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    1960 Karmann Ghia Workshop Manual Body

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    Márcio K.

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    1960 Karmann Ghia Workshop Manual Body

    Uploaded by

    Márcio K.
    188 views139 pages

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    © © All Rights Reserved

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    Download as pdf
    188 views139 pages

    1960 Karmann Ghia Workshop Manual Body

    Uploaded by

    Márcio K.

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
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    of 139
    pmTeegi Gesaany to@:stoMns-20 i) Bod General “The two-door, ei-steel,epen betlomed body ef sireariined pontoon thope ir bolted to the widened platform frame and secled with U-ection rubber eeoling strips. The tirang side members under the éoors combine ‘with the pllformt frome and tunnel to farm @ bend and twist proof foundcilon. The fenders are welded to the ovter body panels “The body is divided inte front luggage compariment, paisenger compartment ond rear engine comportment by perliions. The engine compartment is vonilleted by meont of a series of sci inthe rear hood. The area ‘of these cooling air slots musf not be resiricied by ihe instllotin of accessories “The body Is comprited ofthe following pate, which ors welded logelher: ‘© Front section outer panel, inner wheel housings, relafarcement plate; Intrument panel end hinge ilors bb Rear luggage compartment floor plate ‘e- Rear quarier panos with whee! houtings 4 Side members = Root 1+ Front and rear panels + Doors “The 1000 nim (3P.2") wide half dors hove no top frames and are aaehed tthe (rant body pillars by eon. ‘cealed, odjesieble hlnges. When the vevticily curved windsw panes ore in the elated poslion They bear Sireally on the body weatharatep. ‘The doors ore lockable and have press bution cantrels in the rigid outer handles end bations-on the insid The door opening angie ix controlled by «check strop with an lnlarenediale stop. A slnap cn the driver's aide and an ari rest wth grip revess on the possengr's side are provided for pulling the daors from inside, ‘The daor la sealed In the doot frame by means of an all-round, moulded foam rubber srp. “The hood cf the front compartment, which contoing he fuel Hank; spare wheel end tools, and the engtne ‘compariment hood ave locks which ore controlled from the vehlele Inlerkor by Bowden cables. The ¢onteel Knob for the front hood is Tecaled undernesth the instrument panel on the llt Nand side. After the frent hood hos bon relecied Ie safety calch neor the leak must be pushed to-the rear Before the hood con be opened. ned by means ofc kok silvated oh the left side of the emergeney soet reinforcement poncl The number plole lamp i shaped te form a handle for ling ths heod which is held inthe open pasion By springs of he Ringes, Description of Body Karmann Ghia Coupé Windows “The windshield is curved ond inclined ot approx. $4°_ The maximum clear width is 1200 mm (67.2757) ond the max. clear height 425 mm (18.79°). The rear windew extends round the sides of the reof contour and ls Inctiogd «1 49°, The maximum clear width fs 1400 mm (&889°) and the height 430 mm (16.72%), The windows con be flly lowered by rolery handles ond ore seoled ol the fixed side windows and the reat by @ rubber nesthersirip, - 2 All windows ore of heat-treated solely glors: The windshield hos o specally treated xone which remoins tleor even when the glast is damaged. Far cartein countries windshields af laminated glost ore installed, Front Seats The wide, edjustable, Individual secs ore held in runners which wise slightly wards the feont. The seal boeks gan be adjusted to thece aifarent angles. The seat frarier ore af tubULaF Heel and the