Volkswagen ID.4: Side member

• Assembly overview - outer side member
• Assembly overview - side member reinforcement
• Renewing outer side member
• Renewing side member reinforcement
• Renewing side member reinforcement (crash bar)

Assembly overview - outer side member

Overview shown for left side of vehicle as an example

1. Outer side member

• Subpart
• ⇒ Rep. gr. 51; Renewing outer side member

2. Separating cut

• Parting cut can be combined with others in cases where extent of damage requires multiple cuts.

3. Moulded foam inserts

• ⇒ Rep. gr. 00; Moulded foam inserts

4. Bonded area

Assembly overview - side member reinforcement

Overview shown for left side of vehicle as an example

1. Side member reinforcement

• ⇒ Rep. gr. 51; Renewing side member reinforcement

2. Bonded area
3. Bolt

• Qty. 2
• 55 Nm

4. Bolt

• Underbody, front
• Qty. 2
• 55 Nm

5. Bolt

• Underbody, rear
• Qty. 3
• 55 Nm

Assembly overview - side panel reinforcement (crash bar)

Overview shown for left side of vehicle as an example

1. Side panel reinforcement

• Aluminium component
• ⇒ Rep. gr. 51; Renewing side member reinforcement (crash bar)

2. Bonded area

Renewing outer side member

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.

NOTICE

Bonding properties of adhesive may be impaired if adhesive components are not hardened sufficiently.

• After bonding, the vehicle must not be moved and left at room temperature (at least 15ºC) for 8 to 10 hours.
• During this time, the vehicle must be standing on a level surface.

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

• Make separating cut -2- in a straight line as shown.

• Separate original joint.
• Remove side member -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.
• Transfer separating cut -2- to new part -1-, and cut in a straight line.

• Drill or alternatively punch holes of 8 mm in diameter in new parts -1-, -3- and -4- for SG plug weld seam.
• Grind welding surfaces and bonding surfaces on new part -1- and -3- down to bare metal and clean.
• Lightly sand down bonding surfaces in area of wheel arch.
• Prepare moulded foam inserts -1- 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.
• Fix new part in position -1- with mole grips.
• Weld in new part -1-, RP spot weld seam.
• Weld parting cuts (either MIG solder seam or SG stepped weld seam).
• 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 and SG plug weld seam.
• Reform wheel housing flange.
• Remove excess adhesive and seal wheel arch.

Vehicles with type plate.

• Reattach type plate after painting ⇒ p3.1.2 late"

Vehicles with safety certificate.

• Reattach safety certificate after painting ⇒ c3.1.3 ertificate"

Renewing side member reinforcement

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.

NOTICE

Bonding properties of adhesive may be impaired if adhesive components are not hardened sufficiently.

• After bonding, the vehicle must not be moved and left at room temperature (at least 15ºC) for 8 to 10 hours.
• During this time, the vehicle must be standing on a level surface.

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

A-pillar reinforcement part section removed ⇒ Rep. gr. 51; Renewing A-pillar reinforcement, part section.

B-pillar reinforcement removed ⇒ Rep. gr. 51; Renewing B-pillar reinforcement.

• Unscrew bolts -2-, -3- and -4-.

• Separate original joint.
• Remove side member reinforcement -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 its wheels or straightening bracket set.

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

• 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 A-pillar reinforcement part section ⇒ Rep. gr. 51; Renewing A-pillar reinforcement, part section.
• Install B-pillar reinforcement ⇒ Rep. gr. 51; Renewing inner B-pillar.
• Tighten bolts -2-, -3- and -4-.

Tightening torques

• ⇒ o6.2 verview - side member reinforcement"

Renewing side member reinforcement (crash bar)

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

Side member reinforcement removed ⇒ Rep. gr. 51; Renewing side member reinforcement.

• Separate original joint.

• Detach side member reinforcement -1- from body.
• 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 its wheels or straightening bracket set.
• Grind welding surfaces and bonding surfaces on new part -1- down to bare metal and clean.

• 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 side member reinforcement ⇒ Rep. gr. 51; Renewing side member reinforcement.