warning SKODA OCTAVIA 1997 1.G / (1U) Body Repairs Workshop Manual

Downloaded from www.Manualslib.com manuals search engine OCTAVIAGeneral Notes00
Edition 02.03
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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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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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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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51Middle Body
Edition 02.03
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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 areproduced 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.
Note: If the outer lower sill or outer B pillar and possi- bly also the rear side part are damaged, then the door frames can be used as a spare partwithout reinforcement (stamped part). Separation points
- Position the separation cuts according to the
damage.
Notes: Do not damage internal reinforcement of A
pillar.
Do not cut in the area of the hinge attach-ments.
- Detach original joint
- Drill off weld spots to lower sill reinforcement in the area of top and bottom lower sill.
- Drill off weld spots to inner A pillar. Replacement part Section of A pillar
Sound insulation 1UO 864 667 C, 1UO 864 667 D, 1UO 864 667 E
Preparing new part
- Transfer separation cut to new part and cut
to shape
- Prepare new part, drill
∅ 7 mm holes.
Foam lining
- Replace noise insulation page 00-19.1.

Downloaded from www.Manualslib.com manuals search engine OCTAVIARear Body53
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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.
Note: If the outer lower sill or outer B pillar and possi- bly also outer A pillar are damaged, then the door frames can be used as a spare part with-out reinforcement (a stamped part). Separation points
- Cut out side part roughly
- Grind through outer edge of wheelhouse. Note:
Do not damage inner wheelhouse liner.
- Detach original joint
- Remove remaining pieces. Replacement parts Side part
Adhesive: DA 001 730 A1
Sound insulation 1U6 863 665
Preparing new part
- Drill
∅ 7 mm holes for shielded arc plug weld
in the area to tailgate water channel
- Transfer separation cuts to new part and cut to shape.