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Skoda OCTAVIA II 2004 Workshop Manual

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Service
Workshop Manual
OCTAVIA II 2004 ➤
Body repairs
Edition 02.04
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Service Department. Technical Information

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Summary of Contents for Skoda OCTAVIA II 2004

  • Page 1 Service Workshop Manual OCTAVIA II 2004 ➤ Body repairs Edition 02.04 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document.
  • Page 2 Service List of Workshop Manual Repair Groups R e p a i r G r o u p 00 - General Instructions 50 - Front body 51 - Middle body 53 - Rear body Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A.

  • Page 3: Table Of Contents

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 Contents 00 - General Instructions ..........
  • Page 4 OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 Replace gearbox mount ........... .

  • Page 5: General Instructions

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 00 – General Instructions Technical Data Vehicle identification data 1.1.1 Vehicle identification number The vehicle identification number is type-punched into the right suspension strut dome. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A.

  • Page 6: Safety Measures

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 Safety measures Safety instructions When performing the works described, comply with all country- specific safety regulations. In case of doubt refer to the competent authorities. Safety measures For all operations take the legally prescribed personal and gen‐...

  • Page 7: Welding Work

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 Welding work WARNING Toxic zinc oxide is released when welding galvanized steel sheet. It is therefore essential to guarantee good ventilation of the workplace and removal of smoke and gases using suitable suction equipment, e.

  • Page 8: Fuel Tank And Fuel Conveying Hoses

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 WARNING It is recommended to hold an eye bath flask within reach. If liquid refrigerant gets into the eyes thoroughly rinse the eyes out with water for approximately 15 minutes. Subsequently ap‐...

  • Page 9: Safety Instructions For Seat Belt Tensioners

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 2.12 Safety instructions for seat belt tension‐ Safety measures ⇒ Body Work; Rep. Gr. 69 . WARNING Always remove the seat belt tensioner units before commenc‐ ing any cutting, straightening and body panelling work near these units.

  • Page 10: Basic Instructions

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 Basic Instructions Accident repair sequence Diagnosis of vehicles damaged by acci‐ dent When repairing vehicles damaged by accident often damage to the chassis or to the suspension of the engine-gearbox assembly, which may later have serious consequences, goes undetected.

  • Page 11: Severance Cuts

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 Severance cuts Severance cuts that influence the rigidity of the body and hence also the reliability and safety of the vehicle must be performed according to the instructions given in this workshop manual.

  • Page 12: Repair Of High-Strength Body Panels

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 The welding time is correctly selected if the welding spots can be made without spatters. Welding tongs ♦ Use hard copper electrodes (copper, chrome, zirconium alloy) with high heat resistance (>400°C).

  • Page 13: Body - Glued Joints

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 Body - glued joints 3.8.1 Types of glueing To increase the rigidity and firmness of the body, increasingly more glued and spot welding joints are created at the factory. Firmness - glued joints In the case of glued joints the panels are only joined together with glue.

  • Page 14: Removing The Underbody Protection And Sealing Seams

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 The adhesive surfaces in the welding area must be free from pri‐ mer and glue residues as well as from dust and grease. Applying the standard zinc spray is omitted in the adhesive area.

  • Page 15: Explanation Of The Symbols

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 Explanation of the symbols Explanation of the signs for welding op‐ erations Spot weld seam (single row) Spot weld seam (double row) Spot weld seam (double row offset) Inert gas shielded plug weld...

  • Page 16: Explanation Of The Signs For The Processes

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 Explanation of the signs for the process‐ Burr with burring pliers to perform overlapping welding Make holes with a hole punch for subsequent inert gas shielded plug welding Drill for subsequent inert gas shielded plug welding or rebore welding points (original welding).
  • Page 17 OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 Glueing Precision sealing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document.

  • Page 18: Tools

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 Tools Special tools and workshop equipment required ♦ Right angle grinder e.g. EBU 18 -E2- ♦ Right angle grinder e.g. WS-125 and wire brush ♦ Welding point loosening tool e.g. Variodrill -V.A.G 1731- ♦...

  • Page 19: Anti-Corrosion Measures

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 Anti-corrosion measures Corrosion prevention The body is manufactured in sheet metal galvanized on both sides. The series protection against corrosion must be restored after re‐ pairs by using the materials prescribed by the manufacturer, as this is indispensable in order to guarantee corrosion prevention.

  • Page 20: Cutting Galvanized Body Parts

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability Cutting galvanized body parts with respect to the correctness of information in this document.

