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Repair Group overview for Body Repairs
Repair Group
00 - Technical data
50 - Body - front
51 - Body - centre
53 - Body - rear
Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed.
All rights reserved. No reproduction without prior agreement from publisher.
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Original joint
2.2 Used joining techniques
3 Vehicle identification data
3.1 Vehicle identification number
3.2 Type plate
3.3 Safety certificate
4 Safety information
5 The following body work requires the HV
8 Renewing front wheel housing (part section)
8.2 Removing
9 Renewing front left longitudinal member, part section
Renewing front left longitudinal member (part section – second parting cut)
8.3 Safety certificate
8.4 Removing .
8.5 Installing
9 Renewing B-pillar reinforcement
9.1 Tools
9.2 Type plate
9.3 Safety certificate
9.4 Removing
9.5 Installing
10 Renewing outer side member
10.1 Tools
10.2 Type plate
10.4 Removing
10.5 Installing
11 Renewing side member reinforcement
11.2 Removing
11.3 Installing
12 Renewing side panel reinforcement, crash bar
12.2 Removing
12.3 Installing
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2 Overview of parts
4.2 Removing
5 Renewing sealing channel support
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2Basic instructions
Only selected labour operations are described in this workshop manual.
For labour operations that are not described, remove genuine part and install replacement to restore original condition.
The descriptions deal with repairs methods that deviate from those applied on standard vehicles.
If sub-parts are supplied, adapt these to fit (unless otherwise in‐structed), butt these up, and weld them in with a SG continuous weld seam.
2.1Original joint
The term “original joint” refers to the welded joint, which was made at the time the vehicle was manufactured.
These welded joints must be restored when carrying out body repairs.
Make sure the standard number of spot welds is not fallen short of in the event of repairs.
Methods which are different from the original joint are described ⇒ page 2
Gases/vapours hazardous to health are generated when welding, soldering or cutting using tools which produce sparks in foam-treated areas.
– Never weld, solder or cut closer than 15 mm to moulded foam inserts.
– Make sure to use an extraction system during the work.
Heed safety precautions ⇒ General Information; Body Repairs, General Body Repairs; Safety precautions.
Make sure to use an extraction system when carrying out weld‐ing and grinding work.
Clean the exhaust extraction system at regular intervals.
Never carry out welding and grinding processes in same room at same time.
Remove dust regularly from work areas.
Do not blow off dust deposits with compressed air.
Make sure to observe the respective country-specific accident prevention and health and safety regulations. ID.4 2021 ➤ Body Repairs - Edition 06.2022
2021 ➤ Body Repairs - Edition 06.2022
5The following body work requires the HV electrical system to be deenergised.
Always de-energise the high-voltage system via Guided Fault Finding, De-energising high-voltage system.
A high-voltage technician must de-energise the system prior to welding, grinding and cutting work in the vicinity of high-voltage components.
A high-voltage technician must de-energise the system prior to body work with the alignment jig.
De-energisation measures may only be carried out by electrical‐ly instructed persons.
For information refer to the vehicle-specific repair manual.
⇒ Power unit; Rep. gr. 93; Electric motor; Hazard rating of highvoltage system
AGdoesnotguaranteeoracceptanyliabilitywi
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6When the high-voltage battery is re‐moved, observe the following:
NOTICE
Risk of damage to underbody. – The vehicle must not be moved as long as the high-voltage battery is removed. ID.4 2021 ➤ Body Repairs - Edition 06.2022 6. When the high-voltage battery is removed, observe the following:
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2021 ➤
Body Repairs - Edition 06.2022
7Moulded foam inserts
Various cavities in the bodywork of this vehicle are fitted with moulded foam inserts.
The moulded foam inserts reduce the amount of driving noise that is transmitted into the interior.
The exact location of these moulded foam inserts is shown at the beginning of the respective repair description.
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In the event of repair, proceed as follows: –Remove any foam material left on vehicle.
ID.4
–Apply corrosion protection ⇒ General information, paintwork - passenger cars; Rep. gr. 00; General notes.
Prerequisites
Before continuing with this procedure, ensure that the part for replacement has been prepared for installation, e.g. cut, adap‐ted to fit; received corrosion protection measures.
Renewing moulded foam insert
–Re-use moulded foam insert or cut to fit from universal plate.
–Attach moulded foam insert to body using butyl adhe‐sive/sealing cord.
–Then apply either butyl adhesive/sealing cord or 2-compo‐nent filler foam to moulded foam insert.
