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Repair Manual
ID.4 2021 ➤, ID.4 2023 ➤, ID.5 2022 ➤,
ID.3 2020 ➤, ID.7 2024 ➤
Safety Precautions and Repair Information
Edition 03.2023
Service
Service Department. Technical Information
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List of Workshop Manual Repair Groups
Repair Group
00 - General, Technical Data
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.
Service
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2023 Volkswagen AG, Wolfsburg D4B807EE08E
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Contents
00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 General Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety Precautions when Working on Vehicles with High-Voltage System . . . . . . . . . . . . 2
1.3 Safety Precautions when Working on Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 Safety Precautions when Working on A/C Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5 Safety Precautions during Road Test with Testing Equipment . . . . . . . . . . . . . . . . . . . . . . 4
1.6 Safety Precautions when Working on the Passenger Protection System . . . . . . . . . . . . . . 4
1.7 Safety Precautions when Working with Chemicals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.8 Working with Compressed-Gas Canisters, Safety Precautions . . . . . . . . . . . . . . . . . . . . . . 5
1.9 Working with Batteries, Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.10 Safety Precautions when Working with Special Tools and Equipment . . . . . . . . . . . . . . . . 6
2 Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 Laws, Standards, Guidelines and Risk Assessments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Repair Manual, Information on Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3 Replacement Parts, Working Materials and Expendable Items . . . . . . . . . . . . . . . . . . . . . . 8
2.4 Transport and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.5 Qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.6 Environmental Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.7 Guidelines for Clean Working Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.8 Identification Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.9 Bolts and nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.10 Impact Wrench, Using . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.11 Contact Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.12 Seals and Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.13 Adhesive Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.14 Disconnecting the Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.15 Line Routing and Securing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.16 Circlips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.17 Working on Refrigerant Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.18 Working on Seat Occupant Detection System for Front Passenger Airbag Deactivation . . 15
2.19 Vehicle Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.20 Vehicles Involved in Collisions, Evaluating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
ID.4 2021 ➤, ID.4 2023 ➤, ID.5 2022 ➤, ID.3 2020 ➤, ID.7 2024 ➤
Safety Precautions and Repair Information - Edition 03.2023
Contents i
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ID.4 2021 ➤, ID.4 2023 ➤, ID.5 2022 ➤, ID.3 2020 ➤, ID.7 2024 ➤
Safety Precautions and Repair Information - Edition 03.2023
ii Contents
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00 – General, Technical Data
1 Safety Precautions
(Edition 03.2023)
10004NJ4T723.017.1 - 03/2023
K0059384521 - 03.31.2023
⇒ S1.1 afety Precautions”, page 1
⇒ P1.2 recautions when Working on Vehicles with High-Voltage
System”, page 2
⇒ P1.3 recautions when Working on Cooling System”, page 3
⇒ P1.4 recautions when Working on A/C Systems”, page 3
⇒ P1.5 recautions during Road Test with Testing Equipment”,
page 4
⇒ P1.6 recautions when Working on the Passenger Protection
System”, page 4
⇒ P1.7 recautions when Working with Chemicals”, page 5
⇒ w1.8 ith Compressed-Gas Canisters, Safety Precautions”,
page 5
⇒ w1.9 ith Batteries, Safety Precautions”, page 5
⇒ P1.10 recautions when Working with Special Tools and
Equipment”, page 6
1.1 General Safety Precautions
Risk of accident due to the vehicle rolling.
When working on a vehicle, it always needs to be secured
against rolling.
♦ Automatic transmission/dual clutch transmission: select “P”.
♦ Manual transmission: engage 1st gear.
♦ Set the parking brake.
There is a risk of injury due to the radiator fan.
Body parts can be pinched or pulled in if the radiator fan starts
running by itself.
♦ When working near the radiator, maintain a distance from
the radiator fan.
♦ Do not reach into the radiator fan when disconnecting the
connector.
There is a risk of injury due to UV radiation and glare.
Eye and skin damage are possible when the headlamps are
turned on.
♦ Do not look into the beam of light.
♦ Turn off the ignition and all electrical equipment.
♦ Place the vehicle key and other start authorization systems
(such as smartphones) outside of the vehicle.
♦ Do not operate the flashers.
♦ Only assemble the LED headlamps according to the repair
manual.
ID.4 2021 ➤, ID.4 2023 ➤, ID.5 2022 ➤, ID.3 2020 ➤, ID.7 2024 ➤
Safety Precautions and Repair Information - Edition 03.2023
1. Safety Precautions 1
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Risk of suffocation due to refrigerant R744.
During procedures in which the 12V battery is disconnected,
the vehicle interior carbon dioxide concentration sensor is not
working.
♦ Only perform procedures in the vehicle interior with open
doors.
1.2 Safety Precautions when Working on
Vehicles with High-Voltage System
High voltage increases the risk of fatal injury
The high-voltage system is under high voltage. Electrocution by
direct contact or electric arc can cause severe bodily injury or
fatal injury.
♦ When working on the high-voltage system, the high-voltage
system must be de-energized.
