rebuild of 92 cabriolet

[betsy95]

ok so i have decided to fix up my 92. other than first purchasing a Bentley, any suggestions on where to start? She has many many things that need repair. the clutch is shot, the radiator has a hole, the heater core is no good, brake lines and connections are shot due to being parked in the woods for a year, i had the head gasket test performed (where they check the antifreeze for exhaust) and that came back bad, which is strange because i have been driving it for atleast a year that way and it still runs great. awesome gas mileage she doesn't burn oil. oh yeah and the starter that has been on its way out finally went the other day. that was the straw that broke the camels back and lead me to buy my latest VW a 2004.5 Passat GlS. the body has very little rust, i have recently put a new outer shell on. so what do you think, is she worth the fixing? i am not overly mechanical and this would be a spare time project. any suggestions? thanks for the input!

[briano1234]

Yes, it is worth saving, you didn't say automatic or manual transmission.
http://reflectionsandshadows.com/a1-tech/
and
www.cabby-info.com

Are two of the sites that you need to peruse.

[inlovewithavdubengine]

ok so i have decided to fix up my 92. other than first purchasing a Bentley, any suggestions on where to start?

First of all you need patience, and a passion for what you're doing. You will also need:
Tools;
-A good set of metric sockets.
-A set of metric combination-wrenches ranging from 8mm-19mm.
-5mm & 6mm Allen-head key, you might as well get L-wrenches in those sizes too just in case.
-A 12mm triple square
-*An 8mm triple square as well
-The best torque wrench you can afford or borrow.
-Smaller ratchets, "Swivel heads", etc, whatever else floats your boat in the socket department.
-Standard-issue VW Lug Wrench/Breaker bar.
-Assorted Phillips and Flathead screwdrivers.
-Vice grips (optional, but very nice to have for certain applications, like installing the brake shoes)
-Pliers (I mostly use tongue-in-groove, for removing hose clamps, but do have a few types on hand if needed)
-Hammer and/or rubber mallet
-Chisel and/or crowbar (seriously; for things like prying off your drums & opening the fuel tank cover under your backseat)
-A floor jack (the one included with the spare tire in your trunk MIGHT do the trick, but I don't in any way recommend it considering the kind of stuff you're going to be doing)
-2 Jackstands
-Scrap pieces of lumber come in handy, as shims and wheel blocks for example.
-One of these: http://images1.americanlisted.com/nl...l_29563355.jpg
-A bunch of plastic containers for catching fluids and keeping your bolts organized.
-Plenty of rags and work clothes
-You might decide to pull the entire engine, in which case an engine hoist and an engine stand would be indispensable.
-I have this magnet with a handle that always come in handy for when I drop important pieces into inaccessible places
-Thread sealer and/or plumber's tape.
-Some WD-40
-If you strip anything, you're going to need a drill, bits, taps, and thread coils, so either get these or always make sure that you are using the right tools and apply the proper amount of force.


Parts;
-A new set of gaskets: at the very least, a new head gasket, and new intake and exhaust gaskets. If you're getting water in your oil you might want to pull off the oil pan, clean the sludge, new oil pan gasket. Check out your valve cover gasket too, you might need a new one. I went with cork. Check out your water pump for possible leaks, too. Like I said, more or less a full set.
-A new radiator (unless you can find a way to repair it, it could even be just a hose leak)
-A new starter motor
-New spark plugs, why not
-A new oil filter. Check out your fuel and air filters too, but those last longer.
-New brake shoes, cylinders, springs, bearings, axle grease, etc, possibly for every wheel, but it's probably just those nefarious rear drum brakes. You could swap discs into the back but that's more on the pricey side.
-Possibly a new clutch. You won't know what's "shot" until you remove the transmission unit and poke around.
-Good time to change most of your belts. I removed my A/C while I was in there, too.
-May or may not need a new set of valve lifters, or other little things. Like I said, you won't know until you start wrenching.
-If your car is anything like mine, you'll want to new bolts to replace most of ones you take out. Allen heads, especially, are way better when they're new. You'll only be spending pocket change on these and it's worth it not to be dealing with stripped edges, corrosion, and worn out threads.
-Fluids as needed: may include motor oil, brake fluid, power steering fluid, antifreeze/coolant/water, 10W-30 Motor oil, GL-4 Gear oil, Gasoline, wiper fluid, beer, etc.

