Skoda Otavia Workshop Manual

Body repairs

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Workshop Manual

OCTAVIA

Body Repairs

Service Department. Technical Information

S00.5119.50.20

Edition 08.96

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Summary of Contents for Skoda Otavia

Page 1: Body Repairs
Service Workshop Manual OCTAVIA Body Repairs Service Department. Technical Information S00.5119.50.20 Edition 08.96...
Page 2 The Workshop Manual is intended only for use within the ŠKODA Organisation; it is not permitted to pass it on to third parties. Printed in Czech Republic © 1996 ŠKODA, automobilová a.s.
Page 3 Service List of Supplements to Workshop Manual Edition: 04.04 OCTAVIA Body Repairs Replaces List of Supplements - Edition: 09.03 Subject Edition Article Number Supple- ment 08.96 Basic Edition S00.5119.50.20 03.97 Supplements to Repair Groups 00, 51, 53 S00.5119.51.20 06.98 Octavia Estate S00.5119.52.20 03.00 Octavia Estate 4x4...
Page 5: Table Of Contents
OCTAVIA Service Contents General Notes Page Vehicle identification data ......................00-1 Vehicle identification number ä M99 ..................00-1 Vehicle identification number M00 ä ..................00-1 Type plate ..........................00-1.1 Vehicle data sticker ........................00-1.1 Safety information ........................00-2 Safety precautions ........................00-2 Safety at work measures ......................
Page 6 Service OCTAVIA Straightening rig .......................... 00-22 General view of Celette with VAS 5020/1 ................. 00-22 General view of front straightening angle positions ..............00-24 General view of centre straightening angle positions ............... 00-28 General view of rear straightening angle positions ..............00-30 General view of Celette with VAS 5020/8 (Octavia Estate 4x4) ..........
Page 7 OCTAVIA Service Replacing side part (Octavia RS) ..................... 53-9.1 Replacing rear side part (Octavia Estate) ................53-10 Replacing inner side part (Octavia Estate) ................53-14 Replacing rear wheelhouse ...................... 53-15 Replacing rear wheelhouse (Octavia RS) ................53-16 Replacing wheelhouse liner - part section ................53-18 Replacing towing lug ........................
Page 9: Vehicle Identification Data
OCTAVIA General Notes Vehicle identification data Vehicle identification number ä M99 K The vehicle identification number is stamped in the rear cross panel of the engine compartment. It is visible through a window in the cover of the plenum chamber. K The vehicle identification number from 04.99 is also indicated in the bottom left corner of the windscreen.
Page 10: Type Plate
OCTAVIA General Notes Body type and equipment Engine type Airbag system Model Internal code Model year Manufacturing plant Vehicle body number Note: For detailed information regarding the individual characters ⇒ Inspection and Maintenance Type plate K Type plate -arrow A- is attached to the front of the left suspension strut dome.
Page 11 OCTAVIA General Notes Edition 01.01 ------------ 00-1.2 ------------ S00.5119.55.20...
Page 12: Safety Precautions
OCTAVIA General Notes Safety measures Safety precautions When performing the works described comply with all country-specific safety regulations. In case of doubt refer to the competent authori- ties. Safety at work measures For all operations take the legally prescribed personal and general protection measures. This includes e.g.
Page 13: Welding Work
OCTAVIA General Notes 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 and windows). Welding work Warning! As toxic zinc oxide is contained in the fumes pro- duced during steel sheet welding suitable exhaust...
Page 14 OCTAVIA General Notes Note: The refrigerant circuit must be exhausted, if elec- trical welding must be carried out close to the refrigerant hoses. During electrical welding in- visible ultraviolet rays are produced that pen- etrate the refrigerant hoses and decompose the refrigerant.
Page 15: Electronic Control Units
OCTAVIA General Information Fuel tank or piping conveying fuel Extreme caution is required when carrying out grinding and welding work in the area of the fuel tank or other parts which convey fuel. If doubt exists, such parts should be removed. If the fuel tank and fuel pipes have to be removed from the vehicle, they should be stored in accordance with safety precautions.
Page 16: Basic Information
OCTAVIA General Information Basic information Procedure for accident repairs Diagnosis of damage Removing adjoining parts Itemising parts required ä ä Is it economic to eliminate ä damage by panel beating? Protect the vehicle by covering over Protect the vehicle by covering over undamaged parts undamagd parts Repair damaged part by panel beating, with...
