Skoda Octavia II 2004 Instruction manual

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Workshop Manual
OCTAVIA II 2004 ➤
Body repairs
Edition 02.04
Service
Service Department. Technical Information

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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.�
List of Workshop Manual Repair Groups
Repair Group
00 - General Instructions
50 - Front body
51 - Middle body
53 - Rear body
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Service
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2015 ŠKODA AUTO a. s. S0057140020

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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.�
Contents
00 - General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Vehicle identification data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.3 Straightening bench work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.4 Disassembling components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.5 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.6 Paint, windows, upholstery, trims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.7 Welding work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.8 Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.9 Fuel tank and fuel conveying hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.10 Electronic control units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.11 Airbag system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.12 Safety instructions for seat belt tensioners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Basic Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Accident repair sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 Diagnosis of vehicles damaged by accident . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 Condition of the body or parts when delivered to the paintshop . . . . . . . . . . . . . . . . . . . . 6
3.4 Straightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.5 Severance cuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.6 Welding of galvanized body panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.7 Repair of high-strength body panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.8 Body - glued joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.9 Removing the underbody protection and sealing seams . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.10 Body sections and individual parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.11 Original welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4 Explanation of the symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.1 Explanation of the signs for welding operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.2 Explanation of the signs for the processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6 Anti-corrosion measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.1 Corrosion prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.2 Long-term body protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.3 Cutting galvanized body parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7 Injecting foam in the body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.1 Replace noise insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.2 Overview of foam-filled points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8 The jig alignment bench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8.1 Overview of the jig alignment bench Celette with straightening square set . . . . . . . . . . . . 19
8.2 Overview of front alignment bracket positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
8.3 Overview of the middle alignment bracket positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
8.4 Overview of the rear alignment bracket positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
9 Karosserie-Kontrollspaltmaße . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
9.1 Karosserie vorn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
9.2 Karosserie hinten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
50 - Front body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1 Repairing the front body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.1 Replacing wing support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.2 Replace engine mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
OCTAVIA II 2004 ➤
Body repairs - Edition 02.04
Contents i

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with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
1.3 Replace gearbox mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.4 Replacing upper frame side rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.5 Replacing the front frame side rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.6 Replacing the front frame side rail offcut part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.7 Replace cover plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
51 - Middle body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1 Repairing the body in the middle I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1.1 Octavia - Replacing roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1.2 Octavia combi - Replacing roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1.3 Replacing the front roof cross member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1.4 Replace middle roof cross member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1.5 Replacing the rear roof cross member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
1.6 Replacing pillar A on the outside . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1.7 Replacing pillar A inside . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2 Repairing middle body II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.1 Replacing pillar B outside . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.2 Replacing the outside bottom side rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
2.3 Replace bottom side rail pipe reinforcement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
53 - Rear body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
1 Repairing rear body I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
1.1 Replacing the rear wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
1.2 Octavia combi - Replacing the rear wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
1.3 Replacing the wheel house offcut part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
1.4 Replacing reinforcement of pillar C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2 Repairing rear body II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2.1 Replacing the end cover plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2.2 Octavia combi - Replacing end cover plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
2.3 Replacing the utility plate on the rear light carriers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2.4 Octavia combi - Replacing the utility plate on the rear light carriers . . . . . . . . . . . . . . . . . . 84
2.5 Octavia combi - Replacing reinforcement of end part . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
2.6 Replacing end part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.7 Octavia combi - Replacing end part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2.8 Replacing the luggage compartment floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2.9 Replacing rear frame side rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
2.10 Replace towing lug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
OCTAVIA II 2004 ➤
Body repairs - Edition 02.04
ii Contents