Service;
Drums rotated
Compression tests, smog certification, etc, as needed
POSSIBLY look at getting your head assembly planed but it's probably fine.


Just remember, one step at a time. Have a clean work area or develop a system so you wont be losing tools and pieces. Put your battery somewhere safe. Familiarize yourself with the anatomy of the engine compartment. Dab a little paint on your timing marks if it'll help later. If you have any mechanic-type buddies, hit them up, sometimes four hands are better than one.
The way I see it, you just have 3 things to repair: Brakes, Head gasket, and Clutch.. everything else is secondary or just a part you'll replace while you work on the other things.
Make a plan of attack, decide what you want to do first. Installation is the reverse of removal. There's lots of good people here for you if you need any advice.

[inlovewithavdubengine]

There's one more tool I forgot: I think there's a smaller triple square for the transaxle/halfshaft bolts, but I'm not sure what size it is. Anyone know?

[briano1234]

8mm



Available at GermanAutoparts.com

[betsy95]

thanks! i already have a few parts like the rear brakes and clutch and other random things i have picked up along the way. i am looking forward to testing my skills (they are few) and patience. luckily i do have lots of people that i can drill when i get lost or confused. is there a way i can start Olay up with out the starter? like can i bypass it some how? the car is stuck at my sisters and i don't want to pay for a tow. i'm cheap like that. also the latches foe the top are not doing so good any more, they come undone while i am driving down the road. any suggestions on where to get more? they are not many cabbys in the junkyards around here. thanks again!

[inlovewithavdubengine]

To my knowledge, there is no way to start the car without, well, a starter. When you turn the key all the way clockwise into the "start" position, a circuit is completed between the car's battery and an electromagnetic motor apparatus that we lovingly call "the starter."

http://www.youtube.com/watch?v=hGMxG...eature=related

The starter is bolted on to the engine with a couple of the same bolts that hold the transmission, you'll find it just beneath the motor for your radiator fan. It features a little pop-out gear that turns your flywheel, which is another gear-like object that also serves to contain your clutch. If your engine is timed correctly, the timing belt on the other end of the flywheel/crankshaft will provide turning motion to several other moving parts; at the very least your camshaft, water pump, distributor, and alternator; power steering and air-conditioning optional. These things quickly start moving themselves thanks to the fuel-compression-spark-exhaust process, the starter is no longer engaged, and it's off to the beach you go.

The only alternative I can conceive is somehow taking the gear from your broken starter, attaching a pneumatic drill, sticking it in there and praying for a miracle. That would be quite dangerous, anyhow figuring out how to do that would probably be more work than just fixing your starter or getting a new one. I suppose you could try repairing the starter yourself but that's not exactly my forte at this moment and doesn't sound like yours either.

Check your local shops, there's probably even a starter SPECIALIST nearby who will fix your starter or trade your broken one for a working one at a discounted price.

[twinair]

Replace all ground straps and battery cables and alternator cables. Also replace your grounds and replace your grounds and replace your grounds. You're gonna wanna replace all of the grounds.

[betsy95]

haha! i was hoping that maybe i could pop the barely there clutch or something.

[inlovewithavdubengine]

hmmmmm.... actually, I suppose you could pop the clutch. If you turn the key into the ignition position while a strong friend or two pushes your car, ideally downhill. Put it in 1st gear with your foot on the clutch and release it, and with a little luck your engine will turn over.... the problem is, the clutch is no good either! Just get it towed, or put the new starter in while it's at your sister's. The starter is a piece of cake.

Once you have that, you can try starting it in gear and bring it home.