Page 103 of 150
Downloaded from www.Manualslib.com manuals search engine OCTAVIAMiddle Body51
Edition 02.03
S00.5119.56.20------------ 5
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Welding in
- Match up and tack-weld new part with vehi- cle standing on its wheels or on straighten-
ing angle set.
- Weld in lower sill reinforcement, shielded arc
plug weld.
Page 105 of 150
Downloaded from www.Manualslib.com manuals search engine OCTAVIAMiddle Body51
Edition 02.03
S00.5119.56.20
Replacement parts Lower sill tube reinforcement
Welding in
- Match up and tack-weld new part with vehi- cle standing on its wheels or on straighten-
ing angle set.
- Weld in lower sill tube reinforcement, shiel-
ded arc plug weld.
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Page 107 of 150
Downloaded from www.Manualslib.com manuals search engine OCTAVIAMiddle Body51
Edition 02.03
S00.5119.56.20
Replacement part Inner lower sill
Reinforcement for lift platform attachment
Preparing new part
- Weld reinforcement with lower sill, spot weld
seam.
- Make holes in new part with punch pliers.
Welding in
- Match up and tack-weld new part with vehi- cle standing on its wheels or on straighten-
ing angle set.
- Weld in inner lower sill, shielded arc plug
weld.
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Page 122 of 150
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53Rear Body
Edition 03.97
Replacing boot floor
Rear end panel and lock carrier already re- moved.
Separation points
- Detach original joint to side members and
left reinforcement.
- Position front separation cut about 100 mm behind cross member between wheel-houses.
- Remove remaining pieces.
Note: If the side connection panels are damaged,these have to be straightened or replaced.
Replacement parts Boot floor
Left boot floor reinforcement
Preparing new parts
- Pierce new part in connection area to wheel-
house.
- Drill
∅ 7 mm holes in the rear connection
area to side members. (RP spot weld in the area of spot weld tongs.)
Page 123 of 150
Downloaded from www.Manualslib.com manuals search engine Rear Body53
Edition 03.97
Welding in
- Match up boot floor with vehicle standing on
its wheels or on straightening rig and check gaps with end panel and tailgate fitted.
- Tack weld boot floor.
- Take off end panel.
- Weld in boot floor, RP spot weld.
- Weld in left reinforcement of boot floor, RP
spot weld.
- Weld separation cut, SG continuous weld
staggered.
- Weld in remaining joint, SG plug weld.
Page 133 of 150
Downloaded from www.Manualslib.com manuals search engine OCTAVIARear Body53
Edition 02.03
S00.5119.56.20------------ 5
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7 - ------------
Replacing rear side part (Octavia)
1 - Foam-lined area
Warning! In view of the fact that gases which are particu- larly harmful to persons and the environment are produced during welding, cutting with tools and equipment which produce sparks, or tin-plating in foam-lined areas, it is prohibited in all cases to use such methods.
Note: If the outer lower sill or outer B pillar and possi- bly also outer A pillar are damaged, then the door frames can be used as a spare part with-out reinforcement (a stamped part). Separation points
- Cut out side part roughly
- Grind through outer edge of wheelhouse. Note:
Do not damage inner wheelhouse liner.
- Detach original joint
- Remove remaining pieces. Replacement parts Side part
Adhesive: DA 001 730 A1
Sound insulation 1U6 863 665
Preparing new part
- Drill
∅ 7 mm holes for shielded arc plug weld
in the area to tailgate water channel
- Transfer separation cuts to new part and cut to shape.
