Mazda 5. Manual — part 68

BODY STRUCTURE [PANEL REPLACEMENT]

09–80B–35

09

9. Apply spot weld sealer to the area indicated by (D).

35mm

{1.38in}

{0.39in}

{0.07in}

{2.56in}

{1.18in}

{0.39in}

(A)2

(A)2

L=10mm x 1

L=10mm x 1

{3.15in}

3

80mm

3

65mm

30mm

t=1.8mm

(B)1

(C)2

1

10

4

(C)2

(C)1

(C)1

(C)1

(C)2

(D)

SIDE SILL REINFORCEMENT
(FRONT)

CUT-AND-JOIN LOCATION FOR SIDE
SILL REINFORCEMENT (FRONT)

CUT-AND-JOIN LOCATION FOR
FRONT PILLAR REINFORCEMENT
(UPPER)

FRONT PILLAR REINFORCEMENT
(UPPER)

NEW FRONT PILLAR
REINFORCEMENT (UPPER)

FRONT PILLAR REINFORCEMENT
(LOWER)

REINFORCEMENT

REINFORCEMENT

REINFORCEMENT

DPE0980B081

09–80B–36

BODY STRUCTURE [PANEL REPLACEMENT]

10. After temporarily installing new parts, make sure the related parts fit properly.

End Of Sie

CENTER PILLAR (OUTER) REMOVAL

DPE098070350B01

1. Rough cut area (A), drill the 100 locations indicated by (B), then remove the center pillar (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.

12

2

90mm

{3.54in}

25

27

2

2

3

480mm

{18.90in}

CUT-AND-JOIN LOCATION FOR
FRONT PILLAR (OUTER)

CUT-AND-JOIN LOCATION FOR
FRONT PILLAR (OUTER)

DPE0980B080

BODY STRUCTURE [PANEL REPLACEMENT]

09–80B–37

09

End Of Sie

CENTER PILLAR (OUTER) INSTALLATION

DPE098070350B02

1. When joining and cutting the new and existing parts, trial fit the new part in position, and then measure and

adjust the body as necessary to conform with standard dimensions.

2. Drill holes for plug welds before installing new parts.

Note

• The shape for the right side is different. In areas where the outer, reinforcement, inner, and other parts are

in 3-4 layers, drill holes for plug welds in all but the innermost panel.

3. Before installing new parts, apply spot weld sealer to the tire arch line.
4. After temporarily installing new parts, make sure the related parts fit properly.

70mm

240mm

{9.45in}

50mm

{1.97in}

(B)2

40mm {1.57in}

{2.76in}

20mm

{0.79in}

40mm {1.57in}

INSULATOR

INSULATOR

(B)1

(B)11

(B)23

(A)

(A)

(B)30

(B)3

(B)29

(B)1

(A)

B

B

A

A

C

C

B-B

C-C

A-A

CUT-AND-JOIN LOCATION FOR
CENTER PILLAR (OUTER)

CUT-AND-JOIN LOCATION FOR
CENTER PILLAR (OUTER)

CUT-AND-JOIN LOCATION FOR
CENTER PILLAR (OUTER)

ROUGH CUT LOCATION FOR
CENTER PILLAR (OUTER)

ROUGH CUT LOCATION FOR
CENTER PILLAR (OUTER)

CENTER PILLAR (OUTER)

ROUGH CUT LOCATION FOR
CENTER PILLAR (OUTER)

DPE0980B083

09–80B–38

BODY STRUCTURE [PANEL REPLACEMENT]

End Of Sie

240mm

2

40mm

20mm

1

1

11

23

30

3

29

{9.45in}

{0.79in}

{1.57in}

CENTER PILLAR (OUTER)

CUT-AND-JOIN LOCATION FOR
CENTER PILLAR (OUTER)

CUT-AND-JOIN LOCATION FOR
CENTER PILLAR (OUTER)

CUT-AND-JOIN LOCATION FOR
CENTER PILLAR (OUTER)

DPE0980B084