Mazda CX-7 2007 Bodyshop Manual
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2007-2012
Mazda CX-7
Bodyshop
Manual
FOREWORD
This bodyshop manual is intended for
use by technicians of Authorized Mazda
Dealers to help them service and repair
Mazda vehicles. It can also be useful to
owners and operators of Mazda vehicles in
performing limited repair and maintenance
on Mazda vehicles.
For proper repair and maintenance, a
thorough familiarization with this manual is
important, and it should always be kept in a
handy place for quick and easy reference.
All the contents of this manual, including
drawings and specifications, are the latest
available at the time of printing.
As modifications affecting repair or
maintenance occur, relevant information
supplementary to this volume will be made
available at Mazda dealers. This manual
should be kept up-to-date.
Mazda Motor Corporation reserves the
right to alter the specifications and contents
of this manual without obligation or
advance notice.
All rights reserved. No part of this book may
be reproduced or used in any form or
by any means, electronic or mechanical
including photocopying and recording and
the use of any kind of information storage
and retrieval system-without permission in
writing.
Mazda Motor Corporation
HIROSHIMA, JAPAN
CONTENTS
GENERAL INFORMATION
CONSTRUCTION
PANEL REPLACEMENT
BODY
WATER-PROOF AND RUST
STRUCTURE
PREVENTIVE
DIMENSIONS
PLASTIC BODY PARTS
APPLICATION:
This manual is applicable to vehicles beginning
with the Vehicle Identification Numbers (VIN),
shown on the following page.
© 2006 Mazda Motor Corporation
PRINTED IN U.S.A., MARCH 2006
Form No. 3419–1U–06C
Part No. 9999–95–093F–07
Title
Section
00
80A
80B
80C
80D
80E

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Summary of Contents for Mazda CX-7 2007

  • Page 1 DIMENSIONS use by technicians of Authorized Mazda Dealers to help them service and repair PLASTIC BODY PARTS Mazda vehicles. It can also be useful to owners and operators of Mazda vehicles in performing limited repair and maintenance APPLICATION: on Mazda vehicles.
  • Page 2 VEHICLE IDENTIFICATION NUMBERS (VIN) JM3 ER29L✻7# 100001— JM3 ER293✻7# 100001—...
  • Page 3: Table Of Contents

    GENERAL INFORMATION SECTION 00-00 Toc of SCT GENERAL INFORMATION ..00-00 Toc of SCT 00-00 GENERAL INFORMATION Selection of Cut-and-join Locations . . . 00-00–10 VEHICLE IDENTIFICATION NUMBER (VIN) CODE ..... . 00-00–2 Removal of Associated Parts .
  • Page 4: General Information

    Body, Gross vehicle weight class (1814 2267 kg) Resraint system 2= with Curtain and Side air bags Carline, Series ER= Mazda CX-7 JM3= Mazda/Multi-purpose vehicle category/U.S.A. World manufacturer identification acxuuw00002316 End Of Sie VEHICLE IDENTIFICATION NUMBERS (VIN) id000000600100 JM3 ER29L*7# 100001—...
  • Page 5: How To Use This Manual

    GENERAL INFORMATION HOW TO USE THIS MANUAL id000000600900 Efficient Replacement of Body Panels • This section contains information on the body panels in regard to the welding types, number of spot welds, and cut-and-join locations that are necessary for panel removal and installation. •...
  • Page 6: Symbols Of Panel Replacement

    GENERAL INFORMATION Symbols of Panel Replacement • The following 6 symbols are used to indicate the type of weld that is used when replacing body panels. SYMBOL MEANING SYMBOL MEANING Spot welding Continuous MIG welding (Cut-and-join location) arc welding (plug welding) Braze welding spot welding Rough cut location...
  • Page 7 GENERAL INFORMATION Example Shows vehicle section When there are no specific indications, all of UNDERBODY FLAT-PLANE DIMENSIONS units are in millimeters (mm). 00-00 The dimensions on the left mm {in} and right in regard to the center Shows outline drawing of the vehicle are different.
  • Page 8: Body Dimensions (Straight-Line Dimensions)

    GENERAL INFORMATION Body Dimensions (Straight-line Dimensions) • Straight-line dimensions are the actual dimensions between two standard points. FRONT FENDER INSTALLATION NUT {32.17} STRAIGHT-LINE DIMENSIONS acxuub00000035 • When there are no specific indications, the standard points and dimensions are symmetrical in regard to the center of the vehicle.
  • Page 9: Symbols Of Body Dimensions

    GENERAL INFORMATION Example ROOM STRAIGHT-LINE DIMENSIONS (1) Shows vehicle section Shows point 00-00 Shows outline drawing symbol Shows dimension 1,128 {44.41} 1,263 1,067 {49.72} {42.01} No indication are shown 1,048 {41.26} within the outline drawing. 1,398 {55.04} 1,406 {55.35} {31.46} {33.50} Shows point indication Without apostrophe:RH...
  • Page 10: Service Precautions

    GENERAL INFORMATION SERVICE PRECAUTIONS id000000600200 Arrangement of Workshop • Arrangement of the workshop is important for safe and efficient work. Safety Precautions • Protective head covering and safety shoes should always be worn. Depending upon the nature of the work, gloves, safety glasses, ear protectors, face shield, etc., should also be used.
  • Page 11: Use Of Pulling Equipment

    GENERAL INFORMATION Use of Pulling Equipment • When using pulling equipment, keep away from the pulling area and use safety wires to prevent accidents. 00-00 Safety wires acxuub00000041 Prevent Short Circuits • Turn the ignition switch to the LOCK position. •...
  • Page 12: Prevention Of Body Deformation

    GENERAL INFORMATION Prevention of Body Deformation • Use a clamp or a jack for removal and reinforce at and around the rough-cutting location to prevent deforming of the body. acxuub00000066 Selection of Cut-and-join Locations • For parts where complete replacement is not feasible, careful cutting and joining operations should be followed.
  • Page 13: Determination Of Welding Method

    GENERAL INFORMATION 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 gas shielded-arc welder to make the plug welds. 00-00 {0.12in}or more acxuub00000049 Making Holes for CO Arc Welding •...
  • Page 14: Efficient Installation Of Body Panels

