Volkswagen ID.3: Body centre, roof, frame. A-pillar

• Assembly overview – A-pillar
• Assembly overview – A-pillar reinforcement
• Renewing A-pillar
• Renewing A-pillar reinforcement (part section)

Assembly overview – A-pillar

Assembly overview – A-pillar

Overview is shown for left side of vehicle as an example.

1 - A-pillar

❏ Subpart

❏ → Rep. gr.51; Renewing A-pillar

2 - Moulded foam inserts

❏ → Rep. gr.00; Moulded foam inserts

3 - Separating cut

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

4 - Bonded area

5 - Separating cut

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

6 - Separating cut

❏ Keep in mind cut lines required for new part.

❏ 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.

8 - Separating cut

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

Assembly overview – A-pillar reinforcement

Assembly overview – A-pillar reinforcement

Overview is shown for left side of vehicle as an example.

1 - A-pillar reinforcement

❏ → Rep. gr.51; Renewing A-pillar reinforcement (part section)

2 - Moulded foam inserts

❏ → Rep. gr.00; Moulded foam inserts

3 - Bolt

❏ 55 Nm

4 - Bonded areas

5 - Separating cut

Renewing A-pillar

Renewing A-pillar

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.

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 15°C) 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 → Rep. gr.00; Tools.

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

Removing

– Make separating cut -2- and -3- in a straight line, as shown in illustration.

– Separate original joint.

– Remove A-pillar -1-.

– Remove any foam residue -1-.

– Remove remaining material.

– Completely remove adhesive residue.

– Sand bonding and welding surfaces down to bare metal, and clean them.

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.

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

– Drill or - alternatively - punch holes of 8 mm in diameter for SG plug weld seam in new part -1- to -6-.

– Lightly sand bonding surfaces on new part -1- from inside.

– 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 it in position.

– Check fit with attachments.

– 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).

Renewing A-pillar reinforcement (part section)

Renewing A-pillar reinforcement (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.

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 15°C) 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 → Rep. gr.00; Tools.

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

Removing

A-pillar (part section) removed → Rep. gr.51; Renewing A-pillar.

– Unscrew bolt -3-.

– Make separating cut -2- in a straight line.

– Separate original joint.

– Remove A-pillar reinforcement -1-.

– Remove any foam residue -2-.

– Separate original joint.

– Remove remaining piece of A-pillar reinforcement -1-.

– Remove remaining material.

– Completely remove adhesive residue.

– Sand bonding and welding surfaces down to bare metal, and clean them.

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.

– Detach hinge reinforcement -3- from new part -1-.

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

– Transfer number and position of holes from removed section to new part -1-.

– Drill 8 mm Ø holes for SG plug weld seam or stamp.

– 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 it in position.

– Check fit with attachments.

– Weld in new part -1- (SG plug weld seam).

– Tighten bolt -3-.

– Prepare moulded foam insert -2- for installation and insert.

– Apply 2-component body adhesive to entire surface.

– Adapt new part -1- to fit, and fix it in position.

– Check fit with attachments.

– Weld in new part -1- (RP spot weld seam, SG plug weld seam and SG continuous weld seam).

– Install A-pillar part section → Rep. gr.51; Renewing A-pillar.

Tightening torques

♦ → Rep. gr.51; Assembly overview – A-pillar reinforcement

Body centre, roof, frame. RoofBody centre, roof, frame. B-pillar