Bodyshop Manual GENERAL INFORMATION 00 PANEL REPLACEMENT 80C BODY STRUCTURE DIMENSIONS PLASTIC BODY PARTS 80F

Transcription

1 Bodyshop Manual FOREWORD This bodyshop manual is intended for use by technicians of Authorized Mazda Dealers to help them service and repair Mazda vehicles. It can also be useful to owners and operators of Mazda vehicles in performing limited repair and maintenance on Mazda vehicles. For proper repair and maintenance, a thorough familiarization with this manual is important, and it should always be kept in a handy place for quick and easy reference. All the contents of this manual, including drawings and specifications, are the latest available at the time of printing. As modifications affecting repair or maintenance occur, relevant information supplementary to this volume will be made available at Mazda dealers. This manual should be kept up-to-date. CONTENTS Title Section GENERAL INFORMATION 00 BODY STRUCTURE CONSTRUCTION PANEL REPLACEMENT WATER-PROOF AND RUST PREVENTIVE DIMENSIONS PLASTIC BODY PARTS CONSTRUCTION STANDARD VALVES APPLICATION: This manual is applicable to vehicles beginning with the Vehicle Identification Numbers (VIN), shown on the following page Mazda North American Operations PRINTED IN U.S.A., JULY 2009 Form No U 09G Part No F 09 80A 80B 80C 80D 80E 80F Mazda North American Operations reserves the right to alter the specifications and contents of this manual without obligation or advance notice. All rights reserved. No part of this book may be reproduced or used in any form or by any means, electronic or mechanical including photocopying and recording and the use of any kind of information storage and retrieval system-without permission in writing. Mazda North American Operations HIROSHIMA, JAPAN

2 VEHICLE IDENTIFICATION NUMBERS (VIN) 2009 MY 1YV HP80A 95 M YV HP80H 95 M YV HP81A 95 M YV HP81B 95 M YV HP81H 95 M YV HP82A 95 M YV HP82B 95 M YV HP82H 95 M MY 1YV HZ8AA A5 M YV HZ8AH A5 M YV HZ8BA A5 M YV HZ8BB A5 M YV HZ8BH A5 M YV HZ8CA A5 M YV HZ8CB A5 M YV HZ8CH A5 M00001

3 GENERAL INFORMATION 00 SECTION Toc of SCT GENERAL INFORMATION Toc of SCT GENERAL INFORMATION VEHICLE IDENTIFICATION NUMBER (VIN) CODE MY MY VEHICLE IDENTIFICATION NUMBERS (VIN) MY MY HOW TO USE THIS MANUAL Efficient Replacement of Body Panels Symbols of Panel Replacement Body Dimensions (Flat-plane Dimensions) Body Dimensions (Straight-line Dimensions) Symbols of Body Dimensions AIR BAG SYSTEM SERVICE WARNINGS Air Bag Module Inspection Air Bag Module Handling Side Air Bag Module Handling SAS Control Module Handling Side Air Bag Sensor Handling Pre-tensioner Seat Belt Inspection SERVICE PRECAUTIONS Arrangement of Workshop Safety Precautions Vehicle Protection Remove Dangerous Articles Use of Pulling Equipment Prevent Short Circuits EFFICIENT REMOVAL OF BODY PANELS Body Measurements Prevention of Body Deformation Selection of Cut-and-join Locations Removal of Associated Parts Rough Cutting of Damaged Panel EFFICIENT INSTALLATION OF BODY PANELS Checking Preweld Measurements And Watching Welding Notes Spot Welding Notes Checking Weld Strength INSTALLATION PREPARATIONS Rough Cutting of New Parts Determination of Welding Method Making Holes for CO 2 Arc Welding Application of Weld-through Primer ANTICORROSION, SOUND INSULATION, AND VIBRATION INSULATION Body Sealing Application of Undercoating Application of Rust Inhibitor Application of Floor Silencer BODY COLORS Color Code and Color Name Verification of Primary Color Mixture for Body Color ABBREVIATION IDENTIFICATION NUMBER LOCATIONS Vehicle Identification Number (VIN) Engine Identification Number End of Toc BM: GENERAL INFORMATION

4 GENERAL INFORMATION VEHICLE IDENTIFICATION NUMBER (VIN) CODE 2009 MY id Y V H P 8 0 A * 9 5 M Serial No. M00001 to M99999 N00001 to N99999 Plant Model year 5= AAI, Flat Rock, Michigan/U.S.A. 9= 2009 Check digit *= 0 to 9, X Engine type A= L5 (2.5 L)(Made in Mexico) *1 H= L5 (2.5 L)(Made in Hiroshima) B= MZI-3.7 (3.7 L) Grade, Body type 0= Standard grade, Sedan 1= Base grade, Sedan 2= High grade, Sedan Carline, series Car identifier Air bag 8= Mazda6 P= Passenger car H= With front, side and curtain air bag World manufacturer identification 1YV= Mazda passenger car, produced at AAI *1: Vehicles with the following VIN are equipped with a Hiroshima-manufactured engine. 1YVHP81A095M YVHP81A095M YVHP81A095M YVHP81A095M YVHP81A095M YVHP81A095M YVHP81A095M YVHP81A095M YVHP81A195M YVHP81A195M YVHP81A195M YVHP81A195M YVHP81A295M YVHP81A295M YVHP81A295M YVHP81A295M YVHP81A295M YVHP81A295M YVHP81A295M YVHP81A295M YVHP81A295M YVHP81A395M YVHP81A395M YVHP81A395M YVHP81A395M YVHP81A395M YVHP81A395M YVHP81A495M YVHP81A495M YVHP81A495M YVHP81A495M YVHP81A495M YVHP81A495M YVHP81A495M YVHP81A595M YVHP81A595M YVHP81A595M YVHP81A595M YVHP81A595M YVHP81A595M YVHP81A595M YVHP81A595M YVHP81A595M YVHP81A595M YVHP81A695M YVHP81A695M YVHP81A695M YVHP81A695M YVHP81A695M YVHP81A695M YVHP81A695M YVHP81A795M YVHP81A795M YVHP81A795M YVHP81A895M YVHP81A895M YVHP81A995M YVHP81A995M YVHP81A995M YVHP81A995M YVHP81A995M YVHP81A995M YVHP81A995M YVHP81AX95M YVHP81AX95M YVHP81AX95M YVHP81AX95M YVHP81AX95M YVHP81AX95M YVHP81AX95M YVHP82A095M YVHP82A295M YVHP82A495M YVHP82A495M YVHP82A695M YVHP82A895M YVHP82A995M48184 am6xuw