spring interiors ‘are of interlacked esil springs. Seats and see! berks ore padded with rubberized h Rear Seats The eel end back rei of the eear bendh ore upholsered and serve at on emergency stat, The bockrea an be folded down ond the spece used of on edditonel luggage compartment Instrument Panel Infront ofthe driver, tothe lef ofthe steering column, ithe speedometer whieh rend up te 140 ep. h, (27 MPH Ih the warning lighis let info-the diol. In the eenier i the fuel gouge and on the Pigh! The elects clack. ‘The canter portian of the Instrument ponel Is preporeé for The installation ef radia se! ond loud epecker (On ts right side is an eshiray end 0 gloxe Box with Iid. The combined igntion/storter switch and the Goke contrat are on the left acor the speedometer, the ight switch and the windshield wiper switch are on the right by the clock. Tho top part of the instrument panel is covered with padded, nonerelecing material. Interior Trit Tho door ond ide (rim pansls ore envered with leatheratie, The seale of0 fnluhed iw lestherele oF eth ‘according 10 choice. The flcor, ‘rant partition, frame tunnel and side members are covered with rubber matiing. The floor is alto cooled with an addiliancl sound cbrarbing melericl The luggage compariment ‘and the luggage space liside the body is fined with haircord carpet. Bath doors are ited with pocke®. The rear view mirror on q bell and socket mounting and two padded sun visors are tached inthe ceater ofthe ‘ool, A grab hendle is provided an the instrument ganol in feont of the pesienger. Heating and Ventilation ‘hr wormed by the engine is token vie flexitte metal pipes. sound dampers and frame side members to the ‘ulets at foot level nthe front comperienent ond othe windshield, Fresh cit far weaillion enters al openings in the front panel and passes vio dues arranged on each sde tothe defroster vents. The fresh eit flow ts tgulotad by velvet the Gusts, The vlves are-operated by regultor levers — one for cash side — located tre the Insrome pone! ofthe lef side. The worm ond ), previonly 13 rn (397), The few locks Dror Ina Past Nombers: front 161 829 50P- ror $64 817 SOB “Ty lec pine are ovallable separately ox spares (Per! (No 141 813671 A) end ore sulobe for Ihe tron! ete vor pede The new tack can be service snl in coir vebiele. ‘Viner insating Ht should be. mole thot isiené ol the ‘hwo wavhors cureenly used ‘whi heve an outide Migmaler of {7 mm C47") twe washers (Pat Now 16 ‘S23317 of N 11.679) with on cui tometer ef at Tees 22m (27°) should be ed ‘he oe lack pn sao alle for previous ype lack. (Pen Not Tei 823508, fronts ond "Wei Sar 588, roa Iter Socks re vied up there lacks ell no longer be ‘epi 1.- Greate head lnek eeble end Invert Inte guide fake, 2 The lick ls30 constructed thal ifthe lack cable bbreoke the Tatch plate which raloing the lock ball when the heod H elosed springs back avtomatically. The ball i then free ond the hood ah be opened sfler pushing beck the sefely haok, When etachlng tho lock cable the arm under the lock Which carries the coble elamp screw mus be lurned agains the spring tension vil the faich plate projects inte the opening forthe lock tall In this position the lock coble should be Inserled inte the lock and secured to the ‘arr bp Yightesing’ the elarhp ‘sett. Bead surplus bee, 3 Secu g heed lock, Intell lock alt and valely hook. 5+ Open and close the hood severd! ini fo check length of lock bolt ond pasition af loc, II nesersery_edjast the position of the lock by moving I! in the slongaled holes and the lock bball length by loosening the lock suls and Wenig the Bel in oF Oat, 6- Check the lock cable adjustment If requleed ‘gis! cable, Band surplus oble Back sgoin, 7 Greate lock bot Rear Hood Removal and Installation Removal “The reriovet ond instlietion ef the rear hood is simplified ifthe job is carried out by tua. mechanics. “The