Engine Mechanical:
Engine mechanical: cylinder head, cylinder block, camshaft, crankshaft, connecting rods, pistons, lubrication system (oil pump, oil filter).
Engine Control:
Engine control systems: fuel injection (Bosch K-Jetronic for later models), ignition system, emission control systems (including charcoal canister).
Cooling System:
Cooling system: radiator, cooling fan system, thermostat, engine coolant.
Fuel System:
Fuel system: fuel tank, fuel pump, fuel injectors, fuel lines.
Exhaust System:
Exhaust system: exhaust pipes, muffler components.
Transmission Manual:
Manual transaxle system: clutch system (master cylinder, release cylinder, clutch unit), gears, shafts, maintenance, oil specifications.
Transmission Automatic:
Automatic transaxle system: automatic transaxle assembly, fluid specifications, maintenance.
Drivetrain:
Drivetrain: front drive shaft, rear axle hub, rear axle beam, differential case assembly.
Suspension Front:
Front suspension system: front suspension, front suspension arm, front stabilizer bar, front shock absorber.
Suspension Rear:
Rear suspension system: rear suspension, rear coil spring, rear shock absorber Assy, rear axle hub, rear axle beam.
Steering System:
Steering system: steering system, steering column, steering sensor, power steering, power steering link Assy.
Brake System:
Brake system: brake system, brake master cylinder, brake booster, brake fluid, brake pedal, brake actuator, front brake, rear brake.
Wheels Tires:
Wheel and tire system: wheel and tire system, front wheel alignment, rear wheel alignment.
Electrical Lighting:
Lighting system: headlamp Assy, license plate lamp Assy, front marker lamp Assy, rear combination lamp Assy, center stop lamp Assy.
Electrical Instruments:
Instrument panel, combination meter.
Electrical Starting Charging:
Starting system: starter Assy, starter switch, charging system, generator Assy.
Electrical Ignition:
Ignition system: distributor, ignition coils, spark plugs.
Electrical Audio Visual:
Audio & Visual System: radio receiver Assy, amplifier antenna Assy, antenna cord sub-assy.
Body Exterior:
Body repair: front bumper, rear bumper, hood, fender panel mudguard, roof drip side finish moulding, side mudguard, back door, back door glass.
Body Interior:
Interior: instrument panel, seat, seat belt, roof headlining, sun roof system, cigarette lighter Assy, horn button Assy.
Climate Control:
Heater & Air Conditioner: heater radiator Assy, heater or boost ventilator control, air conditioning system, air conditioning blower Assy, air conditioner refrigerant.
Wiper Washer:
Wiper and Washer System: windshield wiper motor Assy, wiper rubber, rear wiper motor Assy, rear wiper rubber, washer nozzle.
Safety Systems:
Supplemental Restraint System, Air Bag Sensor Front, Air Bag Sensor Rear, Seat Position Air Bag Sensor, Side Air Bag Sensor Assy, Center Air Bag Sensor Assy, Curtain Shield Air Bag Assy, Passenger Air Bag Assy, Seat Belt Warning System.
Windows Doors:
Power window control system, front door, rear door, front door glass weatherstrip, rear door glass weatherstrip, back door glass.
Maintenance:
Routine maintenance, lubrication, fluid checks and changes, filter replacements.
Troubleshooting:
Diagnostic procedures, fault finding, common issue resolution.
Repair:
Detailed repair instructions for all major systems and components.
Overhaul:
Engine overhaul, transmission rebuild, suspension component replacement.
Electrical Diagnostics:
Wiring diagrams, wire harness repair, electrical component testing.
Wheel Alignment:
Front and rear wheel alignment procedures and specifications.
Body Repair:
Body panel repair, glass replacement, trim installation.
Depth:
Complete factory-level technical information, suitable for professional mechanics and dedicated enthusiasts.
Diagnostic Codes:
Includes diagnostic information, though formal OBD-II codes are not applicable to this era; focuses on system symptom analysis.
Torque Specs:
Extensive torque specifications for all fasteners and critical components.
Tolerances:
Includes precision measurement and tolerance specifications for engine and mechanical components.
Oil Change Interval:
Typically every 5,000 - 7,500 miles or annually, depending on usage. Refer to manual for precise intervals.
Major Service Interval:
Major services (e.g., valve adjustment, ignition timing) often recommended at 15,000 - 30,000 mile intervals.
Engine Oil:
Air-cooled engine oil requirements vary. Historically, specific multi-viscosity oils like 20W-50 or 15W-50 (often with high zinc content) were recommended. Refer to manual for specific viscosity and API/ACEA classifications for your model year.
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Manual Transmission Fluid:
Specific gear oil for manual transaxles, typically GL-4 or GL-5 rated. Refer to manual for viscosity and specifications (e.g., SAE 75W-90 or 80W-90).
Automatic Transmission Fluid:
Specific ATF fluid, refer to manual for type and capacity.
Engine Oil Leaks:
Common due to age and numerous seals in the air-cooled engine; requires regular inspection and maintenance.
Valve Adjustment:
Requires periodic adjustment to maintain performance and engine health.
Fuel System Maintenance:
K-Jetronic systems require careful maintenance; injector seals and pressure regulators can be common service items.
Rust Corrosion:
As with many cars of this era, rust can be a concern in common areas like fender wells, rocker panels, and floor pans, especially in humid climates.
Electrical Gremlins:
Aging wiring harnesses and connectors can lead to intermittent electrical issues.