5 GENERAL INFORMATION 2010 MY 1 Y V H Z 8 A B * A 5 M Serial No. M00001 to M99999 N00001 to N Plant 5= AAI, Flat Rock, Michigan/U.S.A. Model year A= 2010 Check digit *= 0 to 9, X Engine type A= 2.5 L (L5) (Made in Mexico) B= 3.7 L (MZI-3.7) (Made in Hiroshima) H= 2.5 L (L5) (Made in Hiroshima) Grade, Body type A= Standard grade, Sedan B= Base grade, Sedan C= High grade, Sedan Carline, series 8= Mazda6 Car identifier Z= Passenger car Air bag H= With front, side and curtain air bag End Of Sie VEHICLE IDENTIFICATION NUMBERS (VIN) 2009 MY 1YV HP80A*95 M YV HP80H*95 M YV HP81A*95 M YV HP81B*95 M YV HP81H*95 M YV HP82A*95 M YV HP82B*95 M YV HP82H*95 M MY 1YV HZ8AA*A5 M YV HZ8AH*A5 M YV HZ8BA*A5 M YV HZ8BB*A5 M YV HZ8BH*A5 M YV HZ8CA*A5 M YV HZ8CB*A5 M YV HZ8CH*A5 M00001 End Of Sie World manufacturer identification 1YV= Mazda passenger car, produced at AAI am6xuw id

6 HOW TO USE THIS MANUAL GENERAL INFORMATION id Efficient Replacement of Body Panels This section contains information on the body panels in regard to the welding types, number of spot welds, and cut-and-join locations that are necessary for panel removal and installation. The type of weld and position are indicated by symbols. Some sections have notes concerning the operation being performed. Thoroughly read and understand the notes before carrying out any procedures. Example REAR FENDER PANEL REMOVAL Shows operation section Shows procedure, caution and note Caution Avoid cutting with a flame as the insulator (shaded) is flammable. 1.The rear fender panel and wheel house are joined with glue at the wheel arch line. NOTE Drill the 17 weld locations indicated by (A), from the room side. Shows a dimensions A Shows a cross location A BRAZE WELDING 250mm {9.84in} Shows a insulator CUT-AND-JOINT LOCATION ROUGH CUT LOCATION 17 (A) mm {1.18in} Shows number of weld Shows welding region Shows a cross A-A acxuub Symbols of Panel Replacement The following 6 symbols are used to indicate the type of weld that is used when replacing body panels. SYMBOL MEANING SYMBOL MEANING Spot welding Continuous MIG welding (Cut-and-join location) CO 2 arc welding (plug welding) Braze welding CO 2 spot welding Rough cut location acxuub

7 GENERAL INFORMATION Body Dimensions (Flat-plane Dimensions) Flat-plane dimensions are the dimensions measured by projecting certain reference points onto a plane surface. FRONT FENDER INSTALLATION NUT {31.89} FLAT-PLANE DIMENSIONS acxuub

8 GENERAL INFORMATION When there are no specific indications, the standard points and dimensions are symmetrical in regard to the center of the vehicle. The hypothetical lines may differ according to the vehicle model. The schematic diagram shows the vehicle as it is projected from the underbody. Example Shows vehicle section UNDERBODY FLAT-PLANE DIMENSIONS The dimensions on the left and right in regard to the center of the vehicle are different. Shows outline drawing LH RH Shows dimension 1,016 {40.00} 455 {17.91} 469 {18.46} 1,106 {43.54} 760 {29.92} 605 {23.82} {25.59} 650 {25.59} 650 {25.59} 650 {45.83} 1, {21.37} {19.05} 1,073 {37.91} A B C D E F G H I J K L Shows point symbol Shows hypothetical standard line 687 {27.05} 654 {25.75} 1,084 {42.84} 579 {22.80} 479 {18.86} 436 {17.17} 436 {17.17} 445 {17.52} 512 {20.16} 660 {25.98} 1,043 {41.06} 666 {26.22} , {16.54} {7.17} {3.66} {5.67} {4.72} {40.55} {5.51} {29.92} {2.68} {14.92} When there are no specific indications, all of units are in millimeters (mm). mm {in} Point symbol A B C D E Designation Crossmember No,1 standard hole Front side frame standard hole Front suspension mounting block surface hole center Front suspension mounting bolt Front frame rear standard hole Hole diameter or bolt or nut size mm {in} φ 16 {0.62} φ 16 {0.62} φ 80 {3.14} M14 {0.55} φ 16 {0.62} Hole diameter Point Designation or bolt or nut symbol size mm {in} F G H I Front frame rear standard hole Rear side frame standard hole Link bracket Rear suspension housing φ 18 {0.62} φ 16 {0.62} { } φ 12 {0.47} J Rear side frame standard hole φ 16 {0.62} K Rear suspension housing φ 31 {1.22} L Rear side frame standard hole φ 12 {0.47} Shows slot Shows bolt size Shows hole diameter ac9uub Body Dimensions (Straight-line Dimensions) Straight-line dimensions are the actual dimensions between two standard points

9 GENERAL INFORMATION FRONT FENDER INSTALLATION NUT 817{32.17} STRAIGHT-LINE DIMENSIONS acxuub

10 GENERAL INFORMATION When there are no specific indications, the standard points and dimensions are symmetrical in regard to the center of the vehicle. Example ROOM STRAIGHT-LINE DIMENSIONS (1) Shows vehicle section Shows point symbol A Shows outline drawing B Shows dimension E 1,128 {44.41} F No indication are shown within the outline drawing. 1,398 {55.04} 1,067 {42.01} C H 1,263 {49.72} 1,048 {41.26} I Shows dimension location 799 {31.46} 1,406 {55.35} 851 {33.50} G D When there are no specific indications, all of units are in millimeters (mm). Shows details of the standard point location A Shows position and shape of the points B C D E,E' mm {in} Shows point indication Without apostrophe:rh With apostrophe:lh Fr Fr Fr Fr Fr F G Fr H I Fr Fr Fr Point symbol A B C D E Designation Front pillar inner designation Front pillar inner designation Harness installation hole Front floor pan designation Adjuster installation hole Hole diameter Hole diameter Point or bolt or nut Designation or bolt or nut symbol size mm {in} size mm {in} φ 16 {0.62} F Trim installation hole φ 18 {0.71} G Harness installation hole φ 16 {0.62} φ 17 {0.67} H Chaker bracket installation hole { } φ 31 {1.22} I Chaker bracket installation hole φ 12 {0.47} M14 {0.55} Shows bolt size φ 16 {0.62} Shows hole diameter Shows slot am3uub