    GENERAL INFORMATION EFFICIENT INSTALLATION OF BODY PANELS id000000600500 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. acxuub00000069 Welding Notes • For the number of weld points, welding should be Spot welding performed in accordance with the following Repair weld...
  • Page 15: Checking Weld Strength

    GENERAL INFORMATION • Before spot welding, make a trial weld using the Test piece method same material as the body panel to check the weld strength. 00-00 Nugget diameter :4/5 of tip acxuub00000071 Checking Weld Strength • Installation locations of the engine, chassis, and Chisel dimensions seat belts are designated as important safety locations for weld strength.
  • Page 16: Anticorrosion, Sound Insulation, And Vibration Insulation

    GENERAL INFORMATION ANTICORROSION, SOUND INSULATION, AND VIBRATION INSULATION id000000600600 Body Sealing • Apply body sealer where necessary. • For locations where application of body sealer is difficult after installation, apply it before installation. acxuub00000059 Application of Undercoating • Apply an undercoat to the required location of the body. acxuub00000060 Application of Rust Inhibitor •...
  • Page 17: Abbreviation

    GENERAL INFORMATION ABBREVIATION id000000600700 Control module Center Dynamic stability control 00-00 Front Hydraulic unit Left Metallic Mica Right Rear End Of Sie 00-00–15...
  • Page 19 BODY & ACCESSORIES SECTION 09-80A Toc of SCT BODY STRUCTURE BODY STRUCTURE [CONSTRUCTION] ..09-80A [DIMENSIONS] ... 09-80D BODY STRUCTURE BODY STRUCTURE [PANEL REPLACEMENT] .
  • Page 20: Body Structure [Construction]

    BODY STRUCTURE [CONSTRUCTION] BODY COMPONENTS CONSTRUCTION[CONSTRUCTION] id098007739700 acxuub00000025 09-80A–2...
  • Page 21: Ultra High-Tension Steel

    BODY STRUCTURE [CONSTRUCTION] x:Applied -:Not applied Thickness Ultra high- High- Rust proof Part Name tension tension steel mm {in} steel steel Hood 0.70 {0.028} Front bumper bracket 2.00 {0.079} Front 1.80 {0.071} 09-80A Front side frame (inner) Rear 2.30 {0.091} Shroud side panel 1.60 {0.063} Shroud side member...
  • Page 22: Body Structure

    BODY STRUCTURE [CONSTRUCTION] Ultra high- High- Thickness Rust proof Part Name tension tension steel mm {in} steel steel Side frame outer 0.70 {0.028} Rear door panel 0.70 {0.028} Front door panel 0.70 {0.028} Crossmember No.2 1.20 {0.047} Seat bracket 1.20 {0.047} Front floor pan 0.65 {0.026} Front B frame...
  • Page 23: Range Of Use And Cautions For Service