hood con then be properly supported ond damage to the rear upper panel avoided. HBr Is net possible, « suitable pices of wosllan fo pladic material should be placed over the rear ‘upper panel before Worle cormences 1 = Open rear hose, 2-Unclip the eens plate laenp cable and pull B oul of the clamping plate on the hood. 3+ Rerneye two bolls from the hinges en each side ‘of the hood, A= Remeve the hood, 5H necessary, rahiove the hinges ater tihng the sound damping materiel. of remeve the hood lock lastatlation 4 = Check condition of weathersirip and reploce if necessary, Whon renewing the rear hood Seothersrip remove all traces of ol cement seth benatae aid secure the new weatherstrip In position with Genuine VW Universal Adhesive D 42, 2 Boll the heod loosely to the hinges se that it con be moved in the elongated heles to obtain Proper sesting ond sesling all reynd, Then fully tighten the bolts Arash the sprigs to the hinges so thet tho hhood remains in the open paslion 4+ Open ond close the hood several times to cheeks ock operation, I necessary, edjust the lock in ‘the clengeted holes. © ) ® cag nae a nese Removal 1: Open rear hood. 2+ Unscrew lock bol ~W 3+ Remove four belts. Rear Hood Lock Removal and Installation ‘Ss Leosen cable clamp srew aad remove cable from catch. Romeve lock, “pr 5 =Pull lock cable out of guide tube, al A61 5 Instellation 1 Grease lock cable ond Insert Into guide tube. 2+ The lock Is $0 constructed tho if the fork cable breaks tbe leich plate, which retains the feck boll when the haed Is closed, springs back futomaticaly. The bolt le then free and the hood con be epened When attaching the lock cable the orm under the lack which gareles the coble clamp serew must be ened ogsins! the spring tension until ‘he laleh plot prejeets inte the opening forthe Teck belt In this position the lock cable should be inserted into the lock ond secured to the ‘arm by lightening the clamp scren. Bend surplus ceble back 3 Secure heed tek. Intell Hoek tol, §- Open and sloze the hood several times to checie Tenglh of lock boll and position of lock, H nesetsary; adjust the potion of the lock by moving 1 inthe elongoted holes, ond the loc bat length by fotsening the leek nuts ond tering the bel in or out. 6 Cheek the Ise eoble adjustment. I required, ‘just eable. Bend surplus cable boek, 7 Greate lack Batt, Notes > - Fram 20d February 1960 and Chassis Noy 2897 216 Ie redid pine of the leont ond rear bood docks have Giometer ef 8 tam (34%), prevoasy 18 mm (39°) The few Backs bor the Por Norbert least 144 628.500 & reat 161 827 509 A “Toe fog pint are evellabie separaely os spares (Part Fo SE BES UPVA) od are sutble forthe treat ond Pear hoods, “Te ne tock ean be service [soled in ealer vice. hen ising Ih thowtd be Roled thet Inseod of the fe woahers eurreniiy ied which ave an outido ‘ameter ef 17 pom (47) to wars (Part os 4 829 ‘S'or N11 70) witn-on guUde diameter ef ot lec 2E rim (87°) should be used. “The new lock pn nwo sate for previdus ype lod, (Port Non 4086735805, tues and “at 227808. reer [sce socks ore used up these Tooks will no Tanger Be ferpleds i Bumpers Front Bumper Remeval ond Installation = Removal @ 3 a 1 i = i 2 2 Ramer bumper brad balls an eoch de. F i §o « i: = 3 Remove retaining bolts trem both ovlor paris, q «Pall bumper complete with oversiters and brackets, cut ofthe frost porel. = Remove bumper brackel covers. ctl. = Unscrew the fa bale at eoch side end remove brackets spacers ond overriders = Unserew hve Belts ot eazh side and detach outer parts from bumper eanler part 8 Remove bumper brocket grommets, € | | | | a 6 Inglatiotion = Checkecondition of seok for overtiders, bumper S| rockets and bumper bracka! covers ond renew if necestomy Fr - Bolt outer pats 10 bumper center part 9-Belt brackets with boniper to body. Replace both evier port bolts ond check thal Clearance Between bumper ond body is aniferm. 