♦ Have a high-voltage technician (HVT) or a high-voltage ex‐
pert (HVE) de-energize the high-voltage system.
♦ Procedures requiring the system to be de-energized:
Refer to ⇒ Rep. Gr. 00; High-Voltage System Danger Classifi‐
cation.
There is a risk of fatal injury due to electric and magnetic fields
The high-voltage system emits electric and magnetic fields. Fa‐
tal or serious bodily injuries are possible if active implants (such
as pacemakers or insulin pumps) malfunction.
♦ Individuals with active implants must not perform any work
on high-voltage systems.
There is a risk of fatal injury due to high voltage if high-voltage
components and cables are damaged.
The high-voltage system is under high voltage. Electrocution by
direct contact or electric arc can cause fatal or serious bodily
injury if high-voltage components and high-voltage cables are
damaged.
♦ Visually inspect the high-voltage components and the high-
voltage cables.
♦ Do not use cutting, shaping, or sharp-edged tools near high-
voltage components and high-voltage cables.
♦ Do not weld, solder, or use thermal bonding or hot air near
high-voltage components and high-voltage cables.
There is a risk of damaging the high-voltage cables.
Incorrect handling can damage the insulation on high-voltage
cables or high-voltage connectors.
♦ Do not use the high-voltage cables and the high-voltage
connectors for support.
♦ Do not support tools on the high-voltage cables and the
high-voltage connectors.
♦ Do not force high-voltage cables to bend or kink.
♦ Pay attention to the coding when connecting the high-volt‐
age connectors.
There is a risk of injury due to an activated parking heater and
A/C.
The parking heater and A/C can switch on unintentionally on
electric and hybrid vehicles with an activated parking heater
and A/C. Parts of the body can be pinched or pulled by the
ID.4 2021 ➤, ID.4 2023 ➤, ID.5 2022 ➤, ID.3 2020 ➤, ID.7 2024 ➤
Safety Precautions and Repair Information - Edition 03.2023
2 Rep. Gr.00 - General, Technical Data
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radiator fan starting to run by itself, the fresh air blower, and
moving parts on the heater and A/C unit.
♦ Deactivate the parking air conditioning and timer functions
for the parking air conditioning.
1.3 Safety Precautions when Working on
Cooling System
There is a risk of scalding due to hot coolant.
The cooling system may be under pressure. There is a risk of
scalding due to hot steam and hot coolant.
♦ Wear safety gloves.
♦ Wear protective eyewear.
♦ Reduce the pressure by covering the coolant expansion tank
cap with a suitable towel and carefully opening it.
1.4 Safety Precautions when Working on
A/C Systems
There is a risk of explosions from ignition sources.
There is a risk of explosions due to ignition sources near the
A/C systems and refrigerant canisters. Leaking refrigerant can
ignite and cause an explosion. Severe bodily injury or death
caused by explosions possible.
♦ Do not bring any ignition sources near A/C systems and
refrigerant canisters.
There is a risk of asphyxiation and poisoning from refrigerant.
Refrigerant fumes can cause problems ranging from a dry
cough and nausea to asphyxiation and poisoning. Refrigerant
is heavier than air and will collect in the lower areas.
♦ Do not inhale refrigerant fumes.
♦ Only work on the refrigerant circuit in well-ventilated areas.
♦ Store the refrigerant canister in a well vented room.
♦ Do not work in or near to lower areas.
♦ Switch on the exhaust extracting system.
There is a risk of getting frostbite from the refrigerant.
When working on the A/C system, refrigerant under pressure
can escape. Frostbite on the skin and other parts of the body is
possible.
♦ Wear safety gloves.
♦ Wear protective eyewear.
♦ Evacuate or drain refrigerant and open the refrigerant circuit
immediately.
♦ If more than 10 minutes elapse after extracting or drain‐
ing the refrigerant and the refrigerant circuit has not been
opened, extract or drain the refrigerant again. Pressure de‐
velops in the refrigerant circuit due to evaporation.
ID.4 2021 ➤, ID.4 2023 ➤, ID.5 2022 ➤, ID.3 2020 ➤, ID.7 2024 ➤
Safety Precautions and Repair Information - Edition 03.2023
1. Safety Precautions 3
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1.5 Safety Precautions during Road Test
with Testing Equipment
There is a risk of injury due to unsecured testing equipment.
If the front passenger side airbag unit deploys during an acci‐
dent, testing equipment which is not properly secured will be
tossed around dangerously.
♦ Secure testing equipment on the rear seat.
♦ Have a second person operate testing equipment on the
rear seat.
♦ For a two seater the front passenger airbag must be deacti‐
vated and moved into the rearmost position.
1.6 Safety Precautions when Working on
the Passenger Protection System
There is a risk of involuntary deployment of passenger protec‐
tion.
Passenger protection pyrotechnic components can be triggered
unintentionally. Fatal or serious bodily injuries are possible.
♦ Work on passenger protection should only be performed by
specially trained personnel.
♦ Repairs near passenger protection pyrotechnic components:
mechanical or thermal load or injury can result in the loss
of restraint functions in a collision or lead to unintentional
deployment.
