Volkswagen beetle 1972 Operating instructions

Volkswagen Owner’s
Beetle, Super Beetle Maintenance
and Repair
Guide

1972 Models

Errata
Pages 42,43 and 129
The valve clearance as listed on these pages should
be changed to read 0-006 inch (0.15 mm).
Page 54
The V shaped notch in the pulley is the actual 5
After Top Dead Center mark to be used for the set¬
ting of the ignition timing. Do NOT make a mark to
the left of the notch as illustrated (top illustration)
and described in paragraph b-

Volkswagen Owner's
Beetle, Super Beetle Maintenance
and Repair
Guide

© 1371 Volkswagen ol America, 3re.
AH fights reserved
An Information contained in inis booklet li based on the latest product
irilermasi&n available al the time of printing, The fight is reserved lo make
Changes al riny limn without notice.
^ ■ 00 ‘tHM-fl
first GdHinn. 3.71
Printed in U S A.

Introduction
The Beetle and Super Beetle are unique cars in many ways Surely, one way must be
that they seem to invite tinkering
Partly, this comes from the very personal feeling owners have toward their VW$ More
than just transportation, they are. for many, a part of the family
But also, this willingness to pick up a screw driver and "do it yourself' comes from the
simple, uncluttered design of the cars themselves
They are easy to get at And owners who might normally consider a spark plug a poten¬
tial antagonist, will check distributor points or change a coil at the sound of an engine
cough
This book is to keep them, and you. out of trouble — and to make maintaining a Volks
wagen not only a little less expensive, but a little more fun
Perhaps you have no intention of ever lifting a finger over your car s engine This book is
still for you. because it can tell you a lot about your VW you might never normally have
known And should you ever need help, you will be able to quote chapter and verse to
someone else
But before you start any of the maintenance tasks, repairs, or adiustments described in
this booklet, be sure to read the chapter on Preparation
You'll want to choose the right tools and gather the essential materials before you start
your job And you'll also want to read the instructions carefully and keep the book open
before you as you progress through each step
We've tried to limit the tasks in this book to those easily performed and requiring few
tools But what is easy for your neighbor (who stuffs V 8 engines into old VWs) may not
be easy for you
That's where your Authorized VW Dealer comes in You may enioy changing a tail light,
but you may prefer to have your dealer tune the carburetor In fact, unless you are quite
certain of your skills, we might suggest you ask your dealer to perform tasks especially
related to safety, like brake repairs or adjustments
He’s also the man to turn to for Volkswagen tools and Volkswagen spare parts. And.
remember there's only one place to get a VW Diagnosis — especially the four free ones
that come with the car And that. too. is at your dealer's Have your car diagnosed
according to schedule and you can be sure no little, hidden problems will grow to haunt
you as big. expensive ones
A FEW WORDS ABOUT WORDS
Throughout the book you will fmd paragraph headings such as NOTE. CAUTION, or
WARNING A NOTE contains information you'll want to make note of before starting the
lob A CAUTION points out information you'll need to prevent you from damaging your
car And a WARNING points out information you'll need to prevent you from damaging
yourself Please, take heed
As we have suggested, understanding and caring for your Volkswagen should deepen
your relationship with it And that, really, is the reason for providing you with this guide

Table of Contents
Chmfrtmr
7him
\
2
3
4
6
Preparation and Tool List
Troubleshooting.
T U-fie 1 UP . .. ...
Jacking and Support wig
Left Side with Both Wheels Off the Ground .
Right Side with Bath Wheels Off the Ground.
jacking Either Side wflh Support Stand
Under Front and Rear
What Should Be Done Regularly
Maintenance . ■ ■ r ... r ■ r ■ n n r ■ . - . .^ i . . . ■ - r ■ . ■ r . . r r T ■ ■
Lubrication...... ..,..*...
Engine ...... . ...
Checking Engine Oil Lave I ...... ...
Transmission .,, , t11 . . .
Transmission - Automatic Stick Shift
Air Cleaner
Front Aide. .
Door end Hood Locks
B rttflif . ■ i.... ■ i.
Spark Plugs ^ . . ..
Valve Clearance. . .
Ignition Distributor . ......
Distributor Contact Breaker Points
Condenser
Dwell Angle Check and Adjuaimaet. ...,.
Ignition Timing Procedure .......
Carturolor Idle Spaed Adjustment.....
Ttwottia Valve Positioner
V- Bolt *..
Fuel Pump Filter... —
Clutch Pedal Free Ray . __, ... .
Exhaust Muffler
Tail Pipes
Steering Damper (Beetle)
Steering Damper (Super Beetle!
1
4
12
14
16
15
16
IB
IS
19
21
25
25
20
23
32
34
36
39
41
46
47
SO
52
53
55
5b
57
60
61
62
69
70
73
t

Chapter
THto
Page
Shock Absorbers 76
Brake Fluid Reservoir 78
Windshield Washer 78
6 General Service 80
Electrical System 80
Bulb Replacement 89
Headlights 90
Headlight Assembly 91
Front Turn Signal/Parking Light or Side Marker
Light Bulbs 93
Front Turn Signal and Parking Light Assembly 94
Rear Turn Signal. Stop and Tail Light or Back up
Light Bulbs 98
Tail Light Assembly 96
License Plate Light Bulb 98
Interior Light 98
Fuses 99
Windshield Wiper Blades 101
Windshield Washer Spray Jets 103
Checking Tire Condition 103
Wheels 105
Front Seats 109
Roar Foot well Heating 110
Front Bumper 112
Rear Bumper 113
Rubber Moldng for Bumpers 114
Front Fenders 115
Rear Fonders 112
Running Board "8
7 Beauty Care 120
8 Accessories '23
9 Technical Data '29

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Chapter 1
Preparation and Tool List
Before going into details there are several general rules you will want to consider
First, be careful Carelessness can cause miury to yourself and damage to your car or
personal property Second remember that incorrect servicing will change the perform
ance of your car It may alo change the effectiveness of the exhaust emission control
or may otherwise impair the safety and dependability of your Volkswagen
To prevent injury to yourself, follow these rules:
e Never work under the car unless it is on support stands
• When working under the car. make sure it is on level ground, has the wheels blocked
and the engine cannot be started
e Be alert and cautious around the engine while it is running
• Never run the engine unless the area is well ventilated
• Tie long hair back behind your head
• Oress for the occasion, do not wear neckties or loose clothing
• Remove all iewelry
• When working around fuel, never smoke or have anything in the area that can ignite the
fuel Keep a fire extinguisher in close reach
• Oo not store fuels, oils, or cleaning fluids in food containers
• When working on the fuel system or electrical system always disconnect the battery
Keep a fire extinguisher in close reach
To prevent damage to your car or personal property, follow these rules:
e Always use only the proper replacement parts which can be obtained from your
Authorized VW Dealer
• Always use the proper tools
• If you do not have the proper tools or have doubts whether you can do the repair or
adjustment yourself have it done by your dealer or by a qualified mechanic
• Be sure you have adequate lighting when working on any part of the car
• Follow the instructions in this booklet very closely Do not try to short -cut them
• Use containers to catch any drained or spilled fuel or oil Spilled oils and fuels create a
fire hazard and are especially damaging to asphalt surfaces Be sure to wipe up spills
immediately
• Be careful how you dispose of your oil Do not discard it in streams, down sewage drains,
or on garden soil Check your local ordinances
1