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 22 of 150
Downloaded from www.Manualslib.com manuals search engine 00General Information
Edition 08.96
Removing underbody sealant and weld seams
Underbody sealant and weld seams must be removed with a wire brush wheel clamped in the angle grinder or in the compressed air
straight grinder.
Note
It is essential to wear eye protection and pro-tective gloves. The pieces of wire which may fly off are very sharp.
A further possibility is to heat the underbody sea- lant or the weld seams with a hot air fan (max. 420 °C) and to remove the softened underbody
sealant or the weld seams with the scraper. This procedure is particularly recommended for poorly accessible areas of work.
Important!
The vapours produced are toxic and should be ex-tracted using suitable extraction equipment, e.g.V.A.G 1586.
Remove paint and primer with paint remover.
Body sections and part sections
„Sections“ refer to sections of single parts which are supplied from the Parts Depot already cut to shape. „Part sections“, in contrast, have to be cut to shape in the body shop from replacement parts.
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 46 of 150
Downloaded from www.Manualslib.com manuals search engine 00General Information
Edition 08.96
General view of front straightening jig items
36 - Mount for front side member
38 - Mount for front side member / tip of
wheelhouse
8 - Attachment for engine support
9 - Attachment for gearbox support
Page 61 of 150
Downloaded from www.Manualslib.com manuals search engine Front Body50
Edition 08.96
Repairing front body Replacing right engine bracket
Separation points of engine brake
- Detach original joint, with the exception of
weld spot -a-.
- Cut off front part section.
- Drill out weld spot -a- with 7 mm drill.
- Take off remaining piece.Replacement part Engine bracket
Preparing new part
- Drill holes for SG plug weld, 7 mm.
Welding in
- Fit in new part and fix on straightening jig.
- Weld in bracket, SG plug weld.
- Weld spots -a- from outside of wheelhouse,
SG plug weld.
Page 98 of 150
Downloaded from www.Manualslib.com manuals search engine OCTAVIA
51Middle Body
Edition 02.03
S00.5119.56.20
Welding in
- Match up and tack-weld new part with vehi- cle standing on its wheels or on straighten-
ing angle set.
- Weld in inner B pillar, spot weld seam
- Weld connection area to lower sill, shielded
arc continuous seam.
- Weld separation cuts, shielded arc continu- ous seam
------------ 5
1
9 .
3 - ------------
Page 100 of 150
Downloaded from www.Manualslib.com manuals search engine OCTAVIA
51Middle Body
Edition 02.03
S00.5119.56.20
Replacing outer lower sill
Separation points Notes:
If outer A and B pillars and possibly also the
rear side part are damaged, then the door frames can be used as a spare part without reinforcement ( a stamped part).
Do not damage internal reinforcement in the lower sill area.
Perform the separation cut on a vehicle standing on its wheels or on straightening angles
- Position separation cuts according to the damage.
- Drill off weld spots
------------ 5
1
1 0 - ------------
Page 101 of 150
Downloaded from www.Manualslib.com manuals search engine OCTAVIAMiddle Body51
Edition 02.03
S00.5119.56.20
Replacement part Outer lower sill (a stamped part)
Preparing new part
- Transfer separation cut to new part and cut
to shape.
Welding in
- Match up and tack-weld new part with vehi- cle standing on its wheels or on straighten-
ing angle set.
- Weld in outer lower sill, spot weld seam
- Butt-weld cut area, shielded arc continuous
seam
------------ 5
1
11 - ------------
