Volkswagen ID.4: Rear longitudinal member

• Assembly overview - longitudinal member cover plate
• Assembly overview - rear longitudinal member, part section (second separating cut)
• Renewing rear longitudinal member, part section
• Renewing rear longitudinal member, part section (second parting cut)

Assembly overview - longitudinal member cover plate

Overview shown for left side of vehicle as an example

1. Cover plate

• Longitudinal member
•  ⇒ Rep. gr. 53; Renewing longitudinal member cover plate

2. Separating cut
3. Bonded area
4. Moulded foam insert

• ⇒ Rep. gr. 00; Moulded foam inserts

Assembly overview - rear longitudinal member, part section

Overview shown for left side of vehicle as an example

1. Rear longitudinal member

•  ⇒ Rep. gr. 53; Renewing rear longitudinal member, part section

2. Separating cut
3. Longitudinal member support

Assembly overview - rear longitudinal member, part section (second separating cut)

Overview shown for left side of vehicle as an example

1. longitudinal member

• ⇒ Rep. gr. 53; Renewing rear longitudinal member, part section (second parting cut)

2. Subframe mounting
3. Cross member connecting piece
4. Spring plate

• Renew after removing

5. Sealing plate
6. Web plate
7.  Moulded foam insert

• ⇒ Rep. gr. 00; Moulded foam inserts

8. Cross panel for rear longitudinal member
9. Longitudinal member support

Renewing longitudinal member cover plate

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

If separating cuts are made too deep, underlying reinforcement could be damaged.

• Only make separating cuts with body saw.
• Rewelding of reinforcements 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.

If adhesive is applied prematurely, bond could be impaired - New part must be welded in within 90 minutes.

Removing

Centre luggage compartment floor part section removed ⇒ Rep.

gr. 53; Renewing centre luggage compartment floor.

• Separate original joint.

• Remove longitudinal member cover plate -1-.
• Remove any foam residue -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 moulded foam inserts, see ⇒ Electronic parts catalogue (ETKA)
• 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 its wheels or straightening bracket set.
• Lightly roughen bonding surfaces in area of moulded foam insert.

• Drill or alternately punch 8 mm holes for SG plug weld seam in new part -1-.
• Grind welding surfaces and bonding surfaces on new part -1- down to bare metal and clean.
• Prepare moulded foam insert -1- for installation and insert.

• Apply 2-component body adhesive to entire surface.
• Adapt new part -1- to fit and fix in position.

• Weld in new part -1-, SG plug weld seam and RP spot weld seam.
• Install centre luggage compartment floor part section ⇒ Rep.

  gr. 53; Renewing centre luggage compartment floor.

Renewing rear longitudinal member, 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

If separating cuts are made too deep, underlying reinforcement could be damaged.

• Only make separating cuts with body saw.
• Rewelding of reinforcements 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

Centre luggage compartment floor part section removed ⇒ Rep.

gr. 53; Renewing centre luggage compartment floor.

Longitudinal member cover plate part section removed ⇒ Rep.

gr. 53; Renewing longitudinal member cover plate.

• Separate original joint.

• Remove longitudinal member support -1-.
• Mark separating cut -2- all around on rear longitudinal member -1- in accordance with dimension -a-, and cut in a straight line.

• Dimension -a- = 95 mm

• Remove longitudinal member part section -1-.
• Remove remaining material.

• Grind 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 -3- to new part -2-, and cut in a straight line.

• Grind bonding surfaces and welding surfaces on new part -1-, -2- and -4- down to bare metal and clean.
• Adapt new part -1- to fit and fix in position.

• Check fit with add-on parts.
• Weld in new part -1- all around, SG continuous 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-, 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-, RP spot weld seam.
• Install centre luggage compartment floor part section ⇒ Rep.

  gr. 53; Renewing centre luggage compartment floor.

• Install longitudinal member cover plate part section ⇒ Rep.

  gr. 53; Renewing longitudinal member cover plate.

Renewing rear longitudinal member, part section (second parting cut)

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

If separating cuts are made too deep, underlying reinforcement could be damaged.

• Only make separating cuts with body saw.
• Rewelding of reinforcements 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

Centre luggage compartment floor part section removed ⇒ Rep.

gr. 53; Renewing centre luggage compartment floor.

Longitudinal member cover plate part section removed ⇒ Rep.

gr. 53; Renewing longitudinal member cover plate.

• Remove any foam residue -4-.

• Separate original joint on rear longitudinal member -1-.
• Detach spring plate -2-, sealing plate -3- and end plate -5-.
• Separate original joint.

• Remove longitudinal member part section -1-.
• Remove remaining material.

• Grind welding surfaces back to bare metal and clean.

Installing

Replacement parts

• For allocation of moulded foam inserts, see ⇒ Electronic parts catalogue (ETKA)
• 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.
• Grind bonding surfaces and welding surfaces on new part -1- and -3- down to bare metal and clean.

• Drill 8 mm diameter holes for SG plug weld seam in new part -2-.
• 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- to -4- down to bare metal and clean.

• Apply 2-component body adhesive to entire surface.

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

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

• Adapt new part -6- to fit and fix in position.
• Weld in new part -6-, RP spot weld seam.
• Adjust new part -1- to -5- to fit and fix in position.
• Check fit with add-on parts.
• Weld in new part -1- to -5- (SG plug weld seam and RP spot weld seam).
• Prepare moulded foam insert -7- for installation and insert.
• 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-, RP spot weld seam.
• Install centre luggage compartment floor part section ⇒ Rep.

  gr. 53; Renewing centre luggage compartment floor.

• Install longitudinal member cover plate part section ⇒ Rep.

  gr. 53; Renewing longitudinal member cover plate.