♦ Do not perform an electric continuity test or measurement in
the ignition circuits. Only perform the visual inspection of the
wire routing with the ignition switched off.
♦ The pyrotechnic components may be checked only when
they are installed and with a vehicle diagnostic tester ap‐
proved by the manufacturer.
♦ Pyrotechnic components must not be opened or repaired.
Always use new parts.
♦ Only use original components without damage.
♦ Only disconnect and connect the airbag control module con‐
nector if the control module is securely bolted to the body.
♦ The airbag control module contains vehicle-specific data. Do
not install in other vehicles.
♦ Follow the instructions for transport and storage of passen‐
ger protection components.
Refer to ⇒ Rep. Gr. 00; Transport and Storage.
There is a risk of inhaling dust and gases immediately after
pyrotechnic components are ignited.
Dust and gases are released immediately after pyrotechnic
components are ignited. Health risks can occur due to inhaling
dusts and gases.
♦ Allow the vehicle to air out.
♦ Clean the interior while wearing a mouth and nose protec‐
tion.
♦ Avoid skin contact with pyrotechnic components.
♦ Follow any local applicable disposal guidelines.
ID.4 2021 ➤, ID.4 2023 ➤, ID.5 2022 ➤, ID.3 2020 ➤, ID.7 2024 ➤
Safety Precautions and Repair Information - Edition 03.2023
4 Rep. Gr.00 - General, Technical Data
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Risk due to passenger protection with limited functionality
The passenger protection functionality may be limited after a
collision. Fatal or serious bodily injuries are possible.
♦ Check the passenger protection after a collision.
Refer to ⇒ Rep. Gr. 00; Passenger Protection for Vehicles In‐
volved in Collisions, Evaluating.
1.7 Safety Precautions when Working with
Chemicals
There are health risks
Chemical substances can be absorbed via the skin, the respi‐
ratory system or by swallowing. This can lead to acute and
chronic health complications.
♦ Observe the material safety data sheets and supplementary
information from the manufacturers.
♦ Do not eat, drink, smoke etc., when handing chemical sub‐
stances.
♦ Use personal protective equipment.
1.8 Working with Compressed-Gas Canis‐
ters, Safety Precautions
Risk of damage to health and property damage.
Incorrect handling of compressed-gas canisters can lead to
damages to health and property damage.
♦ When working with compressed-gas canisters, certain coun‐
try-specific laws, standards and guidelines must be kept in
mind.
♦ Observe the material safety data sheets and supplementary
information from the manufacturers.
♦ Use personal protective equipment.
1.9 Working with Batteries, Safety Precau‐
tions
Risk of damage to health and property damage.
Leaking acid can cause chemical burns. Oxyhydrogen gas that
results from charging can lead to an explosion.
♦ Use personal protective equipment.
♦ Pay attention to the information and operating instructions
on the battery.
♦ Touch the vehicle body before touching the battery in order
to prevent sparks from static discharge.
♦ Keep countermeasures ready.
♦ Only perform battery procedures in suitable and well-ventila‐
ted locations.
♦ Procedures which produce sparks, like sanding, welding,
separation procedures and open flames are prohibited.
♦ Batteries showing the “ALI (Acid Level Indicator)” in a bright
yellow must be replaced. These cannot be tested or charged
and a jump start cannot be given.
♦ Do not place any tools on batteries.
ID.4 2021 ➤, ID.4 2023 ➤, ID.5 2022 ➤, ID.3 2020 ➤, ID.7 2024 ➤
Safety Precautions and Repair Information - Edition 03.2023
1. Safety Precautions 5
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♦ Do not tilt batteries if electrolyte can leak from the vent open‐
ings.
♦ It is relevant for safety reasons to which side the battery
vents!
♦ For applications in which a gas breather hose is used, pay
attention to the correct seating of the gas breather hose and
that the vent opening is closed on the opposite side.
1.10 Safety Precautions when Working with
Special Tools and Equipment
Safety Precautions when Working with Special Tools and
Equipment
Risk of injury due to improper use and handling of special tools
and equipment.
♦ Checking the special tools and equipment for function and
damage before using them.
♦ Wear appropriate protective wear.
♦ Pay attention to the operating instructions that came with the
special tools or equipment.
♦ When working with extraction tools, make sure they are se‐
curely placed and that forces apply evenly.
♦ Pay attention to the repair information.
Refer to ⇒ Rep. Gr. 00; Repair Manual, Information on Applica‐
tion.
ID.4 2021 ➤, ID.4 2023 ➤, ID.5 2022 ➤, ID.3 2020 ➤, ID.7 2024 ➤
Safety Precautions and Repair Information - Edition 03.2023
6 Rep. Gr.00 - General, Technical Data
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Description
Simplify your vehicle's maintenance and repair with the reliable and comprehensive Volkswagen ID.4 GTX manual. This digital guide is designed for both professional mechanics and DIY enthusiasts, providing detailed instructions and diagrams to help you troubleshoot, repair, and maintain your vehicle in a cost-effective manner.
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The manual covers various aspects of your vehicle's maintenance and repair, including:
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