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VW Karmann Ghia Repair & Spare Parts Manuals

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This workshop manual is the most comprehensive manual available for repairing and maintaining your Volkswagen Karmann Ghia. Suitable for the home workshop mechanic or professional technician this manual will help you repair, restore and maintain your VW Karmann Ghia. Very easy step by step instructions with lots of diagrams.

Volkswagen Karmann Ghia
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

Spare Parts Catlogue for Volkswagen 1200
Spare Parts Catalogue for
Karmann Ghia
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

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


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


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


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


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


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


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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All our repair manuals are in PDF format. Some of the larger files are zipped (.ZIP). For .ZIP files you will require an unzip program (like Win Zip). If you don't have a zip program on your computer, you can download a free version of Win Zip here. If you do not have a PDF reader on your computer you can download Adobe PDF reader free from this link Adobe PDF Reader
PLEASE save the repair manual to your hard drive, memory stick or cd.

Find more workshop repair manuals for other makes and models at
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11/27/2015 12:24:34 PM UTC