Page 17 OCTAVIA General Notes Matching up new parts and inspecting gaps with attached parts Restoring body foam lining Protecting spot weld flanges against corrosion with zinc spray Welding in new part Face-grinding visible weld seams and filling in Replacing fine seal/stone chip protection Painting as necessary Touching up underbody...
Page 18: Diagnosis Of Vehicles Damaged In An Accident
OCTAVIA General Information 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...
Page 19: As-Delivered Condition Of Bodywork Or Single Parts For The Paintshop
OCTAVIA General Information As-delivered condition of body or of single parts for the paint shop Before handing over a repaired vehicle or a sing- le part to the paint shop, the surface which has been repaired or panel-beaten and treated with filler, as appropriate, has to be prepared with emery paper of a roughness of P 80 to P 100 to ensure that the shape matches the adjoining...
Page 20: Welding Galvanized Body Panels
OCTAVIA General Information Welding galvanised body panels Important! It is important to ensure proper ventilation of the workbay and extraction of the gases by suitable extraction equipment, e.g. V.A.G 1586, as toxic zinc oxide is produced in the welding fumes when welding galvanised steel panels.
Page 21 OCTAVIA General Information Spot welding (RP) galvanised panels Pay attention to the following points when resis- tance spot welding galvanised panels: Welding transformer ♦ Increase the welding current by 10% up to a max. of 30%. If the welding transformer is fitted with a „welding time control“...
Page 22: Removing Underbody Sealant And Weld Seals
OCTAVIA General Information 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.
Page 23: Original Joint
OCTAVIA General Information Original joint „Original joint“ refers to the weld joint which was made during the production of the vehicle. Such weld joints should be re-created to the ma- ximum extent possible during body repairwork. An important point to note is that the number of weld spots made when carrying out body repairs should not be less than the number in standard production but, for safety reasons, should rather...
Page 24: Explanation Of Symbols
OCTAVIA General Information Explanation of symbols Explanation of symbols for welding work K Spot weld seam (single row) Spot weld seam (double row) Spot weld seam (double row offset) Shielded arc plug weld ∅ K Shielded arc stepped weld (has to be ground off, if necessary, to match shape of body) Shielded arc continuous weld (has to be ground off, if necessary, to match the shape of body)
Page 25 OCTAVIA General Information Explanation of symbols for methods K Stepping with stepping pliers in order to carry out an overlap weld. Plugging with plugging pliers in order to carry out subsequent shielded arc plug welding. Drilling in order to carry out subsequent shielded arc plug welding or to drill out weld spots (original joint).
Page 26 OCTAVIA General Information K Cavity protection K Bonding Fine sealing ¡ ¢ £ ------------ ------------ Edition 08.96 S00.5119.50.20...
Page 27: Tools
OCTAVIA General Notes Tools 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) ♦...
Page 28: Corrosion Protection Measures
OCTAVIA General Information Corrosion protection measures Corrosion protection The body is manufactured from sheets galvani- sed on both sides. It is essential to re-create the standard corrosion protection after carrying out body repairs using the material specified by the manufacturer as this is a precondition for ensuring the absence of corrosion.
Page 29 OCTAVIA General Information Separating galvanised body parts Preparatory work Remove underbody sealant and weld seams ⇒ Basic information, page 00-12. Cutting operation Do not use cutting operations which involve heat, e.g. cutting torch. It is best to use mechanical cutting methods, e.g.
Page 30: Body Foam Lining
OCTAVIA General Notes Body foam lining Various body cavities of this vehicle are lined with foam. The position of the foam linings is indicated at the beginning of the individual re- pair instructions. The foam lining is designed to reduce the trans- mission of running noises into the interior.
Page 31: Body Dimensions
OCTAVIA General Notes Body dimensions Front body ¡ 1 9 . 2 a - 1328 mm d - 1316 mm ♦ Distance between the hinge attach- ♦ Distance between top longitudinal ments. members for wheelhouse. b - 1119 mm All dimensions are quoted without a tolerance ♦...
Page 32: Middle Body
OCTAVIA General Notes Middle body e - 1517 mm Note: ♦ Distance between B pillars, from mid- The dimensions stated are used for inspection dle of closing bow opening on right to purposes only. The straightening angle set takes middle of closing bow opening on left. priority.
Page 33 OCTAVIA General Notes ¦ f - 1490.8 mm Note: ♦ Distance between pillars, from mid- The dimensions stated are used for inspection ¡ ¢ £ ¤ ¥ dle of closing bow opening on right to purposes only. The straightening angle set takes middle of closing bow opening on left.