–Secure new part in position. Gently press new part, in vicin‐ity of moulded foam insert, until it makes contact and then weld in.
The foam filler hardens within 25 minutes.
–Do not do perform shielded arc welding (SG) within 15 mm of moulded foam element.
–Carry out cavity protection to repair area after painting vehi‐cle.
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Repairs - Edition 06.2022
8Galvanized body parts, high- and higher-strength and hot-formed body panels
Work on galvanized and strengthened body panels must com‐ply with guide lines in Workshop Manual ⇒ General Informa‐tion; Body Repairs, General Body Repairs; Basic information for body repairs
The body of the vehicle is predominantly manufactured from galvanised steel panels.
The following illustrations show those parts of the body manu‐factured from hot-formed body panels.
The side member reinforcement insert is made of extruded alu‐minium sheath.
grey Mild steel 2 red Ultra-high performance, hotformed steel
3 blue Extruded aluminium sheath
Body, view from above
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For reasons of clarity, the complete outer side panel and the roof are not shown in the illustration.
Body, view from below
8. Galvanized body parts, high- and higher-strength and hot-formed
For reasons of clarity, the outer side panels and the right side panel reinforcement are not shown in the illustration.
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9Laser welding
On this vehicle, some sections of the roof and body are welded by laser.
With laser welding, a high-energy beam of light is directed over the seam to be welded by optical lenses or optical fibre.
During the welding process, the upper panel is pierced by melt‐ing and the lower panel becomes partially molten, creating a welded joint without the need of additional material.
For repairs other than roof repairs, the laser weld seam is re‐placed by an SG plug weld seam or RP spot weld seam.
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10Gaps/shut lines
⇒ f10.1 ront”, page 16
⇒ c10.2 entre”, page 17
⇒ -10.3 rear”, page 19
Note
♦ Usesettinggauge-3371-forcheckingoradjusting.
♦ Gapsarealwaysgiveninmillimetres.
10.1Body, front
View, front end ID.4 2021 ➤ Body Repairs - Edition 06.2022
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Maß - a -
❑Gap between bonnet and bumper
❑3.7 mm ±0.7 mm
Maß - b -
❑Height difference, bon‐net to bumper
❑1.2 mm ±0.6 mm
Maß - c -
❑Height difference, wind‐screen to roof
❑- 2.1 mm ±0.8 mm
Maß - d -
❑Gap between wind‐screen and roof
❑3.3 mm ±0.5 mm
Maß - e -
❑Gap between wing and bumper
❑0.5 mm +0.5 mm
Maß - f -
❑Height difference, wing to bumper
❑0.0 mm ±0.5 mm
Maß - g -
❑Gap between headlight and bumper
❑1.9 mm ±0.5 mm
10.2Body, centre
Side view
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Maß - a -
❑Gap between wing and front door
❑3.5 mm ±0.5 mm
Maß - b -
❑Height difference, wing to front door
❑0.0 mm ±0.1 mm
Maß - c -
❑Height difference, front door to rear door
❑0.0 mm ±0.5 mm
Maß - d -
❑Gap between front door and rear door
❑4.4 mm ±0.5 mm
Maß - e -
❑Height difference, rear door to side panel
❑0.0 mm ±0.5 mm
Maß - f -
❑Gap between rear door and side panel
❑3.5 mm ±0.5 mm
Maß - g -
❑Gap between front door and side member (sill)
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⇒ w11.1 ork for determining body dimensions”, page 21
⇒ f11.2 ront”, page 21
⇒ c11.3 entre”, page 22
⇒ -11.4 rear”, page 27
⇒ p11.5 anel, front”, page 28
⇒ p11.6 anel, centre”, page 29
⇒ p11.7 anel, rear”, page 30
Volkswagen
11.1Preliminary work for determining body dimensions
Repair instructions
–Remove any bolts, screws, plugs, trims and attachments before starting the measuring process.
–The telescopic measuring rod of the respective measuring system must be used to determine the body dimensions. Ensure measuring probes are always of even length to prevent inaccuracies when measuring.
