Mazda 5. Manual — part 69
BODY STRUCTURE [PANEL REPLACEMENT]
09–80B–39
09
CENTER PILLAR REINFORCEMENT AND INNER REMOVAL
DPE098070350B03
1. Rough cut area (A), drill the 9 locations indicated by (B), then remove the center pillar reinforcement.
2. Drill the location indicated by (C) from the bottom, as it cannot be seen from the interior.
95mm
{3.74in}
30mm {1.18in}
(B)9
(A)
CENTER PILLAR REINFORCEMENT
CUT-AND-JOIN LOCATION FOR
CENTER PILLAR REINFORCEMENT
ROUGH CUT LOCATION FOR
CENTER PILLAR REINFORCEMENT
DPE0980B085
09–80B–40
BODY STRUCTURE [PANEL REPLACEMENT]
3. Rough cut area (D), drill the 6 locations indicated by (B), then pull out the center pillar (inner).
End Of Sie
CENTER PILLAR REINFORCEMENT AND INNER INSTALLATION
DPE098070350B04
1. Make a reinforcement panel using the material from the center pillar (inner) and the center pillar reinforcement.
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.
(E)6
(C)1
160mm
{6.30in}
45mm
{1.77in}
(D)
CENTER PILLAR (INNER)
CUT-AND-JOIN LOCATION FOR
CENTER PILLAR (INNER)
ROUGH CUT LOCATION FOR
CENTER PILLAR (INNER)
DPE0980B086
BODY STRUCTURE [PANEL REPLACEMENT]
09–80B–41
09
4. To install the center pillar (inner), trial-fit the new and existing parts, weld the existing parts and the
reinforcement, and then butt weld the new and existing parts.
5. Because the center pillar reinforcement cannot be welded to the existing parts from the inside of the inner, drill
2 plug weld holes at the locations indicated by (A) on the existing parts. Install the reinforcement and the
existing parts by plug welding from the outside, then butt weld the new and existing parts.
Caution
• Press fit the reinforcement panal and the body side material, and then plug weld them.
55mm
35mm
t=1.2mm
L=10mm x 4
140mm
{0.05in}
{1.38in}
{2.17in}
{0.39in}
{5.51in}
6
1
NEW CENTER PILLAR (INNER)
EXISTING CENTER
PILLAR (INNER)
CUT-AND-JOIN LOCATION FOR
CENTER PILLAR (INNER)
REINFORCEMENT
DPE0980B088
09–80B–42
BODY STRUCTURE [PANEL REPLACEMENT]
6. Grind the butt welded area with a disc grinder to finish the surface.
End Of Sie
SIDE SILL PANEL (OUTER) REMOVAL
DPE098070270B01
1. Remove the side sill panel (outer).
Caution
• Avoid cutting with a blow torch or similar tools as the insulator (shaded area) is flammable.
2. Remove the spot weld sealer using a disc grinder.
L=10mm x 3
50mm
35mm
t=1.6mm
9
1
(A)2
95mm
{3.74in}
{0.06in}
{0.39in}
{1.38in}
{1.97in}
CENTER PILLAR REINFORCEMENT
REINFORCEMENT
REINFORCEMENT
CUT-AND-JOIN LOCATION FOR CENTER
PILLAR REINFORCEMENT
DPE0980B087
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