11 GENERAL INFORMATION Symbols of Body Dimensions The following 8 symbols are used to indicate the standard points. SYMBOL MEANING SYMBOL MEANING Center of circular hole Center elliptical hole Notch Panel seam, bead, etc. (arrow only) Bolt tip Center of rectangular-shaped hole Edge of rectangular-shaped hole End Of Sie AIR BAG SYSTEM SERVICE WARNINGS acxuub id Air Bag Module Inspection Inspecting an air bag module using a tester can operate (deploy) the air bag module, which may cause serious injury. Do not use a tester to inspect an air bag module. Always use the on-board diagnostic function to diagnose the air bag module for malfunctions. NO GOOD am6xuw Air Bag Module Handling Before removing the air bag module or disconnecting the air bag module connector, always switch the ignition to off, disconnect the negative battery cable, and then wait for 1 min or more to allow the backup power supply of the SAS control module to deplete its stored power. Handling a live (undeployed) air bag module that is pointed toward your body could result in serious injury if the air bag module were to accidentally operate (deploy). When carrying a live (undeployed) air bag module, point the deployment surface away from your body to lessen the chance of injury in case it operates (deploys). A live (undeployed) air bag module placed with its deployment surface to ground is dangerous. If the air bag module were to accidentally operate (deploy), it could cause serious injury. Always place a live (undeployed) air bag module with its deployment surface up. GOOD GOOD NO GOOD NO GOOD am6xuw am6xuw

12 GENERAL INFORMATION Side Air Bag Module Handling Before removing the side air bag module or disconnecting the side air bag module connector, always switch the ignition to off, disconnect the negative battery cable, and then wait for 1 min or more to allow the backup power supply of the SAS control module to deplete its stored power. When a side air bag module operates (deploys) due to a collision, the interior of the seat back (pad, frame, trim) may become damaged. If a side air bag does not operate (deploy) normally from a seat back that has been reused, a serious accident may result. After a side air bag has operated (deployed), always replace both the side air bag module and the seat back (pad, frame, trim) with new parts. After servicing, verify that the seat operates normally and that the wiring harness is not caught. SAS Control Module Handling Removing the SAS control module or disconnecting the SAS control module connector with the ignition switch at the ON position can activate the sensor in the SAS control module and operate (deploy) the air bags and pre-tensioner seat belts, which may cause serious injury. Before removing the SAS control module or disconnecting the SAS control module connector, always switch the ignition to off, disconnect the negative battery cable, and then wait for 1 min or more to allow the backup power supply of the SAS control module to deplete its stored power. Connecting the SAS control module connector with the SAS control module not securely fixed to the vehicle is dangerous. The sensor in the SAS control module could send an electrical signal to the air bag modules and pre-tensioner seat belts. This will operate (deploy) the air bags and pre-tensioner seat belts, which may result in serious injury. Therefore, before connecting the connector, securely fix the SAS control module to the vehicle. Because a sensor is built into the SAS control module, once the air bags and pre-tensioner seat belts have operated (deployed) due to a collision or other causes, the SAS control module must be replaced with a new one even if the used one does not have any visible external damage or deformation. The used SAS control module may have been damaged internally, which may cause improper operation. If the SAS control module is reused, the air bags and pre-tensioner seat belts may not operate (deploy) normally, which could result in a serious accident. Always replace the SAS control module with a new one. The SAS control module cannot be bench-checked or self-checked. Side Air Bag Sensor Handling Removing the side air bag sensor or disconnecting the side air bag sensor connector with the ignition switch at the ON position can activate the side air bag sensor and operate (deploy) the side air bag, which may cause serious injury. Before removing the side air bag sensor or disconnecting the side air bag sensor connector, always switch the ignition to off, disconnect the negative battery cable, and then wait for 1 min or more to allow the backup power supply of the SAS control module to deplete its stored power. If the side air bag sensor is subjected to shock or the sensor is disassembled, the side air bag may accidentally operate (deploy) and cause injury, or the system may fail to operate normally and cause a serious accident. Do not subject the side air bag sensor to shock or disassemble the sensor. Because a sensor is built into the side air bag sensor, once the air bag has operated (deployed) due to a collision or other causes, the side air bag sensor must be replaced with a new one even if the used one does not have any visible external damage or deformation. If the side air bag sensor is reused, the side air bag may not operate (deploy) normally, which could result in a serious accident. Always replace the side air bag sensor with a new one. The side air bag sensor cannot be bench-checked or self-checked. Pre-tensioner Seat Belt Inspection Inspecting a pre-tensioner seat belt using a tester can operate (deploy) the pre-tensioner seat belt, which may cause serious injury. Do not use a tester to inspect a pre-tensioner seat belt. Always use the on-board diagnostic function to diagnose the pre-tensioner seat belt for malfunctions. End Of Sie NO GOOD am6xuw

13 GENERAL INFORMATION SERVICE PRECAUTIONS Arrangement of Workshop Arrangement of the workshop is important for safe and efficient work. id Safety Precautions Protective head covering and safety shoes should always be worn. Depending upon the nature of the work, gloves, safety glasses, ear protectors, face shield, etc., should also be used. WELDING GLASSES EAR PROTECTORS WELDING GLOVES COTTON GLOVES DUST SAFETY SAFETY MASK GLASSES SHOES FACE SHIELD am3uub Vehicle Protection Use seat covers and floor covers. Use heat-resistant protective covers to protect glass areas and seats from heat or sparks during welding. Protect items such as moldings, garnishes, and ornaments with tape when welding. acxuub Remove Dangerous Articles Remove the fuel tank before using an open flame in that area. Plug connection piping to prevent fuel leakage. acxuub