Page 34: Body Dimensions
OCTAVIA General Notes Body dimensions Front floor assembly a - 956 mm d - 777 mm ♦ Distance between front longitudinal ♦ Diagonal distance between attach- members. ment points of front suspension. b - 949 mm e - 610 mm ♦...
Page 35 OCTAVIA General Notes Middle floor assembly f - 1694 mm h - 1360 mm ♦ Diagonal distance between rear at- ♦ Distance between the lower sills. tachment points of front suspension and inspection points ( 20 mm) in j - 830 mm front of rear axle mount.
Page 36 OCTAVIA General Information Rear floor pan k - 1270 mm m - 946 mm ♦ Distance between suspension mounts. ♦ Distance between the holes (20 mm ) of the rear side members. L - 1716 mm ♦ Diagonal dimension between suspen- All dimensions without indication of tolerance sion mounts and holes (20 mm ) of...
Page 37 OCTAVIA General Information ------------ 00-21.2 ------------ Edition 03.97 S00.5119.51.20...
Page 38: Body Panel Gaps
OCTAVIA General Notes Body panel gaps Front body for Vehicles ä 07.00 Special tool e.g. 3371 can be used for aligning 5 - 2.5 + 1 mm or inspecting. 6 - 3.0 + 1.5 mm 1 - 6.0 + 1 mm 7 - 3.8 + 1.2 mm 2 - 3.5 + 1 mm 8 - 4.8 + 1.5 mm...
Page 39 OCTAVIA General Notes Front body for Vehicles 08.00 ä Special tool e.g. 3371 can be used for aligning 5 - 2.5 + 1 mm or inspecting. 6 - 3.0 + 1.6 mm 1 - 3.0 + 2 mm 7 - 3.8 + 1.2 mm 2 - 2.8 + 1 mm 8 - 4.8 + 1.5 mm 3 - 4.7 + 1 mm...
Page 40 OCTAVIA General Notes Rear body (Octavia) for Vehicles ä 07.00 Special tool e.g. 3371 can be used for aligning 5 - 2.2 + 1 mm or inspecting. 6 - 3.7 + 1.3 mm 1 - 3.0 + 1.6 mm 7 - 5.7 + 2.4 mm 2 - 3.0 + 1.6 mm 8 - 3.4 + 1.3 mm 3 - 3.7 + 1.3 mm...
Page 41: Rear Body (Octavia) For Vehicles 08.00 Ä
OCTAVIA General Notes Rear body (Octavia) for Vehicles 08.00 ä Special tool e.g. 3371 can be used for aligning 5 - 1.5 + 1 mm or inspecting. 6 - 3.7 + 1.3 mm 1 - 3.0 + 1.6 mm 7 - 4.7 + 2.3 mm 2 - 3.0 + 1.6 mm 8 - 3.4 + 1.3 mm 3 - 3.7 + 1.3 mm...
Page 42: Rear Body (Octavia Estate) For Vehicles Ä 07.00
OCTAVIA General Notes Rear body (Octavia Estate) for Vehicles ä 07.00 Special tool e.g. 3371 can be used for aligning 4 - 4.0 + 1.5 mm or inspecting. 5 - 4.5 + 1.5 mm 1 - 3.5 + 1.6 mm 6 - 5.3 + 2.5 mm 2 - 3.5 + 1.6 mm 7 - 4.0 + 2 mm...
Page 43: Rear Body (Octavia Estate) For Vehicles 08.00 Ä
OCTAVIA General Notes Rear body (Octavia Estate) for Vehicles 08.00 ä Special tool e.g. 3371 can be used for aligning 4 - 3.7 + 2 mm or inspecting. 5 - 3.9 + 1.5 mm 1 - 3.0 + 1.6 mm 6 - 5 - 2.6 mm 2 - 3.0 + 1.6 mm 7 - 3.7 + 2 mm...
Page 44: Straightening Rig
OCTAVIA General Notes Straightening rig General view of Celette with VAS 5020/1 Notes: ♦ The circled position numbers are those of the alignment bracket supports for the su- ♦ This overview does not replace the detailed perstructure with or without assemblies. design plan from the company Celette.
Page 45 OCTAVIA General Information 6 - MZ 142 20 - Bracket without MZ and straightening jig mount -22- 8 - MZ 260 22 - Angle mount -20- 10 - MZ 200 without components; MZ 080 with components 26 - MZ 140 13 - Centring piece, identical on left and 28 - MZ 080 right, only with components installed...
