Volkswagen ID.4: Side panel

• Assembly overview - side panel
• Renewing side panel, part section

Assembly overview - side panel

Overview shown for left side of vehicle as an example

1. Side panel

• Subpart
• ⇒ Rep. gr. 53; Renewing side panel, part section

2. Separating cut

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

3. Reinforcement

• Observe replacement part blank

4. Moulded foam inserts

• ⇒ Rep. gr. 00; Moulded foam inserts

5. Bonded area
6. Separating cut

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

7. Separating cut

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

Permitted separating cuts on side panel

MIG brazed seams or SG stepped weld seams are permitted at the separating cuts shown in the illustration.

Separating cuts can be made and combined according to extent of damage.

Renewing side panel, 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

• Separating cut -2- must be in a straight line.

• Separate original joint of side panel -1-.
• Grind through outer edge at wheel arch.
• Make separating cut -2- in a straight line.

• Separate original joint.
• Remove side panel -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.

• Lightly sand down bonding surfaces in area of wheel arch.
• Grind bonding surfaces and welding surfaces back to bare metal and clean.
• Drill 8 mm diameter holes for SG plug weld seam.
• Prepare moulded foam inserts -1- for installation.

• 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 and SG plug weld seam.
• Weld parting cuts (either MIG solder seam or SG stepped weld seam).
• Remove excess adhesive and seal wheel arch.
• Weld in new part -1- (either MIG brazed seam or SG stepped weld seam).