5 Replace bumper bracket covers 19 thet the => rubber seal contacts body all round. F Rear Bumper Removal and Installation A-62 3 4 4A = q 4+ femave two bumpar bracket bétls and one ‘outer port securing bolt on cach side. 2 Pull bumper, complole with overriders and Drackels out of the rear pont 3+ Remove one everrider bolt on eath side ond ddetech avecciders and spacers 4 -Remove bumper bracket covers. 5 - Dotech brazkalt from bumper. 4: Unscran two bolis ot cach side and detach outer parts from bumper cerler port. inne na Ceeaney 4, soess2 88-20 Installation 4 Cheek condition of seals, ronew if necessory fend repicce. 2s Insiatl Bumper with brackets Secure outer parts and check thot clearance ‘betwson bumper ond body is uniform. 4 Replace bumper bracket covers so thot the EF rubber seal contacts body all round, F Front Bumper Removal and Installation (USA Version} © Removal, {1 Rerave balls from both brackets 2 Remeve bolts from beth outer pars 3+ Pull bumper, complete with bows, eerriders tnd breekels out of the frent panel. 4: Remove Ihe overrider suppert mult gn each tlds. Q@ $= Datos bew aller removing the balls on both sider A q 4 = Remove bumper trockel covers q Unsere tne bells ot eoeh aide af bumper and remove brackets, spaturs and verriders 7+ Unscrew two bolts ot each siée and detach ‘outer parts from bumper center part. B- Remove bracket grommets from tren! pant Instaltation Zi 4- Check condition of reate, renew if necessary Sond replece, 1E~ Ball evter parte te bumper senier port 3-Bolt bumper bows, overridees, spacers ond ‘rackets together. ££ Boll bumper with rockets fo body 5 Secure outer ports ond check the! clearance between bumper ond body is uniform, 6+ Replace bumper brackel corers so thet the ‘ubber seal contacts body all round, ) & Fs : i © Rear Bumper Removal and Installation (USA Version) Removal = Remave two overrider support bolts on each 1 spport = site 7 + Remove two brorke! bolts cad one ovter part securing bolt an each side. -Remare bumper, complete with bows, overs riders end bomper brackel. k < Deloch bow efler romouing the bells on each Es BE side Unscrew fwo bolls af ecch side ond detach ‘ouler ports from bumper emer part Installation Bes adnan os tne aenmery Stare : i: ll binoen batia edridey ad burnger brat loge ¢ ‘8+ Pass brothel through holes provided and ball then tothe body. Secure beth outer parts and ‘cheek the! the elearance belween bumper and body Te uniform. > = Boll averrider supports to body. 5 Replece bumper brackel covers se thot the rubber seal cantezts he body all round. chan 22h 901688 Remaw 1 Remeve tue serews holding deor check tpring mounting. 2 Loostn thefour Phillips screws ofthe door hinge “with @ punch screwdriver: Hold the doer ond Temnove the sere With @ Philips sxredeiver. 9 Remove the door, Doors and Windows Door Removal and Installation door and fit lato the pening inthe body 9 that i gligns correctly with the body front side panel “The hinges are screwed fo movable threeded plates to focilate coreect door elignment 2. Chetk doe meaiherdéip and renew if neces sary. Cement neve sirip Info position with Genwine YW Universo! Adhesive D 12 B- Adjust the striker plate 10 thet door ix lush rth the quarter panel ond opens ond clores cealy, (Gee Adjertment of Striker Plats) 4 Cheek rubber bulfer for wear and replace if necessary. Hot ‘Wit afte fom 6th Augus! 