    BODY STRUCTURE [CONSTRUCTION] ULTRA HIGH-TENSION STEEL[CONSTRUCTION] id098007745600 Characteristics of Ultra High-Tensile Steel Plates • Ultra high-tensile steel plates have enhanced tensile strength compared to previous high-tensile steel plates. • Because the strength is maintained even though the plates are thin-walled, the ultra high-tensile steel plates are used for the frames and the main frame parts which form the cabin, reducing the weight of the vehicle.
  • Page 24 BODY STRUCTURE [CONSTRUCTION] REAR FRAME REINFORCEMENT FIXING REINFORCEMENT REAR FRAME CROSSMEMBER No.3 GUSSET REINFORCEMENT (FRONT) REAR SIDE FRAME (REAR) CROSSMEMBER No.3 REINFORCEMENT SIDE SILL REINFORCEMENT FRONT SIDE FRAME (INNER,FRONT) REAR FRAME GUSSET REINFORCEMENT REAR SIDE FRAME (FRONT) REAR FRAME REINFORCEMENT (FRONT) CROSSMEMBER No.3 (REAR) TUNNEL PANEL (REAR) TORQUE BOX C...
  • Page 25 BODY STRUCTURE [PANEL REPLACEMENT] 09-80B BODY STRUCTURE [PANEL REPLACEMENT] FRONT BUMPER BRACKET REMOVAL FRONT SIDE FRAME [PANEL REPLACEMENT]... 09-80B–2 (PARTIAL CUTTING) REMOVAL FRONT BUMPER BRACKET [PANEL REPLACEMENT] ... 09-80B–24 INSTALLATION RH .
  • Page 26: Front Bumper Bracket Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] FRONT BUMPER BRACKET REMOVAL[PANEL REPLACEMENT] id098008743100 1. Remove the front bumper bracket. FRONT BUMPER BRACKET BOLT acxuub00000072 End Of Sie 09-80B–2...
  • Page 27: Front Bumper Bracket Installation[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] FRONT BUMPER BRACKET INSTALLATION[PANEL REPLACEMENT] id098008743200 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2. Tighten the bolts at section (A) to the specified torque and install the front bumper bracket. Tightening torque 15.7—22.6 N·m {161—230 kgf·cm, 139—200 in·lbf} 09-80B...
  • Page 28: Tiedown Reinforcement Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] TIEDOWN REINFORCEMENT REMOVAL[PANEL REPLACEMENT] id098008800200 1. Remove the tiedown reinforcement. TIEDOWN REINFORCEMENT TIEDOWN REINFORCEMENT acxuub00000074 End Of Sie 09-80B–4...
  • Page 29: Tiedown Reinforcement Installation[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] TIEDOWN REINFORCEMENT INSTALLATION[PANEL REPLACEMENT] id098008800300 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2. Drill holes for the plug welding before installing the new parts. 3. After temporarily installing new parts, make sure the related parts fit properly. 09-80B TIEDOWN REINFORCEMENT TIEDOWN REINFORCEMENT...
  • Page 30: Shroud Upper Panel Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] SHROUD UPPER PANEL REMOVAL[PANEL REPLACEMENT] id098008800400 1. Remove the shroud upper panel. Note • When removing the shroud upper panel and the shroud side panel separately, drill the 3 locations indicated by (A). SHROUD UPPER PANEL (A)3 SHROUD SIDE PANEL acxuub00000076...
  • Page 31: Shroud Upper Panel Installation[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] SHROUD UPPER PANEL INSTALLATION[PANEL REPLACEMENT] id098008800500 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2. Drill holes for the plug welding before installing the new parts. 3. After temporarily installing new parts, make sure the related parts fit properly. 09-80B SHROUD UPPER PANEL SHROUD SIDE PANEL...
  • Page 32: Cowl Side Reinforcement Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] COWL SIDE REINFORCEMENT REMOVAL[PANEL REPLACEMENT] id098008741700 1. Remove the cowl side reinforcement. COWL SIDE REINFORCEMENT acxuub00000078 End Of Sie 09-80B–8...
  • Page 33: Cowl Side Reinforcement Installation[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] COWL SIDE REINFORCEMENT INSTALLATION[PANEL REPLACEMENT] id098008741800 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2. Drill holes for the plug welding before installing the new parts. 3. After temporarily installing new parts, make sure the related parts fit properly. 09-80B COWL SIDE REINFORCEMENT acxuub00000079...
  • Page 34: Wiper Bracket Component Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] WIPER BRACKET COMPONENT REMOVAL[PANEL REPLACEMENT] id098008750000 1. Remove the wiper bracket. WIPER BRACKET acxuub00000080 End Of Sie 09-80B–10...
  • Page 35: Wiper Bracket Component Installation[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] WIPER BRACKET COMPONENT INSTALLATION[PANEL REPLACEMENT] id098008750100 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2. Drill holes for the plug welding before installing the new parts. 3. After temporarily installing new parts, make sure the related parts fit properly. 09-80B WIPER BRACKET acxuub00000081...
  • Page 36: Apron Reinforcement (Upper) Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] APRON REINFORCEMENT (UPPER) REMOVAL[PANEL REPLACEMENT] id098008800000 1. Drill the 1 location indicated by (A) from the bottom, as they cannot be seen from the outer side. 2. Remove the apron reinforcement (upper). APRON REINFORCEMENT (UPPER) (A)1 acxuub00000082 End Of Sie 09-80B–12...
  • Page 37: Apron Reinforcement (Upper) Installation[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] APRON REINFORCEMENT (UPPER) INSTALLATION[PANEL REPLACEMENT] id098008800100 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2. Drill holes for the plug welding before installing the new parts. 3. After temporarily installing new parts, make sure the related parts fit properly. 09-80B APRON REINFORCEMENT (UPPER) acxuub00000083...
  • Page 38: Apron Reinforcement (Lower) Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] APRON REINFORCEMENT (LOWER) REMOVAL[PANEL REPLACEMENT] id098008741300 1. Remove the apron reinforcement (lower). APRON REINFORCEMENT (LOWER) acxuub00000084 End Of Sie 09-80B–14...
  • Page 39: Apron Reinforcement (Lower) Installation[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] APRON REINFORCEMENT (LOWER) INSTALLATION[PANEL REPLACEMENT] id098008741400 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2. Drill holes for the plug welding before installing the new parts. 3. After temporarily installing new parts, make sure the related parts fit properly. 09-80B APRON REINFORCEMENT (LOWER) acxuub00000085...
  • Page 40: Wheel Apron Panel (Front) Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] WHEEL APRON PANEL (FRONT) REMOVAL[PANEL REPLACEMENT] id098008741100 1. Remove the wheel apron panel (front). WHEEL APRON PANEL FRONT (RH) WHEEL APRON PANEL FRONT (LH) acxuub00000086 End Of Sie 09-80B–16...
  • Page 41: Wheel Apron Panel (Front) Installation[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] WHEEL APRON PANEL (FRONT) INSTALLATION[PANEL REPLACEMENT] id098008741200 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2. Drill holes for the plug welding before installing the new parts. 3.
  • Page 42: Wheel Apron Component Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] WHEEL APRON COMPONENT REMOVAL[PANEL REPLACEMENT] id098008746000 1. Remove the wheel apron component. WHEEL APRON COMPONENT WHEEL APRON COMPONENT RH : 22 LH : 21 acxuub00000088 End Of Sie 09-80B–18...
  • Page 43: Wheel Apron Component Installation[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] WHEEL APRON COMPONENT INSTALLATION[PANEL REPLACEMENT] id098008746100 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2. Drill holes for the plug welding before installing the new parts. 3. After temporarily installing new parts, make sure the related parts fit properly. 09-80B WHEEL APRON COMPONENT WHEEL APRON COMPONENT...
  • Page 44: Front Side Frame Component Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] FRONT SIDE FRAME COMPONENT REMOVAL[PANEL REPLACEMENT] id098008741900 1. Rough cut area (A), drill the 14 locations indicated by (B). FRONT SIDE FRAME COMPONENT (B)5 (A) ROUGH CUT LOCATION (B)3 acxuub00000090 09-80B–20...
  • Page 45 BODY STRUCTURE [PANEL REPLACEMENT] 2. Drill the 2 locations indicated by (C), and remove the front side frame component. Note • The 2 weld locations indicated by (C) cannot be seen from the interior. (C)2 09-80B (B)2 FRONT SIDE FRAME COMPONENT (B)4 acxuub00000091 End Of Sie...
  • Page 46: Front Side Frame Component Installation[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] FRONT SIDE FRAME COMPONENT INSTALLATION[PANEL REPLACEMENT] id098008742000 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2. Drill holes for the plug welding before installing the new parts. 3.
  • Page 47 BODY STRUCTURE [PANEL REPLACEMENT] 5. After temporarily installing new parts, make sure the related parts fit properly. 6. Weld the remaining weld locations and install the front side frame component. 09-80B FRONT SIDE FRAME COMPONENT acxuub00000093 End Of Sie 09-80B–23...
