night by adjusting the lever upward or downward at the bottom of the mirror, 13 =— >. 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 Ashtray You will find an ashtray in the center just beneath the instrument panel Pull to open it. To remove the tray depress 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 engages 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 wheel, 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 premature 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 failed. 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 specified maintenance intervals. Keep in mind that the braking distance increases very rapidly as the speed increases. 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 between: 12 and 31 mph in 2nd gear 22 and 50 mph in 3rd gear 31 and 62 mph in 4th gear 15 4 - Gearshift lever The Manual Transmission is fully synchronized. The four forward gears and a reverse gear are arranged as Illustrated. The shift pattern is also shown on the dashboard. 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 16 Reverse 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 partially 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 parking 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 instructions to familiarize yourself with the operation of the transmission. For details on the operation of the brake pedal, the accelerator pedal and the parking brake lever, see pages 15 and 16. The Automatic Stick Shift transmission consists of a torque converter. a power-operated clutch for shifting, and a mechanical three speed transmission. 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 conditions. 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 permit the gears in the transmission to be shifted. Because the power-operated clutch is actuated by the first slight movement 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 recommended for use in city traffic, slow moving lines of vehicles, and whenever maximum 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. 17 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. Starting 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. Shifting 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 gearshift lever, and again step on the accelerator. For easier selection of the driving ranges 1 and 2, which are used most, the gearshift lever always stays on the right side when in Neutral, as shown in the ¡llustra- tion, on the previous page. Stopping 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 driving range apply the foot or parking brake to prevent the vehicle from creeping. Parking 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 brake. 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 only. Summer starting Operate the starter while slowly depressing the accelerator pedal. Winter starting First depress the accelerator pedal fully and release slowly to activate the automatic 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 Note: 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. 19 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 folding 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 springs. To close and lock the lid, press down on the license plate housing until you hear a click. Te e a ee el Heater/Defroster 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 instrument 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 defroster/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 distribution of heat to the front and rear footwells. 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. ventilation 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 knobs. 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 point. 21 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, 77 = "о 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 window. pu 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: OFF — LOW — MEDIUM — HIGH 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. 23 So 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 conditioning 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. 24 If the windows fog over on the exterior on warm, humid days, turn the air temperature 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 temperature 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 lubricated. After the winter months and before extended summer usage, the air conditioner should be checked and, if necessary, serviced by an Authorized VW Dealer. The condenser should be checked periodically 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 fins. An air-conditioned Volkswagen should only be raised on a lift that provides adequate 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 battery. Note: When a VW Air Conditioner is installed, the vehicle capacity weight will be reduced 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 odorless. 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 indicator 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. PS 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 25 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. Front A towing eye is welded to the right-hand side of the lower axle tube. Rear 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. Эс 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 warning 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. EE оННОНННйй ATF warning light Stop at once... if the ATF warning light comes on. It indicates that the Automatic Transmission Fluid may have reached too high a temperature. 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 continue 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. Battery 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 temperatures. Lights and the rear window defogger 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 condition. 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 afterwards. Squirt lock de-icer, anti-freeze or glycerine into the lock cylinders to prevent 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 temperatures 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. 27 BA) Ant Tires Your Volkswagen Karmann Ghia is aquipped with tubeless bias ply tires, Volkswagen tires comply with all appli- -able Federal Motor Vehicle “Safety Standards. Tire pressures For good car handling and long tire service life, it is important to maintain recommended 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. JA Spare tire pressure Since the spare tire supplies the pressure 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 maintained 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 recommend 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. + EEE À A 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 indicators 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 occur. 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 replacement tires that show the same specifications 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 traction. 