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

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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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  Edition 08.96

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.
Long-life body protection
- Prime bright metal sheet parts immediately
after carrying out repairs (corrosion protecti-on primer ALN 002 003 10 or ALK 007 003 10).
- Spray outer skin sheets from the inside with top coat before welding in place.
- Always apply zinc spray (D 007 500 04) to both sides of spot welded flanges.
Note
Areas which are subsequently shielded arc-wel-ded, must not be pre-treated with zinc spray.
- Prime weld seam areas from the inside and outside with corrosion protection primer ALN002 003 04 before sealing.
- Apply sealing compound only to primed sheet metal parts and allow to harden sufficiently before further treatment with paint.
- Seal sheet metal overlaps, sheet edges, butt joint, weld seams etc. completely with sealing compound.
- Re-create the underbody sealant using long- life underbody sealant material.
- Protect all the cavities in the area of the repair after applying the top coat.
- After the cavity protection material has dried, open the water drains.

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50Front Body



 Edition 08.96

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. Replacement parts Side member section
Impact shock absorber mount
Preparing new part
- Transfer separating cut to new part and cut
off shaded area.

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Edition 08.96




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 toeach other. It is essential to maintain the originalspacing.
- Weld in impact shock absorber mount page 50-12.

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Edition 08.96


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.