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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.�
00 – General Instructions
1 Technical Data
1.1 Vehicle identification data
1.1.1 Vehicle identification number
The vehicle identification number is type-punched into the right
suspension strut dome.
The vehicle identification number can also be found at the bottom
left of the front window corner.
1 - Manufacturer's world code
2 - Body type and fixtures and fittings
3 - Engine fitted
4 - Airbag system
5 - Vehicle type
6 - Internal code
7 - Model year
8 - Manufacturing plant
9 - Body number
Note
Extensive information about the significance of individual mark‐
ings ⇒ Inspection and Maintenance; Rep. Gr. 02 .
OCTAVIA II 2004 ➤
Body repairs - Edition 02.04
1. Technical Data 1

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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.�
2 Safety measures
2.1 Safety instructions
When performing the works described, comply with all country-
specific safety regulations. In case of doubt refer to the competent
authorities.
2.2 Safety measures
For all operations take the legally prescribed personal and gen‐
eral protection measures. This includes e.g. the wearing of safety
spectacles, gloves, safety shoes and ear protectors.
2.3 Straightening bench work
Extremely high forces act upon the body damaged by accident
being straightened using hydraulic 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.
One should, therefore, always make absolutely sure that no per‐
son is present in or around the danger zone.
2.4 Disassembling components
Secure the vehicle on the lift platform before its centre of gravity
shifts considerably because of successive disassembly opera‐
tions.
Lift the vehicle ⇒ Inspection and Maintenance .
2.5 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; Rep. Gr. 27 .
2.6 Paint, windows, upholstery, trims
It is prohibited to park other vehicles without protection in the
premises used as a body repair shop (risk of fire resulting from
flying sparks, destruction of the paint work and windows).
OCTAVIA II 2004 ➤
Body repairs - Edition 02.04
2 Rep. Gr.00 - General Instructions

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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.�
2.7 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. g. -V.A.G 1586 A- . Before starting weld‐
ing operations on the vehicle protect the rest of the vehicle by
placing fireproof blankets or matting around the work area. If
this measure is thoroughly implemented it will not be necessary
to remove all the interior vehicle equipment. There must, how‐
ever, always be a fire extinguisher within reach during welding
operations for safety reasons. If the mechanic performing the
welding operation is unable to supervise the inside of the ve‐
hicle, a second person must be called upon. The gases gen‐
erated during welding are toxic and must be removed by
suction.
Note
♦ Remove battery before all welding operations.
♦ Disconnect the AC generator.
♦ Disconnect the earth connections of the electronic control
units.
2.8 Air Conditioning
It is prohibited to weld, or hard or soft solder on parts of the filled
air conditioning. This also applies for welding and soldering op‐
erations on the vehicle if there is any risk that parts of the air
conditioning heat up. When undertaking paint repair operations
the temperature of the objects placed in the drying oven or in its
pre-heating zone must not exceed 80°C since heating creates a
strong overpressure that may result in the system exploding.
Note
♦ The refrigerant circuit must be drained if electrical welding is
to be carried out close to the refrigerant hoses. During elec‐
trical welding invisible UV rays are produced that penetrate the
refrigerant hoses and decompose the refrigerant.
♦ Exhaust the refrigerant ⇒ Heating, Air Conditioning; Rep. Gr.
87 .
An empty air conditioning system must only be filled by a service
centre. This is why it is recommended to only empty the system
when required according to prescribed safety measures.
If repairs on the vehicle make it necessary to drain the refrigerant
avoid any contact with the liquid refrigerant or with the refrigerant
vapours.
Wear gloves to protect your hands and safety spectacles for your
eyes. The intensive effect of refrigerant on unprotected body parts
will cause frostbite.
OCTAVIA II 2004 ➤
Body repairs - Edition 02.04
2. Safety measures 3