  • Page 21: Injecting Foam In The Body

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 Injecting foam in the body Various hollow spaces in this vehicle are filled with foam. Their location is detailed in the individual repair descriptions. The injection of foam reduces the transmission of vehicle noises into the passenger compartment.
  • Page 22 OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 1 - 1Z0 864 627 2 - 1Z0 864 627A 3 - 1Z0 864 649 4 - 1Z0 864 621 5 - 1K0 864 625 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A.

  • Page 23: The Jig Alignment Bench

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 The jig alignment bench Overview of the jig alignment bench Celette with straightening square set Note Use straightening square set -VAS 6210- (VW Touran) together with straightening square sets -VAS 6210/1- ♦...
  • Page 24 OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 left and right 26 - MZ 080 28 - MZ 140 or MZ 080 30 - MZ 140 32 - Spacer ❑ identical on both left and right 34 - MZ 200...
  • Page 25 OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 12 - MZ 080 14 - Spacer ❑ identical on both left and right 20 - MZ 080 24 - Holder without MZ, sup‐ port -25- 25 - Support ❑ Production hole at the...

  • Page 26: Overview Of Front Alignment Bracket Positions

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 Overview of front alignment bracket positions Note Fixation supports on the left side of the vehicle correspond to the fixation supports on the right side of the vehicle, unless otherwise indicated.
  • Page 27 OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 10 - Fixation supports for en‐ gine mounting ❑ only on right side 11 - Fixation supports for gear‐ box mount ❑ only on left side Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A.
  • Page 28 OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 10 - Support for engine mount‐ 11 - Support for gearbox mount Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document.
  • Page 29 OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 8 - Fixation support to check the production hole in the frame side rail 12 - Fixation support for as‐ sembly carrier attachment 16 - Fixation point for suspen‐ sion strut mounting 20 - Fixation support for as‐...
  • Page 30 OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 8 - Support for front frame side rail 12 - Support for assembly car‐ rier attachment 16 - Support for suspension strut mounting 17 - Centering piece ❑ identical on both left and right Protected by copyright.
  • Page 31 OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 20 - Support for assembly car‐ rier attachment 22 - Spacer ❑ identical on both left and right 24 - Bracket 25 - Support ❑ The hole can get de‐ formed during transport...

  • Page 32: Overview Of The Middle Alignment Bracket Positions

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 Overview of the middle alignment bracket positions Note Fixation supports on the left side of the vehicle correspond to the fixation supports on the right side of the vehicle, unless otherwise indicated.
  • Page 33 OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 26 - Support to check the bot‐ tom side rail 28 - Support ❑ for production hole 30 - Support for rear axle mounting 32 - Spacer ❑ identical on both left and right Protected by copyright.

  • Page 34: Overview Of The Rear Alignment Bracket Positions

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 Overview of the rear alignment bracket positions Note Fixation supports on the left side of the vehicle correspond to the fixation supports on the right side of the vehicle, unless otherwise indicated.
  • Page 35 OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 34 - Support for rear axle mounting 36 - Support for suspension strut mounting 40 - Support ❑ for production hole in frame side rail 51 - Support to check the rear frame side rail Protected by copyright.

  • Page 36: Karosserie-Kontrollspaltmaße

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 Karosserie-Kontrollspaltmaße Karosserie vorn Zum Einstellen oder Kontrollieren kann das Sonderwerkzeug z. B. -3371- verwendet werden. 1 - 5,7 ± 0,8 mm 2 - 0,8 ± 0,6 mm 3 - 3,5 ± 0,5 mm 4 - 3,3 ±...

  • Page 37: Karosserie Hinten

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 Karosserie hinten Zum Einstellen oder Kontrollieren kann das Sonderwerkzeug z. B. -3371- verwendet werden. 1 - 4,5 ± 0,5 mm 2 - 4,5 ± 0,5 mm 3 - 4 ± 0,5 mm 4 - 4,9 ±...

  • Page 38: Front Body

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 50 – Front body Repairing the front body Replacing wing support 1.1.1 Removing original part – Bore out the rivets. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A.

  • Page 39: Replace Engine Mounting

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 1.1.3 Installing Special tools and workshop equipment required ♦ Riveting tongs – Rivet on wing support to upper frame side rail. Replace engine mounting 1.2.1 Removing original part – Bore out the welding points.

  • Page 40: Replace Gearbox Mount

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 1.2.3 Preparing the new part – Drill holes for the inert gas shielded plug weld, ∅ 7 mm. 1.2.4 Part welding – Weld in the new part, inert gas shielded plug weld.

