Volkswagen ID.3: Body centre, roof, frame. Side member

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

Assembly overview – outer side member

Assembly overview – outer side member

Overview is 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

Assembly overview – side member reinforcement

Overview is 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

❏ Front underbody

❏ Qty. 2

❏ 55 Nm

5 - Bolt

❏ Rear underbody

❏ Qty. 3

❏ 55 Nm

Assembly overview - side panel reinforcement (crash bar)

Assembly overview - side panel reinforcement (crash bar)

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

1 - Side panel reinforcement

❏ Aluminium component

❏ → Rep. gr.51; Renewing side panel reinforcement (crash bar)

2 - Bonded area

Renewing outer side member

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 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- in a straight line as shown.

– Separate original joint.

– Remove side member -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.

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

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

– Lightly sand 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 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).

– Weld parting cuts (either MIG solder seam or SG stepped weld seam).

– Fold wheel arch flange over.

– Remove excess adhesive, and seal wheel arch.

Vehicles with type plate.

– Reattach type plate after painting → Chapter „Type plate“.

All vehicles (continued)

Vehicles with safety certificate.

– Reattach safety certificate after painting → Chapter „Safety certificate“.

Renewing side member reinforcement

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 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 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 adhesive residue.

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

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 it in position.

– Check fit with attachments.

– 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 B-pillar reinforcement.

– Tighten bolts -2-, -3- and -4-.

Tightening torques

♦ → Rep. gr.51; Assembly overview – side member reinforcement

Renewing side panel reinforcement (crash bar)

Renewing side panel 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 → Rep. gr.00; Tools.

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 adhesive residue.

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

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 it in position.

– Check fit with attachments.

– Weld in new part -1- (RP spot weld seam).

– Install side member reinforcement → Rep. gr.51; Renewing side member reinforcement.

Body centre, roof, frame. B-pillarBody, rear. Rear cross member