  • Page 48: Front Side Frame (Partial Cutting) Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] FRONT SIDE FRAME (PARTIAL CUTTING) REMOVAL[PANEL REPLACEMENT] id098008742100 Caution • The rough cut area indicates the maximum size range of the installation position. 1. Rough cut area (A), drill the 18 locations indicated by (B), and then remove the front side frame. ROUGH CUT AND CUT-AND-JOIN LOCATION (B)8...
  • Page 49 BODY STRUCTURE [PANEL REPLACEMENT] Caution • The rough cut area indicates the maximum size range of the installation position. 1. Rough cut area (A), drill the 18 locations indicated by (B), and then remove the front side frame. 09-80B (A) ROUGH CUT AND CUT-AND-JOIN LOCATION (B)8 FRONT SIDE FRAME (OUTER, LH)
  • Page 50: Front Side Frame (Partial Cutting) Installation[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] FRONT SIDE FRAME (PARTIAL CUTTING) INSTALLATION[PANEL REPLACEMENT] id098008742200 Caution • The cut-and-joint area indicates the maximum size range of the installation position. 1. Make a reinforcement panel using the material from the front side frame (inner). 2.
  • Page 51 BODY STRUCTURE [PANEL REPLACEMENT] 25mm {0.98in} L=30mm x 2 {1.18in} t=2.3mm {0.09in} EXTRUSION BEAD 09-80B EXTRUSION BEAD REINFORCEMENT L=70mm x 2 10mm 15mm {2.76in} {0.39in} {0.59in} 85mm {3.35in} FRONT SIDE FRAME (INNER, RH) CUT-AND-JOIN LOCATION acxuub00000112 09-80B–27...
  • Page 52 BODY STRUCTURE [PANEL REPLACEMENT] 7. Install the front side frame reinforcement. FRONT SIDE FRAME REINFORCEMENT (RH) L=50mm {1.97in} L=50mm {1.97in} acxuub00000094 8. Install the suspension mount reinforcement. 9. Install the suspension mount bolt. Tightening torque 1.0—5.0 N·m {11—50 kgf·cm, 8.9—44 in·lbf} 09-80B–28...
  • Page 53 BODY STRUCTURE [PANEL REPLACEMENT] 09-80B L=15mm {0.59in} SUSPENSION MOUNT REINFORCEMENT SUSPENSION MOUNT BOLT L=20mm {0.79in} am8rrb00000041 09-80B–29...
  • Page 54 BODY STRUCTURE [PANEL REPLACEMENT] 10. Because the front side frame (outer) cannot be welded to the existing parts from the inside of the panel, drill 5 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.
  • Page 55 BODY STRUCTURE [PANEL REPLACEMENT] Caution • The cut-and-joint area indicates the maximum size range of the installation position. 1. Make a reinforcement panel using the material from the front side frame (inner). 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.
  • Page 56 BODY STRUCTURE [PANEL REPLACEMENT] 25mm {0.98in} L=30mm x 2 {1.18in} t=2.3mm {0.09in} EXTRUSION BEAD EXTRUSION BEAD REINFORCEMENT L=70mm x 2 10mm 15mm {2.76in} {0.39in} {0.59in} FRONT SIDE FRAME (INNER, LH) 105mm {4.13in} CUT-AND-JOIN LOCATION acxuub00000114 09-80B–32...
  • Page 57 BODY STRUCTURE [PANEL REPLACEMENT] 7. Install the front side frame reinforcement. FRONT SIDE FRAME REINFORCEMENT (LH) 09-80B L=50mm {1.97in} L=50mm {1.97in} acxuub00000095 8. Install the suspension mount reinforcement. 9. Install the suspension mount bolt. Tightening torque 1.0—5.0 N·m {11—50 kgf·cm, 8.9—44 in·lbf} 09-80B–33...
  • Page 58 BODY STRUCTURE [PANEL REPLACEMENT] L=15mm {0.59in} SUSPENSION MOUNT REINFORCEMENT SUSPENSION MOUNT BOLT L=20mm {0.79in} am8rrb00000044 09-80B–34...
  • Page 59 BODY STRUCTURE [PANEL REPLACEMENT] 10. Because the front side frame (outer) cannot be welded to the existing parts from the inside of the panel, drill 5 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.
  • Page 60: Torque Box Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] TORQUE BOX REMOVAL[PANEL REPLACEMENT] id098008607100 1. When removing the torque box, the nut plate may interfere and make removal difficult. Therefore, drill the 3 locations indicated by (A) and then open the nut plate outward. 2. Drill the 25 locations indicated by (B). (B)9 (B)1 (B)2...
  • Page 61 BODY STRUCTURE [PANEL REPLACEMENT] 3. Rough cut area (C), drill the 2 locations indicated by (D), then remove the torque box. 09-80B ROUGH CUT LOCATION TORQUE BOX (D)2 acxuub00000146 End Of Sie 09-80B–37...
  • Page 62: Torque Box Installation[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] TORQUE BOX INSTALLATION[PANEL REPLACEMENT] id098008607200 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2. Drill holes for the plug welding before installing the new parts. 3. After temporarily installing new parts, make sure the related parts fit properly. TORQUE BOX TORQUE BOX acxuub00000147...
  • Page 63 BODY STRUCTURE [PANEL REPLACEMENT] 09-80B L=90mm {3.54in} TORQUE BOX acxuub00000148 End Of Sie BM: FRONT FRAME REAR 09-80B–39...
  • Page 64: Front Frame (Rear) Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] FRONT FRAME (REAR) REMOVAL[PANEL REPLACEMENT] id098008742500 1. Remove the front frame rear component. FRONT FRAME REAR COMPONENT FRONT FRAME REAR COMPONENT acxuub00000137 End Of Sie 09-80B–40...
  • Page 65: Front Frame (Rear) Installation[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] FRONT FRAME (REAR) INSTALLATION[PANEL REPLACEMENT] id098008742600 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2. Drill holes for the plug welding before installing the new parts. 3. After temporarily installing new parts, make sure the related parts fit properly. 09-80B FRONT FRAME REAR COMPONENT...
  • Page 66: Front Pillar Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] FRONT PILLAR REMOVAL[PANEL REPLACEMENT] id098008744700 1. Rough cut area (A), drill the 78 locations indicated by (B). 2. Drill the 1 locations indicated by (C) from the interior. 3. Remove the front pillar (outer). (C)1 50mm {1.97in} 40mm {1.57in} CUT-AND-JOIN LOCATION...
  • Page 67 BODY STRUCTURE [PANEL REPLACEMENT] 09-80B (B)10 FRONT PILLAR (OUTER) (B)25 (B)2 ROUGH CUT LOCATION CUT-AND JOIN LOCATION (B)2 40mm 40mm {1.57in} {1.57in} (B)7 acxuub00000097 09-80B–43...
  • Page 68 BODY STRUCTURE [PANEL REPLACEMENT] 4. Rough cut area (D). 5. Drill the 2 locations indicated by (E) from the interior. 6. Remove the front pillar reinforcement. 125mm CUT-AND JOIN {4.92in} LOCATION 30mm ROUGH CUT {1.18in} LOCATION FRONT PILLAR REINFORCEMENT (E)2 ROUGH CUT CUT-AND JOIN LOCATION...
  • Page 69 BODY STRUCTURE [PANEL REPLACEMENT] 7. Rough cut area (F), drill the 3 locations indicated by (G), and then remove the front pillar (inner). 8. Remove the spot weld sealer using a disc grinder. 09-80B 190mm {7.48in} CUT-AND JOIN 30mm {1.18in} LOCATION FRONT PILLAR (INNER) ROUGH CUT...
  • Page 70: Front Pillar Installation[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] FRONT PILLAR INSTALLATION[PANEL REPLACEMENT] id098008744800 1. 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. 2.
  • Page 71 BODY STRUCTURE [PANEL REPLACEMENT] 5. Make a reinforcement panel using the material from the front pillar reinforcement. 6. Because the front pillar reinforcement cannot be welded to the existing parts from the inside of the panel, 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.
  • Page 72 BODY STRUCTURE [PANEL REPLACEMENT] 8. Make a reinforcement panel using the material from the front pillar reinforcement. 9. Because the front pillar reinforcement cannot be welded to the existing parts from the inside of the panel, drill 3 plug weld holes at the locations indicated by (C) 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.
  • Page 73 BODY STRUCTURE [PANEL REPLACEMENT] 11. After temporarily installing new parts, make sure the related parts fit properly. 12. Drill the 1 locations indicated by (D) from the interior. 13. Weld the 81 locations indicated by (E) and install the front pillar (outer). (D)1 09-80B 50mm {1.97in}...
  • Page 74 BODY STRUCTURE [PANEL REPLACEMENT] (E)10 FRONT PILLAR (OUTER) (E)26 (E)2 CUT-AND JOIN LOCATION (E)2 40mm {1.57in} (E)8 acxuub00000103 End Of Sie BM: CENTER PILLAR 09-80B–50...
  • Page 75: Center Pillar Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] CENTER PILLAR REMOVAL[PANEL REPLACEMENT] id098008743900 1. Rough cut area (A), drill the 57 locations indicated by (B), then remove the center pillar (outer). 09-80B 40mm {1.57in} 20mm {0.79in} CUT-AND JOIN LOCATION ROUGH CUT CENTER PILLAR LOCATION (OUTER) (B)19 (B)21...
  • Page 76 BODY STRUCTURE [PANEL REPLACEMENT] 2. Rough cut area (C), drill the 3 locations indicated by (D). Caution • Avoid cutting with a blow torch or similar tools as the insulator (shaded area) is flammable. 3. Drill the 3 locations indicated by (E) from the interior. 4.
  • Page 77 BODY STRUCTURE [PANEL REPLACEMENT] 5. Rough cut area (F), drill the 2 locations indicated by (G), then remove the center pillar (inner). 190mm {7.48in} 30mm CUT-AND JOIN {1.18in} LOCATION 09-80B ROUGH CUT LOCATION CENTER PILLAR (INNER) (G)2 acxuub00000106 End Of Sie 09-80B–53...