Page 46 OCTAVIA General Information 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 47 OCTAVIA General Information 8 - Mount for engine support ¡ ¢ £ 9 - Mount for gearbox support ------------ ------------ Edition 08.96 S00.5119.50.20...
Page 48 OCTAVIA General Information 6 - Mounting point of front side member 14 - Mounting point of suspension strut attachment ¡ ¢ £ 10 - Mounting point of subframe ------------ ------------ Edition 08.96 S00.5119.50.20...
Page 49 OCTAVIA General Information 6 - Mount for front side member 14 - Mount for suspension strut attach- ment ¡ ¢ £ 10 - Mount for subframe ------------ ------------ Edition 08.96 S00.5119.50.20...
Page 50 OCTAVIA General Information General view of middle straightening jig items ¡ ¢ £ 18 - Mounting ounting point of subframe 26 - Mounting point of hole in floor panel 22 - Mounting point of front production 28 - Mounting point of hole in side member mount ------------ ------------...
Page 51 OCTAVIA General Information 18 - Mount for subframe 26 - Mount for hole in floor panel ¡ ¢ £ 20 - Bracket for item 22 28 - Mount for hole in side member 22 - Mount for front production mount ------------ ------------ Edition 08.96...
Page 52 OCTAVIA General Information General view of rear straightening jig positions ¡ ¢ 30 - Mounting point for rear suspension 40 - Mounting point for hole in side mem- attachment 32 - Mounting point for suspension strut attachment ------------ ------------ Edition 03.97 S00.5119.51.20...
Page 53 OCTAVIA General Information 30 - Mount for rear axle attachment 32 - Mount for suspension strut attach- ment Insert pin only after fitting on the body. ¡ ¢ £ 31 - Spacer, identical on left and right 40 - Mount for hole in side member Use only if rear suspension removed.
Page 54 ¤ ¥ ¦ § ¨ © ¦ ¦ ¦ ! " # $ ¤ ¥ $ OCTAVIA General Notes General Estate 4x4) ♦ The item numbers in the illustrations are iden- Notes: ¡...
Page 61: Front Body Page
OCTAVIA Front Body 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.
Page 62: Replacing Reinforcement Of Top Longitudinal Member
Front Body OCTAVIA Replacing top longitudinal member Separation points Make the separation cut according to the severity of the damage. Release original welding at the top and bot- tom by drilling off the spot weld seams. Replacement part ♦ Top longitudinal member Preparing new part Transfer the separation cut onto the new part and cut to the required dimensions.
Page 63 Front Body OCTAVIA Replacing inner part of top longitu- dinal member Separation points l Longitudinal member has already been sepa- rated Make the separation cut at the inner part of the top longitudinal member according to the severity of the damage. Drill off spot weld seams.
Page 64: Replacing Front Wheelhouse
Front Body OCTAVIA Replacing front wheelhouse Separation points l Pillar A already cut out. l Inner part of top longitudinal member already Release the original welding. cut out. Removing remaining pieces. Edition 04.04 ------------ 50-4 ------------- S00.5119.58.20...
Page 65 OCTAVIA Front Body Replacement part ♦ Front wheelhouse ♦ Suspension strut mount Preparing new part Drill holes for shielded arc plug weld, Ø 7 mm. Welding in Match up new parts and fix on straightening angle. Spot-weld wheelhouse at bottom of longitu- dinal member, spot weld seam.
Page 66: Replacing Front Wheelhouse (Octavia Rs And 4X4)
Front Body OCTAVIA Replacing front wheelhouse (Octavia RS and 4x4) The procedure is basically identical to that for the Octavia ⇒ page 50-4. Carry out additional operations: Drill off spot weld seams of reinforcement between lock carrier and wheelhouse. Preparing new part Drill ∅...
Page 67 Front Body OCTAVIA Replacement part ♦ Wheelhouse Preparing new part Transfer the separation cut plus 10 mm for overlapping on the new part and cut to size. Burr separation cut on the body side. Welding in Fit new part and fix onto a straightening bench.
Page 68 OCTAVIA Front Body Front side member part section Separation points Position separating cut at side member de- pending on damage. Notes: ♦ If the damage extends beyond the separating point indicated, the side member should be replaced complete. ♦ Make a straight separating cut. Remove remaining pieces.
