Volkswagen Karmann Ghia
1961-1965
Workshop Repair Manual & Spare Parts Catalogue

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This workshop repair manual is for the following Volkswagen models made between 1961-1965

• Karmann Ghia Convertible
• Karmann Ghia Coupe
• Beetle Karmann Ghia Convertible
• 1200 Beetle

PLUS BONUS

Everything is included in our Workshop Repair Manuals so you can

• trouble shoot and diagnose mechanical and other problems
• easy to understand step by step instructions with lots of photos and diagrams
• repair, rebuild or replace worn parts
• do your own regularly maintenance

No more greasy Workshop Manuals! Just print off the pages you need and start fixing your VW.

This Repair Manual is in printable 'pdf' format. To learn more about downloading this file or to download Adobe pdf reader free please go to our Download Help page.

Below is a list of the information contained in this Repair Manual

Engine And Clutch

• Description
• Engine Removal & Installation
• Engine Disassembly & Assembly
• Front Engine Cover Plate – Remove & Assemble
• Fan Belt – Remove, Assemble & Adjust
• Distributor & Ignition Coil - Remove & Assemble
• Fan Housing - Remove & Assemble
• Crankshaft Pulley - Remove & Assemble
• Fuel Lines - Remove & Assemble
• Manifold & Pre Heating Pipe - Remove & Assemble
• Muffler & Heater Assembly - Remove & Assemble
• Cylinder Cover Plates - Remove & Assemble
• Clutch - Remove & Assemble
• Cylinder Head Covers - Remove & Assemble
• Rocker arm Shafts - Remove & Assemble
• Cylinder Heads - Remove & Assemble
• Valves & Push Rod Tubes - Remove & Assemble
• Deflector Plates - Remove & Assemble
• Cylinders - Remove & Assemble
• Pistons - Remove & Assemble
• Oil Cooler - Remove & Assemble
• Oil Pump - Remove & Assemble
• Oil Strainer - Remove & Assemble
• Fuel Pump - Remove & Assemble
• Distributor Drive Pinion - Remove & Assemble
• Flywheel - Remove & Assemble
• Crankcase - Remove & Assemble
• Camshaft & Crankshaft - Remove & Assemble

Clutch

• General Description
• Clutch – Removal, Repair & Installation
• Clutch – Trouble Shooting
• Automatic Clutch Description
• Automatic Clutch Operation
• Automatic Clutch – Removal Disassembly, Repair, Assembly & Installation
• Control Valve – Removal & Installation
• Gearshift Lever – Cleaning & Adjusting
• Vacuum Tank – Removal & Installation
• Automatic Clutch – Trouble Shooting

Fuel System

• General Description
• Solex 28 PICT Carburetor – Description, Removal, Repair & Installation
• Solex 28 PICT - 1 Carburetor – Description, Removal, Repair & Installation
• Solex Carburetor – Trouble Shooting
• Fuel Pump - Description, Removal, Repair & Installation
• Fuel Pump – Trouble Shooting
• Fuel Tank - Removal, De Rusting & Installation

Front Axle

• General Description
• Front Axle – Removal, Disassembly, Assembly & Installation
• Brake Drums – Removal, Reconditioning & Installation
• Wheel Bearings – Removal, Replacing & Assembly
• Torsion Arm Link Pins & Bushes – Removal, Replacing and Assembly
• King Pin Bushes - Removal, Replacing and Assembly
• Springs & Shock Absorbers - Removal, Replacing and Assembly
• Torsion Arms - Removal and Assembly

Steering

• General Description
• Steering Damper - Removal, Replacing Rubbers and Assembly
• Tie Rods - Removal, Replacing and Assembly
• Steering Wheel - Removal and Installing
• Steering Gear - Removal and Installing
• Steering – Trouble Shooting

Wheel Alignment

• General Description
• Camber & King Pin – Adjustment
• Toe In & Toe Out – Adjustment

Worm & Roller Steering

• General Description
• Tie Rods - Removal, Replacing and Assembly
• Steering Gear - Removal and Installing

Rear Axle & Transmission

• General Description
• Rear Axle – Removal and Assembly
• Rear Axle – Disassembly & Assembly
• Rear Wheels Bearings – Remove, Replace & Assemble
• Rear Axle Tubes & Shafts – Remove & Install
• Transmission Cover – Remove & Install
• Differential & Transmission – Remove, Disassembly, Assembly & Installation
• Selector Forks – Adjustment
• Main Drive Shaft Oil Seal – Remove, Replace & Install
• Drive Pinion – Disassembly, Recondition & Assemble
• Main Drive Shaft - Disassembly, Recondition & Assemble
• Differential - Disassembly, Recondition & Assemble

Rear Suspension

• General Description
• Spring Plates & Torsion Bars – Remove, Replace & Install
• Shock Absorbers – Remove, Replace & Install
• Rear Wheel Track & Alignment – Adjustment

Brakes

• General Description
• Master Cylinder – Removal, Reconditioning & Installation
• Brake Hoses – Remove, Replace & Install
• Front Brake Shoes - Remove, Replace & Install
• Front Wheel Cylinders - Removal, Reconditioning & Installation
• Disc Brakes Pads - Remove, Replace & Install
• Brake Caliper – Remove, Repair & Install
• Rear Brake Shoes - Remove, Replace & Install
• Rear Wheel Cylinders - Removal, Reconditioning & Installation
• Hand Brake Lever – Remove & Install
• Hand Brake Cable – Remove, Replace & Install
• Filling, Bleeding & Adjusting Brakes
• Brake System – Trouble Shooting

Wheels

• General Description
• Hub Cap Retaining Springs – Remove, Replace & Install

Lubrication & Maintenance

• General Description
• Lubricants & Specifications
• Lubrication Chart
• Maintenance Chart

Technical Data

• Technical Data – August 1960 – July 1965
• Tolerances & Wear Limits

Electrical System

• General Description
• Wiring Diagrams
• Generator - Removal, Reconditioning & Installation
• Generator – Trouble Shooting
• Starter Motor - Removal, Reconditioning & Installation
• Starter Motor – Trouble Shooting
• Distributor – Maintenance
• Distributor Points – Remove, Replace & Adjust
• Distributor – Remove Disassembly, Assembly & Replace
• Lightening System – Bulb Replacement & Adjustment
• Windshield Wiper Motor – Remove & Replace
• Windshield Wiper Motor – Trouble Shooting
• Windshield Wiper – Troubles, Causes & Remedies
• Electric Horn – Removal, Repair & Install
• Electric Horn Ring – Removal & Install
• Speedo Meter Cable – Remove & Replace

Frame

• General Description
• Frame – Removal & Installation
• Peddle Assembly (LHD, RHD) – Removal & Installation

Body

• Body Sedan - Dismantle, Replacement & Assembly
• Body Convertible - Dismantle, Replacement & Assembly
• Body Karmann Ghia Coupe - Dismantle, Replacement & Assembly
• Body Karmann Ghia Convertible - Dismantle, Replacement & Assembly

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