11.2Body, front
Vehicle front end
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Maß - a -
❑Between wheel hous‐ings
❑1155 mm ±2.0 mm
Maß - b -
❑Between upper right longitudinal member and left wheel housing diagonal distance
❑1327 mm ±2.0 mm
Maß - c -
❑Between upper longitu‐dinal members
❑1467 mm ±2.0 mm
Maß - d -
❑Between inner upper holes in longitudinal member
❑782 mm ±2.0 mm
Maß - e -
❑Between outer lower holes in longitudinal member
❑959 mm ±2.0 mm
11.3Body, centre
⇒ a11.3.1 perture”, page 22
⇒ b11.3.2 etween A-pillars”, page 23
⇒ b11.3.3 etween B and C-pillars”, page 24
⇒ d11.3.4 oor aperture”, page 25
⇒ d11.3.5 oor aperture”, page 26
11.3.1Windscreen aperture
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ID.4 2021 ➤ Body Repairs - Edition 06.2022
Maß - a -
❑Windscreen aperture vertical distance
❑1021 mm ±2.0 mm
Maß - b -
❑Windscreen aperture diagonal distance
❑1582 mm ±2.0 mm
11.3.2Distance between A-pillars
isnotpermit yliabilitywith respect
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ID.4 2021 ➤
Body Repairs - Edition 06.2022
Maß - a -
❑Between A-pillars
❑Measure on inner sides of body flanges
❑1513 mm ±2.0 mm
11.3.3Distance between B and C-pillars
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Repairs - Edition 06.2022
Maß - a -
❑Between B-pillars
❑Measure on inner sides of body flanges
❑1479 mm ±2.0 mm
Maß - b -
❑Between C-pillars
❑Measure on inner sides of body flanges
❑1473 mm ±2.0 mm
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11.3.4Front door aperture
Maß - a -
❑Door aperture horizon‐tal distance
❑Measure on inner sides of body flanges
❑910 mm ±2.0 mm
Maß - b -
❑Door aperture vertical distance
❑Measure on inner sides of body flanges
❑961 mm ±2.0 mm
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11.3.5Rear door aperture
Maß - a -
❑Door aperture vertical distance
❑Measure on inner sides of body flanges
❑1044 mm ±2.0 mm
Maß - b -
❑Door aperture horizon‐tal distance
❑Measure on inner sides of body flanges
❑757 mm ±2.0 mm
11.4Body - rear
Rear lid aperture ID.4 2021 ➤
Repairs - Edition 06.2022
ID.4 2021 ➤ Body Repairs - Edition 06.2022
Maß - a -
❑Rear lid horizontal dis‐tance
❑Measure on inner sides of body flanges
❑1127 mm ±2.0 mm
Maß - b -
❑Rear lid vertical dis‐tance
❑Measure on inner sides of body flanges
❑1004 mm ±2.0 mm
11.5Floor panel, front
Underbody, front
Maß - a -
❑Between longitudinal members
❑791 mm ±2.0 mm
Maß - b -
❑Between right longitu‐dinal member and mounting bracket (for subframe) on left diago‐nal distance
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❑419 mm ±2.0 mm
11.6Floor panel, centre
Underbody, centre
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Maß - a -
❑Between side members
❑Measure on inner sides of body flanges
❑1533 mm ±2.0 mm
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11.7Floor panel, rear
Underbody, rear
Maß - a -
❑Between battery frame mountings
❑726 mm ±2.0 mm
Maß - b -
❑Between longitudinal members
❑1008 mm ±2.0 mm
Maß - c -
❑Between longitudinal members, diagonal dis‐tance
❑1174 mm ±2.0 mm
Maß - d -
❑Between mounting brackets (for subframe)
❑918 mm ±2.0 mm
Maß - e -
❑Between mounting bracket (for subframe) and cross panel
❑366 mm ±2.0 mm
ID.4
ID.4 2021 ➤
Body Repairs - Edition 06.2022
12Straightening bracket set
• If body structural damage or deviation from dimensions giv‐en in the repair manual is suspected and/or damage is visi‐ble to structural components, the vehicle must be placed on a Volkswagen AG approved alignment jig system and measured.
Explanation of structural damage to body
A damaged (dented, cracked, buckled) component and/or the position of the structural component on the body has changed.
A structural component includes all components of the body, except outer body panels and components which are bolted on.
If dimensions deviate, the vehicle must be repaired according to respective repair manual.
♦ Measurement and alignment system, basic -VAS 6526-
♦ Measurement and alignment system, professional -VAS 6527-
♦ Measurement and alignment system, professional plus -VAS 6528-
12.1Overview of setup, entire body
Note
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–Separate original joint.
–Detach front longitudinal member cross panel -1- from body.
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–Remove remaining material.
–Completely remove remaining adhesive.
–Grind bonding surfaces and welding surfaces back to bare metal.