Page 69 OCTAVIA Front Body Welding in Fit in new part and fix on straightening jig. Butt-weld side member, SG continuous weld. Spot-weld remaining joint, RP spot weld. Note: The weld spots should be positioned parallel to each other. It is essential to maintain the original spacing.
Page 70 OCTAVIA Front Body Replacing front side member Separation points Detach original joint. Note: Take off side member. Separating cut of side member 5 mm ahead of original joint. ------------ 50-10 ------------ Edition 08.96 S00.5119.50.20...
Page 71 OCTAVIA Front Body Replacement parts ♦ Side member ♦ Impact shock absorber mount Preparing new part Transfer separating cut to new part and cut to shape. Welding in Fit in new part and fix on straightening jig. Weld separating cut, SG continuous weld. Spot-weld remaining joint, RP spot weld.
Page 72 Front Body OCTAVIA Replacing metallic impact absorber support Separation points Notes: ♦ Before replacing the right metallic impact absorber support, first the front towing lug must be removed ⇒ page 50-13. ♦ The metallic impact absorber support is welded on all four sides to the longitudinal member.
Page 73: Replacing Front Towing Lug
Front Body OCTAVIA Replacing front towing lug Separation points Grind off the inert gas shielded full seam in- terrupted on the connecting surface for the front longitudinal member and the metallic impact absorber support. Replacement part ♦ Towing lug Welding in Weld in front towing lug, inert gas shielded full seam interrupted, whereby the measure -a- = 70 mm must be absolutely kept.
Page 75: Middle Body Page
OCTAVIA Middle Body Repairing centre body Replacing roof (Octavia) Separation points Drill off weld spots. Note: Do not damage roof frames. They must be re- Grind open shielded arc continuous seams placed if they do get damaged. in the area to the tailgate water channel. 1 ¢...
Page 76 OCTAVIA Middle Body 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.
Page 77: Replacing Roof (Octavia Estate)
OCTAVIA Middle Body Replacing roof (Octavia Estate) 1 ¢ 2 . 1 Separation points Drill off weld spots Note: Do not damage roof frames. They must be re- Grind open shielded arc continuous seams placed if they do get damaged. in the area to the tailgate water channel.
Page 78 OCTAVIA Middle Body 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.
Page 79: Welding In T Pins (Octavia)
OCTAVIA Middle Body Welding in T pins (Octavia) 1 - 45 ± 2 mm 8 - 175 ± 2 mm 2 - 129 ± 2 mm 9 - 165 ± 2 mm 3 - 132 ± 2 mm Dimension -a- = 6.7 ± 2 mm 4 - 186 ±...
Page 80: Welding In T Pins (Octavia Estate)
OCTAVIA Middle Body Welding in T pins (Octavia Estate) 1 - 43 ± 2 mm 10 - 146 ± 2 mm 2 - 140 ± 2 mm 11 - 204 ± 2 mm 3 - 180 ± 2 mm 12 - 159 ± 2 mm 4 - 198 ±...
Page 81: Replacing Front Roof Cross Member
OCTAVIA Middle Body Replacing front roof cross member G 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 1 ¢...
Page 82: Replacing Rear Roof Cross Member (Octavia)
OCTAVIA Middle Body Replacing rear roof cross member (Octavia) G Roof already cut out Separation points Detach original joint. Remove cross member. 1 ¢ 4 ------------ ------------- Edition 02.03 S00.5119.56.20...
Page 83 OCTAVIA Middle Body Replacement parts ♦ Rear roof frame Welding in Fit and fix new part. Weld in new part, spot weld seam. 1 ¢ ------------ ------------- Edition 02.03 S00.5119.56.20...
Page 84: Replacing Centre Roof Cross Member (Octavia Estate)
OCTAVIA Middle Body Replacing centre roof cross mem- ber (Octavia Estate) G Roof already cut out Separation points Detach original joint Replacement part ♦ Centre cross member Welding in Fit and fix centre roof cross member. Weld in centre roof cross member, spot weld seam.
Page 85: Replacing Rear Roof Cross Member (Octavia Estate)
OCTAVIA Middle Body Replacing rear roof cross member (Octavia Estate) G Roof already cut out Separation points Detach original joint. Remove rear cross member. 1 ¢ . 2 ------------ ------------- Edition 02.03 S00.5119.56.20...
Page 86 OCTAVIA Middle Body Replacement parts ♦ Rear roof cross member Welding in Fit and fix rear roof cross member. Weld in rear roof cross member, spot weld seam. 1 ¢ . 3 ------------ ------------- Edition 02.03 S00.5119.56.20...