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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.�
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‐
ply eye drops into the eyes and immediately contact a physi‐
cian, even if the eyes are not painful. The physician must be
told that the frostbite was caused by refrigerant R12 or R134a.
If refrigerant comes into contact with other body parts in spite
of observing these safety measures, rinse the part of the body
effected immediately and thoroughly with water for at least 15
minutes.
Although refrigerant is not flammable it is nevertheless prohibited
to smoke in a room filled with refrigerant vapour. The high tem‐
perature of a lit cigarette entails a chemical reaction of the refrig‐
erant gas. Inhaling the released toxic products will cause an
irritating cough and nausea.
2.9 Fuel tank and fuel conveying hoses
Extreme caution is recommended for grinding and welding oper‐
ations at the level of the fuel tank or other fuel conveying parts.
In case of doubt remove such parts. The fuel tank and fuel hoses
removed from the vehicle must be stored in compliance with the
safety instructions.
2.10 Electronic control units
Remove the battery.
Disconnect all earth connections of the electronic control units
⇒ Current flow diagrams, Electrical fault finding and Fitting loca‐
tions.
Connect the earth connection of the electric welding tool directly
to the part to be welded. Make absolutely sure that there is no
electrically insulating part between the earth connection and the
welding point.
Electronic control units and electrical wiring must not touch the
earth connection or the welding electrode.
2.10.1 Handling electronic control units when
carrying out repair work after accidents
Electronic control units must only be replaced, if at least one of
the following conditions is met:
♦ The housing is noticeably deformed or damaged.
♦ The contact surface or the console is deformed, from the out‐
side the control unit indicates that there is no damage.
♦ The plug connection is damaged or corroded due to humidity.
♦ The fault “control unit defective” occurs during functional test
or during self diagnosis.
If electronic components, e.g. the ABS control unit, are removed
when carrying out repair work and then are re-used, it is neces‐
sary to check their proper operation after the assembly, e.g by
self-diagnosis.
2.11 Airbag system
Safety measures ⇒ Body Work; Rep. Gr. 69 .
Repair instructions ⇒ Body Work; Rep. Gr. 69 .
OCTAVIA II 2004 ➤
Body repairs - Edition 02.04
4 Rep. Gr.00 - General Instructions

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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.�
2.12 Safety instructions for seat belt tension‐
ers
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. Replace both seat belts following an accident in
which one or both seat belt tensioners was/were deployed.
Note
The seat belt system must be inspected after every accident! If
there is a damage, replace the safety belt ⇒ Body Work; Rep.
Gr. 69 .
OCTAVIA II 2004 ➤
Body repairs - Edition 02.04
2. Safety measures 5

