Volkswagen beetle 1972 - Owner's Maintenance Manual

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Table of Contents7
Preparation and Tool List10
To Prevent Injury10
To Prevent Damage to Your Car of Personal Property10
Tool List11
Troubleshooting13
Engine will Not Turn over or Turns over too Slowly to Start13
Engine Turns over but will Not Start14
Engine Stalls Shortly after Starting18
Engine Stalls While Vehicle Is Driven18
Oil Pressure Warning Light Comes on While Driving20
Generator and Cooling Warning Light Comes on While Driving20
Automatic Stick Shift Lever Cannot be Shifted20
Tune up21
Necessary Tune up Tasks Explained in the Manual22
Jacking and Supporting23
Right Side with both Wheels off the Ground24
Left Side with both Wheels off the Ground25
Jacking Either Side with Support Stand under Front and Rear25
Maintenance27
Maintenance Requirements28
Lubrication28
Engine Oil Change30
Draining Engine Oil31
Removing Oil Strainer31
Installing Strainer32
Replacing Engine Oil33
Checking Engine Oil Level34
Transmission34
Gaining Access to Transmission34
Checking Transmission Fluid Level35
Lowering the Car36
Transmission - Automatic Stick Shift37
Air Cleaner38
Transmission Servicing38
Removing Air Cleaner39
Cleaning and Servicing39
Installing Air Cleaner40
Front Axle41
Front Axle Servicing42
Door and Hood Locks43
Lubricating Door Lock Cylinder43
Lubricating Door Lock Mechanism43
Lubricating Hood Locks and Hinges44
Checking and Filling Battery45
Removing Battery46
Installing Battery47
Spark Plugs48
Removing Spark Plugs49
Spark Plugs Cleaning and Inspection49
Spark Plugs Adjustment49
Installing Spark Plugs50
Valve Clearance50
Adjusting Valve Clearance51
Ignition Distributor54
Removing and Inspecting Distributor Cap54
Removing and Inspecting Distributor Rotor55
Installing Rotor and Cap55
Distributor Contact Breaker Points56
Replacing Contact Breaker Points57
Adjusting Contact Breaker Points58
Removing Condenser59
Installing Condenser60
Dwell Angle Check and Adjustment61
Ignition Timing Procedure62
Carburetor Idle Speed Adjustment64
Throttle Valve Positioner64
Checking Fast Idle65
Checking and Adjusting Throttle Valve Closing Time65
V-Belt66
Checking Tension66
V-Belt Adjustment67
Replacing Belt68
Fuel Pump Filter69
Removing Old Filter69
Installing New Filter69
Clutch Pedal Free Play Checking70
Clutch Pedal Free Play Adjustment70
Exhaust Muffler71
Exhaust Muffler Removal72
Exhaust Muffler Inspection74
Exhaust Muffler Installation75
Tail Pipes Removal78
Steering Damper - Beetle79
Tail Pipes Installation79
Removing Steering Damper79
Checking Steering Damper80
Installing Steering Damper81
Steering Damper - Super Beetle82
Shock Absorbers85
Removing Rear Shock85
Checking Rear Shock Absorber86
Installing Rear Shock Absorber86
Brake Fluid Reservoir87
Windshield Washer87
Checking Brake Fluid Level87
Filling Windshield Washer88
General Service89
Electrical System89
Charging Circuit89
Starter Circuit90
Ignition Circuit90
Interior Lights and Ignition Key Warning Buzzer90
Instrument Panel Light90
Exterior Lights91
Lights Independent of the Ignition System91
Light Dependent on the Ignition Switch91
Turn Indicator Lights/Brake Lights91
Instruments92
Fuel Gauge92
Oil Pressure Warning Light92
Horn/Windshield Wiper92
Automatic Stick Shift - Super Beetle Only93
Rear Window Defogger - Super Beetle Only93
Fan Motor - Standard on Super Beetle93
Wiring Diagram94
Bulb Replacement98
Removing Headlights99
Installing Headlights99
Removing Headlight Assembly100
Installing Headlight Assembly101
Adjusting Headlights101
Front Turn Signal/Parking Light or Side Marker Light Bulbs102
Front Turn Signal and Parking Light Assembly Removal103
Replacing Bulb103
Rear Turn Signal, Stop and Tail Light or Back-Up Light Bulbs104
Front Turn Signal and Parking Light Assemly Installation104
Tail Light Assembly Removal105
Tail Light Assembly Installation106
License Plate Light Bulb107
Interior Light107
Fuses108
Replacing a Fuse in Fuse Box109
Replacing Fuse in Separate Holder109
Windshield Wiper Blades110
Replacing Wiper Blades110
Replacing Wiper Blade Rubber Fillers110
Removing Rubber Filter111
Installing Rubber Filter111
Windshield Washer Spray Jets112
Checking Tire Condition112
Adjusting Spray Jets112
Cleaning Spray Jets112
Tire Wear113
Wheels114
Removing a Wheel114
Installing a Wheel115
Removing Spare Wheel115
Rotating Tires - Five-Wheel Interchange116
Rotating Tires - Four-Wheel Interchange/Standard and Snow Tires117
Snow Tire Procedure117
Removing Front Seat118
Rear Footwell Heating119
Installing Front Seat119
Adjusting Rear Footwell Heater Flaps119
Positioning Heater Flap Cables120
Removing Front Bumper121
Installing Front Bumper121
Removing Rear Bumper122
Installing Rear Bumper122
Rubber Molding for Bumpers123
Removing Molding123
Installing Molding123
Removing Front Fender124
Installing Front Fender125
Removing Rear Fender126
Running Board127
Installing Rear Fender127
Removing Running Board128
Installing Running Board128
Beauty Care129
Washing129
Waxing130
Polishing130
Caring for Chrome130
Caring for Windshield Wiper Blades130
Caring for Door and Window Weatherstrips131
Cleaning Cloth Upholstery131
Cleaning Leatherette131
Caring for Convertible Tops131
Accessories132
Rear-Mounted Ski Rack132
"Formula Vee" Bumber Overrides133
"Formula Vee" Taper Tips Exhaust Pipes133
"Formula Vee" Fanfare Horn Set133
Vent Shades134
Gravel Guard134
Trim Group134
Interior Accessories135
"Formula Vee" Gear-Shift Knob135
"Formula Vee" Sports Gearshift Lever135
Cigarette Lighter135
Utility Light136
Door Storage Compartment136
Parcel Shelf136
"Formula Vee" Steering Wheel Cover137
Technical Data138
Engine Data138
Transmission Data138
Automatic Stick Shift Data138
Electrical System Data139
Dimensions and Weights140
Capacities140
General Specifications141
Performance141
Index143
Super Beetle View and Parts Identification148
Beetle View and Parts Identification150

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