3.3Installing
⇒ n3.3.1 ew part”, page 41
⇒ i3.3.2 n”, page 42
3.3.1Preparing new part
Spare part
♦ Front longitudinal member end plate (replacement part des‐ignation according to ⇒ Electronic parts catalogue (ETKA) ⇒ cover plate)
–Sand welding surfaces on new part -1- down to bare metal.
3.3.2Welding in
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2021
Body Repairs - Edition 06.2022
–Adapt new part -1- to fit with vehicle positioned on straight‐ening bracket set, and fix it in position.
–Check fit with add-on parts.
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–Weld in new part -1- (SG plug weld seam).
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2021 ➤ Body Repairs - Edition 06.2022
RO: 50 40 56 50
4Renewing battery tray reinforcement
⇒ 4.1 , page 45
⇒ 4.2 , page 45
⇒ 4.3 , page 46
CAUTION
Gases/vapours hazardous to health are generated when welding, soldering or cutting using tools which produce sparks in foam-treated areas.
– Never weld, solder or cut closer than 15 mm to moulded foam inserts.
– Make sure to use an extraction system during the work.
Heed the safety precautions ⇒ page 7
Body work for which HV electrical system must be de-energised
⇒ page 8
Assembly overview
1 - Battery tray reinforcement
❑Front
2 - Battery tray reinforcement
❑Rear
3 - Bonded areas
❑Cannot be restored
4.1Tools
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♦ Front battery tray reinforcement (replacement part designa‐tion according to ⇒ Electronic parts catalogue (ETKA) ⇒ front left battery tray reinforcement)
♦ Rear battery tray reinforcement (replacement part designa‐tion according to ⇒ Electronic parts catalogue (ETKA) ⇒ rear left battery tray reinforcement)
–Drill holes (8 mm diameter) for SG plug weld seam into new part -1- and -2-.
4.3.2Welding in
–Adapt new part -1- and -2- to fit with vehicle positioned on straightening bracket set, and fix it in position.
–Check fit with add-on parts.
–Weld in new part -1- and -2-, SG plug weld seam.
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RO: 50 72 55 03
5Renewing upper wheel housing lon‐gitudinal member - part section
⇒ 5.1 , page 50
⇒ 5.2 , page 50
⇒ 5.3 , page 52
CAUTION
Gases/vapours hazardous to health are generated when welding, soldering or cutting using tools which produce sparks in foam-treated areas.
– Never weld, solder or cut closer than 15 mm to moulded foam inserts.
– Make sure to use an extraction system during the work.
Heed the safety precautions ⇒ page 7
Body work for which HV electrical system must be de-energised
– Rewelding reinforcement is not permitted due to safety reasons.
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–Make parting cut -2- on upper wheel housing longitudinal member -1- as shown in illustration.
–Separate original joint.
–Detach upper wheel housing longitudinal member -1- from body.
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–Remove remaining material.
–Completely remove remaining adhesive.
–Grind bonding surfaces and welding surfaces back to bare metal.
5.3Installing
⇒ n5.3.1 ew part”, page 52
⇒ i5.3.2 n”, page 53
5.3.1Preparing new part
Replacement parts
♦ Longitudinal member for upper wheel housing (replacement part designation according to ⇒ Electronic parts catalogue (ETKA) ⇒ longitudinal member)
♦ 2-component body adhesive ⇒ Electronic parts catalogue (ETKA)
–Transfer separating cut -2- to new part -1-, and perform separating cut.
–Drill 8 mm holes for SG plug weld seam into new part -1-.
–Grind bonding surfaces and welding surfaces back to bare metal.
5.3.2Welding in
NOTICE
Bonding properties of adhesive may be impaired.
– New part must be welded in within 90 minutes.
–Apply 2-component body adhesive to entire surface.
NOTICE
Strength could be impaired.
– The RP weld points must be set as far as possible from the outer edge of the welding flange.
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–Adapt new part -1- to fit with vehicle positioned on straight‐ening bracket set, and fix it in position.
–Check fit with add-on parts.
–Weld in new part -1- (RP spot weld seam, SG plug weld seam).
–Weld parting cut (SG stepped weld seam).
Body Repairs - Edition 06.2022
RO: 50 53 55 53
6Renewing upper inner wheel hous‐ing longitudinal member
⇒ 6.1 , page 57
⇒ 6.2 , page 57
⇒ 6.3 , page 59
CAUTION
Gases/vapours hazardous to health are generated when welding, soldering or cutting using tools which produce sparks in foam-treated areas.
