Front Strut / Shock Tower: Service and Repair

Suspension Strut Mount

CAUTION!
Observe safety precautions. Refer to Safety precautions

Special tools, testers and auxiliary items required

• Single hand angle grinder (VAS 5167)

• Air pressure adhesive pistol (V.A.G 2005 B)

• Gas-shielded welder 250A (VAS 6388)

• Rechargeable Riveter (VAS 5279A)

• Body repair saw (V.A.G 1523A)

Separating areas

• Upper longitudinal member already removed.

CAUTION!
Do not damage adjacent cast parts.

• Observe general notes for aluminum with punch rivets accessible from one side.

- Make the separating cut on the bar piece plenum chamber using a body saw (V.A.G 1523A).

- Cut the original joint on the suspension strut tower mount support with an rechargeable riveter (VAS 5279A).

- Remove the large punch rivets. Use the rechargeable riveter (VAS 5279A)D13 and D14 punch from the (VAS 5279/2) or rechargeable riveter (VAS 5279B) with D13 and D14 punch.

- Remove the small punch rivets. Use the rechargeable riveter (VAS 5279A)S1 and E2 punch from (VAS 5279/2) or rechargeable riveter (VAS 5279B) with S1 and E2 punch.





• Observe general notes for aluminum with punch rivets accessible from one side.

- Loosen rivet to inner A-pillar that is accessible on one side.

- Cut the original joint with an rechargeable riveter (VAS 5279A).





Replacement Parts

• Pop rivet

• Punch rivets

• Suspension strut mounting

• Body adhesive DA 001 730 A2

• Observe general notes for adhesive connections.

Preparing New Parts

- Prepare flange on body and new part for welding.

- Prepare flange on body and new part for riveting.

Welding in

- Install new part using straightening bracket.

• Welding with gas-shielded arc continuous weld seam can be done instead of riveted connections.

Riveting

- Weld the window crossmember to the suspension strut tower mount with a SG continuous seam using the gas-shielded welder 250A (VAS 6388).

- Rivet the suspension strut tower mount to the upper longitudinal member using the rechargeable riveter (VAS 5279A).

- Rivet the suspension strut tower mount to the longitudinal member using the rechargeable riveter (VAS 5279A).

Imprint the drilled holes from the outside toward the inside. Use the rechargeable riveter (VAS 5279A)D15 and D16 punch from (VAS 5279/2) or the rechargeable riveter (VAS 5279B) with D15 and D16 punch.

- Weld the new part with a gas-shielded arc continuous weld seam using the gas-shielded welder 250A (VAS 6388).





- Weld the separation cut in the plenum chamber bulkhead with a gas-shielded arc continuous weld seam using the gas-shielded welder 250A (VAS 6388).

- Weld the new part with a gas-shielded arc continuous weld seam using the gas-shielded welder 250A (VAS 6388).





Rivet the remainder of the joint with a rechargeable riveter (VAS 5279A).

Imprint the drilled holes from the outside toward the inside. Use the rechargeable riveter (VAS 5279A)D15 and D16 punch from (VAS 5279/2) or the rechargeable riveter (VAS 5279B) with D15 and D16 punch.