Volkswagen ID.4: Front wheel housing

• Assembly overview - front wheel housing
• Renewing front wheel housing
• Renewing front wheel housing (part section)

Assembly overview - front wheel housing

Overview shown for left side of vehicle as an example

1. Front wheel housing

• ⇒ Rep. gr. 50; Renewing front wheel housing

2. Reinforcement for tensioning strap backing plate
3. Reinforcement for tensioning strap support
4. Reinforcement for front wheel housing
5. Upper reinforcement

• Renew after removing

6. Strut bracket
7. Front suspension turret
8. Bonded areas

Assembly overview - front wheel housing, part section

Overview shown for left side of vehicle as an example

1. Front wheel housing

• ⇒ Rep. gr. 50; Renewing front wheel housing (part section)

2. Reinforcement for tensioning strap backing plate
3. Reinforcement for tensioning strap support
4.  Reinforcement for front wheel housing
5. Upper reinforcement

• Renew after removing

6. Strut bracket
7. Bonded areas

Renewing front wheel housing

WARNING

Gases/vapours hazardous to health are generated when welding, soldering or cutting using tools which produce sparks in foam-treated areas.

• Do not weld, solder or cut closer than 15 mm to moulded foam inserts.
• Use an extraction system during work.

NOTICE

Do not damage underlying reinforcements.

Rewelding of reinforcement is not permitted due to safety reasons.

NOTICE

If welds are positioned too far on outside, strength could be impaired

• RP weld points must be placed as far as possible from outer edge of welding flange.

NOTICE

If adhesive is applied prematurely, bond could be impaired

• New part must be welded in within 90 minutes.

Observe safety information ⇒ Rep. gr. 00; Safety information

Only tools and workshop equipment authorised by Volkswagen AG may be used ⇒ 2.1 .

Removal and installation are described for left side of vehicle as an example.

Removing

Upper inner longitudinal member removed ⇒ Rep. gr. 50; Renewing upper inner longitudinal member

• Separate original joint of upper reinforcement -5- and remove

• Separate original joint of reinforcement for front wheel housing -4- and remove.
• Separate original joint of reinforcement for tensioning strap backing plate -2- and remove.
• Separate original joint of reinforcement for tensioning strap support -3- and remove.
• Separate original joint on wheel housing -1- on outside and inside and remove.

• Remove remaining material.

• Completely remove remaining adhesive.
• Grind bonding surfaces and welding surfaces back to bare metal and clean.

Installing

Replacement parts

• For allocation of 2-pack body adhesive, see ⇒ Electronic parts catalogue (ETKA)

Important

• New parts must be adapted and attached with the vehicle standing on the straightening bracket set.

• Drill 8 mm diameter holes for SG plug weld seam in new part -1-.

• Grind bonding surfaces and welding surfaces on new part -1- and -2- down to bare metal and clean.
• Grind bonding surfaces and welding surfaces on new part -1- down to bare metal and clean.

• Drill 8 mm diameter holes for SG plug weld seam in new part -3-.

• Grind bonding surfaces and welding surfaces on new part -1- to -4- down to bare metal and clean.
• Apply 2-component body adhesive to entire surface of new part -1-.

• Adapt new part -1- to new part -2-, and fix in position.
• Weld in new part -1- and -2-, RP spot weld seam.
• Apply 2-component body adhesive to entire surface.

• Adapt new part -1- to fit and fix in position.

• Apply 2-component body adhesive to entire surface.
• Adapt new part -2- to fit and fix in position.
• Check fit with add-on parts.
• Weld in new part -1- and -2-, SG plug weld seam and RP spot weld seam.
• Apply 2-component body adhesive to new part -2- and -3-.

• Adjust new part -2- and -3- to fit and fix in position.
• Check fit with add-on parts.
• Weld in new part -2- and -3-, RP spot weld seam.
• Apply 2-component body adhesive to new part -1- and -4-.
• Adjust new part -1- and -4- to fit and fix in position.
• Check fit with add-on parts.
• Weld in new part -1- and -4-, SG plug weld seam and RP spot weld seam.
• Upper inner longitudinal member of wheel housing already removed ⇒ Rep. gr. 50; Renewing upper inner longitudinal member

Renewing front wheel housing (part section)

WARNING

Gases/vapours hazardous to health are generated when welding, soldering or cutting using tools which produce sparks in foam-treated areas.

• Do not weld, solder or cut closer than 15 mm to moulded foam inserts.
• Use an extraction system during work.

NOTICE

Do not damage underlying reinforcements.

Rewelding of reinforcement is not permitted due to safety reasons.

NOTICE

If welds are positioned too far on outside, strength could be impaired

• RP weld points must be placed as far as possible from outer edge of welding flange.

NOTICE

If adhesive is applied prematurely, bond could be impaired

• New part must be welded in within 90 minutes.

Observe safety information ⇒ Rep. gr. 00; Safety information Only tools and workshop equipment authorised by Volkswagen AG may be used ⇒ 2.1 .

Removal and installation are described for left side of vehicle as an example.

Upper inner longitudinal member of wheel housing removed ⇒ Rep. gr. 50; Renewing upper inner longitudinal member

Removing

• Separate original joint of upper reinforcement -5- and remove.

• Separate original joint of reinforcement for front wheel housing -4- and remove.
• Separate original joint of reinforcement for tensioning strap backing plate -2- and remove.
• Separate original joint of reinforcement for tensioning strap support -3- and remove.
• Make separating cut -2- in a straight line as shown

• Separate outer and inner original joints.
• Remove front wheel housing -1-.
• Remove remaining material.

• Completely remove remaining adhesive.
• Grind bonding surfaces and welding surfaces back to bare metal and clean.

Installing

Replacement parts

• For allocation of 2-pack body adhesive, see ⇒ Electronic parts catalogue (ETKA)

Important

• New parts must be adapted and attached with the vehicle standing on the straightening bracket set.

• Transfer separating cut -2- to new part -1-, and cut in a straight line.

• Grind bonding surfaces and welding surfaces on new part -1- down to bare metal and clean.
• Grind bonding surfaces and welding surfaces on new part -1- down to bare metal and clean.

• Drill 8 mm diameter holes for SG plug weld seam in new part -3-.

• Grind bonding surfaces and welding surfaces on new part -1- to -4- down to bare metal and clean.
• Apply 2-component body adhesive to entire surface of new part -1-.

• Adapt new part -1- to new part -2-, and fix in position.
• Weld in new part -1- and -2-, RP spot weld seam.
• Apply 2-component body adhesive to entire surface.

• Adapt new part -1- to fit and fix in position.

• Check fit with add-on parts.
• Weld in new part -1-, SG continuous weld seam and RP spot weld seam.
• Apply 2-component body adhesive to new part -2- and -3-.

• Adjust new part -2- and -3- to fit and fix in position.
• Check fit with add-on parts.
• Weld in new part -2- and -3-, RP spot weld seam.
• Apply 2-component body adhesive to new part -1- and -4-.
• Adjust new part -1- and -4- to fit and fix in position.
• Check fit with add-on parts.
• Weld in new part -1- and -4-, SG plug weld seam, SG continuous seam and RP spot weld seam.
• Upper inner longitudinal member of wheel housing already removed ⇒ Rep. gr. 50; Renewing upper inner longitudinal member