– Never weld, solder or cut closer than 15 mm to moulded foam inserts.
– Make sure to use an extraction system during the work.
Heed the safety precautions ⇒ page 7
Body work for which HV electrical system must be de-energised
–Transfer separating cut -2- to new part -1-, and cut in a straight line.
–Grind bonding surfaces and welding surfaces back to bare metal.
–Sand bonding surfaces and welding surfaces on new part -1down to bare metal.
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GAnegawskloVybthgirypoC.tnemucodsihtninoitamrof –Drill 8 mm diameter holes for SG plug weld seam in new part -3-. –Sand bonding surfaces and welding surfaces on new part -1 to 4- down to bare metal. ID.4 2021 ➤ Body Repairs - Edition 06.2022
–Apply 2-component body adhesive to entire surface of new part -1-.
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–Adapt new part -1- to new part -2-, and fix in position.
–Weld in new part -1- on new part -2- (RP spot weld seam).
8.3.2Welding in
NOTICE
Bonding properties of adhesive may be impaired.
– New part must be welded in within 90 minutes.
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–Apply 2-component body adhesive to entire surface.
NOTICE
Strength could be impaired. – The RP weld points must be set as far as possible from the outer edge of the welding flange.
la rup op s e s , i n p a r t o r in w hole,
–Adapt new part -1- with vehicle standing on its wheels or alignment bracket set and fix in position.
–Check fit with add-on parts.
–Weld in new part -1-, RP spot weld seam and SG continuous weld seam.
–Apply 2-component body adhesive to new part -2- and -3-.
–Adapt new part -2- and -3- to fit with vehicle positioned on straightening bracket set, and fix it in position.
–Check fit with add-on parts.
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–Weld in new part -2- and -3- (RP spot weld seam).
–Apply 2-component body adhesive to new part -1- and -4-.
–Adapt new part -1- and -4- to fit with vehicle positioned on straightening bracket set, and fix it in position.
–Check fit with add-on parts.
–Weld in new part -1- and -4- (RP spot weld seam, SG plug weld seam and SG continuous weld seam).
–Install upper inner wheel housing longitudinal member ⇒ page 59
RO: 50 79 55 09
9Renewing front left longitudinal member, part section
⇒ 9.1 , page 88
⇒ 9.2 , page 88
⇒ 9.3 , page 91
CAUTION
Gases/vapours hazardous to health are generated when welding, soldering or cutting using tools which produce sparks in foam-treated areas.
– Never weld, solder or cut closer than 15 mm to moulded foam inserts.
– Make sure to use an extraction system during the work.
Heed the safety precautions ⇒ page 7
Body work for which HV electrical system must be de-energised
– Rewelding reinforcement is not permitted due to safety reasons.
–Mark separating cut -2- all around on front longitudinal mem‐ber -1- in accordance with dimension -a- and cut in straight line.
Dimension -a- = 83 mm
–Separate original joint.
–Remove front longitudinal member part section -1- from body.
Engineering the offset
Body Repairs - Edition 06.2022
isnotpermittedunlessauthorisedbyV
–Mark separating cut -2- on front longitudinal member -1- in accordance with dimension -a- and cut in a straight line.
Dimension -a- = 40 mm
–Separate original joint.
–Detach remaining piece of front left longitudinal member -1from body.
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–Remove remaining material.
–Completely remove remaining adhesive.
–Grind bonding surfaces and welding surfaces back to bare metal.
9.3Installing
⇒ n9.3.1 ew part”, page 91
⇒ i9.3.2 n”, page 93
9.3.1Preparing new part
Replacement parts
♦ Front longitudinal member (replacement part designation ac‐cording to ⇒ Electronic parts catalogue (ETKA) ⇒ longitudi‐nal member)
♦ Cover plate (replacement part designation according to ⇒ Electronic parts catalogue (ETKA) ⇒ cover plate for longi‐tudinal member)
Repairs - Edition 06.2022
♦ Front longitudinal member end plate (replacement part des‐ignation according to ⇒ Electronic parts catalogue (ETKA) ⇒ cover plate) ID.4 2021 ➤
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Body Repairs - Edition 06.2022
♦ 2-component body adhesive ⇒ Electronic parts catalogue (ETKA)
–Sand bonding surfaces and welding surfaces on new part -1down to bare metal. ID.4 2021 ➤
–Transfer separating cut -2- to new part -1-, and cut in a straight line.
