1961-1965 Volkswagen 1200 Types 11 14 15 Workshop Manual PDF Download

Description

Volkswagen 1200 Types 11, 14 and 15 Workshop Manual – 1961-1965

This Workshop Manual reproduces the original Volkswagen service and repair information for 1961 through 1965 Type 1 models and covers the 1200 Sedan, 1200 Convertible, 1200 Karmann Ghia Coupe and 1200 Karmann Ghia Convertible. Its 1,364 pages are arranged as a complete workshop reference rather than a short maintenance guide: engine and clutch, fuel system, front axle and steering, rear axle, brakes/wheels/tires, lubrication and maintenance, technical data, electrical system, frame and body are each developed as major sections with removal, disassembly, adjustment, repair and workshop-equipment information.

File Details

• Manual type: Workshop Manual
• Brand: Volkswagen
• Models: Volkswagen 1200, Types 11, 14 and 15
• Production range stated by the manual: 1961 through 1965 Type 1 models
• Covered vehicles: 1200 Sedan, 1200 Convertible, 1200 Karmann Ghia Coupe, 1200 Karmann Ghia Convertible
• Language: English
• Pages: 1,364
• File format: PDF
• ISBN: 0-8376-0390-0
• VWoA Inc. Part No.: LPV 800 121
• VW Inc. Part No.: MAN 101 113
• Bentley Stock No.: V165

Important historical scope

The publisher explains that this is a reproduction of the original Volkswagen service and repair information and that historic, deleted information has been retained for reference. The introduction identifies it as the service and repair information available to the authorized Volkswagen dealer technician in 1965. It also cautions that the manual is a present-day guide to service and repair only with awareness of its age: workshop practices, safety precautions, materials, specifications and procedures may have changed since publication. For a buyer working on an early Volkswagen, that dated character is part of the value because the procedures, specifications and model changes are presented in the period documentation.

Chapters Covered

• M – Engine and Clutch – engine description; removal and installation; disassembly and assembly; cooling; intake, exhaust and heating; cylinder head and valves; cylinders and pistons; oil circulation; crankcase; crankshaft, connecting rods and camshaft; engine test-bench work; clutch description, removal, repair and overhaul; release bearing; clutch cable; pedal free-play; automatic clutch description, removal, disassembly, gearshift-clutch repair, control valve, servo/vacuum tank and adjustment procedures.
• K – Fuel System – descriptions for 28 PICT and 28 PICT-1 carburetors; Solex 28 PICT and 28 PICT-1 carburetor service; fuel pump; fuel tank; special hints and workshop equipment.
• V – Front Axle and Steering – front-axle removal and installation, suspension and steering service, steering components and related adjustment procedures.
• H – Rear Axle – rear-axle description; removal and installation; disassembly and assembly; early and late rear-wheel bearings; rear-axle tubes and shafts; transmission case; drive pinion, main drive shaft and differential; drive-pinion/ring-gear adjustment; gear control; rear suspension; special hints and workshop equipment.
• B – Brakes, Wheels and Tires – hydraulic-brake description, master cylinder, brake lines, front and rear wheel brakes, hand brake, filling/bleeding/adjustment, turning brake drums and fitting new linings; wheels, tires and special instructions; disc brakes.
• S – Lubrication and Maintenance – general lubrication, lubricants and lubricant specifications, lubrication chart, special hints, workshop equipment and the maintenance chart.
• T – Technical Data – technical data up to July 1965, data from August 1960, and tolerances and wear limits.
• E – Electrical System – description and wiring diagrams, generator, starting motor, battery, ignition system, lighting for Sedan/Convertible and Karmann Ghia versions, electrical accessories, instruments, electric cables, special hints, workshop equipment and special instructions.
• R – Frame – chassis/frame service and related workshop procedures.
• A – Body – body repair and adjustment information for the covered Sedan, Convertible and Karmann Ghia body configurations.

The section lettering is useful in a large manual because each major system works almost like a separate workshop book. The engine section alone progresses from basic construction through removal, complete disassembly, valve and piston work, crankshaft and camshaft service, clutch repair and automatic-clutch equipment. Rear-axle and brake sections similarly go from description through dismantling, measurement, adjustment and reassembly. Electrical material separates Sedan/Convertible and Karmann Ghia lighting and instrument differences instead of forcing every body style into one diagram.

1192 cc air-cooled engine and fuel-system data

The technical-data section identifies the engine as a four-cylinder, four-cycle, air-cooled unit with the cylinders horizontally opposed in two pairs. Bore is 77 mm (3.031 in), stroke 64 mm (2.520 in) and displacement 1192 cc (72.74 cu in), with a 7.0:1 compression ratio. Maximum DIN output is listed as 34 bhp at 3600 rpm and maximum DIN torque as 8.4 mkg (61 ft lb) at 2400 rpm. Dry engine weight is approximately 108 kg (238 lb). The manual provides valve-clearance data, valve timing, piston/cylinder and bearing tolerances, wear limits and the specifications needed to judge components during overhaul.

Fuel-system information includes the Solex 28 PICT-1 downdraft carburetor with accelerator pump and automatic choke, a 22.5 mm venturi, model-dependent air-correction jetting and other jet sizes. The mechanical diaphragm fuel pump is specified with a maximum pressure of 0.2 kg/sq cm (2.8 psi) and minimum delivery of 24 litres per hour at 3400 rpm. Fuel-tank capacity is 40 litres, including a 5 litre reserve. These figures sit beside detailed carburetor, fuel-pump and fuel-tank procedures in section K.

Drivetrain, chassis and service specifications

Technical data describes a single-disc dry clutch, spiral-bevel final drive with a 4.375:1 ratio and independent suspension front and rear. Steering is worm-and-roller with a divided tie rod and steering damper. Wheels are listed as 4J x 15 with 5.60-15 tubeless tires. The hydraulic brakes operate on all four wheels and the hand brake acts mechanically on the rear wheels. Tire-pressure tables distinguish light and heavier occupant loads, while the technical-data and wear-limit pages give the measurements needed when inspecting or rebuilding parts.

Capacity data includes 2.5 litres for the engine crankcase, 3.0 litres for the transmission case and differential when filled to capacity, 0.25 litre for the brake system and approximately 0.25 litre for the oil-bath air cleaner refill. The manual also records period performance and consumption data, gear-speed relationships, model weights and changes by chassis or engine number where Volkswagen revised specifications during production.

Electrical diagrams and body-specific information

Section E begins with wiring diagrams and then covers generator, starting motor, battery and ignition before separating lighting, accessories, instruments and cable information by body style. The technical pages specify battery ignition, firing order 1-4-3-2, breaker-point gap, spark-plug gap and period Bosch component identifications. Lighting wattages, wiper and washer equipment and fuse arrangements are also documented. That makes the electrical section useful both for tracing an original circuit and for checking whether a component belongs to the period configuration shown by the manual.

A workshop reference for period-correct service

Use this manual for engine removal and overhaul, carburetor and fuel-pump work, clutch service, front and rear axle repairs, steering adjustment, brake rebuilding and bleeding, lubrication and maintenance, tolerance and wear-limit checks, charging and ignition diagnosis, wiring work, frame service and body repairs on the covered 1961-1965 Volkswagen Type 1 models. The original procedures and technical data help keep measurements, adjustments and assembly sequences tied to the correct period Volkswagen information. After payment, the complete 1,364-page manual is supplied as an instant PDF download with no shipping, readable on a phone, tablet or computer and printable for workshop or restoration use.