Mazda 5. Manual — part 56

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GENERAL INFORMATION

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.

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

30—50 mm {1.18—1.97 in} and then rough-cut
the damaged panel.

End Of Sie

INSTALLATION PREPARATIONS

DPE000000000B04

Rough Cutting of New Parts

• For cut-and-join areas, allow for an overlap of 30—50 mm {1.18—1.97 in} with the remaining area on the body

side and then rough-cut the new parts.

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.

MZJ2038B003

Wiring harness

Rough cut location

Cut-and-join location

MZZ2038B001

Over lap

Over lap

Body side rough cut location

New part rough cut location

30-50mm{1.18-1.97in}

30-50mm{1.18-1.97in}

MZZ2038B002

GENERAL INFORMATION

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00

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})

• 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.

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

3mm
{0.12in}or more

MZZ2038B003

Panel thickness (ø)

Hole diameter (ø)

0.60—0.90 {0.02—0.03}

5 {0.19}

0.91—1.20 {0.04—0.05}

6 {0.23}

1.21—1.80 {0.051—0.07}

8 {0.31}

1.81—4.50 {0.071—0.17}

10 {0.39}

φ

10mm{0.39in}

Outer panel

Middie panel

Inner panel

30

°

30

°

MZZ2038B004

MZJ2038B008

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GENERAL INFORMATION

EFFICIENT INSTALLATION OF BODY PANELS

DPE000000000B05

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.

Welding Notes

• For the number of weld points, welding should be

performed in accordance with the following
reference standards.

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.

• 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.

MZJ2038B009

Spot welding
Original weld

If 3mm
{0.12in} or more

Original number of
welds x 1.3 or more

CO2 arc welding
Original spot weld

Repair weld

Repair weld

Original number of welds
or more

DPE2038B005

D

70 - 120

°

t

MZZ2038B009

MZJ2038B012

GENERAL INFORMATION

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• Before spot welding, make a trial weld using the

same material as the body panel to check the
weld strength.

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.

• 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

Test piece method

Nugget diameter
:4/5 of tip

MZZ2038B006

Chisel dimensions

25mm
{0.98in}

8mm{0.31in}

{0.20in}

{0.20in}

20

°

Weld location

Within 5mm

Within 5mm

MZZ2038B007

Two panels

Weld location

Three panels

Weld location

One location

Two location

Four panels

Weld location

Three location

MZZ2038B008