–Transfer separating cut -3- to new part -4-, and cut in a straight line.
–Grind bonding surfaces and welding surfaces back to bare metal.
9.3.2Welding in NOTICE
Strength could be impaired.
– The RP weld points must be set as far as possible from the outer edge of the welding flange.
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2021 ➤ Body Repairs - Edition 06.2022
NOTICE
Bonding properties of adhesive may be impaired. – New part must be welded in within 90 minutes.
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–Apply 2-component body adhesive over entire area of RP spot weld seam.
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–Adapt new part -1- and -2- to fit with vehicle positioned on straightening bracket set, and fix it in position.
–Check fit with add-on parts.
–Weld in new part -1- and -2- (RP spot weld seam and SG continuous weld seam).
NOTICE
Strength could be impaired.
– SG continuous weld seam must not be reworked (ground or smoothed).
Body Repairs - Edition 06.2022
–Apply 2-component body adhesive to entire surface.
–Adapt new part -1- with vehicle standing on its wheels or alignment bracket set and fix in position.
–Check fit with add-on parts.
–Weld in new part -1-, RP spot weld seam.
–Renew studs if present ⇒ page 131 ID.4 2021
ID.4 2021 ➤
Body Repairs - Edition 06.2022
RO: 50 79 55 10
10Renewing front right longitudinal member, part section
⇒ 10.1 , page 97
⇒ 10.2 , page 97
⇒ 10.3 , page 100
CAUTION
Gases/vapours hazardous to health are generated when welding, soldering or cutting using tools which produce sparks in foam-treated areas.
– Never weld, solder or cut closer than 15 mm to moulded foam inserts.
– Make sure to use an extraction system during the work.
Heed the safety precautions ⇒ page 7
Body work for which HV electrical system must be de-energised
⇒ page 8
Assembly overview
isnotpermittedunlessauthorisedbyVolkswagen AG Volkswagen AGdoesnotguaranteeoracceptanyliabilitywi
–Grind bonding surfaces and welding surfaces back to bare metal.
GAnegawskloVybthgirypoC.tnemucodsihtninoi
⇒ n10.3.1 ew part”, page 100
⇒ i10.3.2 n”, page 102
10.3.1Preparing new part
Replacement parts
♦ Front longitudinal member (replacement part designation ac‐cording to ⇒ Electronic parts catalogue (ETKA) ⇒ longitudi‐nal member)
♦ Cover plate (replacement part designation according to ⇒ Electronic parts catalogue (ETKA) ⇒ cover plate for longi‐tudinal member)
♦ Front longitudinal member end plate (replacement part des‐ignation according to ⇒ Electronic parts catalogue (ETKA) ⇒ cover plate)
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♦ 2-component body adhesive ⇒ Electronic parts catalogue (ETKA) –Sand bonding surfaces and welding surfaces on new part -1down to bare metal. ID.4 2021 ➤ Body Repairs - Edition 06.2022
GAnegawskloVybthgirypoC.tne
–Transfer separating cut -2- to new part -1-, and cut in a straight line.
–Transfer separating cut -3- to new part -4-, and cut in a straight line.
–Grind bonding surfaces and welding surfaces back to bare metal.
10.3.2Welding in NOTICE
Strength could be impaired.
– The RP weld points must be set as far as possible from the outer edge of the welding flange.
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Repairs - Edition 06.2022
NOTICE
Bonding properties of adhesive may be impaired. – New part must be welded in within 90 minutes. –Apply 2-component body adhesive over entire area of RP spot weld seam.
thgirypocybdetcetorP
ID.4 2021 ➤
Body Repairs - Edition 06.2022
–Adapt new part -1- and -2- to fit with vehicle positioned on straightening bracket set, and fix it in position.
–Check fit with add-on parts.
–Weld in new part -1- and -2- (RP spot weld seam and SG continuous weld seam).
NOTICE
Strength could be impaired.
– SG continuous weld seam must not be reworked (ground or smoothed).
–Apply 2-component body adhesive to entire surface.
–Adapt new part -1- with vehicle standing on its wheels or alignment bracket set and fix in position.
–Check fit with add-on parts.
–Weld in new part -1-, RP spot weld seam.
–Renew studs if present ⇒ page 131
Repairs - Edition 06.2022
RO: 50 79 55 03
11Renewing front left longitudinal member (part section – second part‐ing cut)
⇒ 11.1 , page 106
⇒ 11.2 , page 106
⇒ 11.3 , page 109
CAUTION
Gases/vapours hazardous to health are generated when welding, soldering or cutting using tools which produce sparks in foam-treated areas.
