Page 20 of 150
Downloaded from www.Manualslib.com manuals search engine 00General Information
Edition 08.96
Welding galvanised body panels
Important!
It is important to ensure proper ventilation of theworkbay and extraction of the gases by suitableextraction equipment, e.g. V.A.G 1586, as toxic zincoxide is produced in the welding fumes when
welding galvanised steel panels.
Note: As the resistance spot welding method (RP) cau-ses a slight erosion of the zinc layer only in thecentre of the weld spot and the zinc protective
ring which is produced at the same time aroundthe weld spot, protects it from corrosion, prefe-
rence should be given to this welding method in
contrast to shielded arc welding (SG).
Shielded arc welding (SG) of galvanised pa- nels Pay attention to the following points in order to produce good repair welded joints: The amperage at the welding transformer has to be increased.
At the same time, the infeed of the electrodewire has to be adjusted as merely increasing the voltage only produces a greater arc (re- duced fusion penetration, more porous weld structure).
Use a cylindrical instead of a conical gas nozzle (splatters at a gas nozzle which is too narrow results in formation of pores).
Guide torch about 12 mm above the material being welded at a neutral angle or at up to 10°.
Use the softest possible wire grades.
Both CO
2 as well as mixed gases can be
used for shielding.
Page 111 of 150
Downloaded from www.Manualslib.com manuals search engine Rear Body53
Edition 03.97
Repairing rear body Replacing rear end panel
Separation points
- Detach original joint at left and right of tail
light carrier.
- Pull tail light carrier down and forward behind side part and remove.
- Detach original joint to boot floor and rear
lock carrier.
- Take off rear end panel.
Page 112 of 150
Downloaded from www.Manualslib.com manuals search engine
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 118 of 150
Downloaded from www.Manualslib.com manuals search engine OCTAVIA
53Rear Body
Edition 02.03
S00.5119.56.20
------------ 5
3
3 .
3 - ------------ Replacing rear light supporting panel (Octavia Estate)
End panel already cut out.
Note: The rear light supporting panel can only be re- placed in connection with water channel part section. Separation points
- Detach original joint for side part.
- Separate water channel. Notes:
Place separation cut at least 30 mm above bolted connection for tailgate stop.
Do not damage side part and inner side when separating water channel.
First of all separate roughly the connection from water channel to side part and thenseparate from the inside with rod grinder the area situated below the side part.
- Detach remaining original joint Replacement parts Rear light supporting panel
Water channel
Seal 1 U6 809 875
Preparing new part
- Transfer separation cut to water channel and cut to shape.