14 Use of Pulling Equipment When using pulling equipment, keep away from the pulling area and use safety wires to prevent accidents. GENERAL INFORMATION SAFETY WIRES am3uub Prevent Short Circuits Turn the ignition switch to the LOCK position. Disconnect the battery cables. Battery cable Securely connect the welding machine ground near the welding area. End Of Sie acxuub GROUND EFFICIENT REMOVAL OF BODY PANELS Body Measurements Before removal or rough-cutting, first measure the body at and around the damaged area against the standard reference dimension specifications. If there is deformation, use frame repair equipment to make a rough correction. am3uub id acxuub

15 Prevention of Body Deformation Use a clamp or a jack for removal and reinforce at and around the rough-cutting location to prevent deforming of the body. GENERAL INFORMATION acxuub Selection of Cut-and-join Locations For parts where complete replacement is not feasible, careful cutting and joining operations should be followed. If the location to be cut is a flat area where there is no reinforcement, the selected cutting location should be where the welding distortion will be minimal. acxuub Removal of Associated Parts Protect moldings, garnishes, and ornaments with tape when removing associated parts. Rough Cutting of Damaged Panel Verify that there are no parts (such as pipes, hoses, and wiring harness) nearby or on the opposite side of a panel which could be damaged by heat. For cut-and-join areas, allow for an overlap of mm { in} and then rough-cut the damaged panel. End Of Sie Wiring harness EFFICIENT INSTALLATION OF BODY PANELS Checking Preweld Measurements And Watching Align to the standard reference dimensions, based upon the body dimensions illustration, so that new parts are installed in the correct position. Rough cut location Cut-and-join location acxuub id acxuub

16 GENERAL INFORMATION Welding Notes For the number of weld points, welding should be performed in accordance with the following reference standards. SPOT WELDING ORIGINAL WELD REPAIR WELD ORIGINAL NUMBER OF WELDS x 1.3 OR MORE CO 2 ARC WELDING ORIGINAL SPOT WELD IF 3 mm {0.12 in} OR MORE REPAIR WELD ORIGINAL NUMBER OF WELDS OR MORE am3uub Spot Welding Notes The shape of the spot welder tip is D=(2 t)+3. If the upper panel thickness is different from that of the under panel, adjust to the thinner one D t Because the weld strength is affected by the shape of the spot welder tip, the optimum condition of the tip should always be maintained. Spot welds should be made at points other than the originally welded points. ac9uub Before spot welding, make a trial weld using the same material as the body panel to check the weld strength. TEST PIECE METHOD acxuub NUGGET DIAMETER :4/5 OF TIP am3uub

17 GENERAL INFORMATION Checking Weld Strength Installation locations of the engine, chassis, and seat belts are designated as important safety locations for weld strength. Check weld strength by driving a chisel between the panels at every fourth or fifth weld spot, and every tenth regular weld location. CHISEL DIMENSIONS 25 mm {0.98 in} mm {0.31 in} WELD LOCATION WITHIN 5 mm {0.20 in} WITHIN 5 mm {0.20 in} am3uub Drive the chisel between the panels according to the number of panels as shown below. To determine weld strength, drive the chisel between the panel and check whether the panels come apart. If the panels come apart, make another weld near the original weld. Restore the shape of the checked area. End Of Sie TWO PANELS THREE PANELS WELD LOCATION ONE LOCATION WELD LOCATION TWO LOCATION FOUR PANELS WELD LOCATION THREE LOCATION am3uub

18 INSTALLATION PREPARATIONS GENERAL INFORMATION id Rough Cutting of New Parts For cut-and-join areas, allow for an overlap of mm { in} with the remaining area on the body side and then rough-cut the new parts mm{ in} mm{ in} OVER LAP OVER LAP BODY SIDE ROUGH CUT LOCATION NEW PART ROUGH CUT LOCATION am3uub Determination of Welding Method If the total thickness at the area to be welded is 3 mm {0.12 in} or more, use a CO 2 gas shielded-arc welder to make the plug welds. 3 mm {0.1 in} OR MORE am3uub Making Holes for CO 2 Arc Welding For places that cannot be spot welded, make a hole for CO 2 arc welding using a punch or drill as follows. (mm {in}) Panel thickness (φ) Hole diameter (φ) { } 5.0 {0.20} { } 6.0 {0.24} { } 8.0 {0.31} { } 10.0 {0.394} Grind the shaded section indicated in the diagram below and create a hole in the part where the 3 4 plates are put together. Also, weld the plates together tightly so that gaps do not develop φ10.0 mm {0.394 in} OUTER PANEL MIDDLE PANEL INNER PANEL am3uub

19 GENERAL INFORMATION Application of Weld-through Primer For treatment against corrosion, remove the paint grease, and other material from the portion of new part and body to be welded, and apply weld-through primer. End Of Sie ANTICORROSION, SOUND INSULATION, AND VIBRATION INSULATION Body Sealing Apply body sealer where necessary. For locations where application of body sealer is difficult after installation, apply it before installation. acxuub id acxuub Application of Undercoating Apply an undercoat to the required location of the body. acxuub

20 GENERAL INFORMATION Application of Rust Inhibitor Apply rust inhibitor (wax, oil, etc.) to the back of the welded areas. acxuub Application of Floor Silencer Apply floor silencer by heating with an infrared ray lamp. End Of Sie WM: GENERAL INFORMATION BODY COLORS Color Code and Color Name Color Code Color Name A2N High performance white NN Ebony black 36W LT. ice blue MC 36Y Sangaria red MC 37B Kona blue MC 37C Black cherry MC 37D Comet gray MC 38H Brilliant silver MC Verification of Primary Color Mixture for Body Color Confirm the primary color mixture for the body color at the paint manufacturer URL. End Of Sie BM: GENERAL INFORMATION ABBREVIATION Fr LH RH Rr Front Left Hand Right Hand Rear acxuub id id End Of Sie WM: GENERAL INFORMATION

