Pepe - My cabriolet build

[DEGS]

Oh, I know where that is. Got rid of the crapily wired stereo pretty quick. Doesn't look like this will be easy to re-connect without pulling the dash though. Thanks.

[YJSAABMAN]

www.brokevw.com for just about all of your transmission questions.

[Spokane Pepe]

Thanks for the link

Work is keeping me from my build, but soon Ill be back in the garage.

[Spokane Pepe]

Started work on the interior panels and going over the car again. Its been a while since I had time to work on it. April picked out the color of the car and so now I need to gear up to apply paint. I still have some body sanding to do along with getting the garage ready to allow for paint to go on this cabriolet.

[Spokane Pepe]

Is there a way to remove the crankshaft pulley that I am missing? It looks like there are 4 hex head bolts that are a allen wrench type and or one big 19mm nut in the center.

My problem is I dont have a allen wrench that will clear the lip of the pulley.

[Spokane Pepe]

I solved the previous question but I have another one.

How do I remove the camshaft pulley? I am replacing the pulley and cant get it off.

[YJSAABMAN]

I solved the previous question but I have another one.

How do I remove the camshaft pulley? I am replacing the pulley and cant get it off.

Can't get the bolt loose? Or can't get it free from the cam? There's a hex on the cam under the valve cover you can use to hold the cam while you crank on the bolt. Do you have the belt off yet? It can keep tension on the pulley making it difficult to get off the cam, as well.

[Spokane Pepe]

Nope I have not removed it yet, waiting for someone to respond. I am going to look for the screw and see if this can work now.

Thanks for the info.

As for today's progress, I attempted to install these gauges but quickly realized they are round not square and would not work. I did however put in a new [used] lcd clock and got the center cluster cleaned up.

Gauges - going to have to sell / trade them I guess


New clock


Center console ready to be installed.

[Spokane Pepe]

No YJSAABMAN I did not see any hex screws to retain the cam so that I can unbolt the pulley. Can you show me where its located?



or this one

[mouser98]

Great thread. Love the work you have done and your color choice. Looking forward to more updates. Do work!

[Spokane Pepe]

Okay I am scraping the pulley idea, I dont have time and the stock one is working. It was more or less for a learning experience.

But now before I put on the timing belt I want to double check with you to see if I have all the parts lined up correctly.

1. Camshaft pulley is lined up with head.
2. Mid pulley is lined up with rotor and groove on distributor
3. Crankshaft pulley is lined up with the tab on flywheel

Is that all I need to check? Also the tab on the transmission has nothing to line it up with (no grove or line) unless the line is under the trans hole cover plug?

[Spokane Pepe]

Order up! Parts came in yesterday and I am itching to get out in the garage and get my hands dirty. At this point I have removed the timing cover, timing belt, pulleys, AC and alternator. I need to get the cam, crank seals installed and the new timing belt parts back together.

The list of new parts this time includes:



Parts for the cabriolet
Distributor Cap
Distributor Rotor
Fuel Filter
Instrument Lights
Oil Dip Stick
Oil Dip Stick Funnel
Oil Filler Cap; Oil Filler Cap Gasket
Oil Filler Cap
Radiator Cap/Expansion Tank Cap
Radiator Hose lower
Radiator Hose upper
Spark Plugs
Timing Cover
Windshield Washer Hose
Windshield Washer Pump
Windshield Washer Pump Grommet

Autohausaz kicks ass for good reasonable parts!


I will have to rent a press again to install the new tie-rod. The last one I broke while pressing it in the control arm because I used the wrong press adapter and did not pay attention. This time ill prevail or you’ll see me pulling my hair out.

Once I get the last motor mount removed this will all go together quickly, but that’s getting ahead of myself. The last motor mount is a real bugger in terms of location and accessibility. My goal this weekend is to put most of these new parts on and get this cabriolet back on all 4 wheels.

[Spokane Pepe]

Pump is a perfect match.