1959 ond Chess Na. 42339597 a fle (Part Ne LAT BD 27) was pro “fed on the lower part of the aoor to ene © Proper fil'in tne door opening. he howing (Pan Heres ny 289) (rhe aller secured tu a reese in ine quarter panel Tock pile The eaor tier ‘oimet be isalad th woes of reviond ype. 5 Oil the hinges: moking sore thot the oll alate are dlean, “ie hinges wore modifies on 28 Ape 1859 ot Chase Rov BSIS 10 and ore now rede sf ight rok The Negeri (erie, 1% orapw tng nbs sradh noel ou selatenone. Wacn tata rewire Upoer de hinges in vie of previous typ te cat Up tor oe echere most be colo ar on pening of Grresponding ane ode i he Mage pile, ins font Wieden the mow yp door check sap et we The door lock eyinder imust be lubricated only wih jondered geaphils oud bever with i orgreare. The Key {howl be sipped in the graphite powder Esered in he {ih ond toreed Bock ond lech several fi Door and Striker Plate Adjustment ‘Wien he sciker plates have been removed the postion of ths doors inthe door openings should be checked «follows 1 + Tightnsst of hinge securing esvews, 2+ Alignment of door and fron! side paneh - 3+ No distortion in the door, 4 Alignment of door end quarter panel, 5 Uniform gop between door end hinge pillar, {6 Unifarm gop between door end lock piller Witness requirernests are aot mat the following adjusiments sheuld be carried out Re 2+ Loosen door hinges a! the hinge pillar only. Move the doar in er ox! 5 required and tighten hinge Re 3 Eliminete distortion inthe doar and revad) st door butlers Fe 4 Install ond oes! the striker plate, The stiker plate is enereety adjusted, if + the door liga withthe quarler panel, 1b opproximately 1 mm play sé be fll between the ole ond! the striker plate when forcing the door in-end out by the handle. “To align the door with the quarter panel move the wether plote in or out the required amount. lay Will oct Between fock oné striker plate ifthe top partof the dear latch does nat rei! agains the steer ple Incorrect Gorred a= 4 mm (O80 IWihe ploy i excessive eosen aerava' and 2 lg ly and mave the selcer plate out ot he ope smell amount | Tighten the screws ogoin ond chet pla. | “The top avrace af he latch must be exaclly porate! fo ond fo close contact with the donee! surface of he dcr plot. An eeturete check tan be nade ils ng compound. the door springs beck when slammed to screws 1 ond 2 shavlé be leasened end the siviker plote moved inmards lightly ofthe tp. Re 5 -t1 the gop betmesa the door end the hinge pillar i nel uniform over the whefe leng!b, the dear shout ‘be moved the required artounls by adjvsing the hingss Re 8 (The following method should ony be weed In isolated and very difficlcoxes). ‘Wien the aap between the door ond lock pillor widens tomards the top instead of being uniform over ‘the whele length, looien the bosy mounting screws at poinls A and Bu Lit the body of pela! “A” ond insert a 3.5 mm thie packing piece (manueclored from o Sedon sliding roof vido plate Port No, 115 875 244 A ax shaw in sketeh) oP Phi point, Tighten the tedy mounting serews again Fo oterque of mkg (220. Iba), Ifthe gap width ie tll nod correet, another packing pises mus! be Inserted. ‘The gop between door and tock pillor should be 4 mm wide. -Anvessentiol condition for dace window odjusiment fs the correct fit of the doar 16 the door ope ment of the dor window ean bs carried out When these operations ara completes, the adjusts b —— KF] i net tL i To stnats asi In he dab ack when the vee . ovement aie pe Ina ces fauing Q er 0S oe Sota Gh neh is Wninglceo! plone ker lle wed rer am a me s6° te “Te sire plate win boviing — Porte. 148 B87 295798 Bete mm 1007 if SPIES BPG heater i venir who co Asm a0" ss i dines Se mm) 70" : Steck of th letter leet bead Up ily fet nm) ae z ihe ens type frevoate oa pare por 1's emp 2@ | Door Window Removal and Installation Removal 1 Prose window regulolor handle and inside door handle exeuteheans again the door tim panel Until the dowel pins ove visible. Knock ‘Obl the pine with a punch ené remove window regulotor, door hondle and escutcheons. 2 = Remove the door trim panel by pulling the clips fu! of the door. Care muit be token te eveld demoging the paintwork. 