Page 18 of 150
Downloaded from www.Manualslib.com manuals search engine 00General Information
Edition 08.96
Diagnosing vehicles damaged in an accident
When repairing vehicles damaged in an acci- dent, it is sometimes the case that damage to the chassis or components suspension is not discovered and this may subsequently result in severe consequential damage. When inspecting vehicles which have been damaged in an acci- dent where it is suspected that considerable stresses were involved, it is therefore necessary to pay particular attention to the following com- ponents - irrespective of the check of the chassis alignment which should always be carried out as well:
If it is suspected that the floor assembly has been damaged and/or twisted, the vehicle has to be inspected on the frame straighten-
ing rig and straightened, if necessary.
Inspect the steering and steering linkage to ensure that they operate properly over the entire movement. Carry out a visual inspec- tion for twisting or cracks.
Inspect all components of the running gear such as steering arms, suspension struts, steering knuckles, anti-roll bars, subframe, axle beams and the attachment points of such parts for twisting or cracks.
Examine wheels, tyres for signs of damage, concentricity and imbalance. Examine the tyres for cuts to the tread and the side walls. Check the tyre inflation pressure.
Examine the suspension of the engine, gear- box, axles and exhaust system for signs of damage.
The final step is a reasonable road test after carrying out repairs as an assurance that the vehicle is safe for the road and can be han- ded over to the customer without hesitation.
Page 31 of 150
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.
------------ 0 0
1 9 .
2 ------------
Page 76 of 150
Downloaded from www.Manualslib.com manuals search engine OCTAVIA
51Middle Body
Edition 02.03
S00.5119.56.20
Replacement parts Roof
Adhesive DA 001 730 A1
Welding in
- Apply adhesive to the lateral flanges, front,
centre and rear cross member.
- Position roof and fix it. Note: The new part must be welded within 30 minutes after applying adhesive as otherwise the adhe-
sion may be poor.
Warning! Check adjustment with the windscreen and tailgate.
- Weld in roof, spot weld seam. Note: When welding the longitudinal sides make sure the spot weld tongs are positioned in the re- cessed surfaces inside the vehicle.
- Weld roof in the area of the tailgate water
channel, shielded arc continuous seam.
------------ 5
1
2 - ------------
Page 78 of 150
Downloaded from www.Manualslib.com manuals search engine OCTAVIA
51Middle Body
Edition 02.03
S00.5119.56.20
Replacement parts Roof
Adhesive DA 001 730 A1
Welding in
- Apply adhesive to the lateral flanges, front,
centre and rear cross member.
Note: The new part must be welded within 30 minutes after applying adhesive as otherwise the adhe-
sion may be poor.
- Position roof and fix it.
Warning! Check adjustment with the windscreen and tailgate.
- Weld in roof, spot weld seam
- Weld roof in the area of the tailgate water
channel, shielded arc continuous seam.
------------ 5
1
2 .
2 - ------------
Page 112 of 150
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53Rear Body
Edition 03.97
Replacement parts Left and right tail light carrier
Rear end panel
Preparing new parts
- Drill
∅ 7 mm holes in tail light carrier in
connection area to end panel.
Welding in
- Match up end panel in the assembly with tail light carriers and tack weld.
- Check operation of lock and gaps of tailgate.
- Weld in tail light carriers, RP spot weld.
- Weld in remaining joint, SG plug weld.
- Weld in end panel, RP spot weld.
Page 115 of 150
Downloaded from www.Manualslib.com manuals search engine Rear Body53
Edition 03.97
Replacing rear lock carrier
End panel already removed.
Separation points
- Detach original joint to side reinforcements.
Note:
If the side reinforcements are damaged, thesehave to be straightened or replaced.
Replacement part Rear lock carrier
Welding in
- Match up rear lock carrier together with rear end panel and tack weld.
- Check operation of lock and gaps of tailgate.
- Take off end panel.
- Weld in rear lock carrier, RP spot weld.
Page 117 of 150
Downloaded from www.Manualslib.com manuals search engine OCTAVIARear Body53
Edition 02.03
S00.5119.56.20
Replacement part Rear end panel
Preparing new part
- Match up and tack-weld end panel.
- Check closing and gap dimensions of rear bonnet.
Welding in
- Weld in end panel, weld spot seam
------------ 5
3
3 .
2 - ------------
Only on Estate 4x4
- Additionally weld shielded arc continuous
seam interrupted in the lateral connection
area to the luggage compartment floor.
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.
