1997 SKODA OCTAVIA Body Repairs Workshop Manual

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Downloaded from www.Manualslib.com manuals search engine OCTAVIA
00General Notes
Edition 02.03
S00.5119.56.20
------------ 00-2
------------ Safety measures Safety precautions
When performing the works described comply with all country-specific safety regulations. In case of doubt refer to the competent authori- ties.
Safety at work measures
For all operations take the legally prescribed personal and general protection measures. This includes e.g. the wearing of safety spectacles, gloves, safety shoes and ear protectors.
Work on straightening rig
Extremely high forces act upon the body dam- aged by accident being straightened using hy- draulic pressure or traction devices on the straightening bench. Always bear in mind that these forces may suddenly be released e.g. by
the sliding of a fastening claw. Therefore make absolutely sure no person is present in or around the danger zone.
Removing components
Secure the vehicle on the lift platform before itscentre of gravity shifts considerably because ofsuccessive disassembly operations.
Battery
Remove the battery before welding. Always remove the battery before performing
spark-generating work close to the battery. Note: If the battery earth strap is disconnected and connected, carry out additional operations
Electrical System; Repair Group 27.

Downloaded from www.Manualslib.com manuals search engine OCTAVIAGeneral Notes00
Edition 02.03
S00.5119.56.20------------ 0
0

3 ------------
Paint, windows, upholstery, trims
It is prohibited to park other vehicles without protection in the premises used to repair the bodies (risk of fire resulting from flying sparks, battery destruction, deterioration of the paint andwindows).
Welding work
Warning! As toxic zinc oxide is contained in the fumes pro- duced during steel sheet welding suitable exhaust
systems, e.g. V.A.G 1586 must be provided to prop-erly ventilate the workshop and evacuate the gases.
Before starting welding operations on the vehi- cle, protect the rest of the vehicle by placing fire-
proof blankets or matting around the work area. If this measure is thoroughly implemented, it will
not be necessary to remove all the interior vehi-
cle equipment. However, for safety reasons a fire extinguisher must always be within reach during welding operations. If the mechanic per- forming the welding operation is unable to su-
pervise the inside of the vehicle, a second per- son must be called upon. The gases during welding are toxic and must be exhausted. Notes: Remove battery before all welding opera- tions.
Disconnect AC generator and ignition trans- former
Disconnect the earth connections of the electrical control units
page 00-5.
Air conditioning
It is prohibited to weld or hard or soft solder on parts of the filler air conditioning. This also ap- plies for welding and soldering operations on the vehicle if there is any risk that parts of the air conditioning heat up. During paint repairs the temperature of the objects placed in the drying oven or in its pre-heating zone must not exceed
80 °C because heating causes a strong over-pressure that may result in the system explod- ing.

Downloaded from www.Manualslib.com manuals search engine OCTAVIA
00General Notes
Edition 02.03
S00.5119.56.20
Note: The refrigerant circuit must be exhausted, if elec- trical welding must be carried out close to the refrigerant hoses. During electrical welding in- visible ultraviolet rays are produced that pen-
etrate the refrigerant hoses and decompose the refrigerant. Remedial measures: Exhaust the refrigerant circuit Heating, Air conditioning, Repair Group 87
Warning! Observe the safety measures for working with air conditioning Heating, Air conditioning, Repair
Group 87.
------------ 0 0


4 ------------

Downloaded from www.Manualslib.com manuals search engine General Information00

Edition 03.97


Fuel tank or piping conveying fuel
Extreme caution is required when carrying out grinding and welding work in the area of the fuel tank or other parts which convey fuel. If doubt exists, such parts should be removed. If the fuel tank and fuel pipes have to be removed from the vehicle, they should be stored in accordance with safety precautions.
Electronic control units
Remove battery. Separate earth connections of the electronic control units.
Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder
Connect the earth of the electric welding equip- ment directly to the part to be welded. When doing this, ensure that no electrically insulating parts are located between the earth connections and the welding point. Do not allow electronic control units and electric cables to come into contact with the earth connection or the welding electrode.
Airbag system
Safety information General Body Repairs, Repair Group 69
Repair information General Body Repairs, Repair Group 69
Safety precautions for seat belt tensioners
Safety information General Body Repairs, Repair Group 69
Important!
Remove the seat belt tensioner units beforecommencing any cutting, straightening and panelbeating work in the area of these units.
If one or both seat belt tensioners have beenactivated in an accident, both seat belts have tobe replaced (the seat belts no longer rewind).
Repair information General Body Repairs, Repair Group 69

Downloaded from www.Manualslib.com manuals search engine 00General Information
Edition 08.96

Basic information Procedure for accident repairs


Diagnosis of damage Removing adjoining parts Itemising parts required

Is it economic to eliminate
damage by panel beating?yes no





B
A


Protect the vehicle by covering over
undamaged parts Protect the vehicle by covering over
undamagd parts
Repair damaged part by panel beating, with or without filler depending on damage Have new parts primed from inside
Carry out fine filler work (scores, pores) as necessary Eliminate damage by straightening to restore
original shape so that adjoining contour/body dimensions are again correct
Replace fine sealing/chip protection as necessary Cut out damaged part roughly
Remove remaining parts