Front Strut / Shock Tower: Service and Repair

Front Wheel Housing

Observe safety precautions.

• The wheel housing upper longitudinal member is already removed. Refer to => [ Upper Wheel Housing Longitudinal Member ] .






1 Suspension strut mounting

2 Wheel housing

3 Front longitudinal member

4 Longitudinal member cover plate

• Due to the different types of steel and material strength, use only welding equipment approved by Volkswagen AG to perform any service work.

• For a list of welding equipment and body tools approved by Volkswagen AG, refer to ServiceNet.

Removing






- 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.

Installing

• Use only welding equipment approved by Volkswagen AG. Refer to ServiceNet.

Preparing New Parts

• Wheel housing

• Suspension strut mounting

• Suspension strut mounting reinforcement

- Drill 8 mm holes into suspension strut mounting reinforcement for the for gas-shielded arc plug weld seam.






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











• Distance between the holes: approximately 25 - 30 mm.

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






- Fit and secure the new parts using the alignment bracket mountings - 15 -, - 17 -, - 18 - and - 19 -.

- Check fit with neighboring components.

Welding

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






- Drill holes - 1 - (10 mm) for bolting suspension strut and also secure suspension strut mounting with reinforcement to alignment bracket mounting - 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 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

• Use item 19 from the straightening bracket set supplement for Golf, MY 2004 (VAS 6240/2) to check dimension - a -.

- Install the wheel housing upper longitudinal member.