  • Page 41: Replacing Upper Frame Side Rail

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 1.3.2 Spare part ♦ Gearbox mount 1.3.3 Preparing the new part – Drill holes for the inert gas shielded plug weld, ∅ 7 mm. 1.3.4 Part welding – Weld in the new part, inert gas shielded plug weld.
  • Page 42 OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 – Grind out the inert gas shielded full seam interrupted. – Bore out the welding points. – Removing outer part of upper frame side rail. – Remove any residues. 1.4.3 Spare part ♦...
  • Page 43 OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 1.4.5 Part welding – Attach the new part. The vehicle can stand on its wheels or on the alignment bracket. – Weld in the new part, an RP spot seam. – Weld in the new part, inert gas shielded plug weld.
  • Page 44 OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 – Bore out remaining spot weld seams. – Removing inner part of upper frame side rail. – Remove any residues. 1.4.7 Spare part ♦ Inner part of upper frame side rail 1.4.8...

  • Page 45: Replacing The Front Frame Side Rail

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 1.4.9 Part welding – Attach the new part. The vehicle can stand on its wheels or on the alignment bracket. – Weld in the new part, inert gas shielded plug weld.
  • Page 46 OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 – Disconnect the front frame side rail. 1.5.2 Spare part ♦ Front frame side rail 1.5.3 Preparing the new part – Transpose the cut line onto the new part and separate off the shaded area.
  • Page 47 OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 – Weld front frame side rail, inert gas shielded plug weld. – Weld in the front frame side rail, an inert gas shielded full seam. – Weld in cover plate ⇒ page 45 Protected by copyright.

  • Page 48: Replacing The Front Frame Side Rail Offcut Part

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 Replacing the front frame side rail offcut part 1.6.1 Removing original part – Bore out support for upper frame side rail. – Cut the frame side rail in the area of the laser welding seam.

  • Page 49: Replace Cover Plate

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 1.6.4 Part welding – Align the front frame side rail on the alignment bench. – Weld front frame side rail, inert gas shielded full seam inter‐ rupted. – Seal up the welded section, for example by using two-compo‐...
  • Page 50 OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 – Weld in cover plate from all sides, inert gas shielded full seam. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document.

  • Page 51: Middle Body

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 51 – Middle body Repairing the body in the middle I Octavia - Replacing roof 1.1.1 Removing original parts Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A.
  • Page 52 OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 – Bore out the welding points at the front and rear roof cross member. – Grind open full seam on the rear roof cross member. – Cut the roof immediately next to the laser welding seam.
  • Page 53 OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 – Insert the butyl adhesive sealing cord -2- into the framework and form out according to fig. to a height of approx. 12 mm, so that when self-adhering the roof the adhesive area is partially closed and the 2K body glue -3- cannot drip out (in the fig.
  • Page 54 OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 – For the correct bead section, the glue mixture -2- must be cut to measure on the 4th notch. – Insert cartridges into the cartridge press -VAS 5237- and on approval apply glue on the paper (until the adhesive is cor‐...

  • Page 55: Octavia Combi - Replacing Roof

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 – Weld the rear roof with the rear roof cross member, inert gas shielded full seam. – Weld in the rear roof, an RP spot seam. – Before painting, carry out protection of hollow spaces on the roof -arrow-.
  • Page 56 OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted Note unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document.
  • Page 57 OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 1.2.2 Spare parts ♦ Roof ♦ 2K body glue -D 180 KD3 A2- (2 Sets) ♦ Butyl glue for the sealing cord -AKD 497 010 04 R10- ♦ Universal cleaning agent -HHA 381 011- ♦...
  • Page 58 OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 – Apply butyl glue for the sealing cord on the roof cross mem‐ bers. 1.2.4 Stick on Note All adhesive surfaces must be cleaned thoroughly - basic re‐ ♦ quirement for the adhesion.
  • Page 59 OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 – Position the roof on the body. To do so support the roof from underneath with positioning wedges. At the same time respect dimensions -a- = 3.5 ± 0.5 mm (measure e.g. with a drill ∅ 3.5 mm).
  • Page 60 OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document.

  • Page 61: Replacing The Front Roof Cross Member

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 Replacing the front roof cross member 1.3.1 Removing original parts Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document.

  • Page 62: Replace Middle Roof Cross Member

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 – Weld the front roof cross member, an inert gas shielded full seam. – Weld in the front roof cross member, RP spot seam. Replace middle roof cross member Note Only on vehicles without sliding roof.
  • Page 63 OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document.