21 GENERAL INFORMATION IDENTIFICATION NUMBER LOCATIONS Vehicle Identification Number (VIN) id am6uuw Engine Identification Number L5 1YV HP80H*95 M00001, 1YV HP81H*95 M00001, 1YV HP82H*95 M YV HP80A*95 M00001, 1YV HP81A*95 M00001, 1YV HP82A*95 M00001 FRONT am6xuw FRONT am6xuw MZI-3.7 FRONT End Of Sie am6xuw

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23 BODY & ACCESSORIES 09 SECTION Toc of SCT BODY STRUCTURE [BODY STRUCTURE] A BODY STRUCTURE [PANEL REPLACEMENT] B BODY STRUCTURE [WATER-PROOF AND RUST PREVENTIVE] C BODY STRUCTURE [DIMENSIONS] D BODY STRUCTURE [PLASTIC BODY PARTS] E BODY STRUCTURE [CONSTRUCTION STANDARD VALUES] F 09-80A Toc of SCT 09-80A BODY STRUCTURE [BODY STRUCTURE] BODY COMPONENTS CONSTRUCTION [BODY STRUCTURE] A 2 ULTRA HIGH-TENSION STEEL [BODY STRUCTURE] A 4 Characteristics of Ultra High-Tensile Steel Plates A 4 Range of Use and Cautions for Service A 4 End of Toc BM: CONSTRUCTION 09-80A 1

24 BODY STRUCTURE [BODY STRUCTURE] BODY COMPONENTS CONSTRUCTION [BODY STRUCTURE] id am6xub A 2

25 . NO. Part Name BODY STRUCTURE [BODY STRUCTURE] Ultra high-tension steel High-tension steel Rust proof steel Thickness (mm {in}) 1 Bonnet 0.7 {0.03} 2 Front bumper bracket 2.6 {0.10} 3 Shroud side panel 2.0 {0.079} 4 Shroud side member 1.2 {0.047} 5 Wheel apron (front) 0.65 {0.026} 6 Wheel housing (lower) 1.2 {0.047} 7 Wheel housing (upper) 2.9 {0.11} 8 Front side frame (inner) Front 1.6 {0.063} Rear 2.3 {0.091} 9 Front side frame (outer) 1.6 {0.063} 10 Apron reinforcement (upper) 1.0 {0.039} 11 Apron reinforcement (lower) 1.2 {0.047} 12 Torque box 1.4 {0.055} 13 Front frame reinforcement (rear) 2.0 {0.079} 14 Wheel apron reinforcement (front) 1.4 {0.055} 15 Front fender panel 0.8 {0.03} 16 Front fender stay 1.4 {0.055} 17 Dash lower panel 0.85 {0.033} 18 Dash lower member 1.6 {0.063} 19 Front pillar reinforcement 1.4 {0.055} 20 Front pillar (inner) 1.6 {0.063} 21 Hinge pillar (inner) 1.2 {0.047} 22 Front pillar reinforcement (upper) 1.6 {0.063} 23 Hinge reinforcement 1.6 {0.063} 24 Cowl side reinforcement 1.2 {0.047} 25 Side sill reinforcement 1.4 {0.055} 26 Side frame (outer) 0.7 {0.03} 27 Side sill (inner) 1.6 {0.063} 28 Roof rail (inner, rear) 1.4 {0.055} 29 B-pillar (inner) 1.2 {0.047} 30 Roof rail reinforcement 1.6 {0.063} Upper 1.6 {0.063} 31 B-pillar reinforcement Center 1.8 {0.071} Lower 1.2 {0.047} 32 Front door panel (outer) 0.7 {0.03} 33 Rear door panel (outer) 0.65 {0.026} 34 Bulkhead junction 0.7 {0.03} 35 Rear pillar (inner) 0.65 {0.026} 36 Wheel house (inner) 0.75 {0.030} 37 Side sill reinforcement (rear) 1.6 {0.063} 38 Package tray 0.6 {0.02} 39 Rear fender rain rail 0.7 {0.03} 40 Corner plate 0.7 {0.03} 41 Trunk lid panel (outer) 0.65 {0.026} 42 Wiper bracket 1.6 {0.063} 43 Dash upper panel 0.9 {0.04} 44 Roof panel 0.75 {0.030} 45 Front header 0.7 {0.03} 46 Roof reinforcement (front) 0.55 {0.022} 47 Roof reinforcement (center) 1.0 {0.039} 48 Roof reinforcement (rear) 0.55 {0.022} 49 Rear header 0.65 {0.026} 50 Front floor pan 0.6 {0.02} 09-80A A

26 End Of Sie ULTRA HIGH-TENSION STEEL [BODY STRUCTURE] BODY STRUCTURE [BODY STRUCTURE] 51 Crossmember No {0.047} 52 Front seat bracket 1.4 {0.055} 53 Front B frame 1.2 {0.047} 54 Crossmember No.4 (front) 1.2 {0.047} 55 Crossmember No.4 (rear) 0.9 {0.04} 56 Crossmember No {0.055} 57 Center floor pan 0.6 {0.02} 58 Rear floor pan 0.65 {0.026} 59 Floor side panel 0.6 {0.02} 60 Rear side frame Front 1.8 {0.071} Rear 1.8 {0.071} 61 Rear end panel 0.65 {0.026} id Characteristics of Ultra High-Tensile Steel Plates Ultra high-tensile steel plates have enhanced tensile strength compared to previous high-tensile steel plates. Because the strength is maintained even though the plates are thin-walled, the ultra high-tensile steel plates are used for the frames and the main frame parts which form the cabin, reducing the weight of the vehicle. Enhanced shock absorption has improved the safety. Range of Use and Cautions for Service Because the ultra high-tensile steel is hard and it may be difficult to reform, when extracting the damaged part using a frame repair machine, perform the work verifying that other parts are not affected. When drilling welded parts, use a well-ground drill bit. After welding, inspect the weld strength. If adhesion is poor, perform CO2 arc welding (plug welding) am6xub A 4

27 BODY STRUCTURE [BODY STRUCTURE] A am6xub NO. Part Name Strength (MPa) 1 Front side frame (inner, front) Hinge pillar (inner) Hinge reinforcement Front pillar (inner) Roof rail (inner, rear) Side sill (inner) Hinge reinforcement (center) B-pillar (inner) Roof rail reinforcement Front pillar reinforcement B-pillar reinforcement (center) B-pillar reinforcement (inner) Rear bumper bracket Front B frame Floor reinforcement Side sill reinforcement Side sill reinforcement (upper) 780 End Of Sie 09-80A 5