  • Page 78: Center Pillar Installation[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] CENTER PILLAR INSTALLATION[PANEL REPLACEMENT] id098008744000 1. Make a reinforcement panel using the material from the center pillar (inner). 2. When joining and cutting the new and existing parts, trial fit the new part, and then measure and adjust the body as necessary to conform with standard dimensions.
  • Page 79 BODY STRUCTURE [PANEL REPLACEMENT] 9. Weld the remaining weld locations, then install the center pillar reinforcement. 50mm {1.97in} 110mm ROUGH CUT AND {4.33in} CUT-AND JOIN LOCATION t=1.2mm {0.05in} 09-80B REINFORCEMENT (B)3 CENTER PILLAR REINFORCEMENT CUT-AND JOIN LOCATION CUT-AND JOIN LOCATION (A)3 (A)3 150mm...
  • Page 80 BODY STRUCTURE [PANEL REPLACEMENT] 11. Install the center pillar (outer). 40mm {1.57in} CUT-AND JOIN LOCATION CENTER PILLAR (OUTER) CUT-AND JOIN CUT-AND JOIN LOCATION LOCATION 120mm 130mm {4.72in} {5.12in} acxuub00000109 End Of Sie BM: SIDE SILL PANEL 09-80B–56...
  • Page 81: Side Sill Panel Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] SIDE SILL PANEL REMOVAL[PANEL REPLACEMENT] id098008743700 1. Rough cut area (A), drill the 82 locations indicated by (B), and then remove the side sill (outer). 09-80B 140mm 80mm {3.15in} {5.51in} CUT-AND JOIN 30mm 30mm LOCATION 100mm {1.18in} {1.18in} {3.94in}...
  • Page 82 BODY STRUCTURE [PANEL REPLACEMENT] 2. Rough cut area (C). Caution • During rough cutting, be careful not to damage the hinge reinforcement and the center pillar reinforcement (inner) indicated by dotted lines in the figure. 3. Drill the 5 locations indicated by (D) from the interior. 4.
  • Page 83: Side Sill Panel Installation[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] SIDE SILL PANEL INSTALLATION[PANEL REPLACEMENT] id098008743800 1. Make a reinforcement panel using the material from the side sill reinforcement. 2. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 3.
  • Page 84 BODY STRUCTURE [PANEL REPLACEMENT] 7. After temporarily installing new parts, make sure the related parts fit properly. 8. Install the side sill (outer). CUT-AND JOIN LOCATION 140mm 80mm {3.15in} {5.51in} CUT-AND JOIN LOCATION 100mm {3.94in} CUT-AND JOIN LOCATION SIDE SILL (OUTER) acxuub00000132 End Of Sie BM: REAR FENDER PANEL...
  • Page 85: Rear Fender Panel Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] REAR FENDER PANEL REMOVAL[PANEL REPLACEMENT] id098008744900 1. Rough cut area (A), drill the 73 locations indicated by (B). Caution • Avoid cutting with a blow torch or similar tools as the insulator (shaded area) is flammable. 2.
  • Page 86 BODY STRUCTURE [PANEL REPLACEMENT] REAR FENDER PANEL (B)6 (B)10 (B)3 (B)1 (B)7 acxuub00000116 09-80B–62...
  • Page 87 BODY STRUCTURE [PANEL REPLACEMENT] 5. Remove the rear fender panel (lower). 09-80B REAR FENDER (LOWER) acxuub00000117 End Of Sie 09-80B–63...
  • Page 88: Rear Fender Panel Installation[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] REAR FENDER PANEL INSTALLATION[PANEL REPLACEMENT] id098008745000 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2. Drill holes for the plug welding before installing the new parts. 3. Install the rear fender panel (lower). REAR FENDER (LOWER) acxuub00000118 4.
  • Page 89 BODY STRUCTURE [PANEL REPLACEMENT] 6. Install the rear fender panel. 09-80B REAR FENDER PANEL acxuub00000119 09-80B–65...
  • Page 90 BODY STRUCTURE [PANEL REPLACEMENT] CUT-AND JOIN 45mm {1.77in} LOCATION 180mm {7.09in} CUT-AND JOIN LOCATION CUT-AND JOIN LOCATION REAR FENDER PANEL 30mm {1.18in} acxuub00000120 End Of Sie BM: REAR END PANEL 09-80B–66...
  • Page 91: Rear End Panel Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] REAR END PANEL REMOVAL[PANEL REPLACEMENT] id098008744500 1. Drill the 2 locations indicated by (A) from the interior. 2. Remove the rear end panel. 3. Remove the spot weld sealer using a disc grinder. 09-80B (A)1 (A)1 REAR END PANEL acxuub00000121 End Of Sie...
  • Page 92: Rear End Panel Installation[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] REAR END PANEL INSTALLATION[PANEL REPLACEMENT] id098008744600 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2. Drill holes for the plug welding before installing the new parts. 3. Apply spot weld sealer to the joints of old and new parts for waterproofing and rust protection. 4.
  • Page 93: Rear Pillar (Outer) Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] REAR PILLAR (OUTER) REMOVAL[PANEL REPLACEMENT] id098008747200 1. Rough cut area (A), drill the 9 locations indicated by (B). Note • When removing the rear pillar (outer) and corner plate separately, drill the 5 locations indicated by (C). 09-80B 210mm {8.27in}...
  • Page 94 BODY STRUCTURE [PANEL REPLACEMENT] 2. Rough cut area (D), drill the 13 locations indicated by (E). 250mm {9.84in} CUT-AND JOIN LOCATION 30mm {1.18in} ROUGH CUT LOCATION REAR PILLAR REINFORCEMENT (E)7 (E)6 acxuub00000124 09-80B–70...
  • Page 95 BODY STRUCTURE [PANEL REPLACEMENT] 3. Remove the corner junction. 09-80B CORNER JUNCTION acxuub00000125 End Of Sie 09-80B–71...
  • Page 96: Rear Pillar (Outer) Installation[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] REAR PILLAR (OUTER) INSTALLATION[PANEL REPLACEMENT] id098008747300 1. When joining and cutting the new and existing parts, trial fit the new part in position, then measure and adjust the body as necessary to conform with standard dimensions. 2.
  • Page 97 BODY STRUCTURE [PANEL REPLACEMENT] 4. Install the rear pillar reinforcement. 09-80B 250mm {9.84in} CUT-AND JOIN LOCATION REAR PILLAR REINFORCEMENT acxuub00000127 09-80B–73...
  • Page 98 BODY STRUCTURE [PANEL REPLACEMENT] 5. After temporarily installing new parts, make sure the related parts fit properly. 6. Install the rear pillar (outer). Note • When replacing the rear pillar (outer) and corner plate separately, weld the 5 locations indicated by (A). CUT-AND JOIN LOCATION 210mm...
  • Page 99: Rear Floor Pan Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] REAR FLOOR PAN REMOVAL[PANEL REPLACEMENT] id098008742700 1. Remove the crossmember No.5. 09-80B CROSSMEMBER No.5 acxuub00000139 09-80B–75...
  • Page 100 BODY STRUCTURE [PANEL REPLACEMENT] 2. Rough cut area (A). Caution • During rough cutting, be careful not to damage the crossmember No.4 indicated by dotted lines in the figure. 3. Drill the remaining locations, then remove the rear floor pan. CUT-AND JOIN LOCATION 60mm {2.36in}...
  • Page 101 BODY STRUCTURE [PANEL REPLACEMENT] 09-80B REAR FLOOR PAN acxuub00000141 End Of Sie 09-80B–77...
  • Page 102: Rear Floor Pan Installation[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] REAR FLOOR PAN INSTALLATION[PANEL REPLACEMENT] id098008742800 1. When joining and cutting the new and existing parts, trial fit the new part in position, then measure and adjust the body as necessary to conform with standard dimensions. 2.
  • Page 103 BODY STRUCTURE [PANEL REPLACEMENT] 09-80B REAR FLOOR PAN acxuub00000143 09-80B–79...
  • Page 104 BODY STRUCTURE [PANEL REPLACEMENT] 6. After temporarily installing new parts, make sure the related parts fit properly. 7. Install the crossmember No.5. CROSSMEMBER No.5 acxuub00000144 End Of Sie BM: REAR SIDE FRAME 09-80B–80...
  • Page 105: Rear Side Frame Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] REAR SIDE FRAME REMOVAL[PANEL REPLACEMENT] id098008801200 1. Rough cut and remove the damaged part of the rear side frame. 09-80B 145mm {5.71in} CUT-AND JOIN LOCATION ROUGH CUT LOCATION REAR SIDE FRAME acxuub00000133 End Of Sie 09-80B–81...
  • Page 106: Rear Side Frame Installation[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] REAR SIDE FRAME INSTALLATION[PANEL REPLACEMENT] id098008801300 1. Make a reinforcement panel using the material from the rear side frame. 2. To cut-and-join the new and existing parts, cut at the locations for the new part indicated in the figure below and bevel the locations where the new and existing parts are joined.
  • Page 107: Roof Panel Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] ROOF PANEL REMOVAL[PANEL REPLACEMENT] BM: ROOF PANEL id098008744300 1. Remove the roof panel. 09-80B ROOF PANEL acxuub00000135 End Of Sie 09-80B–83...
  • Page 108: Roof Panel Installation[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] ROOF PANEL INSTALLATION[PANEL REPLACEMENT] id098008744400 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2. Drill holes for the plug welding before installing the new parts. 3. After temporarily installing new parts, make sure the related parts fit properly. ROOF PANEL acxuub00000136 End Of Sie...
  • Page 109 BODY STRUCTURE [WATER-PROOF AND RUST PREVENTIVE] 09-80C BODY STRUCTURE [WATER-PROOF AND RUST PREVENTIVE] BODY SEALING[WATER-PROOF AND RUST PREVENTIVE TREATMENT RUST PREVENTIVE] ....09-80C–2 [WATER-PROOF AND UNDER COATING[WATER-PROOF AND RUST PREVENTIVE] .
  • Page 110: Body Sealing[Water-Proof And Rust Preventive]

