Page 75 of 150
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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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.
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Page 77 of 150
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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1
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1 - ------------
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.
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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 118 of 150
Downloaded from www.Manualslib.com manuals search engine OCTAVIA
53Rear Body
Edition 02.03
S00.5119.56.20
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3
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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.
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.