Page 87 OCTAVIA Middle Body Edition 06.98 ------------ 51-5.4 ------------- S00.5119.52.20...
Page 88: Replacing A Pillar (Octavia)
OCTAVIA Middle Body Replacing A pillar (Octavia) 1 - Foam-lined areas Warning! In view of the fact that gases which are particu- larly harmful to persons and the environment are produced during welding, cutting with tools and equipment which produce sparks, or tin-plating in foam-lined areas, it is prohibited in all cases to use such methods.
Page 89 OCTAVIA Middle Body Welding in Match up new part and tack-weld with the vehicle standing on its wheels or on the straightening bench set. Weld in A pillar, spot weld. Butt-weld cut areas, shielded arc continuous seam. Weld in remaining joint, shielded arc plug weld.
Page 90: Replacing A Pillar (Octavia Rs)
OCTAVIA Middle Body Replacing A pillar (Octavia RS) The procedure is basically identical to that for the Octavia ⇒ page 51-6. Pay attention to the following additional in- formation and differences: The A pillar is additionally shielded arc-welded in the connection to the lower sill in the area of the door weatherseal.
Page 91: Replacing Inner A Pillar
OCTAVIA Middle Body Replacing inner A pillar 1 - Foam-lined area Warning! In view of the fact that gases which are particu- larly harmful to persons and the environment are produced during welding, cutting with tools and equipment which produce sparks, or tin-plating in foam-lined areas, it is prohibited in all cases to use such methods.
Page 92 OCTAVIA Middle Body Welding in Match up new part and tack-weld with the vehicle standing on its wheels or on the straightening angle set. Weld in inner A pillar, spot weld seam. Butt-weld cut area, shielded arc continuous seam. Weld in remaining joint, shielded arc plug weld.
Page 93 OCTAVIA Middle Body ¡ ¢ £ ¤ ¥ Edition 01.01 ------------ ------------- S00.5119.55.20...
Page 94: Replacing Outer B Pillar
OCTAVIA Middle Body Replacing outer B pillar 1 ¢ 8 Separation points ♦ If the outer lower sill or outer A pillar and possibly also the rear side part are damaged, Position the separation cuts according to the then the door frames can be used as a spare damage.
Page 95 OCTAVIA Centre Body Replacement part ♦ Outer B pillar Preparing new part Transfer separation cut to new part and cut to shape. Match up new part. Welding in Match up new part when vehicle standing on its wheels or on straightening angle set, and tack-weld.
Page 96: Replacing Inner B Pillar
OCTAVIA Middle Body Replacing inner B pillar 1 ¢ 9 . 1 G Outer B pillar already cut out Separation points G Lower sill reinforcement already cut out Position top separation cuts according to the damage. Detach original joint. Removing remaining pieces. ------------ ------------- Edition 02.03...
Page 97 ∅ OCTAVIA Middle Body Replacement parts ♦ Inner B pillar ♦ B pillar reinforcements Preparing new part Transfer separation cut to new part and cut to shape. Drill 7 mm holes in the connection area to lower sill Fit on new part Fit on reinforcements for B pillar and cut to shape.
Page 98 OCTAVIA Middle Body 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 1 ¢...
Page 99 OCTAVIA Middle Body Replacing inner B pillar (Octavia RS) The procedure is basically identical to that for the Octavia ⇒ page 51-9.1 Carry out additional operations: The B pillar is additionally shielded arc-welded in the connection area to the roof reinforcement. Welding in Make two shielded arc continuous seams each 25 mm long in the connection area.
Page 100: Replacing Outer Lower Sill
OCTAVIA Middle Body Replacing outer lower sill 1 ¢ 1 0 Separation points ♦ Do not damage internal reinforcement in the lower sill area. Notes: ♦ Perform the separation cut on a vehicle ♦ If outer A and B pillars and possibly also the standing on its wheels or on straightening rear side part are damaged, then the door angles...
Page 101 OCTAVIA Middle Body 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.
Page 102: Replacing Outer Lower Sill (Octavia Rs)
OCTAVIA Middle Body Replacing outer lower sill (Octavia RS) The procedure is basically identical to that for the Octavia ⇒ page 51-10. Pay attention to the following additional in- formation and differences: The lower sill is additionally shielded arc-welded in the area of the door weatherseal. Welding in Make three shielded arc continuous seams each 25 mm long in the area of the flanges...
