Mazda 5. Manual — part 64

BODY STRUCTURE [PANEL REPLACEMENT]

09–80B–19

09

End Of Sie

2

1

4

3

5

3

2

DPE0980B069

09–80B–20

BODY STRUCTURE [PANEL REPLACEMENT]

FRONT SIDE FRAME COMPONENT REMOVAL

DPE098053300B01

1. Drill the 26 locations indicated by (A).

2. Rough cut area (B) and drill the 58 locations indicated by (C), 4 locations on the driver’s side and 3 locations on

the passenger’s side indicated by (D).

3. Drill the 10 locations indicated by (E) from the bottom.

FRONT SIDE FRAME COMPONENT

(A)3

(A)4

(A)9

(A)10

DPE0980B062

BODY STRUCTURE [PANEL REPLACEMENT]

09–80B–21

09

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FRONT SIDE FRAME COMPONENT INSTALLATION

DPE098053300B02

1. To prepare for installation, cut area (A) on the new front side frame component.
2. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions.
3. Drill holes for plug welds before installing new parts.

(C)1 (D)

(C)2

(C)4

(C)3

(C)17

(C)6

(C)9

(C)3

(C)13

(B)

(E)6

(E)4

DRIVER'S SIDE:4
PASSENGER'S SIDE:3

ROUGH CUT
LOCATIONS

DPE0980B064

09–80B–22

BODY STRUCTURE [PANEL REPLACEMENT]

4. After temporarily installing new parts, make sure the related parts fit properly.
5. Install the part cut in Step 1.
6. Grind the area where the part cut in Step 1 is butt welded with a disc grinder to finish the surface.
7. Weld the remaining weld locations and install the front side frame component.

1

4

DRIVER'S SIDE:4
PASSENGER'S SIDE:3

2

3

17

6

9

3

13

6

4

(A) CUT-AND-JOIN

LOCATIONS

DPE0980B063