Its almost noon and I am at a standstill for two reasons. One I need the battery to charge so I can bump start the starter to break loose the crank bolt, as this is the last seal left to replace. Two I need to find someone to press the old motor mount out and press the new one in. I have most parts cleaned up and painted or a new replacement ready to be installed.






rigging up a way to remove interment pulley


Not bad for a few hours




Got to find someone in town that can press this in/out.

[inlovewithavdubengine]

ha ha... rockin' the golden valve cover! Great minds think alike!

I personally wouldn't have taken the sprocket off my cam line that, are you sure the timing marks are still going to line up?

Other than that, on the intermediate shaft, don't necessarily pay attention to the timing mark inside the distributor, just eyeball it so that the rotor is line to touch the point for the first cylinder's spark plug. This is top dead center. Then, just look at where your sprocket is lined up to and make a paint mark both on the TDC groove and on a reference point on the engine (it should be around where the water pump seals to the block) This will help you when you're ready to make sure everything is timed properly.

[Spokane Pepe]

ha ha... rockin' the golden valve cover! Great minds think alike!

I personally wouldn't have taken the sprocket off my cam line that, are you sure the timing marks are still going to line up?

Yea I went with gold because that was the original color (or close to it) of the parts in the engine bay. Most had so much grease and oil they looked black.

Well the cam and pulley have a key that must line up or it wont fit at all. So that does not consern me to much.

Other than that, on the intermediate shaft, don't necessarily pay attention to the timing mark inside the distributor, just eyeball it so that the rotor is line to touch the point for the first cylinder's spark plug. This is top dead center. Then, just look at where your sprocket is lined up to and make a paint mark both on the TDC groove and on a reference point on the engine (it should be around where the water pump seals to the block) This will help you when you're ready to make sure everything is timed properly.

The interment shaft is my only unknown at this point. The manual says to line the interment pulley up with the crank pulley but this is off when I line it up with the distributor. So either I pick distributor or I pick crankshaft mark.

Looks like working on her today is not going to happen, I cant find someone to press my motor mount in on a Sunday. I might keep cleaning the engine bay last night I sprayed 3 cans of gunk on it.

[YJSAABMAN]

Use a hacksaw to remove the old mount. Take the blade out of the frame, feed it through one of the mount gaps, install saw frame. Now cut through the outer ring of the mount, but not into the bracket. The old mount will all but fall out, now. The slit you cut relieves the tension holding it in.

[Nick Boudin]

Most shops around here have a hydraluic press to do the job for the mount. I had the same issue at first but my old man is a matinance mechanic and had the machine right at work

Cant wait for more updates!

[YJSAABMAN]

Most shops around here have a hydraluic press to do the job for the mount. I had the same issue at first but my old man is a matinance mechanic and had the machine right at work

Cant wait for more updates!

Yes, you need the press to put the new mount in. But with a hacksaw he can hopefully make it a little easier for the shop doing the press work and maybe save himself a few $$.

I've had enough need over the years that I asked for one for x-mas the other year, so I have this in my home garage, now.

[EuroTrash_miT]

Autohausaz kicks ass for good reasonable parts!

I ordered a lot of parts for my cabby last month from them. Super fast shipping with reasonable prices

[Spokane Pepe]

As of today the best deal I have found is 40 - 80 dollars to press the mount in. This is a bit more than I expected and well I am still looking for someone to press this thing in.

[NyCxGTI]

sick build sub'd for the rest of it

[Aaron16V1.8l]

The above is good advice for getting the old mount out and is in older versions of the Bentley for caddys, etc. Use a hacksaw to cut the old one out, just dont cut any deeper than the thickness of the mount (don't cut into the mount bracket). I would get it out first because people will be more likely to press the new one in because they will see how easy it is. I would just drive around to a decent looking shop with it and they should press it in for you cheap (hopefully).

You can also get creative with blocks of wood and a big vice to get it in yourself. I did my passenger side mount that way and it came out perfect.

[Spokane Pepe]

sick build sub'd for the rest of it

What is sub'd?