Page 103 OCTAVIA Middle Body Welding in Match up and tack-weld new part with vehi- cle standing on its wheels or on straighten- ing angle set. Weld in lower sill reinforcement, shielded arc plug weld. 1 ¢ 1 ------------ ------------- Edition 02.03 S00.5119.56.20...
Page 104: Replacing Lower Sill Tube Reinforcement
OCTAVIA Middle Body Replacing lower sill tube reinforcement 1 ¢ 1 G Lower sill reinforcement cut out. Separation points Grind off lower sill tube reinforcement ------------ ------------- Edition 02.03 S00.5119.56.20...
Page 105 OCTAVIA Middle Body Replacement parts ♦ Lower sill tube reinforcement Welding in Match up and tack-weld new part with vehi- cle standing on its wheels or on straighten- ing angle set. Weld in lower sill tube reinforcement, shiel- ded arc plug weld. 1 ¢...
Page 106: Replacing Inner Lower Sill
OCTAVIA Middle Body Replacing inner lower sill 1 ¢ 1 2 G Inner A pillar already cut out. Note: If the inner lower sill is only replaced partially, G Inner B pillar already cut out. the preliminary operations are reduced accord- ingly.
Page 107 OCTAVIA Middle Body Replacement part ♦ Inner lower sill ♦ Reinforcement for lift platform attachment Preparing new part Weld reinforcement with lower sill, spot weld seam. Make holes in new part with punch pliers. Welding in Match up and tack-weld new part with vehi- cle standing on its wheels or on straighten- ing angle set.
Page 108: Replacing Floor Panel Part Section
OCTAVIA Centre Body Replacing floor panel part section l Outer and inner lower sill already removed. Notes: ♦ Do not make any separation cuts in the area Separation points of the centre tunnel. Position separation cut according to damage. ♦ Seat cross member and runner must always be replaced together with floor panel section.
Page 109 OCTAVIA Middle Body Replacement parts ♦ Floor panel ♦ Connection plate for lift platform attachment Preparing new part Transfer separation cut plus 10 mm for over- lapping on the new part and cut to shape. Burr separation cut on the body side Welding in Perform overlapping welding offset on both sides on the separation cut, shielded arc...
Page 111: Rear Body Page
OCTAVIA Rear Body 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.
Page 112 ∅ OCTAVIA Rear Body 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.
Page 113 OCTAVIA Rear Body Replacing end panel (Octavia RS) The procedure is basically identical to that for the Octavia ⇒ page 53-1. Pay attention to the following additional in- formation and differences: The area for attaching the bumper support is reinforced on each side by two additional bolted connections and a retaining plate.
Page 114 OCTAVIA Rear Body ------------ 53-2.2 ------------- Edition 01.01 S00.5119.55.20...
Page 115: Replacing Rear Lock Carrier L
OCTAVIA Rear Body Replacing rear lock carrier l End panel already removed. Separation points Detach original joint to side reinforcements. Note: If the side reinforcements are damaged, these have 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.
Page 116: Replacing Rear End Panel (Octavia Estate And Estate 4X4)
OCTAVIA Rear Body Replacing rear end panel (Octavia Estate and Estate 4x4) Separation points Detach original joint. Take off rear end panel. ------------ 53-3.1 ------------- Edition 03.00 S00.5119.53.20...
Page 117 OCTAVIA Rear Body Replacement part ♦ Rear end panel Preparing new part Match up and tack-weld end panel. Check closing and gap dimensions of rear bonnet. Welding in Weld in end panel, weld spot seam Only on Estate 4x4 Additionally weld shielded arc continuous seam interrupted in the lateral connection area to the luggage compartment floor.
Page 118: Replacing Rear Light Supporting Panel (Octavia Estate)
OCTAVIA Rear Body Replacing rear light supporting panel (Octavia Estate) G 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.
Page 119 OCTAVIA Rear Body Fit on seal -1- in the area of the holes for attaching tailgate stop. Attach water channel part section e.g. with three screws -1- to tail light supporting panel. Welding in Match up tail light supporting panel in com- bination with rear water channel and tack- weld.
Page 121 OCTAVIA Rear Body ¡ ¢ ¡ £ ¤ Edition 06.98 ------------ ------------- S00.5119.52.20...
Page 122 OCTAVIA Rear Body Replacing boot floor l Rear end panel and lock carrier already re- moved. Separation points Detach original joint to side members and left reinforcement. Position front separation cut about 100 mm behind cross member between wheel- houses. Remove remaining pieces.
Page 123 OCTAVIA Rear Body 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.