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29 09-80B BODY STRUCTURE [PANEL REPLACEMENT] FRONT BUMPER BRACKET REMOVAL [PANEL REPLACEMENT] B 2 Symbol Mark B 2 Removal Procedure B 3 FRONT BUMPER BRACKET INSTALLATION [PANEL REPLACEMENT] B 4 Symbol Mark B 4 Installation Procedure B 4 SHROUD SIDE PANEL REMOVAL [PANEL REPLACEMENT] B 5 Symbol Mark B 5 Removal Procedure B 5 SHROUD SIDE PANEL INSTALLATION [PANEL REPLACEMENT] B 6 Symbol Mark B 6 Installation Procedure B 6 SHROUD SIDE MEMBER REMOVAL [PANEL REPLACEMENT] B 7 Symbol Mark B 7 Removal Procedure B 7 SHROUD SIDE MEMBER INSTALLATION [PANEL REPLACEMENT] B 9 Symbol Mark B 9 Installation Procedure B 9 COWL SIDE REINFORCEMENT REMOVAL [PANEL REPLACEMENT] B 11 Symbol Mark B 11 Removal Procedure B 11 COWL SIDE REINFORCEMENT INSTALLATION [PANEL REPLACEMENT] B 12 Symbol Mark B 12 Installation Procedure B 12 WIPER BRACKET COMPONENT REMOVAL [PANEL REPLACEMENT] B 13 Symbol Mark B 13 Removal Procedure B 13 WIPER BRACKET COMPONENT INSTALLATION [PANEL REPLACEMENT] B 14 Symbol Mark B 14 Installation Procedure B 14 APRON REINFORCEMENT (UPPER) REMOVAL [PANEL REPLACEMENT] B 15 Symbol Mark B 15 Removal Procedure B 15 APRON REINFORCEMENT (UPPER) INSTALLATION [PANEL REPLACEMENT] B 16 Symbol Mark B 16 Installation Procedure B 16 APRON REINFORCEMENT (LOWER) REMOVAL [PANEL REPLACEMENT] B 17 Symbol Mark B 17 Removal Procedure B 17 APRON REINFORCEMENT (LOWER) INSTALLATION [PANEL REPLACEMENT] B 18 Symbol Mark B 18 Installation Procedure B 18 WHEEL APRON PANEL (FRONT) REMOVAL [PANEL REPLACEMENT] B 19 Symbol Mark B 19 Removal Procedure B 19 WHEEL APRON PANEL (FRONT) INSTALLATION [PANEL REPLACEMENT] B 21 Symbol Mark B 21 Installation Procedure B 21 WHEEL APRON COMPONENT REMOVAL [PANEL REPLACEMENT] B 23 Symbol Mark B 23 Removal Procedure B 23 WHEEL APRON COMPONENT INSTALLATION [PANEL REPLACEMENT] B 25 Symbol Mark B 25 Installation Procedure B 25 FRONT SIDE FRAME COMPONENT REMOVAL [PANEL REPLACEMENT] B 27 Symbol Mark B 27 Removal Procedure B 28 FRONT SIDE FRAME COMPONENT INSTALLATION [PANEL REPLACEMENT] B 30 Symbol Mark B 30 Installation Procedure B 30 FRONT SIDE FRAME (PARTIAL CUTTING) REMOVAL [PANEL REPLACEMENT] B 32 Symbol Mark B 32 Removal Procedure B 32 FRONT SIDE FRAME (PARTIAL CUTTING) INSTALLATION [PANEL REPLACEMENT] B 35 Symbol Mark B 35 Installation Procedure B 35 TORQUE BOX REMOVAL [PANEL REPLACEMENT] B 45 Symbol Mark B 45 Removal Procedure B 45 TORQUE BOX INSTALLATION [PANEL REPLACEMENT] B 46 Symbol Mark B 46 Installation Procedure B 46 FRONT PILLAR REMOVAL [PANEL REPLACEMENT] B 47 Symbol Mark B 47 Removal Procedure B 47 FRONT PILLAR INSTALLATION [PANEL REPLACEMENT] B 51 Symbol Mark B 51 Installation Procedure B 51 CENTER PILLAR REMOVAL [PANEL REPLACEMENT] B 55 Symbol Mark B 55 Removal Procedure B 55 CENTER PILLAR INSTALLATION 09-80B B

30 [PANEL REPLACEMENT] B 58 Symbol Mark B 58 Installation Procedure B 58 SIDE SILL PANEL REMOVAL [PANEL REPLACEMENT] B 61 Symbol Mark B 61 Removal Procedure B 61 SIDE SILL PANEL INSTALLATION [PANEL REPLACEMENT] B 64 Symbol Mark B 64 Installation Procedure B 64 REAR FENDER PANEL REMOVAL [PANEL REPLACEMENT] B 67 Symbol Mark B 67 Removal Procedure B 67 REAR FENDER PANEL INSTALLATION [PANEL REPLACEMENT] B 71 Symbol Mark B 71 Installation Procedure B 71 REAR FENDER RAIN RAIL AND CORNER PLATE REMOVAL [PANEL REPLACEMENT] B 75 Symbol Mark B 75 Removal Procedure B 75 REAR FENDER RAIN RAIL AND CORNER PLATE INSTALLATION [PANEL REPLACEMENT] B 76 Symbol Mark B 76 Installation Procedure B 76 REAR END PANEL REMOVAL [PANEL REPLACEMENT] B 77 Symbol Mark B 77 Removal Procedure B 77 REAR END PANEL INSTALLATION [PANEL REPLACEMENT] B 79 Symbol Mark B 79 Installation Procedure B 79 FLOOR SIDE PANEL REMOVAL [PANEL REPLACEMENT] B 81 Symbol Mark B 81 Removal Procedure B 81 FLOOR SIDE PANEL INSTALLATION [PANEL REPLACEMENT] B 83 Symbol Mark B 83 Installation Procedure B 83 REAR FLOOR PAN REMOVAL [PANEL REPLACEMENT] B 85 Symbol Mark B 85 Removal Procedure B 85 REAR FLOOR PAN INSTALLATION [PANEL REPLACEMENT] B 87 Symbol Mark B 87 Installation Procedure B 87 REAR SIDE FRAME REMOVAL [PANEL REPLACEMENT] B 90 Symbol Mark B 90 Removal procedure B 90 REAR SIDE FRAME INSTALLATION [PANEL REPLACEMENT] B 91 Symbol Mark B 91 Installation Procedure B 91 ROOF PANEL REMOVAL [PANEL REPLACEMENT] B 92 Symbol Mark B 92 Removal Procedure B 92 ROOF PANEL INSTALLATION [PANEL REPLACEMENT] B 93 Symbol Mark B 93 Installation Procedure B 93 End of Toc BM: BUMPER BRACKET FRONT BUMPER BRACKET REMOVAL [PANEL REPLACEMENT] Symbol Mark id SYMBOL MARK MEANING CONTINUOUS CO 2 ARC WELDING (CUT-AND-JOIN LOCATION) am6xub B 2