  • Page 64: Replacing The Rear Roof Cross Member

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 – Weld in the middle roof cross member, inert gas shielded full seam interrupted. Replacing the rear roof cross member 1.5.1 Removing original parts – Separate the rear roof cross member.

  • Page 65: Replacing Pillar A On The Outside

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 1.5.2 Spare parts ♦ Rear roof cross member 1.5.3 Part welding – Adjust and fix the rear roof cross member. – Adjust roof with rear roof cross member and remove roof again.
  • Page 66 OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 1.6.1 Removing original parts Note If the outer bottom side rail or column B outside and possibly ♦ also the side part is damaged the door frame can be used as a spare part without reinforcement (stamped part).

  • Page 67: Replacing Pillar A Inside

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 – Apply the glue. 2 beads ∅ 4 mm (cut back the nozzle to the required diameter). Note The new part must be welded within 30 minutes as otherwise the adhesion of the glue may be poor.
  • Page 68 OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 – Remove pillar A outside ⇒ page 62 – Remove bottom side rail ⇒ Chap. 51-2 . – Grind out inert gas shielded full seams interrupted. – Bore out the welding points.
  • Page 69 OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 – Clean adhesive surfaces. – Apply the glue. 2 beads ∅ 4 mm (cut back the nozzle to the required diameter). Note The new part must be welded within 30 minutes as otherwise the adhesion of the glue may be poor.

  • Page 70: Repairing Middle Body

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 Repairing middle body II Replacing pillar B outside WARNING Never weld or cut using devices/tools producing sparks or sol‐ der in foam-filled locations as this will generate gases that are particularly harmful for humans and the environment.
  • Page 71 OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 – Arrange the cut points according to the severity of the damage. Do not cut close to the hinge supports. – Bore out the welding points. – Remove the sound insulation.

  • Page 72: Replacing The Outside Bottom Side Rail

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 – Weld in pillar B on the outside, an RP spot seam. – Weld the separation line bluntly as an inert gas shielded full seam. Replacing the outside bottom side rail WARNING Never weld or cut using devices/tools producing sparks or sol‐...
  • Page 73 OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 2.2.1 Removing original parts Note If pillar A on the outside and pillar B on the outside and possibly ♦ also the side part is damaged the door frame can be used as a spare part without reinforcement (stamped part).

  • Page 74: Replace Bottom Side Rail Pipe Reinforcement

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 – Apply the glue. 2 beads ∅ 4 mm (cut back the nozzle to the required diameter). Note The new part must be welded within 30 minutes as otherwise the adhesion of the glue may be poor.
  • Page 75 OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 – Removing reinforcement of pillar C ⇒ Chapter 53-1 . – Grind out inert gas shielded full seams interrupted. – Grind in the residue. 2.3.2 Spare parts ♦ Bottom side rail pipe reinforcement 2.3.3...

  • Page 76: Rear Body

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 53 – Rear body Repairing rear body I Replacing the rear wing WARNING Never weld or cut using devices/tools producing sparks or sol‐ der in foam-filled locations as this will generate gases that are particularly harmful for humans and the environment.
  • Page 77 OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 – Arrange the cut points according to the severity of the damage. – Grind out the laser welding seam in the area of the water channel for the tailgate. Note Do not damage the inside panel of the water channel.

  • Page 78: Octavia Combi - Replacing The Rear Wing

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 1.1.4 Foam filling Replace the sound insulation ⇒ Chapter 00-7 . 1.1.5 Part welding – Fit the new part into place and staple. The vehicle can stand on its wheels or on the alignment bracket.
  • Page 79 OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 1.2.1 Removing original parts Note Do not damage the wheel house. ♦ If the outer bottom side rail or column B outside and possibly ♦ also outer column A are damaged the door frame can be used as a spare part without reinforcement (stamped part).

  • Page 80: Replacing The Wheel House Offcut Part

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 – Apply glue in the area of the border. 2 beads ∅ 4 mm (cut back the nozzle to the required diameter). Note The new part must be welded within 30 minutes as otherwise ♦...

  • Page 81: Replacing Reinforcement Of Pillar C

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 – Lay the cut point according to the damage incurred so that it is possible to offset on the body side. – Bore out the welding points. 1.3.2 Spare part ♦ The wheel house on the outside 1.3.3...
  • Page 82 OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 – Remove bottom side rail ⇒ Chap. 51-2 . – Grind open the welding seams until the bottom side rail rein‐ forcement. – Bore out the welding points. – Separate reinforcement of pillar C 1.4.2...

