Mazda 5. Manual — part 74
BODY STRUCTURE [PANEL REPLACEMENT]
09–80B–59
09
End Of Sie
REAR SIDE FRAME (PARTIAL CUTTING) INSTALLATION
DPE098053810B02
Caution
• The cut-and-joint area indicates the maximum size range of the installation position.
1. Make a reinforcement panel using the material from the rear side frame.
2. To cut and join the new and existing parts, cut the new part at the specified location shown in the figure, and
chamfer the joint surfaces of the new and existing parts.
3. When installing the new parts, trial-fit new and existing parts, and then measure and adjust the body to conform
with standard dimensions.
4. After temporarily installing new parts, make sure the related parts fit properly.
30mm
{1.18in}
2
2
ROUGH CUT LOCATION
CUT-AND-JOIN LOCATION
DPE0980B120
09–80B–60
BODY STRUCTURE [PANEL REPLACEMENT]
5. Trial-fit the new and existing parts, weld the existing parts and the reinforcement, and then butt weld the new
and existing parts.
Caution
• Press fit the reinforcement panel and the body side material, and then plug weld them.
End Of Sie
ROOF PANEL REMOVAL
DPE098070600B01
1. Drill the 81 locations indicated by (A).
2. The side frame (outer) and the roof panel are joined with weld bond at area (B). Use a chisel or similar tool to
separate them, then remove the roof panel.
Caution
• Only the procedure for the right side is described, however, the procedure for the left side is the
same.
3. Remove the weld bond using a disc grinder.
50mm
20mm
t=1.8mm
L=10mm x 2
L=10mm x 4
30mm
{1.18in}
{0.39in}
{0.39in}
REINFORCEMENT
NEW REAR SIDE FRAME
{0.79in}
{1.97in}
{0.07in}
2
2
CUT-AND-JOIN LOCATION
DPE0980B121
BODY STRUCTURE [PANEL REPLACEMENT]
09–80B–61
09
End Of Sie
ROOF PANEL INSTALLATION
DPE098070600B02
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.
Caution
• Area (A) was joined with the weld bond. When installing the roof panel, plug weld the 4 locations
indicated by (B).
• Only the procedure for the right side is described, however, the procedure for the left side is the
same.
3. After temporarily installing new parts, make sure the related parts fit properly.
(A)27
(B)
(A)27
(A)19
(A)8
400mm {15.75in}
WELD BOND APPLICATION AREA
30—50mm
{1.18—1.97in}
110—130mm
{4.33—5.12in}
DPE0980B114
09–80B–62
BODY STRUCTURE [PANEL REPLACEMENT]
End Of Sie
17
6
8
(B)1
3
(B)2
1
(B)1
6
8
19
8
17
(A)400mm
30—50mm
110—130mm
{1.18—1.97in}
{15.75in}
{4.33—5.12in}
DPE0980B115
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