I have a jack and was thinking about welding up some metal jig and pressing it myself. I am debating if its just worth it to have it done by a machine shop.

tonight ill put the car in first gear and pull the parking brake then turn the crankshaft bolt. That should allow me to replace the oil seal.

Then everything gets put back together and ill fire her up again. The paint is getting closer, I just have to keep reading those how to paint car books.

Issues I need to solve soon.
- keep water out of my air compressor lines.
- How to mix paint
- is it etching primer I need or non etching.

Oh the joys of life.

[EuroTrash_miT]

What is sub'd?

"Subscribed".

[Spokane Pepe]

Woot! I got the motor mount pressed in for $23 american and so this weekend I should have the old girl back together (motor speaking).

Here is a picture of the engine getting cleaned up and going back together. I know I need to power wash the thing but I have issues with spraying water in my shop.



Man did I ever screw up this wing window too. Will I be able to find a replacement gasket? Probably not.

[YJSAABMAN]

So did you get your cam pulley swapped out? It looks like it. Sorry for the late reply on it, but no hex screws, just a wrench hex cast into the camshaft to hold it with. Should be there, though I guess not all had it.

[Spokane Pepe]

You have to ask. No I am still trying to remove that dam bolt. I have tried putting it in gear and pulling the emergency brake. Next I guess ill have to try the rope trick but hesitate because it seems dangerous.

If I cant get this crankshaft dampener off then I am going to scream at my dog all day!

What color are the factory heads on a Cabbie? This head looks too new to be original its gold in color too.

[YJSAABMAN]

You have to ask. No I am still trying to remove that dam bolt. I have tried putting it in gear and pulling the emergency brake. Next I guess ill have to try the rope trick but hesitate because it seems dangerous.

If I cant get this crankshaft dampener off then I am going to scream at my dog all day!

What color are the factory heads on a Cabbie? This head looks too new to be original its gold in color too.

Ah!! It's the crank bolt, not the Cam bolt, that's totally different. Be careful and check the bolt over well once you get it out. My MK3 daily was a cheap buy for me because the PO took the center bolt for the timing sprocket out and the last 1/2" stayed in the crank. Not realizing this the PO rammed it back in and it never seated right and the sprocket was loose and ended up chewing/breaking the keyway right off the sprocket and wallowing out the crankshaft.

If you just want to take the ballancer off focus on the 4 allen head bolts, not the center 12 point 19mm bolt.

[LoveMySwag]

This is an awesome thread! Loving the build and the progress, keep up the good work!

[hoff968]

I have audi 90 gauges in my cabby. Its a huge improvement . I kept the wood and it matches my wood shift knob. I hope to get a wood steering wheel to tie it all together. Nice job

Would you mind posting a picture of your Audi guage install please...?

[mileycyrus]

nice work on the door cards and boot....lol.....looks familiar..

[Spokane Pepe]

Ill be back on this project here in a day or two. I have been sailing almost all summer so its time to switch gears and get this old girl done.

[Sean A]

Love the door cards / shift boot man. I need to do something like that soon.

[YJSAABMAN]

Ill be back on this project here in a day or two. I have been sailing almost all summer so its time to switch gears and get this old girl done.

Sailing is a perfectly acceptable excuse in my book! Our season is just ending in the northern Chesapeke. I'm a J/24 sailor, what do you sail?

[gunnarpaul]

What is sub'd?

I have a jack and was thinking about welding up some metal jig and pressing it myself. I am debating if its just worth it to have it done by a machine shop.

tonight ill put the car in first gear and pull the parking brake then turn the crankshaft bolt. That should allow me to replace the oil seal.

Then everything gets put back together and ill fire her up again. The paint is getting closer, I just have to keep reading those how to paint car books.

Issues I need to solve soon.
- keep water out of my air compressor lines.
- How to mix paint
- is it etching primer I need or non etching.

Oh the joys of life.

You use etching on the bare metal. If its not down to bare you can use regular primer.