  • Page 83: Repairing Rear Body

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 Repairing rear body II Replacing the end cover plate 2.1.1 Removing original parts – Bore out the welding points. – Grind out the inert gas shielded full seams on the connecting surface for the end part.

  • Page 84: Octavia Combi - Replacing End Cover Plate

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 – Weld in the end cover plate, an RP spot seam. – Weld in the end cover plate, inert gas shielded plug weld. – Weld in the end cover plate on the connecting surface to the end part, inert gas shielded full seam interrupted.

  • Page 85: Replacing The Utility Plate On The Rear Light Carriers

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 2.2.3 Preparing the new part – Make holes in the end cover plate using punch pliers. 2.2.4 Part welding – Fit the new part into place and staple. The vehicle can stand on its wheels or on the alignment bracket.
  • Page 86 OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document.
  • Page 87 OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 2.3.2 Preparing the new part – Drill holes for the inert gas shielded plug weld, ∅ 7 mm. 2.3.3 Part welding – Attach the new part and check the dimension of the gap with the other parts.

  • Page 88: Octavia Combi - Replacing The Utility Plate On The Rear Light Carriers

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 – Weld the utility plate of the rear light carrier, an RP spot seam. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted –...
  • Page 89 OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 – Bore out the welding points. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document.
  • Page 90 OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 2.4.3 Preparing the new part – Make holes with punch pliers for the utility plate of the rear light carrier. – Clean adhesive surfaces. – Apply the glue. 2 beads ∅ 4 mm (cut back the nozzle to the required diameter).

  • Page 91: Octavia Combi - Replacing Reinforcement Of End Part

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 – Weld the utility plate of the rear light carrier, an RP spot seam. Octavia combi - Replacing reinforce‐ ment of end part Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted 2.5.1...
  • Page 92 OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 – Bore out the welding points. – Grind in the residue. 2.5.2 Spare parts ♦ Reinforcement of end part 2.5.3 Preparing the new part – Drill holes for the inert gas shielded plug weld, ∅ 7 mm.

  • Page 93: Replacing End Part

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 Replacing end part 2.6.1 Removing original parts – Remove the end cover plate ⇒ page 79 – Removing the utility plate of the rear light carrier ⇒ page 81 – Bore out the welding points.

  • Page 94: Octavia Combi - Replacing End Part

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 – Apply the glue. 2 beads ∅ 4 mm (cut back the nozzle to the required diameter). Note The new part must be welded within 30 minutes as otherwise the adhesion of the glue may be poor.
  • Page 95 OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 – Bore out the welding points. – Grind in the residue. 2.7.2 Spare parts ♦ End part ♦ Glue -DA 001 730 A1- ♦ Cleaning agent -D 009 401 04- 2.7.3 Preparing the new part –...

  • Page 96: Replacing The Luggage Compartment Floor

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 – Weld in the end part, inert gas shielded plug weld. – Weld in the reinforcements of the end part ⇒ page 88 Replacing the luggage compartment floor Removing original parts –...
  • Page 97 OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 – Removing luggage compartment floor. – Grind in the residue. 2.8.1 Spare parts ♦ Luggage compartment floor ♦ Glue -DA 001 730 A1- ♦ Cleaning agent -D 009 401 04- 2.8.2 Preparing the new part –...
  • Page 98 OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 – Apply the glue. 2 beads ∅ 4 mm (cut back the nozzle to the required diameter). Note The new part must be welded within 30 minutes as otherwise the adhesion of the glue may be poor.

  • Page 99: Replacing Rear Frame Side Rail

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 Replacing rear frame side rail 2.9.1 Removing original parts – Remove the floor of the luggage compartment ⇒ page 92 – Bore out the welding points in the connecting area to the wheel house.
  • Page 100 OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 2.9.3 Preparing the new part – Transpose the cut line onto the new part and separate off the shaded area. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A.
  • Page 101 OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 – Weld in rear frame side rail with wheelhouse, inert gas shiel‐ ded plug weld. – Weld in the luggage compartment floor ⇒ page 94 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A.

  • Page 102: Replace Towing Lug

    OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 2.10 Replace towing lug 2.10.1 Removing original parts – Bore out the welding points. – Remove towing lug and grind in the residue. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A.
  • Page 103 OCTAVIA II 2004 ➤ Body repairs - Edition 02.04 2.10.4 Part welding – Weld the towing lug, inert gas shielded plug weld. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document.

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