    BODY STRUCTURE [WATER-PROOF AND RUST PREVENTIVE] BODY SEALING[WATER-PROOF AND RUST PREVENTIVE] id098009739800 Sealant is applied to the parts where the panels meet and to the hemmed parts of the door panel and hood panel to provide water proofing and rust proofing. acxuub00000018 09-80C–2...
  • Page 111 BODY STRUCTURE [WATER-PROOF AND RUST PREVENTIVE] 09-80C acxuub00000019 09-80C–3...
  • Page 112 BODY STRUCTURE [WATER-PROOF AND RUST PREVENTIVE] acxuub00000020 End Of Sie 09-80C–4...
  • Page 113: Under Coating[Water-Proof And Rust Preventive]

    2007 Mazda CX-7 Bodyshop Manual (3419–1U–06C) BODY STRUCTURE [WATER-PROOF AND RUST PREVENTIVE] UNDER COATING[WATER-PROOF AND RUST PREVENTIVE] id098009739900 End Of Sie The shaded areas indicated under body locations that are undercoated to prevent noise and rusting. 09-80C acxuub00000154 CHIPPING-RESISTANT COATING[WATER-PROOF AND RUST PREVENTIVE]...
  • Page 114: Rust Preventive Treatment[Water-Proof And Rust Preventive]