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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.�
3 Basic Instructions
3.1 Accident repair sequence
3.2 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. If
it appears the vehicle has been subjected to considerable strain
it is important to the check the following components, in addition
to the mandatory alignment check.
♦ If damage to and/or distortion of the body platform is suspec‐
ted inspect the vehicle on the frame straightening bench, and
straighten if necessary.
♦ Inspect the proper operation of the steering and steering link‐
age over the full steering angle, perform a visual inspection to
check for distortions or cracks.
♦ Check the chassis, all chassis parts such as the strut, sus‐
pension strut, stabilizer, supporting frame, axle body and their
fixation parts for distortion or cracks.
♦ Inspect the wheels and tyres for damage and check the con‐
centricity and imbalance. Inspect the tyres for gashes in the
profile and on the sidewalls, check tyre pressure.
♦ Check the suspensions of the engine, gearbox, axles and ex‐
haust system for damage.
♦ Finally a suitable test drive after repairs will provide the cer‐
tainty that the vehicle is safe to drive and can be quite safely
returned to the customer.
3.3 Condition of the body or parts when de‐
livered to the paintshop
Before handing over a repaired vehicle or parts thereof to the
paintshop, the repaired or planished and filled surface must be
prepared for painting using sandpaper with a grain of P 80 through
to P 100 while carefully following the contours.
These preliminary operations are performed by the body builder
and are included in the time he is granted for the repair.
3.4 Straightening
The body and body platform are series manufactured from cold-
formed body sheet. Therefore the re-shaping of any damage due
to accident should occur in the same way.
Note
♦ The steel sheet may suddenly tear when straightening out
sharp-edged kinks.
♦ If the extent of the damage prevents reshaping against the
accident direction, the damaged part must not be removed
until the connecting surfaces have been straightened.
OCTAVIA II 2004 ➤
Body repairs - Edition 02.04
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3.5 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.
3.6 Welding of galvanized body panels
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. g. -V.A.G 1586 A- .
Note
Resistance spot welding (RP) only causes slight burning of the
zinc layer at the centre of the welding spot and the simultaneously
formed surrounding zinc ring protects it against corrosion. This is
why the inert gas welding procedure is to be recommended for
this welding operation.
3.6.1 SG inert gas shielded arc welding of
galvanized panels
Follow the instructions below to realise good welded joints during
repair:
♦ The current on the welding transformer must be increased.
♦ Simultaneously adjust the wire feed since just increasing the
current will only produce a greater arc (reduced fusion pene‐
tration, porous seam build-up).
♦ Use a cylindrical instead of a conical gas jet (if the gas jet is
too narrow the resulting spatters will lead to pore formation).
♦ Hold the burner some 12 mm above the weld metal bead while
describing an angle ranging between 0 and 10 °.
♦ Preferably use soft wire qualities.
♦ Both CO2 and mixed gases may be used as shield.
3.6.2 RP welding of galvanized sheet metal
panels
When spot welding galvanized panels pay attention to the follow‐
ing points:
Welding transformer
♦ Increase the welding current by 10% to max. 30%.
When using welding transformers with “Welding time control” it is
preferable to increase the welding time.
• Welding time increase in function of the panel thickness (ref‐
erence values):
• 0.7 mm - at least 7 periods
• 0.8 mm - at least 9 periods
• 1.0 mm - at least 11 periods
OCTAVIA II 2004 ➤
Body repairs - Edition 02.04
3. Basic Instructions 7

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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).
♦ Frequently clean the hard copper electrodes or rework to ∅ 4
mm.
♦ Increase the electrode contact pressure.
3.6.3 Detachment test
The best welding results are obtained by first welding test panels
and then subjecting them to a detachment test.
To this end the narrow strip welded as a test must be unrolled or
torn off from the second steel strip under the effect of a force act‐
ing vertically relatively to the sheet surface.
Perfect quality welding spots do not tear on the contact surface
but become “detached”.
3.7 Repair of high-strength body panels
The high-strength panel is optically a normal panel, which has a
higher yield point than normal body panels due to different alloys.
This means that under equal influence of force the dent on a high-
strength panel is not as deep as on a normal body panel.
3.7.1 Remove dents
Dents are removed with standard tools. The larger buckling re‐
sistance results in a larger backspring behaviour, so that if nec‐
essary more forces are needed. If kinks are reshaped, material
fractures can occur.
3.7.2 Straightening
Due to the larger effect on the backspring behaviour of the high-
strength panel, it must be even more over-tensioned than a
normal panel, before it stops in the desired position. Due to the
higher force application, normal panels, which are welded togeth‐
er with high-strength panels, are likewise more strongly ten‐
sioned. In order to prevent the normal panel from yielding or
tearing, an additional anchorage must be supplied.
Note
♦ If the high-strength panel is over-tensioned, it suddenly jumps
to a larger length than desired !
♦ For safety reasons, the warming up of high-strength body pan‐
els as well as normal body panels is forbidden when reshap‐
ing!
3.7.3 Painting
If a drying radiator warms up the high-strength panel too rapidly,
it expands. However, if the panel is firmly connected by means of
welding points or bonding with the reinforcements located behind
it, dents can occur in these places, which remain visible after
cooling. For this reason, heating emitters must only be set slowly
to maximum power. The drying in the drying cabinet is possible
without risk.
OCTAVIA II 2004 ➤
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8 Rep. Gr.00 - General Instructions

