The 1954-1979 VW Beetle, Karmann Ghia Repair Manual by Haynes, covers models indicated.
Complete engine, body and systems maintenance, service and repair information for the do-it-yourself VW Bug and Karmann Ghia mechanic.
Hundreds of close-up photos accompany easy-to-follow text instructions so you can fix it yourself, in the comfort of your own shop. And if you're restoring one of these VWs, this Haynes manual is a must-have.
Note: this manual DOES NOT include Volkswagen diesel engine info.
Aficionados of classic German engineering who are brave enough to tackle the task of undertaking their own repair and maintenance of their vintage vehicles can purchase The VW Beetle & Karmann Ghia Repair Manual 1954-1979 from The Motor Bookstore. Published by Haynes Manuals, this 318-page volume includes hundreds of photos and illustrations that will help owners take care of at-home repairs of the engine, driveline, transmission, brakes, fuel and exhaust systems, electrical systems, cooling, heating and A/C systems as well as general engine overhaul procedures. The Volkswagen mechanic can be you in your own garage, and it could help you save thousands by avoiding the shop of a professional mechanic. Order the 1971 VW Bug repair manual from The Motor Bookstore and get it delivered fast with free shipping.
Book Excerpt: 1954-1979 VW Beetle, Karmann Ghia Repair Manual
CRANKCASE | CLEANING AND INSPECTION
PART A | MANUAL TRANSAXLE
(Refer to illustration 26.6)
- Inspect the crankcase for cracks or any other form of damage. The two mating edges must be free from dents, scratches and burrs which could affect their precise alignment when both are clamped together.
- Check the crankshaft bearing locations for any signs of damage or distortion. If the engine has been run with worn out main bearings, it is possible that the bearings will be 'hammered' into the crankcase by the vibration of the crankshaft.
If this occurs, new bearings will not be a tight fit in their crankcase locations. In such instances the crankcase must be align bored or replaced.
- Make sure that the camshaft bearing surfaces are in good condition. On 1965 and earlier models, if the bearing surfaces are rough, replace the crankcase.
- The studs in the crankcase must be tight in their holes. Any sign of looseness due to worn threads in the crankcase is repairable. Have an automotive machine shop install threaded inserts in the crankcase.
- Determine what size bearings are probably needed from the measurements done in Section 25. Then verify this by temporarily installing the crankshaft bearings in the crankcase halves without the crankshaft.
Refer to Section 32 for information on crankcase assembly. Do not use sealant.
- Working through the openings in the crankcase, measure the inside diameters of the bearings (see illustration) and record the results. Subtract the crankshaft journal outside diameter from the bearing inside diameter to determine the main bearing clearance.
Compare this figure to that listed in this Chapter's Specifications to decide if the bearing clearances are within factory tolerances.
SHIFT LEVER AND SHIFT ROD | REMOVAL AND INSTALLATION
SHIFT LEVER (Refer to illustrations 3.2, 3.4 and 3.9)
- If you're replacing the shift lever, make sure you obtain the correct replacement part. On vehicles produced before August 1967, the lever is straight; on later models, it's curved.
Don't try to swap levers from one model to another unless they're identical. The lever on 1973 and later models is about 1-1/2 inches shorter than those on earlier models.
- Pull back the floor mat, put the shift lever in Neutral and mark the position of the stop plate in relation to the ball housing flange (see illustration) to ensure proper alignment during installation.
CAUTION: Incorrect adjustment of the stop plate in the shift lever assembly can cause shifting problems.
- Remove the mounting bolts from the ball housing flange.
- Remove the shift lever, ball housing, rubber boot and spring as a single unit (see illustration).
- Before removing the stop plate, note the orientation of the raised tab(s) on the stop plate. Some stop plates have a single tab on the right side of the hole which faces up; other plates have two tabs facing up, with the long, low, narrow tab near the driver and the shorter, higher tab on the right.
Regardless of the design, the important thing to remember is that the stop plate must be reinstalled with the tab(s) oriented exactly the same way they were before removal.
- Clean all parts thoroughly.
- Inspect the shift lever collar, stop plate and shift lever ball socket in the shift rod for wear. Replace any worn parts.
- Make sure the shift lever locating pin is secure. Check the spring in the steel ball for tension. Replace it if it's worn.
- Install the stop plate. Make sure it's oriented with the tab(s) facing the same way as before removal (see illustration).
- Lubricate all moving parts with multi-purpose grease.
Subject: 1954, 1955, 1956, 1957, 1958, 1959, 1960, 1961, 1962, 1963, 1964, 1965, 1966, 1967, 1968, 1969, 1970, 1971, 1972, 1973, 1974, 1975, 1976, 1977, 1978, 1979 VW Beetle, Karmann Ghia service, maintenance, repair. ISBN-10: 1850107297 | ISBN-13: 9781850107293 | Haynes 96008