1997 SKODA OCTAVIA Body Repairs Workshop Manual

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Edition 08.96




 
Explanation of symbols for methods

Stepping with stepping pliers in order to carry
out an overlap weld.
Plugging with plugging pliers in order to carry out subsequent shielded arc plug welding. Drilling in order to carry out subsequent shielded arc plug welding or to drill out weld spots (original joint).
Grinding with straight grinder in order to remove the material applied to the weld seam.

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  Edition 08.96

Cavity protection
Bonding Fine sealing

Downloaded from www.Manualslib.com manuals search engine OCTAVIAGeneral Notes00
Edition 02.03
S00.5119.56.20Tools
Tools required

Right angle grinder (e.g. EBU 18-E2)
One-hand right angle grinder (e.g. WS-125) and wire brush
Welding point loosening tool (e.g. Variodrill
V.A.G 1731)
Sheet metal and body saw (e.g. V.A.G 1523)
Welding fume extraction (e.g. V.A.G 1586 A)
Body tool carrier (e.g. V.A.G 1439)
Door tension adjuster (e.g. V.A.G 1438)
Underbody sealant gun (e.g. V.A.G 1379)
Burring pliers
- To burr panels e.g. for overlapping seams
Punch pliers (e.g. V.A.G 1329)
- To punch holes in panels (e.g. for shielded arc plug weld)
Panel nibbler
- To cut out panels without warpage or burr- ing (e.g. when subsequently fitting a glasssun roof)
Pneumatic gun (e.g. V.A.G 1761/1)
- Pneumatic gun to produce seals and apply underbody protection having the same ap- pearance as the original factory finish.
- Moreover all 310 ml cartridges can be used in this gun
Pneumatic gun for 2k window glue (e.g. VAS 5237)
Pressure beaker gun for hollow space seal-
ing (e.g. V.A.G 1538)
Inert gas shielded welding tool
Spot welding and sheet panel machining tool
(e.g. V.A.G 1713)
Rig alignment bench Celette M85 with align-
ing device and straightening angle set VAS 5020/1
Basic equipment (e.g. V.A.G 1366/3)
Rod grinder with wire brush
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  Edition 08.96

Corrosion protection measures Corrosion protection
The body is manufactured from sheets galvani- sed on both sides. It is essential to re-create the standard corrosion protection after carrying out body repairs using the material specified by the manufacturer as this is a precondition for ensuring the absence of corrosion.
Long-life body protection
- Prime bright metal sheet parts immediately
after carrying out repairs (corrosion protecti-on primer ALN 002 003 10 or ALK 007 003 10).
- Spray outer skin sheets from the inside with top coat before welding in place.
- Always apply zinc spray (D 007 500 04) to both sides of spot welded flanges.
Note
Areas which are subsequently shielded arc-wel-ded, must not be pre-treated with zinc spray.
- Prime weld seam areas from the inside and outside with corrosion protection primer ALN002 003 04 before sealing.
- Apply sealing compound only to primed sheet metal parts and allow to harden sufficiently before further treatment with paint.
- Seal sheet metal overlaps, sheet edges, butt joint, weld seams etc. completely with sealing compound.
- Re-create the underbody sealant using long- life underbody sealant material.
- Protect all the cavities in the area of the repair after applying the top coat.
- After the cavity protection material has dried, open the water drains.

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Edition 08.96




 
Separating galvanised body parts
Preparatory work
- Remove underbody sealant and weld seams
Basic information, page 00-12.
Cutting operation
- Do not use cutting operations which involve heat, e.g. cutting torch.
- It is best to use mechanical cutting methods, e.g. weld spot milling, body saw, to avoid any damage to the zinc layer in the area of the cut.
Welding galvanised body sheets Basic information, page 00-10.

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Downloaded from www.Manualslib.com manuals search engine OCTAVIAGeneral Notes00
Edition 02.03
S00.5119.56.20
Body dimensions Front body
a - 1328 mm
Distance between the hinge attach- ments.
b - 1119 mm Distance between the suspension strut supports.
c - 1533.5 mm Diagonal dimension between hinge
attachment for engine bonnet - top longitudinal member for wheelhouse. d - 1316 mm
Distance between top longitudinal members for wheelhouse.
All dimensions are quoted without a tolerance figure ± 2 mm. Note: The quoted dimensions simply serve for check- ing purposes. The straightening angle set is decisive.
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