After a some trouble we finally got my '84 GLs A/C system up and functioning
on R-134a.  Came out nice and cool at around 40 degrees F.  A big thing I
figured out that will help people who are doing the conversion in the future
and have to replace all the o-rings is this:
When you go to take down the overhead A/C unit (evaporator and blower housing)
instead of unhooking the water drain lines on either side of the unit just cut
them about an inch or inch and a half from the wall (becareful they don't get
pulled inside the wall!).  Now you can undo the two bolts and one screw that
hold up the unit (on the '83-'85 models) and drop the thing right down with
very little problem.  When you go to put the unit back up you can reattach the
lines after you have bolted the unit back in place by getting some copper
tubing with a OD of 3/8".  Now you just cut a one inch piece of the copper
tube and use it to join the water drain line back together.  If I didn't tell
you I cut the lines you would never know (plus one is covered up on the
driver's side anyways).  If you don't cut these lines and you have to struggle
with reattaching them to the water tray while holding the unit right against
the ceiling you will soon see why it is much easier to do it my way.
My friend and I are thinking about doing the R-12 to R-134a conversion for any
Volks that need the service so if you are in the area (South Jersey/Philly)
and need some cold A/C this summer please let me know.
Now for the Carat, my Jetta, and my parents Jetta... my work is never done.
Ken Wilford
John 3:16