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3.8 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.
The distance of the high-strength adhesive surfaces to each other
should be no less than 2 mm and no more than 4 mm. If neces‐
sary, the adhesive surfaces must be prepared.
The glued joints are manufactured with the materials indicated in
the repair manual and/or in the SP program.
Spot weld - glued joints
For the spot weld glued joints, an electrically conductive adhesive
is applied between the panels, which makes a problem-free pen‐
etration welding possible.
The distance of the spot weld adhesive surfaces to each other
should not be more than 1mm. If necessary, the adhesive surfa‐
ces must be prepared.
When spot weld glueing, the welding power must not be in‐
creased. The prepress time must be prolonged because of the
adhesive displacement, approx. 30 - 50 periods. The gases re‐
sulting from this must be suctioned off.
3.8.2 Repairs of glued joints
As a replacement for the spot weld adhesive, use the glue -DA
001 730 A1- in combination with the compressed air adhesive gun
-V.A.G 2005- .
Depending on the type of welding, the procedures differ as fol‐
lows:
RP spot welding and glueing
When spot welding and glueing in case of repair the entire scope
on welding spots and glueing is replaced.
In case of welding problems, e.g. with a 3-layer panel connection,
only the outer panel is replaced when the repair spotwelds are
positioned on the old spotwelds.
Inert gas shielded welding and glueing (if spot welding is not pos‐
sible)
If a glueing area with an RP welding tool is not accessible, the
area is welded with an inert gas shielded plug weld.
In this case, it is performed without adhesive in order to obtain the
welding deposit.
3.8.3 Preliminary work with glued joints
The panels to be welded must be adjusted before applying the
glue.
OCTAVIA II 2004 ➤
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3. Basic Instructions 9

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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.
The bright spot flange is moistened with adhesive by means of
the adhesive displacement during spot welding and thus the cor‐
rosion protection is ensured.
3.9 Removing the underbody protection and
sealing seams
In order not to damage the zinc coating of the body both the un‐
derbody protection and the sealing seams can be removed with
a wire brush disc mounted on a right angle grinder or on a pneu‐
matic rod grinder.
Note
Wear protective spectacles and protective gloves. The flying wire
particles that may be ejected are extremely sharp.
It is also possible to heat the underbody protection and sealing
seams with a hot air blower (max. 420 °C) and then remove the
softened underbody protection or the sealing seams with a scra‐
per. This method is especially recommended for locations that are
difficult to reach.
WARNING
The vapours produced are toxic and must be removed using a
suitable exhaust system, e.g. -V.A.G 1586 A- .
Remove the paint and primer with paint stripper.
3.10 Body sections and individual parts
“Sections” refer to the sections of individual parts that are cut to
the required dimensions and directly supplied to the spare part
storeroom.
“Individual parts”, however, are parts which you cut to size from
spare parts.
3.11 Original welding
“Original welding” refers to the welded joints realised during the
manufacturing of the vehicle.
Always endeavour to reconstitute them when performing body
repair operations.
When performing accident repairs it is preferable, for reasons of
security, to exceed the number of series spot welds rather than
fall short of them if there is enough space.
Methods and procedures that differ also from the original welding
are described in this Body Repairs Workshop Manual.
OCTAVIA II 2004 ➤
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with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
4 Explanation of the symbols
4.1 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
Inert gas shielded quilting seam (if necessary must be grinded
flush with the body contours)
Inert gas shielded full seam (if necessary must be grinded flush
with the body contours)
Inert gas shielded full seam interrupted (if necessary must be
grinded flush with the body contours)
Hard soldering
Note
♦ Inert gas shielded plug weld: holes with a diameter ∅ of 7 mm
must be drilled every 20-30 mm at the level of the connecting
points on one of the panels to be connected or else use punch
pliers with a carefully positioned inert gas shielded welding
hole.
♦ Inert gas shielded full seam: if possible the welding seam must
be uninterrupted.
♦ Inert gas shielded quilting seam: the welding seam consists of
a series of successive individual welding spots. Its advantage
being that it requires less heat than the inert gas shielded full
seam.
♦ Inert gas shielded full seam, interrupted: the welding seam
consists of successive inert gas shielded full seams at a dis‐
tance of approx. 20 mm interval interspaced by sections of
equal length.
OCTAVIA II 2004 ➤
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4. Explanation of the symbols 11

