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Old 03-08-2007, 01:12 PM
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SVX_MY_BABY SVX_MY_BABY is offline
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Join Date: Jun 2002
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The general plan the instructions lay out is:

1) Mark the position of the top mount relative to the strut body

2-3) Drill a 3 mm dia hole in exactly the middle of the bottom of the strut body to release any gas/oil pressure. This will also serve as a pilot hole for the larger hole that is drilled later on in step 6.

4) Cut the strut body according to the length of the Koni insert

5) Remove the strut shaft, guts, and drain the fluid

6) Drill a 14 mm diameter hole in the bottom of the strut body.

7) File down any protrusions that may be on the inside of the strut body. (There should be none.)

8) Install the Koni insert, washer, and boot as shown.

9) Torque the allenbolt to 55 ft-lbs

10) Reinstall the spring and top mount using the match mark made in step 1. Do not use old, cracked mud shields.

11) Torque the strut shaft bolt to the spec listed based on the thread diameter.

12) Make sure to get the car aligned.

Second Page:

The top half shows how to set the damping on the rear struts. The bottom half shows how to do the damping on the front struts. The damping range is covered by 720 deg (two full revolutions). Full soft is completely CCW. Full hard is completely CW.
Attached Images
File Type: gif Koni Insert Instructions 1of2.gif (879.6 KB, 289 views)
File Type: gif Koni Insert Instructions 2of2.gif (940.5 KB, 238 views)
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