Manual Details
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Coverage Areas
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Covered Years:
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1954, 1955, 1956, 1957, 1958, 1959, 1960, 1961, 1962, 1963, 1964, 1965, 1966, 1967, 1968, 1969, 1970, 1971, 1972, 1973, 1974, 1975, 1976, 1977, 1978, 1979
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Page Count
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Page Count:
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323
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Manual Type
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Manual Type:
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Workshop Repair Service Manual
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Language
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Language:
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English
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Format
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File Format:
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PDF
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Delivery Method
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Delivery:
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Electronic Delivery via Email
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Printability
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Printable:
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Yes
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Manual Coverage
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Systems Covered
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Engine:
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Complete engine disassembly, assembly, repair, overhaul, tuning, lubrication system.
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Fuel System:
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Fuel tank, fuel lines, fuel pump, carburetor(s) (Solex, Zenith, etc.), fuel filter, adjustment, and troubleshooting.
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Ignition System:
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Distributor, ignition coil, spark plugs, ignition timing, condenser, points, troubleshooting.
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Transmission:
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Manual gearbox (4-speed), clutch, shift linkage, removal and installation, overhaul.
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Electrical System:
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Wiring diagrams, starter motor, generator/alternator, battery, lighting system, horn, wipers, fuses, troubleshooting.
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Brakes:
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Hydraulic system, brake master cylinder, wheel cylinders, brake shoes, brake drums, brake fluid, adjustments, bleeding, troubleshooting.
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Suspension:
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Front torsion bar suspension, rear torsion bar suspension, shock absorbers, kingpins, bushings, adjustments, replacement.
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Steering:
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Steering box, steering column, tie rods, steering knuckles, adjustment, overhaul, troubleshooting.
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Cooling System:
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Air-cooled engine cooling, fan, shrouds, heat exchangers (where applicable).
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Exhaust System:
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Exhaust pipes, muffler, heat exchangers (early models), tailpipe, troubleshooting.
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Body:
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Body panels, doors, windows, seats, interior trim, bumpers, removal and installation of components.
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Procedures Included
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Maintenance:
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Routine servicing, lubrication, fluid changes, filter replacements, tune-ups.
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Diagnostics:
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Troubleshooting guides for common problems across all systems.
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Repair Overhaul:
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Detailed step-by-step instructions for component repair and complete overhaul.
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Removal Installation:
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Procedures for removing and installing major and minor components.
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Adjustments:
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Specific procedures for adjusting ignition timing, carburetor settings, brakes, clutch, etc.
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Technical Depth
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Depth:
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Comprehensive (suitable for professional technicians and experienced DIYers), covers from basic maintenance to full engine and transmission rebuilds.
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Proprietary Components
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Proprietary Instructions:
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Includes instructions for proprietary components, referencing component manufacturers' guidelines where applicable to ensure proper understanding of functions.
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Maintenance
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Service Intervals
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Oil Change Interval:
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Typically every 3,000 miles or 6 months, but manual will specify exact interval and oil type.
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Tune Up Interval:
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Recommended tune-ups at regular intervals for optimal performance and efficiency, details in manual.
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Fluid Specifications
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Engine Oil Type:
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Viscosity grade will vary with climate (e.g., SAE 20W-50 or 30W), and specification (e.g., API SF or SG for later models). Manual is essential for correct specification.
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Brake Fluid Type:
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DOT 3 or DOT 4 hydraulic brake fluid (non-silicone based).
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Transmission Oil Type:
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Specific gear oil for the manual transaxle, viscosity will be provided in the manual (e.g., GL-4).
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Known Issues
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Common Issues:
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Rust (especially in floor pans, rocker panels, and wheel wells), carburetor issues, ignition system tune-up requirements, brake adjustment needs, potential for oil leaks from engine seals.
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Engine Cooling Quirks:
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Air-cooled engines are sensitive to ambient temperature and require proper airflow. Overheating can occur if cooling tins or shrouds are missing or if the fan belt is loose.
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