SKODA OCTAVIA 1997 1.G / (1U) Body Repairs User Guide
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Downloaded from www.Manualslib.com manuals search engine OCTAVIA
00General Notes
Edition 02.03
S00.5119.56.20
------------ 00-2
------------ 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. the wearing of safety spectacles, gloves, safety shoes and ear protectors.
Work on straightening rig
Extremely high forces act upon the body dam- aged by accident being straightened using hy- draulic pressure or traction devices on the straightening bench. Always bear in mind that these forces may suddenly be released e.g. by
the sliding of a fastening claw. Therefore make absolutely sure no person is present in or around the danger zone.
Removing components
Secure the vehicle on the lift platform before itscentre of gravity shifts considerably because ofsuccessive disassembly operations.
Battery
Remove the battery before welding. Always remove the battery before performing
spark-generating work close to the battery. Note: If the battery earth strap is disconnected and connected, carry out additional operations
Electrical System; Repair Group 27.
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Downloaded from www.Manualslib.com manuals search engine OCTAVIAGeneral Notes00
Edition 02.03
S00.5119.56.20------------ 0
0
3 ------------
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.
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00General Notes
Edition 02.03
S00.5119.56.20
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. Remedial measures: Exhaust the refrigerant circuit Heating, Air conditioning, Repair Group 87
Warning! Observe the safety measures for working with air conditioning Heating, Air conditioning, Repair
Group 87.
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Downloaded from www.Manualslib.com manuals search engine General Information00
Edition 03.97
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.
Electronic control units
Remove battery. Separate earth connections of the electronic control units.
Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder
Connect the earth of the electric welding equip- ment directly to the part to be welded. When doing this, ensure that no electrically insulating parts are located between the earth connections and the welding point. Do not allow electronic control units and electric cables to come into contact with the earth connection or the welding electrode.
Airbag system
Safety information General Body Repairs, Repair Group 69
Repair information General Body Repairs, Repair Group 69
Safety precautions for seat belt tensioners
Safety information General Body Repairs, Repair Group 69
Important!
Remove the seat belt tensioner units beforecommencing any cutting, straightening and panelbeating work in the area of these units.
If one or both seat belt tensioners have beenactivated in an accident, both seat belts have tobe replaced (the seat belts no longer rewind).
Repair information General Body Repairs, Repair Group 69
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Downloaded from www.Manualslib.com manuals search engine 00General Information
Edition 08.96
Basic information Procedure for accident repairs
Diagnosis of damage Removing adjoining parts Itemising parts required
Is it economic to eliminate
damage by panel beating?yes no
B
A
Protect the vehicle by covering over
undamaged parts Protect the vehicle by covering over
undamagd parts
Repair damaged part by panel beating, with or without filler depending on damage Have new parts primed from inside
Carry out fine filler work (scores, pores) as necessary Eliminate damage by straightening to restore
original shape so that adjoining contour/body dimensions are again correct
Replace fine sealing/chip protection as necessary Cut out damaged part roughly
Remove remaining parts
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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.
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Edition 08.96
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 paintwork. This preparatory work is part of the operations carried out by the body repair shop and are con- tained in the time allowance for body repairs.
Straightening
The body and floor assembly are manufactured in series production from cold-shaped deep- drawn sheets. For this reason, restoring body panels to the original shape after accident da-
mage should be carried out in the same way.
Notes:
When straightening sharp-edged buckles,
there is a risk of the sheet tearing suddenly.
If the extent of the damage does not allowthe sheet to be restored to its original shape
by straightening it in the opposite direction
of the accident damage, the damaged partmust be cut out only after straightening the
adjoining areas.
Cuts
Cuts which affect the fatigue strength of the body and thus also the operational and road safety of the vehicle, have to be carried out in accordance
with the specifications in this Workshop Manual.
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Downloaded from www.Manualslib.com manuals search engine 00General Information
Edition 08.96
Welding galvanised body panels
Important!
It is important to ensure proper ventilation of theworkbay and extraction of the gases by suitableextraction equipment, e.g. V.A.G 1586, as toxic zincoxide is produced in the welding fumes when
welding galvanised steel panels.
Note: As the resistance spot welding method (RP) cau-ses a slight erosion of the zinc layer only in thecentre of the weld spot and the zinc protective
ring which is produced at the same time aroundthe weld spot, protects it from corrosion, prefe-
rence should be given to this welding method in
contrast to shielded arc welding (SG).
Shielded arc welding (SG) of galvanised pa- nels Pay attention to the following points in order to produce good repair welded joints: The amperage at the welding transformer has to be increased.
At the same time, the infeed of the electrodewire has to be adjusted as merely increasing the voltage only produces a greater arc (re- duced fusion penetration, more porous weld structure).
Use a cylindrical instead of a conical gas nozzle (splatters at a gas nozzle which is too narrow results in formation of pores).
Guide torch about 12 mm above the material being welded at a neutral angle or at up to 10°.
Use the softest possible wire grades.
Both CO
2 as well as mixed gases can be
used for shielding.