– Never weld, solder or cut closer than 15 mm to moulded foam inserts.
– Make sure to use an extraction system during the work.
Heed the safety precautions ⇒ page 7
Body work for which HV electrical system must be de-energised
– Rewelding reinforcement is not permitted due to safety reasons.
. icremmocroetavirprofgniypoCla rup op s e s , i n p a r t o r in w hole, isnotpermittedunlessauthorisedby guaranteeoracceptanyliabilitywi
–Apply textile adhesive tape on left and right roof members parallel to laser solder seams.
–Roughly cut roof -1- out parallel to laser solder seams -2-.
–Separate original joint.
–Remove roof -1- from body. ID.4 2021 ➤ Body Repairs - Edition 06.2022
icremmocroetavirprofgniypoCla rup op s e s , i n p a r t o r in w hole, isnotpermittedunlessauthorisedbyVolk
–Remove remaining material -1-. When doing this, do not damage roof side member.
–Carefully remove remaining material of laser soldered seam from left and right roof side members.
–Completely remove remaining adhesive.
–Grind bonding surfaces and welding surfaces back to bare metal.
–Apply corrosion protection measures to left and right roof side members ⇒ Body, General information, Paint, Technical data, General notes; Pre-treatment of bonded surfaces using 2-component epoxy filler when replacing laser-welded roofs.
ID.4
. roetavirprofgniypoC
–Sand bonding surface for 2-component body adhesive -1back to bare metal.
–Apply corrosion protection measures to sand-through spots on bonding surface for 1-component assembly adhesive -2⇒ General information, paintwork – passenger cars; Rep. gr. 00; General information; Pre-treatment of bonding surfa‐ces when renewing laser-welded roofs .
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–Clean bonding surfaces with cleaning solution.
–Apply glass/paint primer to bonding surface for 1-pack as‐sembly adhesive -2-.
♦ 1-pack assembly adhesive ⇒ Electronic parts catalogue (ET‐KA)
♦ 2-component body adhesive ⇒ Electronic parts catalogue (ETKA)
♦ Adhesive sealant ⇒ Electronic parts catalogue (ETKA)
♦ Glass/paint primer ⇒ Electronic parts catalogue (ETKA)
♦ Felt strips ⇒ Electronic parts catalogue (ETKA)
♦ Cleaning solution ⇒ Electronic parts catalogue (ETKA)
♦ Cavity sealant ⇒ Electronic parts catalogue (ETKA)
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–Sand bonding surfaces and welding surfaces on new part -1and -2- down to bare metal.
–Clean bonding surfaces with cleaning solution.
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–Clean bonding surfaces -2- for 1-component assembly adhe‐sive parallel to roof flange on left and right of new part -1using cleaning solution.
–Apply glass/paint primer to bonding surfaces for 1-pack as‐sembly adhesive -2-.
3.3.2Bonding roof NOTICE
Bonding properties of adhesive may be impaired. – New part must be welded in within 90 minutes.
–Cut approx. 2 mm off nozzle -B- to provide appropriate bead geometry.
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–Apply 1-component assembly adhesive to roof cross mem‐ber.
–Apply 1-component assembly adhesive to left and right roof side members according to dimensions -a-, -b- and -c-.
Dimension -a- = 3 mm
Dimension -b- = 10 mm
Dimension -c- = 14 mm ID.4
kswagen AG Volkswagen AGdoe
–Apply glass/paint primer to bonding surface for 1-pack as‐sembly adhesive.
–Apply 1-component assembly adhesive to inside of new part -1- parallel to roof flange on left and right, according to di‐mensions -a- and -b-.
Dimension -a- = 14 mm
Dimension -b- = 12 mm
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–Cut off first step of static mixer -A- to achieve corresponding bead cross-section.
–Carefully operate double cartridge gun without static mixer until 2-component body adhesive is discharged uniformly from both chambers of connecting piece.
–Screw static mixer onto connecting piece.
–Apply the first 100 mm of 2-component body adhesive to a piece of cardboard, and only then begin to apply the adhe‐sive to the vehicle.
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–Apply 2-component body adhesive to entire surface. ID.4
Body Repairs - Edition 06.2022
–Fill 2-component body adhesive in area of roof side mem‐bers.
Repairs - Edition 06.2022
–Moisten flanges -1- on new part entirely with 2-component body adhesive.