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4.2 Explanation of the signs for the process‐
es
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).
Grind using a rod grinder
Protection of hollow spaces
OCTAVIA II 2004 ➤
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Glueing
Precision sealing
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4. Explanation of the symbols 13

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5 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-
♦ Body saw e.g. -V.A.G 1523-
♦ Welding fumes suction equipment e.g. -V.A.G 1586 A-
♦ Door tension adjuster, e.g. -V.A.G 1438-
♦ Underbody sealant gun, e.g. -V.A.G 1379-
♦ Double cartridge gun -VAS 5237-
♦ Pneumatic gun -V.A.G 2005- for adhesive -DA 001 730 A1-
♦ Burring pliers
– To burr panels e.g. for overlapping seams.
♦ Hole punch, e.g. -V.A.G 1329-
– To punch holes in panels e.g. for SG plug welding.
♦ Panel nibbler
– To cut out panels without warpage or burring, e.g. when sub‐
sequently fitting a glass sun roof.
♦ Compressed air pistol, e.g. -V.A.G 1761/1-
– Pneumatic gun to produce seals and apply underbody protec‐
tion having the same appearance as the original factory finish.
– In addition all 310 ml cartridges can be used in this gun.
♦ Pressure beaker gun for hollow space sealing e.g. -
V.A.G 1538-
♦ Inert gas shielded welding tool
♦ Spot welding and sheet panel machining tool e.g. -VAS 6249-
♦ Straightening bench Celette M85 with straightener and
straightening square sets -VAS 6210- (VW Touran), -VAS
6210/1- (Audi A3) and -VAS 6240/3- (Škoda Octavia II)
♦ Basic equipment e.g. -V.A.G 1366/3-
♦ Rod grinder with wire brush
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with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
6 Anti-corrosion measures
6.1 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.
6.2 Long-term body protection
– Apply a priming coat to the bright sheet metal panels immedi‐
ately after repairs (anti-corrosion primer -ALN 002 003 10- or
-ALK 007 003 10- ).
– New parts, which are not accessible after repairs from the in‐
side, e.g. bottom side rail, should be painted before welding
from the inside with appropriate priming colour of the vehicle.
The welding flanges should be covered with adhesive tape.
– Always apply zinc spray -D 007 500 04- on both sides of spot
welding flanges.
Note
Make sure to avoid pre-treating with zinc spray the locations in‐
tended for subsequent inert gas shielded welding.
– Before sealing apply anti-corrosion primer -ALN 002 003 04-
on the seams from the inside and from the outside.
– Only apply sealing compound to the primer coated panels and
allow to harden sufficiently before proceeding with further
paint applications.
– Use sealing compound to seal the panel overlappings, panel
sides, butt joints, welding seams etc.
– Restore the underbody protection with long-term underbody
protection material.
– After applying the finish paint protect all the hollow spaces
near the repair location. Overview of protective hollow spaces
⇒ page 15 .
– Unblock the water drainage openings once the hollow space
protection material has dried.
6.2.1 Overview of protective hollow spaces
OCTAVIA II 2004 ➤
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6. Anti-corrosion measures 15

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6.3 Cutting galvanized body parts
6.3.1 Preliminary work
– Remove the underbody protection and sealed seams ⇒ Chap.
00-3
6.3.2 Separation process
– Do not use thermic cutting methods, e.g. a cutting torch.
– It is recommended to use mechanical methods e.g. a welding
spot cutter, body saw, so as not to damage the zinc plating at
the cutting location.
6.3.3 Welding of galvanized body panels
⇒ Chapter 00-3 .
OCTAVIA II 2004 ➤
Body repairs - Edition 02.04
16 Rep. Gr.00 - General Instructions