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 slush. 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 mounted 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 maximum 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 pressure. 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 windshield washer system. For road use, adjust the spare tire pressure as specified on the sticker on the lock pillar of the right door. 29 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. Jack 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 plamn. 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 motorists. 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 steps. Further on, we expand on these steps in greater detail. Step 1 - Take out tools, jack and spare wheel, 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. Step Step Never jack the car up by the bumper or the body. Step Step 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 adjustment, 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, disconnect the hose leading to the windshield washer container. Step 2 With the wheels still firmly resting on the ground, remove the hub cap of the defective 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 bolts. 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 clockwise. 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 31 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 counterclockwise. x Step 8 Then go crosswise from one bolt to another tightening them firmly with the socket wrench and breaker bar IC 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 important. 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 reservoir. 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 replaced. 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 conforms to Motor Vehicle Safety Standard 116 must be used. 33 EMULE EEE DD Fuses The 12-point fuse box with plug-in arrange- ment for relays is located under the instrument panel on the right of the steering column. 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 electrical 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 contact 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. ot To close the holder, put both ends together again. press lightly and twist clockwise. 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 shifted ** Trailer hauling only 0101 6 7 8 9 10 il 12 1111017 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 compartment 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) heater. pr 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 regular 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 manufacturer The Auxiliary Heater (optional equipment) must be turned off when filling the fuel tank. 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. Battery 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, all Never drive the car with a disconnected battery as this may damage the electrical system. 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 damage. How often water must be added to the battery depends mainly on operating conditions and on the time of year. As a general 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 electrical equipment. If you have not used your car for an extended period of time, have the battery recharged. 35 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 products 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 DIRECT SUNLIGHT. 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 E Application 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 anti-freeze 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 a spraying water over the dry car to remove 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 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 forming beads and rolling off. Polishing 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. Weatherstrips 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 occur. 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. Tar 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 lukewarm soap/water solution and apply a new wax coat. Insects Remove as soon as possible with a lukewarm soap/water solution or apply insect remover. 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 solution. 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 working 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. 37 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 Headlights 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 “AR nemove three short screws (a) in sealed beam retaining ring and take ring off. Do not alter the position of the long headlight 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 adjustment 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 lens. 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. 39 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. AÑ 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 workshop. Adjusting or replacing V-belt 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 screwdriver 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 loosening and tightening the nut, place a screwdriver 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 adjustment 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 installed. 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. Cleaning, 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 Schedule). 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. 41 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 outside 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 Checking 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 removing 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 conditions, 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. ManualTransmissionoil 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 workshop equipment. Also hypoid oil is generally not marketed in small quantities. Automatic Transmission Fluid 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 compartment. Wipe the dipstick clean first before inserting 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 required amount of ATF. Check for leaks. For ATF specifications, see page 47. Air cleaner a 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 premature 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 necessary. Under normal conditions it is not necessary 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 off. Loosen clamp —B— and pull hose off. For easier reinstallation note the hose attachments; interchanging of hoses affects 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 carefully, 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 year. 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 scraper. 