31 Removal Procedure 1. Grind the 2 locations indicated by (A) shown in the figure. (B) B (A)2 FRONT BUMPER BRACKET (B)2 (B)1 2. Grind the 5 locations indicated by (B) shown in the figure. 3. Remove the front bumper bracket. End Of Sie am6xub B 3

32 FRONT BUMPER BRACKET INSTALLATION [PANEL REPLACEMENT] Symbol Mark id SYMBOL MARK MEANING CONTINUOUS CO 2 ARC WELDING (CUT-AND-JOIN LOCATION) am6zzb Installation Procedure 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2. After temporarily installing new parts, make sure the related parts fit properly. 3. Continuous CO 2 arc weld the 7 locations shown in the figure. 4 FRONT BUMPER BRACKET 2 1 End Of Sie BM: SHROUD PANEL am6zzb B 4

33 SHROUD SIDE PANEL REMOVAL [PANEL REPLACEMENT] Symbol Mark id SYMBOL MARK MEANING SPOT WELDING am6zzb Removal Procedure 1. Drill the 2 locations indicated shown in the figure B SHROUD SIDE PANEL 2 2. Remove the shroud side panel. End Of Sie am6zzb B 5

34 SHROUD SIDE PANEL INSTALLATION [PANEL REPLACEMENT] Symbol Mark id SYMBOL MARK MEANING PLUG WELDING (CO 2 ARC WELDING) am6zzb Installation Procedure 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2. Drill holes for plug welds before installing new parts. 3. After temporarily installing new parts, make sure the related parts fit properly. 4. Plug weld the 2 locations indicated shown in the figure. SHROUD SIDE PANEL 2 End Of Sie am6xub B 6

35 SHROUD SIDE MEMBER REMOVAL [PANEL REPLACEMENT] Symbol Mark id SYMBOL MARK MEANING SPOT WELDING am6zzb Removal Procedure 1. Drill the 6 locations indicated shown in the figure B FRONT FENDER BRACKET 6 2. Remove the front fender bracket. am6xub B 7

36 3. Drill the 7 locations indicated shown in the figure. 3 SHROUD SIDE MEMBER Remove the shroud side member. End Of Sie am6xub B 8

37 SHROUD SIDE MEMBER INSTALLATION [PANEL REPLACEMENT] Symbol Mark id SYMBOL MARK MEANING PLUG WELDING (CO 2 ARC WELDING) am6zzb Installation Procedure 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2. Drill holes for the plug welding before installing the new parts. 3. After temporarily installing new parts, make sure the related parts fit properly. 4. Plug weld the 7 locations indicated shown in the figure B 3 SHROUD SIDE MEMBER Install the shroud side member. am6xub B 9

38 6. Plug weld the 6 locations indicated shown in the figure. FRONT FENDER BRACKET 6 End Of Sie BM: COWL SIDE REINFORCEMENT am6xub B 10

39 COWL SIDE REINFORCEMENT REMOVAL [PANEL REPLACEMENT] Symbol Mark id SYMBOL MARK MEANING SPOT WELDING am6zzb Removal Procedure 1. Drill the 24 locations indicated shown in the figure B COWL SIDE REINFORCEMENT Remove the cowl side panel. End Of Sie am6xub B 11

40 COWL SIDE REINFORCEMENT INSTALLATION [PANEL REPLACEMENT] Symbol Mark id SYMBOL MARK MEANING PLUG WELDING (CO 2 ARC WELDING) am6zzb Installation Procedure 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2. Drill holes for the plug welding before installing the new parts. 3. After temporarily installing new parts, make sure the related parts fit properly. 4. Plug weld the 24 locations indicated shown in the figure COWL SIDE REINFORCEMENT 2 6 am6xub B 12

41 End Of Sie BM: BRACKET WIPER BRACKET COMPONENT REMOVAL [PANEL REPLACEMENT] Symbol Mark id SYMBOL MARK MEANING SPOT WELDING am6zzb Removal Procedure 1. Drill the 16 locations indicated shown in the figure B 7 WIPER BRACKET Remove the wiper bracket. End Of Sie am6xub B 13

42 WIPER BRACKET COMPONENT INSTALLATION [PANEL REPLACEMENT] Symbol Mark id SYMBOL MARK MEANING PLUG WELDING (CO 2 ARC WELDING) am6zzb Installation Procedure 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2. Drill holes for the plug welding before installing the new parts. 3. After temporarily installing new parts, make sure the related parts fit properly. 4. Plug weld the 16 locations indicated shown in the figure. 7 WIPER BRACKET End Of Sie BM: APRON REINFORCEMENT am6xub B 14

43 APRON REINFORCEMENT (UPPER) REMOVAL [PANEL REPLACEMENT] Symbol Mark id SYMBOL MARK MEANING SPOT WELDING am6zzb Removal Procedure 1. Drill the 24 locations indicated shown in the figure B APRON REINFORCEMENT (UPPER) 4 2. Remove the apron reinforcement (upper). End Of Sie am6xub B 15

44 APRON REINFORCEMENT (UPPER) INSTALLATION [PANEL REPLACEMENT] Symbol Mark id SYMBOL MARK MEANING PLUG WELDING (CO 2 ARC WELDING) am6zzb Installation Procedure 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2. Drill holes for the plug welding before installing the new parts. 3. After temporarily installing new parts, make sure the related parts fit properly. 4. Plug weld the 24 locations indicated shown in the figure APRON REINFORCEMENT(UPPER) 4 5. Install the apron reinforcement (upper). End Of Sie am6xub B 16