Page 124: Replacing Luggage Compartment Floor (Octavia Estate 4X4)
OCTAVIA Rear Body Replacing luggage compartment floor (Octavia Estate 4x4) l Rear end panel already cut out. Note: ¡ ¢ £ ¤ If the side connection panels are damaged, ♦ 1 - Bonded areas these must be straightened or replaced. Separation points Replacement parts Detach original joint.
Page 125 OCTAVIA Rear Body Preparing new parts Perforate new part. Drill hole ∅ 7 mm in the rear connecting area to side members. (The number of holes which require to be drilled depends on the length of the spot weld tool used.) Apply adhesive.
Page 127 OCTAVIA Rear Body ¡ ¢ £ ¤ Edition 03.00 ------------ ------------- S00.5119.53.20...
Page 128 OCTAVIA Rear Body Replacing rear side member -attached piece- l End panel already removed. Separation point Detach original joint. Left side only: Cut out reinforcement of boot floor. Notes: ♦ The illustrations show the right-hand side member. ♦ The procedure described is basically also the same, however, for the left-hand side member.
Page 129: Replacing Rear Longitudinal Member (Octavia Estate 4X4)
OCTAVIA Rear Body Replacing rear longitudinal member (Octavia Estate 4x4) l End panel, tail light carrier and luggage com- partment floor already cut out. Warning! As gases which are particularly harmful for per- 1 - Foam-coated area sons and the environment are produced when welding, cutting with spark-producing equipment Before commencing repair work, the remain- and tools, or tin-plating in foam-coated areas, such...
Page 130 OCTAVIA Rear Body Separation points Detach original joint. Grind open area to wheelhouse with rod grinder. Remove remaining pieces. Replacement parts ♦ Rear longitudinal member ♦ Rear insulation ♦ Butyl sealing cord Preparing new part Drill holes for shielded arc plug weld, 7 mm.
Page 132 OCTAVIA Rear Body ¡ ¢ £ ¤ ¥ ------------ ------------- Edition 06.00 S00.5119.54.20...
Page 133: Replacing Rear Side Part (Octavia)
OCTAVIA Rear Body Replacing rear side part (Octavia) 1 - Foam-lined area Warning! In view of the fact that gases which are particu- larly harmful to persons and the environment are produced during welding, cutting with tools and equipment which produce sparks, or tin-plating in foam-lined areas, it is prohibited in all cases to use such methods.
Page 134 OCTAVIA Rear Body Clean flanged area free of dust and grease, e.g. with cleaner D 009 401 04. Apply adhesive in flange area. 2 beads ∅ 4 mm (cut nozzle of tube to match). Notes: ♦ New part must be welded in within 30 min- utes otherwise bond of adhesive will be af- fected.
Page 137 OCTAVIA Rear Body ¡ ¢ £ ¤ ¥ Edition 01.01 ------------ ------------- S00.5119.55.20...
Page 138 Rear body OCTAVIA Replacing rear side part (Octavia Estate) 1 - Foam-lined area Warning! In view of the fact that gases which are particularly harmful to persons and the environment are pro- duced during welding, cutting with tools and equip- ment which produce sparks, or tin-plating in foam- lined areas, it is prohibited in all cases to use such methods.
Page 143 ¤ ¥ ¦ § ¨ © ! ! " # $ % & ' ( ) 0 1 2 3 2 4 ' 5 6 0 2 4 & 9 ) % % 5 ) 0 @ A % 0 7 7 0 1 2 3 2 4 ' 5 6 7 9 ) % % 5 ) 0 @ A %...
Page 147: Replacing Towing Lug
Rear body OCTAVIA Replacing towing lug Separation points Drill off spot weld seams. Replacement parts ♦ Towing lug Preparing new part Make holes in the towing lug using punch pliers. Edition 04.04 ------------ 53-19 ------------- S00.5119.58.20...
Page 148 Rear body OCTAVIA Welding in Weld in towing lug, inert gas shielded plug weld. Replacing towing lug (Octavia 4x4) Separation points Drill off spot weld seams. Grind through inert gas shielded full seam. Edition 04.04 ------------ 53-20 ------------- S00.5119.58.20...
Page 149 Rear body OCTAVIA Preparing new part Make holes in the towing lug using punch pliers. Welding in Weld in towing lug, inert gas shielded plug weld and inert gas shielded full seam inter- rupted. Edition 04.04 ------------ 53-21 ------------- S00.5119.58.20...

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