1997 SKODA OCTAVIA roof

Downloaded from www.Manualslib.com manuals search engine OCTAVIAGeneral Notes00
Edition 02.03
S00.5119.56.20------------ 0
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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 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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Downloaded from www.Manualslib.com manuals search engine OCTAVIAMiddle Body51
Edition 02.03
S00.5119.56.20
Repairing centre body Replacing roof (Octavia)
Separation points
- Drill off weld spots.
- Grind open shielded arc continuous seams
in the area to the tailgate water channel. Note: Do not damage roof frames. They must be re- placed if they do get damaged.
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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.
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Downloaded from www.Manualslib.com manuals search engine OCTAVIAMiddle Body51
Edition 02.03
S00.5119.56.20
Replacing roof (Octavia Estate)
Separation points
- Drill off weld spots
- Grind open shielded arc continuous seams
in the area to the tailgate water channel. Note: Do not damage roof frames. They must be re- placed if they do get damaged.
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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.
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Downloaded from www.Manualslib.com manuals search engine OCTAVIAMiddle Body51
Edition 02.03
S00.5119.56.20Replacing front roof cross member

Roof already cut out
Separation points
- Detach original joint.
- Remove cross member. Replacement part Roof cross member
Welding in
- Fit and fix new part.
- Weld in new part, spot weld seam
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Downloaded from www.Manualslib.com manuals search engine OCTAVIA
51Middle Body
Edition 02.03
S00.5119.56.20
Replacing rear roof cross member (Octavia)

Roof already cut out
Separation points
- Detach original joint.
- Remove cross member.
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