Front Strut / Shock Tower: Service and Repair

Front Wheel Housing

Includes: suspension strut mount

Observe safety precautions.






1 Wheel housing with

2 Front longitudinal member with cover plate

Special tools, testers and auxiliary items required

• Spot welder (inverter) (VAS 6238 A)

• Accessory kit for spot welder (VAS 6238/1 A)

• Spot welder (inverter) (VAS 6239)

• Spot welder (inverter) (VAS 6249)

• Alignment bracket set for Touareg (VAS 6240)

• Alignment bracket set supplement, VW Eos 2006 > (VAS 6240-6)

Removing

• Longitudinal member for upper wheel housing already removed






- Original joint to front longitudinal member cover plate, loosen from wheel housing side to inside and to plenum chamber.






- Loosen remaining joint to plenum chamber.

- Remove residual material.






Installation

• When using different types of steel and materials of different strengths, the tools listed under Special Tools are required to perform body work correctly.

Preparing New Parts

• Wheel housing

• Suspension strut mounting

• Suspension strut mounting reinforcement

- Drill holes for gas-shielded arc plug weld seam in suspension strut mounting reinforcement, 8 mm diameter.






- Drill holes for gas-shielded arc plug weld seam in suspension strut mount, 8 mm diameter.











- Drill holes for gas-shielded arc plug weld seam in wheel housing, 8 mm diameter.

• Distance of holes to each other, approximately 25 - 30 mm.






- Position and secure new parts with using the alignment bracket mountings - 15 -, - 17 -, - 18 - and - 19 - from the alignment bracket set (VAS 6240-6) and adjacent components.

Welding in

- Weld suspension strut mounting - green - with reinforcement - gray -, gas-shielded arc plug weld.






- Drill holes - 1 - with a 10 mm diameter for bolting the suspension strut and secure the suspension strut mounting with the reinforcement to the alignment bracket mount - 2 - with screws.











- Weld in wheel housing with suspension strut mounting, gas-shielded arc plug weld seam and straight-line spot weld seam.






- Restore joint between wheel housing and plenum chamber, gas shielded arc plug weld seam.

- Restore remaining joint to plenum chamber, gas shielded arc plug weld seam.






- Restore original joint between suspension strut mounting - 1 - and suspension strut mounting reinforcement - 2 -, straight line spot weld seam.






- Enlarge holes for suspension strut mounting cover cap.






Dimension - a - = 34 mm

• Item 19 from Alignment Bracket Set Supplement, VW Eos 2006 > (VAS 6240-6) can be used to check dimension - a -.

- Install upper wheel housing longitudinal member.