8 Remove. gecutcheon springs end robber inserts from the window regelator ond dest handle shells, 4 = Remove plastic sheot, 3 Unccrow the four window bottom channel crews ond lower the glass downwards out of the door window aperture. $+ Top the outer trim molding ond window aperture rubber set. hock slightly with sweoder block and rernove, ‘The euler tein moving lo the window aperture ‘one the mele of securing It were licfed 09 0 March 195 (ror Chass Nor 396703. “Try moulding clipe (Port Nt. Ht 883 28) are naw Ud inalead fe coumtersank. head screws over ih the moelding won pusbede “Ths netypatrin oubdngs Porto 14485333, BEANE ied i tornce parm vent iFige ace hfes ave dried owt 23 tm (38) meen 7- Remove outer giars run racks! ond weothers honnel elter pressing out the clips anal with sypport fond imner ron Net ‘ity eect rom ai August 1999 and Chow Nex eS 2g {09 deve evler and tees toner pla logy (ort Mo. 1 887 drip hove been Invalid Ivica ST he Suter. glese rum choneal, to apreve Me ‘irdow operation, Those plugs rust bo remomé Belore the doar TET 8 Lif the glass upwards out ofthe doer, 9 Fhe swindow gless.titt channel oF the rubber vol is damaged it con be replaced. The window lil channel should be tapped off With a rubber hammer and a sulteble block &f wood and replaced In @ similar manner. 10: Remove ax screw toon window regulator, 44+ Puah the regulator inwerds and pell dows wards, Take the regulator linkage with the boll joint sideways ul of the window fi chanel guide rail end rertove rogulalas frat the door 412+ Remove. two serews from the guide rail ond SS HERS. Window litchennel and tke he guide hanns! => cana ow i ; Iastallation 4 Check condilion of door window weatherstip fang renew H necessory To climinote fiction noises between the window gloss and the weatherstrip it is.re= commended thal broke cylinder pate (Part No B 1} 4 rubbed inte the robber lp ond the sweatharsiip finally wriped with a clean Tighlen hexagon heed ond countersunk sere, Trim Moulding for Deor Window Weatherstrip. ¢ Removal and Installation Remeval 1 Poll weatherstrp for door window sealing ovt ‘ofthe aioulding = Remeve loping serews. 3+ Toke off mouiding. K Instlltion 4 Check candion af moulding and weetersrip Gd ren necextory (S 3+ Attach the moulding to the roaf frame 46 that ‘a geod contact Between weatherstip and door ‘Yrindow ie obtolned. noo @ F A Rao 8 = Headlning <= Masiding Ds Westersrip = Beer windeve glass sisngae Semana = ses 18-30 € A-63 9 Door Lock Removal and Installation Removal 1 Remove inner door handle ond window regvialor handle. 2- Remove trim panel and plosiic sheet 4-Remeve avter door handle seloining screws ‘ond take off handle. SRemove four-door lock screws, Place door latch Ii @ vertical poillon and withdraw lock 1=Chacl atl paris for weer and replace where necessary. Grease oll moving parts, 2 Where necessary, he romolt control exrcmbly ‘or the pull rod can be renewed separctly ‘her removing the rivet 2--Check the potion of the cnlétiio rubber Heever on the pull rod. 4 The pull rod hos an elongated hole to faciicte maveinen! in ether dizecion, Whan the tock i nsolled the poll cad. should be pushed fowards the hinge wil ight eezitonee Fe fal ‘rd then balled fo the loek, 5 - Operate the inner door hoadle and eheck that he [eek pene properly before reassembling oor, thir is mot the esse the pull rod must be readjusted. When the Inner handle isin the “open position the Secure the reer end of the carpet wih o carpet oll, Glove Compartment Removal and Installation 1+ Open trent hood periment diber boar “Aho = Unscenseeatotalony sicapiace esr senile eet glove comportscnt. G € a The id tock con be removed wih iain pliers WW 4221 ore subable foo! of focal ant teak Remove two hiage screws en glove compart b ( seat li and take lie of & 44 To detoch the hinges tit necessary to remove the comperiment id spring and the twa rived ims, 5 The two rubber plugs for the Nd

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