45 APRON REINFORCEMENT (LOWER) REMOVAL [PANEL REPLACEMENT] Symbol Mark id SYMBOL MARK MEANING SPOT WELDING am6zzb Removal Procedure 1. Drill the 14 locations indication shown in the figure B APRON REINFORCEMENT (LOWER) 2. Remove the apron reinforcement (lower). End Of Sie am6xub B 17

46 APRON REINFORCEMENT (LOWER) INSTALLATION [PANEL REPLACEMENT] Symbol Mark id SYMBOL MARK MEANING PLUG WELDING (CO 2 ARC WELDING) am6zzb Installation Procedure 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2. Drill holes for the plug welding before installing the new parts. 3. After temporarily installing new parts, make sure the related parts fit properly. 4. Plug weld the 14 locations indicated shown in the figure APRON REINFORCEMENT (LOWER) End Of Sie BM: WHEEL APRON PANEL am6xub B 18

47 WHEEL APRON PANEL (FRONT) REMOVAL [PANEL REPLACEMENT] Symbol Mark id SYMBOL MARK MEANING SPOT WELDING am6zzb Removal Procedure LH 1. Drill the 10 locations indicated shown in the figure B 5 WHEEL APRON PANEL (FRONT) 5 2. Remove the wheel apron panel (front). am6xub B 19

48 RH 1. Drill the 22 locations indicated shown in the figure. 5 WHEEL APRON PANEL (FRONT) Remove the wheel apron panel (front). End Of Sie am6xub B 20

49 WHEEL APRON PANEL (FRONT) INSTALLATION [PANEL REPLACEMENT] Symbol Mark id SYMBOL MARK MEANING PLUG WELDING (CO 2 ARC WELDING) am6zzb Installation Procedure LH 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2. Drill holes for the plug welding before installing the new parts. 3. After temporarily installing new parts, make sure the related parts fit properly. 4. Plug weld the 10 locations indicated shown in the figure B 5 WHEEL APRON PANEL (FRONT) 5 am6xub B 21

50 RH 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2. Drill holes for the plug welding before installing the new parts. 3. After temporarily installing new parts, make sure the related parts fit properly. 4. Plug weld the 22 locations indicated shown in the figure. 5 WHEEL APRON PANEL (FRONT) End Of Sie am6xub B 22

51 WHEEL APRON COMPONENT REMOVAL [PANEL REPLACEMENT] Symbol Mark id SYMBOL MARK MEANING SPOT WELDING am6zzb Removal Procedure LH 1. Drill the 36 locations indicated by (A), drill the 8 locations indicated by (B) shown in the figure B (B)2 (A)3 (A)3 (A)5 (B)3 (B)3 WHEEL APRON COMPONENT (A)23 (A)2 am6xub Note Drill the 8 locations indicated by (B) from the front wheel housing. 2. Remove the wheel apron component B 23

52 RH 1. Drill the 36 locations indicated by (A), drill the 8 locations indicated by (B) shown in the figure. (B)2 (A)5 (A)3 (A)3 (B)3 (B)3 WHEEL APRON COMPONENT (A)22 (A)3 am6xub Note Drill the 8 locations indicated by (B) from the front wheel housing. 2. Remove the wheel apron component. End Of Sie 09-80B 24

53 WHEEL APRON COMPONENT INSTALLATION [PANEL REPLACEMENT] Symbol Mark id SYMBOL MARK MEANING PLUG WELDING (CO 2 ARC WELDING) am6zzb Installation Procedure LH 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2. Drill holes for the plug welding before installing the new parts. 3. After temporarily installing new parts, make sure the related parts fit properly. 4. Plug weld the 36 locations indicated by (A), drill the 8 locations indicated by (B) shown in the figure B (B)2 (A)3 (A)3 (A)5 (B)3 (B)3 WHEEL APRON COMPONENT (A)23 (A)2 am6xub Note Plug weld the 8 locations indicated by (B) from the front wheel housing B 25

54 RH 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2. Drill holes for the plug welding before installing the new parts. 3. After temporarily installing new parts, make sure the related parts fit properly. 4. Plug weld the 36 locations indicated by (A), drill the 8 locations indicated by (B) shown in the figure. (B)2 (A)5 (A)3 (A)3 (B)3 (B)3 WHEEL APRON COMPONENT (A)22 (A)3 am6xub Note Plug weld the 8 locations indicated by (B) from the front wheel housing. End Of Sie BM: FRONT SIDE FRAME 09-80B 26

55 FRONT SIDE FRAME COMPONENT REMOVAL [PANEL REPLACEMENT] Symbol Mark id SYMBOL MARK MEANING SPOT WELDING PLUG WELDING (CO 2 ARC WELDING) ROUGH CUT LOCATION 09-80B am6zzb B 27

56 Removal Procedure 1. Drill the 1 location indicated by (A) shown in the figure. (A)1 FRONT SIDE FRAME COMPONENT (B) 5 (B) 1 (B) 4 (B) 3 am6zzb Note Drill the 1 location indicated by (A) from the interior. 2. Drill the 13 location indicated by (B) shown in the figure B 28

57 3. Rough cut area indicated by (C) shown in the figure B (D) 1 (C) am6zzb Caution During rough cutting, be careful not to damage the front side frame (rear). 4. Drill the 1 location indicated by (D) shown in the figure. 5. Remove the front side frame. End Of Sie 09-80B 29

58 FRONT SIDE FRAME COMPONENT INSTALLATION [PANEL REPLACEMENT] Symbol Mark id SYMBOL MARK MEANING PLUG WELDING (CO 2 ARC WELDING) CONTINUOUS CO 2 ARC WELDING (CUT-AND-JOIN LOCATION) am6zzb Installation Procedure 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2. Drill holes for the plug welding before installing the new parts. 3. After temporarily installing new parts, make sure the related parts fit properly. 4. Plug weld the 1 location indicated by (A) shown in the figure. (A) 1 (B) 5. Cut-and-join area indicated by (B) shown in the figure. am6zzb B 30