    2007 Mazda CX-7 Bodyshop Manual (3419–1U–06C) BODY STRUCTURE [WATER-PROOF AND RUST PREVENTIVE] RUST PREVENTIVE TREATMENT[WATER-PROOF AND RUST PREVENTIVE] id098009740100 acxuub00000023 End Of Sie 09-80C–6...
  • Page 115: Dumping Sheet Replacement[Water-Proof And Rust Preventive]

    BODY STRUCTURE [WATER-PROOF AND RUST PREVENTIVE] DUMPING SHEET REPLACEMENT[WATER-PROOF AND RUST PREVENTIVE] id098009745700 • After repairing the body, attach the dumping sheet to the location shown in the figure for noise insulation. 09-80C acxuub00000024 09-80C–7...
  • Page 117 BODY STRUCTURE [DIMENSIONS] 09-80D BODY STRUCTURE [DIMENSIONS] UNDERBODY FLAT-PLANE CABIN SIDE FRAME STRAIGHT-LINE DIMENSIONS[DIMENSIONS] ..09-80D–2 DIMENSIONS[DIMENSIONS] ..09-80D–7 UNDERBODY STRAIGHT-LINE ROOM STRAIGHT-LINE DIMENSIONS DIMENSIONS[DIMENSIONS] ..09-80D–3 (1)[DIMENSIONS].
  • Page 118: Underbody Flat-Plane Dimensions[Dimensions]

    BODY STRUCTURE [DIMENSIONS] UNDERBODY FLAT-PLANE DIMENSIONS[DIMENSIONS] id098010740400 • The following figures are bottom and side views. {in} {14.13} {15.31} {17.32} {23.86} {20.31} {24.84} {25.00} {6.18} {0.55} {11.65} {2.20} acxuub00000001 Hole diameter Hole diameter Point Point Designation or bolt or nut Designation or bolt or nut symbol...
  • Page 119: Underbody Straight-Line Dimensions[Dimensions]

    BODY STRUCTURE [DIMENSIONS] UNDERBODY STRAIGHT-LINE DIMENSIONS[DIMENSIONS] id098010740500 • The following figure is a bottom view. mm {in} 2,551 1,170 {100.43} {46.06} 1,163 {45.79} 1,150 {45.28} 1,216 {36.14} {47.87} 1,476 {28.74} {58.11} 2,708 {39.13} 1,548 1,010 {34.61} {106.61} {60.94} {39.76} {32.87} 1,129 09-80D {44.45}...
  • Page 120: Front Body Straight-Line Dimensions (1)[Dimensions]

    BODY STRUCTURE [DIMENSIONS] FRONT BODY STRAIGHT-LINE DIMENSIONS (1)[DIMENSIONS] id098010740600 {in} 1,216 {47.87} 1,625 {63.98} {33.19} 1,588 {62.52} 1,464 {57.64} 1,229 {48.39} {37.68} {36.22} {33.66} acxuub00000004 acxuub00000005 Hole diameter Hole diameter Point Point Designation or bolt or nut Designation or bolt or nut symbol symbol size (mm {in})
  • Page 121: Front Body Straight-Line Dimensions (2)[Dimensions]

    BODY STRUCTURE [DIMENSIONS] FRONT BODY STRAIGHT-LINE DIMENSIONS (2)[DIMENSIONS] id098010740700 {in} 1,432 {56.38} 1,151 1,309 {45.31} 09-80D {51.54} 1,320 1,467 {51.97} {57.76} {10.04} 1,258 1,380 {54.33} 1,228 {9.25} {48.35} {23.98} 1,044 {41.10} 1,014 {39.92} acxuub00000006 acxuub00000007 Hole diameter Hole diameter Point Point Designation or bolt or nut...
  • Page 122: Front Body Straight-Line Dimensions (3)[Dimensions]

    BODY STRUCTURE [DIMENSIONS] FRONT BODY STRAIGHT-LINE DIMENSIONS (3)[DIMENSIONS] id098010740800 {in} 1,500 {59.06} 1,474 {58.03} 1,380 {25.28} {54.33} 1,335 {15.16} {52.56} 1,219 {35.75} {47.99} {9.53} 1,108 {43.62} acxuub00000008 acxuub00000009 Hole diameter Hole diameter Point Point Designation or bolt or nut Designation or bolt or nut symbol symbol...
  • Page 123: Cabin Side Frame Straight-Line Dimensions[Dimensions]

