Cowl: Service and Repair

Plenum Chamber

CAUTION!
Observe safety precautions!

• Plenum chamber can only be replaced completely due to strength reasons.

Special tools, testers and auxiliary items required

• Resistance spot welder (VAS 6239 A) or

• Resistance spot welder (VAS 6525) or

• Resistance spot welder (VAS 6530) or

• Resistance spot welder (VAS 6535) or

• Resistance spot welder (VAS 6545)

• Gas-shielded welder 250A (VAS 6045A)

• Drill (VAS 5830)

• Single hand angle grinder (VAS 5167)

• Spot weld breaker (V.A.G 1731)

• Upper longitudinal member already removed.

Removing

- Loosen the original joint using a spot weld remover (V.A.G 1731).

- Remove the remainder using the single hand angle grinder (VAS 5167).





Replacement part

• Plenum chamber

Preparing New Parts

- Drill the holes for the gas-shielded arc plug weld seam using a 7 mm diameter drill (VAS 5830).





Installation

- Weld the new part with a gas-shielded arc continuous weld seam (staggered) using the gas-shielded welder 250A (VAS 6045A).

- Weld the new part with a resistance spot welder, straight-line spot weld seam.

- Weld the new part with a gas-shielded arc plug weld seam using the gas-shielded welder 250A (VAS 6045A).