–Apply 2-component body adhesive to entire surface of new parts -2-.
3.3.3Adjusting roof depth
NOTICE
Risk of damage.
– Do not overtighten tensioning straps.
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AG. Volks
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–Adapt new part -1- with vehicle standing on its wheels or alignment bracket set and fix in position.
–In areas shown, tension tensioning straps -2- transversely over roof to vary height of roof.
–Check dimension -a- on roof to roof side members.
Dimension -a- = 6.0 mm ± 0.5 mm
–Fix position of new part -1- at front roof cross member and rear roof cross member using mole grips.
–If necessary, place felt strips underneath for compensation.
–Excessive 2-component body adhesive must be removed immediately.
3.3.4Welding in NOTICE
Strength could be impaired.
– The RP weld points must be set as far as possible from the outer edge of the welding flange.
ID.4 2021 ➤
Body Repairs - Edition 06.2022
la rup op s e s , i n p a r t o r in w hole, isnotpermittedunlessautho
t . icremmocroetavirprofgniypoC
–Weld in new part -1-, RP spot weld seam.
Repairs - Edition 06.2022
NOTICE
Bonding properties of adhesive may be impaired.
– After bonding, vehicle must remain stationary for 8 to 10 hours at room temperature (min. 15°C) so that adhe‐sive can harden.
– During this time, the vehicle must be standing on a level surface.
– Rewelding reinforcement is not permitted due to safety reasons.
. icremmocroetavirprofgniypoCla rup op s e s , i n p a r t o r in w hole, isnotpermittedunlessauthorisedby guaranteeoracceptanyliabilitywi
Body Repairs - Edition 06.2022
–Apply textile adhesive tape on left and right roof members parallel to laser solder seams.
–Roughly cut roof -1- out parallel to laser solder seams -2-.
–Separate original joint.
–Remove roof -1- from body.
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GAnegawskloVybthgirypoC.tnemucodsihtninoitamr
–Remove remaining material -1-. When doing this, do not damage roof side member.
–Carefully remove remaining material of laser soldered seam from left and right roof side members.
–Completely remove remaining adhesive.
–Grind bonding surfaces and welding surfaces back to bare metal.
–Apply corrosion protection measures to left and right roof side members ⇒ Body, General information, Paint, Technical data, General notes; Pre-treatment of bonded surfaces using 2-component epoxy filler when replacing laser-welded roofs.
thgirypocybdetcetorP . icremmocroetavirprofgniypoCla rup op s e s , i n p a r t o r in w hole,
–Sand bonding surface for 2-component body adhesive -1back to bare metal.
–Apply corrosion protection measures to sand-through spots on bonding surface for 1-component assembly adhesive -2⇒ General information, paintwork – passenger cars; Rep. gr. 00; General information; Pre-treatment of bonding surfa‐ces when renewing laser-welded roofs .
–Clean bonding surfaces with cleaning solution.
–Apply glass/paint primer to bonding surface for 1-pack as‐sembly adhesive -2-.
♦ 1-pack assembly adhesive ⇒ Electronic parts catalogue (ET‐KA)
♦ 2-component body adhesive ⇒ Electronic parts catalogue (ETKA)
♦ Adhesive sealant ⇒ Electronic parts catalogue (ETKA)
♦ Glass/paint primer ⇒ Electronic parts catalogue (ETKA)
♦ Felt strips ⇒ Electronic parts catalogue (ETKA)
♦ Cleaning solution ⇒ Electronic parts catalogue (ETKA)
♦ Cavity sealant ⇒ Electronic parts catalogue (ETKA)
. icremmocroetavirprofgniypoCla rup op s e s , i n p a r t o r in w hole, isnotpermittedunlessauthorisedbyVolkswagen AG. Volkswagen AGdoesnotguaranteeoracceptanyliabilitywith respect
Body Repairs - Edition 06.2022
–Sand bonding surfaces and welding surfaces on new part -1and -2- down to bare metal.
–Clean bonding surfaces with cleaning solution.
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la rup op s e s , i n p a r t o r in w hole,
–Clean bonding surfaces -2- for 1-component assembly adhe‐sive parallel to roof flange on left and right of new part -1using cleaning solution.
–Apply glass/paint primer to bonding surfaces for 1-pack as‐sembly adhesive -2-.
4.3.2Bonding roof NOTICE
Bonding properties of adhesive may be impaired. – New part must be welded in within 90 minutes.
