Mazda 5. Manual — part 81
BODY STRUCTURE [DIMENSIONS]
09–80D–15
09
End Of Sie
BODY STRUCTURE [PLASTIC BODY PARTS]
09–80E–1
09
09–80E
BODY STRUCTURE [PLASTIC BODY PARTS]
PLASTIC PARTS HEAT RESISTING
TEMPERATURE . . . . . . . . . . . . . . . . . . 09–80E–1
REPAIRABLE RANGE OF POLYPROPYLENE
BUMPERS . . . . . . . . . . . . . . . . . . . . . . . 09–80E–1
POLYPROPYLENE BUMPER REPAIR . . 09–80E–3
PROCEDURE . . . . . . . . . . . . . . . . . . . . . 09–80E–3
PLASTIC LIFTGATE. . . . . . . . . . . . . . . . . 09–80E–8
REPAIRABLE RANGE OF POLYCARBONATE;
ABS-RESIN LIFTGATE . . . . . . . . . . . . . 09–80E–9
REPAIR OF POLYCARBONATE;
ABS-RESIN LIFTGATE . . . . . . . . . . . . . 09–80E–11
End of Toc
PLASTIC PARTS HEAT RESISTING TEMPERATURE
DPE098050000B01
Note
• The application of temperatures higher than heat resisting temperatures may result in part deformation.
End Of Sie
REPAIRABLE RANGE OF POLYPROPYLENE BUMPERS
DPE098050000B02
The three types of damaged bumpers shown below are considered repairable. Although a bumper which has been
damaged greater than this could also be repaired, it should be replaced with a new one because such repair would
detract from the looks and quality of the bumper. In addition, such repair is not considered reasonable in terms of
work time.
Part Name
Code
Material Name
Heat resisting
Temperature
°C{°F}
WINDSHIELD MOULDING
PVC
POLYVINYLCHLORIDE
95 {203}
COWL GRILLE
PP
POLYPROPYLENE
95 {203}
FRONT COMBINATION
LIGHT
LENS
PC
POLYCARBONATE
130 {266}
HOUSING
PP
POLYPROPYLENE
90 {194}
RADIATOR GRILLE
PP
POLYPROPYLENE
95 {203}
FRONT BUMPER
PP
POLYPROPYLENE
100 {212}
SIDE TURN LIGHT
LENS
PMMA
ACRYLIC
75 {167}
HOUSING
PC-PBT
POLYCARBONATE-PBT
80 {176}
OUTSIDE MIRROR
ABS
ABS
100 {212}
SIDE STEP MOLDING
PP
POLYPROPYLENE
75 {167}
ROOF MOULDING
PVC
PVC
95 {203}
REAR BUMPER
PP
POLYPROPYLENE
100 {212}
REAR COMBINATION
LIGHT
LENS
PMMA
ACRYLIC
80 {176}
HOUSING AAS
AAS
70
{158}
OUTER HANDLE
LEVER
PC-PBT
POLYCARBONATE-PBT
80 {176}
BASE
PC-PET
POLYCARBONATE-PET
80 {176}
HIGH-MOUNT BRAKE
LIGHT
LENS
PMMA
ACRYLIC
80 {176}
HOUSING
ABS
ABS
100 {212}
REAR SPOILER
PP
POLYPROPYLENE
90 {194}
PILLAR GARNISH
AES
AES
90 {194}
DOOR GARNISH
AES
AES
90 {194}
SHROUD PANEL
PP
POLYPROPYLENE
100 {212}
LIFTGATE
OUTER
PC-ABS
POLYCARBONATE-ABS
100 {212}
INNER
PP(GF40%) POLYPROPYLENE-GLASS FIBER
100 {212}
09–80E–2
BODY STRUCTURE [PLASTIC BODY PARTS]
Repairable Bumpers
1. A bumper with a hole less than 50 mm {1.97 in} in
diameter.
2. A bumper with a crack less than 100 mm {3.94 in}
in length.
3. A bumper with a crack less than 100 mm {3.94 in}
in length that is less than half of the width of the
bumper.
End Of Sie
YMU980PCM
YMU980PCN
LESS THAN HALF OF (A)
(A)
YMU980PCP
BODY STRUCTURE [PLASTIC BODY PARTS]
09–80E–3
09
POLYPROPYLENE BUMPER REPAIR
DPE098050000B03
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PROCEDURE
DPE098050000B04
Repair of polypropylene bumpers having damage that has reached the surface of the polypropylene and are too
Scratch on paint only
Hole or crack through surface
Crack more than 100 mm
{3.94in} long or completely
broken
Bumper
surface
Bumper
surface
not visible
visible
Remove paint
Smooth damaged area
Apply aluminium tape to
reverse side of bumper
Plastic weld damaged area
Rough sand damage area
Degrease damaged area
Apply repair agent to
damaged area and let dry
Sand damaged area
smooth
Sand dam-
aged area
Apply polypropylene primer to damaged
area and let dry
Spray primer surfacer on damaged area
and let dry
Spray primer surfacer on
bumper and let dry
Sand surface of bumper
Sand partial or complete surface of bumper
Degrease bumper
Spray matching body color paint on bumper and let dry
Replace damaged
Bumper
Spray entire bumper
surface with
polypropylene primer
Apply polypropylene primer
to damaged area
YMU980PCQ
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