    BODY STRUCTURE [DIMENSIONS] Hole diameter Hole diameter Point Point Designation or bolt or nut Designation or bolt or nut symbol symbol size (mm {in}) size (mm {in}) φ16 {0.63} Shroud side member datum Front side frame datum hole φ7 {0.28} hole Engine mount bracket datum φ16 {0.63}...
  • Page 124: Room Straight-Line Dimensions (1)[Dimensions]

    BODY STRUCTURE [DIMENSIONS] Hole diameter Hole diameter Point Point Designation or bolt or nut Designation or bolt or nut symbol symbol size (mm {in}) size (mm {in}) φ8.2 {0.32} Side frame outer notch Side frame outer datum hole φ12 {0.47} φ4.5 {0.18} Side frame outer datum hole Side frame outer datum hole...
  • Page 125 BODY STRUCTURE [DIMENSIONS] 09-80D acxuub00000011 Hole diameter Hole diameter Point Point Designation or bolt or nut Designation or bolt or nut symbol symbol size (mm {in}) size (mm {in}) φ6 {0.24} φ16 {0.63} Front pillar inner datum hole Center pillar inner datum hole φ7 {0.28} φ10 {0.39} Front pillar inner datum hole...
  • Page 126: Room Straight-Line Dimensions (2)[Dimensions]

    BODY STRUCTURE [DIMENSIONS] ROOM STRAIGHT-LINE DIMENSIONS (2)[DIMENSIONS] id098010743400 {in} 1,150 {45.28} 1,438 {56.61} H-H' {36.65} 1,408 {55.43} 1,564 {61.57} 1,101 {28.70} {43.35} acxuub00000012 acxuub00000013 Hole diameter Hole diameter Point Point Designation or bolt or nut Designation or bolt or nut symbol symbol size (mm {in})
  • Page 127: Room Straight-Line Dimensions (3)[Dimensions]

    BODY STRUCTURE [DIMENSIONS] ROOM STRAIGHT-LINE DIMENSIONS (3)[DIMENSIONS] id098010746200 {in} {38.27} 1,080 {42.52} {38.19} 09-80D {36.93} H-H' {33.43} 1,596 {62.83} {32.95} acxuub00000014 acxuub00000015 Hole diameter Hole diameter Point Point Designation or bolt or nut Designation or bolt or nut symbol symbol size (mm {in}) size (mm {in}) φ7 {0.28}...
  • Page 128: Rear Body Straight-Line Dimensions (1)[Dimensions]

    BODY STRUCTURE [DIMENSIONS] End Of Sie REAR BODY STRAIGHT-LINE DIMENSIONS (1)[DIMENSIONS] BM: REAR BODY id098010746300 {in} {28.54} 1,030 {40.55} 1,399 {55.08} {22.87} 1,168 {45.98} {37.52} 1,573 {61.93} 1,431 {56.34} {11.97} 1,242 {48.90} {24.76} {18.15} {38.54} {23.62} acxuub00000016 acxuub00000017 Hole diameter Hole diameter Point Point...
  • Page 129 BODY STRUCTURE [DIMENSIONS] Hole diameter Hole diameter Point Point Designation or bolt or nut Designation or bolt or nut symbol symbol size (mm {in}) size (mm {in}) φ12 {0.47} φ12 × 18 Rear end panel datum hole F’ Rear end panel datum slot {0.47 ×...
  • Page 131 BODY STRUCTURE [PLASTIC BODY PARTS] 09-80E BODY STRUCTURE [PLASTIC BODY PARTS] PLASTIC PARTS HEAT RESISTING Repairable Bumpers ....09-80E–2 TEMPERATURE POLYPROPYLENE BUMPER [PLASTIC BODY PARTS] ... 09-80E–1 REPAIR[PLASTIC BODY PARTS] .
  • Page 132 BODY STRUCTURE [PLASTIC BODY PARTS] REPAIRABLE RANGE OF POLYPROPYLENE BUMPERS[PLASTIC BODY PARTS] id098011600100 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.
  • Page 133 BODY STRUCTURE [PLASTIC BODY PARTS] POLYPROPYLENE BUMPER REPAIR[PLASTIC BODY PARTS] id098011600200 Scratch on paint only Hole or crack through surface Crack more than 100 mm {3.94in} long or completely broken Bumper Bumper Remove paint surface surface not visible visible Smooth damaged area 09-80E Apply aluminium tape to reverse side of bumper...
  • Page 134 BODY STRUCTURE [PLASTIC BODY PARTS] PROCEDURE[PLASTIC BODY PARTS] id098011600300 Repair of polypropylene bumpers having damage that has reached the surface of the polypropylene and are too serious to be restored by painting only. Hole Flaw Crack B-B, D-D Section A-A Section Section Top coat layer Primer surface layer...
  • Page 135 BODY STRUCTURE [PLASTIC BODY PARTS] 2. Weld the damaged area. • For repair of a cracked area, melt the crack together with a heat gun and a melting attachment. Heat gun Melt together B-B,C-C Section painted surface Attachment for Polypropylene surface Section after melting melting am8rrb00000052...
  • Page 136 BODY STRUCTURE [PLASTIC BODY PARTS] 4. Sand the surface of the polypropylene gradually as it is easily melted by the abrasion heat. Sand the area to which repair agent will be applied. Sand gradually Sand repair area Paint am8rrb00000056 5. Uniformly apply polypropylene primer with a brush to an area larger than the repaired area. Allow to dry about 10 minutes at 20 °C {68 °F}.
  • Page 137 BODY STRUCTURE [PLASTIC BODY PARTS] 7. Sand the area with #180—240 sandpaper. Note • If excessive force is applied to the area when sanding, the surface will be damaged. • If fuzz remains around the repaired area, melt it with a heat gun. 09-80E am8rrb00000062 8.
  • Page 138 BODY STRUCTURE [PLASTIC BODY PARTS] 11. Add the softener to the urethane primer surfacer and spray it on the repaired area. a. Mixing method Urethane primer surfacer + Softener ..Mixture A Mixture A + hardener ..Mixture B Dilute mixture B with thinner to spray on bumper b.

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