Author Topic: US VW Cabriolet 85  (Read 13939 times)

Offline Madone_si

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Re: US VW Cabriolet 85
« Reply #50 on: 20 January 2021, 00:58 »
Gear stick cover installed


and gave the VW a clean!


Also noticed this heater lever came off way to easily, is this part actually broken (white plastic part) or is this is how its meant to be?
Old Skool Mk1 Golf Gli (82), Mk1 US Cab 85 and 83
SOLD - BLACK SOY 92

Online Agreeable Slick

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Re: US VW Cabriolet 85
« Reply #51 on: 31 March 2021, 12:46 »
Looking awesome Si. Hope you are keeping well.

I made this : ->

Offline Madone_si

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Re: US VW Cabriolet 85
« Reply #52 on: 05 April 2021, 04:03 »
Looking awesome Si. Hope you are keeping well.

Thanks a alot slick. Yeah all is well mate, just working on the home and when parts turn up, can get more work done on cab.
Old Skool Mk1 Golf Gli (82), Mk1 US Cab 85 and 83
SOLD - BLACK SOY 92

Offline Madone_si

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Re: US VW Cabriolet 85
« Reply #53 on: 29 April 2021, 19:09 »
VW heater fix

So with top heater lever not working properly, dismantled the dashboard and found the issue, which is there is plastic part that has broken (Heater control pivot broke) Reading up and being informed from others on another forum, this is a common issue.

The white part in pic should have lever on top and a black plastic holds it in place and that is what has broken off


I followed this process to learn the fix and process (big thanks to Briano)
https://www.volkswagenownersclub.com/threads/my-heater-control-pivot-broke-cabriolet.46441

So here is what I did to fix it.

Once I got the unit out (not the easiest thing to do!) I inspected everything and gave everything a good clean.



In the above picture I drilled through black plastic part that holds the pivot parts in place and placed a bolt, washer and nut on the end. This will help fix the problem.

Added the white plastic back on, added white grease to pivot and moving parts


added the broken black pivot plastic part, now with drilled out hole through it to put the bolt, washers and nut through it to hold in place


Bolt installed from top with washers


Underside showing washers and threadlock (blue)


Nut installed and tightened up enough to lock but allow the pivot setup to work for both levers


Then installed the A/C lever and added grease. I placed a washer underneath ready for install as this is known fix for common issue of a-c-slider-pops-out-of-place. nice easy fix!


Next update, unit install in dashboard and time to do flush, clean and fresh coolant install (including Radiator inspection, replace thermostat and check all coolant pipes!!




« Last Edit: 29 April 2021, 19:17 by Madone_si »
Old Skool Mk1 Golf Gli (82), Mk1 US Cab 85 and 83
SOLD - BLACK SOY 92

Offline Mr_Orange

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Re: US VW Cabriolet 85
« Reply #54 on: 30 April 2021, 11:36 »
Nice repair job !
I hope this gets it all operational again  :smiley:


Build thread clicky

Offline Madone_si

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Re: US VW Cabriolet 85
« Reply #55 on: 30 April 2021, 17:58 »
the cab is always working, just trying to do things to keep it in great health and fix things as I find them. Hopefully will have heating and cooling done this weekend!
Old Skool Mk1 Golf Gli (82), Mk1 US Cab 85 and 83
SOLD - BLACK SOY 92

Offline Madone_si

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Re: US VW Cabriolet 85
« Reply #56 on: 18 May 2021, 23:57 »
Well the last few weeks I've been having fun with my blower fan motor not working (one of the carbon bushes and holder of it was burnt and bent!!)

I've managed to fix that issue (write up of that coming soon) but discovered another issue!!!!

Then I tested out the complete system on all the settings and noticed the Vacuum servo for air recirulation flap was not opening or closing, so I followed this amazing PDF - http://www.cabby-info.com/Files/HVACTesting.pdf and everything was working just perfect until I tested the vacuum distributor and bingo we have a leak.

Part #161820293B - another expensive part, not available from VW!


So some research and looks like there is alot of good info on on various online forums - the best thread on how this unit works was found:

https://www.vwvortex.com/threads/how-that-darned-vacuum-distributor-really-operates-a-detailed-analysis.2883746/?id=2883746&highlight=vacuum+distributor
How That Darned Vacuum Distributor Really Operates

and
https://www.vwvortex.com/threads/vacuum-distributor-on-the-heater-controls-not-the-same-as-the-manual.2860977/
Vacuum distributor on the heater controls…

Next steps!

    Managed to find replacement NOS part (waiting on that to arrive.)
    try and fix my one, I noticed a few people have tried a few tricks and got it to stop leaking, but I am guessing I will have to get a replacement part.

Updated this problem to a few of the dedicated mk1 forums to see what others have done to do a fix (be nice to do the fix and have a spare)

All this issues ended up taking out the complete dashboard which actually will allow me to do some other work without breaking my back!

« Last Edit: 19 May 2021, 00:45 by Madone_si »
Old Skool Mk1 Golf Gli (82), Mk1 US Cab 85 and 83
SOLD - BLACK SOY 92

Offline Madone_si

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Re: US VW Cabriolet 85
« Reply #57 on: 20 May 2021, 19:33 »
Got my new vacuum pipe junction in today and connected it all up.




Tested out each of the cooling/heating positions and everything is working as needed, I come to test out the MAX A/C positions as seen in this http://www.cabby-info.com/Files/HVACTesting.pdf and in photo below, this is the only option that allows your under the passenger dashboard recirculation vent flap to Close and its not closing. About 3 minutes later it really really slowly started to close - which to me is not right.(Tested the pipes to make sure the retracting the diaphragm, forcing the recirculation vent flap closed and that worked just fine so we know that is not the problem)




I then noticed that the new vacuum pipe junction is not moving all the way down into the slot.


and I very gently moved it to as far as it could go into the slot


and as soon as I did that recirculation vent flap closed within 2 seconds - its working as it should!


I repeated this process using the levers and again the top lever just doesn't move the vacuum pipe junction far enough down to get the MAX A/C position to work as required and thus the recirculation vent flap would not close. Moved the vacuum pipe junction down gently again and recirculation vent flap closed within 2 seconds.

So the big question is the new unit broken, the top lever bent, the unit it all connects to out of alignment, at this point I have no idea. Anyone got any ideas?

I took a pic of the vacuum unit apart to give everyone good idea what these look like apart
Old Skool Mk1 Golf Gli (82), Mk1 US Cab 85 and 83
SOLD - BLACK SOY 92

Offline Madone_si

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Re: US VW Cabriolet 85
« Reply #58 on: 12 June 2021, 16:59 »
I managed to fix my heating/cooling issues, with simple fix, update on that and rebuilding of my fan motor too soon.

Well waiting on parts for my steering column, moved onto refurb of my steering wheel.

Treated the steering wheel to cleaning and treatment to wheel itself and then removed the center silver clip an painted it to match the OEM Red trim color.


Had really nice warm weather the last few days, so that helped this work.


Wheel as I got it







Up close you can see little damage on surface




Part details for future reference




Time to prep for sanding and painting




primer, had to do this a few times as primer to get it to point of smooth for red paint.




Few coats of red




Sanded down ready for final red paint




2 coats of Red and 2 coats of clear finish




dryed for 24 hours and then all ready




and installing on wheel!







and all ready for installing in the vw cab again!

« Last Edit: 13 June 2021, 06:09 by Madone_si »
Old Skool Mk1 Golf Gli (82), Mk1 US Cab 85 and 83
SOLD - BLACK SOY 92