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— carefully. Make sure all hoses are properly connected, LUDIIGALION Front axle Lubricate the front axle once a year or at the specified mileage intervals (see Maintenance Schedule). LEN a. A #/ | \\\ Lift the front end of the car to take the weight off the front wheels. This is necessary 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. a 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 engine 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. 45 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] 5 ESTEE 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- SAE Ls exe | 1OW 20- — EZ 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. A 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): SAE 80W 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. 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SaAISJSI Y JI DuraLIP 391j-ejgnos) YiIM NOÁ Áedal pinoys usBemsyJoA 1nO A Bunooysajgnoas | Problem 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 system 9. If spark is fairly good at plugs, trouble is most likely in fuel system A. Caused by improper starting 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 contacts 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 supply. 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 engine. 49 EE ————————————————— Problem 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 shifted FAL located on the left in the engine compartment. Engine with Manual Transmission | Qu 1 LA OL QT Bn 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 Dealer. 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 assistance, 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. Maine Massachusetts New Hampshire Rhode Island Vermont Illinois lowa Minnesota North Dakota South Dakota Wisconsin Kentucky Ohio Indiana Michigan Delaware Pennsylvania Alabama Louisiana Mississippi 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 Connecticut New York Mew lersey Florida Georgia Maryland North Carolina South Carolina Tennessee (East) Virginia West Virginia Washington, D. C. Arizona California Nevada Utah Hawaii Alaska Idaho Montana Oregon Washington Arkansas Kansas Missouri Nebraska Colorado New Mexico Oklahoma Texas Wyoming 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 Es 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. Chassis 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 pressures are listed on a sticker on the lock pillar of the right door. 55 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 | FI 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) Transmission 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) Transmission 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 57 Volkswagen offers a quality product. You can help maintain this quality by having your car serviced regularly. Your authorized 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 condition. À service scnedule that we recommend is listed in the VOLKSWAGEN COMPUTER ANALYSIS and MAINTENANCE RECORD 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. 59 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 maintenance, 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 analysis 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 lubricants. 1 - Engine: Change oil, clean oil strainer. 2 - Manual Transmission: Change oil, clean magnetic drain plug. 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 joints. 7 - Tires and wheels: Check tire pressures, including spare wheel, 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. D3 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, emergency flasher, stop lights, tail lights, back-up lights, turn signals, horn, rear window defogger and brake warning light. 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 analysis, 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. D5 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- tenance. 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. mé 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 transmission. 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 adjustment 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 intervals 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 — ——— — Li Activated charcoal filter: Replace. Every 2 years — at your expense 1 - Brakes: Replace brake fluid. 2 - Brake warning light switch: Check functioning. | — D7 Delivery Inspection | Dealer Stamp) Date Miles 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 в -— 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 Maintenance Computer Analysis (Dealer Stamp) Date Miles (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 Maintenance (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) Date Miles 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) Date Milas 100,000 miles Oil Change Service Maintenance {Dealer Stamp) Date Miles Additional Services Record The boxes to the right indicate a brake service in addition to the preceding Maintenance sche that is required dule. 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 running. PSS Brake Fluid Renewal and checking of brake warning light switch after 2 years of operation (Dealer Stamp) Date Miles 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 operation Speedometer, check operation Kickdown switch, check operation (where applicable) E. After road test ATF level, check Engine idle speed, check and adjust Hemarks: Vehicle In perfect condition: (Signature of Service Adviser) (Date) D 14 anusay UBNJAS 818 Z£E9LO 'M'N 'SHIJ poomajBua JU] ‘YOIHINY JO NADYMSMIOA A9 GIVd 39 11IM 39V1SOd su TE sum 5 = EZ im E E” = 2 Sm 2 y т = 7 =< Е ;5 > o a ir LE9ZO ‘TN ‘poome;6u3 687 “ON MWlad SSY19 1S HI4 Tra A = || NOTICE OF ADDRESS CHANGE NOTICE OF USED CAR PURCHASE please check one of the above boxes Yr. Day VW Chassis Number Initial First Name Last Name Street Number Zip Code State City 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) SrA EEC TRE MST WE PVE A REN] apon diz | | 81215 = 188416 18QWNN | J emu BBN 35114 aLWEeN 1SET | | “ER Aeg "OW 19QUNN SISSEU MA L |] | | sexoqg aAoqe sul JO suo yoauyo eseajd | | IiSvHIYNd YY9 dasn 40 39211LON |] Ii9NVHO SSi4H4AaY 40 32110N ‘uoneiuloju) 818/dWO09 8AIB pue juud sseald poz diz ajers AND 188415 saqunn | | (eu) aWEN 18114 эшем 15€ | | 4A Arg JaqunN sisseyg MA TT] | 59X0Q 8A0QE 84] JO 8U0 9842) asea|d [| dSVHOHNd YHY9 dasn 40 392ILON [|] 39NVHI SS3HCOV 40 32110N LES LO "TN poomajBuz S8/ ON liad SSY192 1SHIA4 LE9ZO ‘FN ‘Ppoome,6u3 G8L ON liad SSV1D 1SHI4 656910 'Г’М№ ‘$419 pooma|bug anuaAy ueajAS 818 PU] ‘YIIHINY 30 NIDYMSHIOA AS OIVd 39 111/M 39DV1SOd S215 pallu 843 U pajew J Asessedse ny dweyg ebeysogd ON TIVIN ATd3 HH SSIiNISNAa 26970 'Г’М ‘5419 pooma|bu3 anuaAy UBA|AS 818 ou] ‘YOIHINY 30 NIDVYMSHITOA A9 QOIVd 39 11I/M 3DV1SOd $93235 perrun ey: Ur pajrew J) AsessocoN duezs obe150d ON ТММ Лаз Ч SSaNISNna co ee Gas-Station-Information Starting 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 windshield 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 side 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

1974 Karmann Ghia Owner`s Manual

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