Mazda 5. Manual — part 59
BODY STRUCTURE [CONSTRUCTION]
09–80A–7
09
End Of Sie
ULTRA HIGH-TENSION STEEL
DPE098007000B06
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).
*1 : Indicates tensile strength of 590 MPa.
*2 : Indicates tensile strength of 780 MPa.
50
Crossmember No.4
-
x
x
1.20 {0.047}
51
Rear side frame
Front
x
-
x
2.60 {0.102}
Rear
x
-
x
1.80 {0.071}
52
Trunk floor pan
-
-
x
0.70 {0.028}
53
Rear end member
-
-
-
1.20 {0.047}
54
Rear end panel
-
-
x
1.40 {0.055}
No.
Part Name
ultra high-
tension
steel
High-
tension
steel
Rust proof
steel
Thickness
(mm) {in}
*1
*1
*1
*1
*2
*1
*1
*1
*1
*1
*1
FRONT PILLAR REINFORCEMENT (UPPER)
CENTER PILLAR REINFORCEMENT (UPPER)
CENTER PILLAR (INNER)
FRONT PILLAR (INNER)
DASH LOWER MEMBER
FRONT B FRAME
REINFORCEMENT
FRONT PILLAR
REINFORCEMENT (LOWER)
SIDE SILL (INNER)
CENTER PILLAR
REINFORCEMENT (LOWER)
CENTER PILLAR
REINFORCEMENR CENTER
REAR SIDE FRAME
DPE0980B131
09–80A–8
BODY STRUCTURE [CONSTRUCTION]
End Of Sie
BODY STRUCTURE [PANEL REPLACEMENT]
09–80B–1
09
09–80B
BODY STRUCTURE [PANEL REPLACEMENT]
FRONT BUMPER BRACKET REMOVAL 09–80B–1
FRONT BUMPER BRACKET
INSTALLATION . . . . . . . . . . . . . . . . . . . 09–80B–2
SHROUD PANEL
REMOVAL/INSTALLATION. . . . . . . . . . 09–80B–3
SHROUD SIDE PANEL REMOVAL . . . . . 09–80B–3
SHROUD SIDE PANEL INSTALLATION. 09–80B–4
COWL SIDE REINFORCEMENT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . 09–80B–5
COWL SIDE REINFORCEMENT
INSTALLATION . . . . . . . . . . . . . . . . . . . 09–80B–6
SHROUD UPPER REINFORCEMENT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . 09–80B–7
SHROUD UPPER REINFORCEMENT
INSTALLATION . . . . . . . . . . . . . . . . . . . 09–80B–8
APRON REINFORCEMENT
(LOWER) REMOVAL . . . . . . . . . . . . . . . 09–80B–9
APRON REINFORCEMENT (LOWER)
INSTALLATION . . . . . . . . . . . . . . . . . . . 09–80B–10
APRON REINFORCEMENT (PARTIAL
CUTTING) REMOVAL . . . . . . . . . . . . . . 09–80B–11
APRON REINFORCEMENT (PARTIAL CUTTING)
INSTALLATION . . . . . . . . . . . . . . . . . . . 09–80B–12
WHEEL APRON PANEL (FRONT)
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . 09–80B–13
WHEEL APRON PANEL (FRONT)
INSTALLATION . . . . . . . . . . . . . . . . . . . 09–80B–14
WHEEL APRON COMPONENT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . 09–80B–15
WHEEL APRON COMPONENT
INSTALLATION . . . . . . . . . . . . . . . . . . . 09–80B–17
FRONT SIDE FRAME COMPONENT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . 09–80B–20
FRONT SIDE FRAME COMPONENT
INSTALLATION . . . . . . . . . . . . . . . . . . . 09–80B–21
FRONT SIDE FRAME (PARTIAL CUTTING)
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . 09–80B–23
FRONT SIDE FRAME (PARTIAL CUTTING)
INSTALLATION . . . . . . . . . . . . . . . . . . . 09–80B–24
TORQUE BOX REMOVAL. . . . . . . . . . . . 09–80B–26
TORQUE BOX INSTALLATION. . . . . . . . 09–80B–27
FRONT FRAME (REAR) REMOVAL . . . . 09–80B–28
FRONT FRAME (REAR) INSTALLATION 09–80B–29
FRONT PILLAR REMOVAL . . . . . . . . . . . 09–80B–30
FRONT PILLAR INSTALLATION . . . . . . . 09–80B–33
CENTER PILLAR (OUTER) REMOVAL . . 09–80B–36
CENTER PILLAR (OUTER)
INSTALLATION. . . . . . . . . . . . . . . . . . . . 09–80B–37
CENTER PILLAR REINFORCEMENT AND INNER
REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . 09–80B–39
CENTER PILLAR REINFORCEMENT AND INNER
INSTALLATION. . . . . . . . . . . . . . . . . . . . 09–80B–40
SIDE SILL PANEL (OUTER) REMOVAL . 09–80B–42
SIDE SILL PANEL (OUTER)
INSTALLATION. . . . . . . . . . . . . . . . . . . . 09–80B–43
SIDE SILL REINFORCEMENT
REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . 09–80B–44
SIDE SILL REINFORCEMENT
INSTALLATION. . . . . . . . . . . . . . . . . . . . 09–80B–44
REAR FENDER PANEL REMOVAL . . . . . 09–80B–44
REAR FENDER PANEL INSTALLATION. 09–80B–45
C-PILLAR REINFORCEMENT
REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . 09–80B–46
C-PILLAR REINFORCEMENT
INSTALLATION. . . . . . . . . . . . . . . . . . . . 09–80B–47
REAR END PANEL REMOVAL . . . . . . . . 09–80B–48
REAR END PANEL INSTALLATION . . . . 09–80B–49
REAR PILLAR (OUTER) REMOVAL . . . . 09–80B–50
REAR PILLAR (OUTER) INSTALLATION 09–80B–51
REAR PILLAR REINFORCEMENT
REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . 09–80B–52
REAR PILLAR REINFORCEMENT
INSTALLATION. . . . . . . . . . . . . . . . . . . . 09–80B–53
REAR FLOOR PAN REMOVAL . . . . . . . . 09–80B–54
REAR FLOOR PAN INSTALLATION . . . . 09–80B–56
REAR SIDE FRAME (PARTIAL CUTTING)
REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . 09–80B–58
REAR SIDE FRAME (PARTIAL CUTTING)
INSTALLATION. . . . . . . . . . . . . . . . . . . . 09–80B–59
ROOF PANEL REMOVAL. . . . . . . . . . . . . 09–80B–60
ROOF PANEL INSTALLATION . . . . . . . . 09–80B–61
End of Toc
FRONT BUMPER BRACKET REMOVAL
DPE098053896B01
1. Remove the front bumper bracket.
Caution
• Only the procedure for the left side is described, the shape of the right side differs.
09–80B–2
BODY STRUCTURE [PANEL REPLACEMENT]
End Of Sie
FRONT BUMPER BRACKET INSTALLATION
DPE098053896B02
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.
FRONT BUMPER BRACKET
DPE0980B048
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