Mazda MX-5 2007 Bodyshop Manual
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2007
Mazda MX-5
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., JUNE 2006
Form No. 3426–1U–06F
Part No. 9999–95–060F–07
Title
Section
00
80A
80B
80C
80D
80E

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Summary of Contents for Mazda MX-5 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) JM1 NC15F✻7# 100001— JM1 NC16F✻7# 100001— JM1 NC25F✻7# 100001— JM1 NC26F✻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 VEHICLE IDENTIFICATION NUMBER Selection of Cut-and-join (VIN) CODE ..... . 00-00–2 Locations .
  • Page 4: General Information

    5= 2-door Open, Convertible Top Body 6= 2-door Open, Power Retractable Hardtop 1= without Side air bag Restraint system 2= with Side air bag Carline, series NC= Mazda MX-5 World manufacturer identification JM1= Mazda/Passenger car amxuub0000001 End Of Sie VEHICLE IDENTIFICATION NUMBER (VIN) id000000100300 JM1 NC15F*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 • When there are no specific indications, the standard points and dimensions are symmetrical in regard to the center of the vehicle. • The hypothetical lines may differ according to the vehicle model. • The schematic diagram shows the vehicle as it is projected from the underbody. Example 00-00 Shows vehicle section...
  • 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 DPE2010B011 00-00–6...
  • Page 9 GENERAL INFORMATION • When there are no specific indications, the standard points and dimensions are symmetrical in regard to the center of the vehicle. Example ROOM STRAIGHT-LINE DIMENSIONS (1) 00-00 Shows vehicle section Shows point Shows outline drawing symbol Shows dimension 1,128 {44.41} 1,263...
  • Page 10: Symbols Of Body Dimensions

    GENERAL INFORMATION Symbols of Body Dimensions • The following 8 symbols are used to indicate the standard points. SYMBOL MEANING SYMBOL MEANING Bolt tip Center of circular hole (arrow only) Center of rectangular-shaped hole Center elliptical hole Edge of rectangular-shaped hole Notch Panel seam, bead, etc.
  • Page 11: Remove Dangerous Articles

    GENERAL INFORMATION Remove Dangerous Articles • Remove the fuel tank before using an open flame in that area. Plug connection piping to prevent fuel leakage. 00-00 MZZ2036B003 Use of Pulling Equipment • When using pulling equipment, keep away from the pulling area and use safety wires to prevent accidents.
  • Page 12: Panels

    GENERAL INFORMATION • Securely connect the welding machine ground near the welding area. End Of Sie Ground MZZ2036B006 EFFICIENT REMOVAL OF BODY PANELS id000000739300 Body Measurements • Before removal or rough-cutting, first measure the body at and around the damaged area against the standard reference dimension specifications.
  • Page 13: Rough Cutting Of Damaged Panel

    GENERAL INFORMATION Rough Cutting of Damaged Panel • Verify that there are no parts (such as pipes, hoses, and wiring harness) nearby or on the opposite side of a panel which could be damaged by heat. • For cut-and-join areas, allow for an overlap of 30—50 mm {1.18—1.97 in} and then rough-cut 00-00 the damaged panel.
  • Page 14: Making Holes For Co Arc Welding

    GENERAL INFORMATION Making Holes for CO Arc Welding • For places that cannot be spot welded, make a hole for CO arc welding using a punch or drill as follows. (mm {in}) Panel thickness (ø) Hole diameter (ø) 0.60—0.90 {0.02—0.03} 5 {0.19} 0.91—1.20 {0.04—0.05} 6 {0.23}...
  • Page 15: Welding Notes

    GENERAL INFORMATION Welding Notes • For the number of weld points, welding should be Spot welding performed in accordance with the following Repair weld Original weld reference standards. Original number of welds x 1.3 or more 00-00 CO 2 arc welding If 3mm Repair weld {0.12in} or more...
  • Page 16: Checking Weld Strength

    GENERAL INFORMATION Checking Weld Strength • Installation locations of the engine, chassis, and Chisel dimensions seat belts are designated as important safety locations for weld strength. Check weld strength 20° by driving a chisel between the panels at every 25mm fourth or fifth weld spot, and every tenth regular {0.98in} weld location.
  • Page 17: Anticorrosion, Sound Insulation, And Vibration Insulation

    GENERAL INFORMATION ANTICORROSION, SOUND INSULATION, AND VIBRATION INSULATION id000000739600 Body Sealing • Apply body sealer where necessary. • For locations where application of body sealer is difficult after installation, apply it before installation. 00-00 CJJ2038B016 Application of Undercoating • Apply an undercoat to the required location of the body. CJJ2038B017 Application of Rust Inhibitor •...
  • Page 18: Application Of Damping Sheet

    GENERAL INFORMATION Application of Damping Sheet • Apply damping sheet by heating with an infrared ray lamp. End Of Sie SOKYU_NG: GENERAL INFORMATION CJJ2038B019 ABBREVIATION id000000000800 Control module Center Dynamic stability control Front Hydraulic unit Left Metallic Mica Right Rear End Of Sie 00-00–16...
  • Page 19 BODY & ACCESSORIES SECTION 09-80A Toc of SCT BODY STRUCTURE BODY STRUCTURE [CONSTRUCTION] ..09-80A [DIMENSIONS] ... 09-80D BODY STRUCTURE[PANEL BODY STRUCTURE REPLACEMENT] .
  • Page 20 BODY STRUCTURE [CONSTRUCTION] BODY COMPONENTS CONSTRUCTION[CONSTRUCTION] id098007739700 amxuub0000000 09-80A–2...
  • Page 21 BODY STRUCTURE [CONSTRUCTION] x:Applied -:Not applied Ultra high- High- Thickness Rust proof Part Name tension tension steel (mm) {in} steel steel Hood* 0.95 {0.037} Shroud upper panel 0.70 {0.028} Shroud lower panel 0.70 {0.028} 09-80A Front bumper bracket 2.00 {0.079} Front side frame (outer) 1.00 {0.039} Front side frame...
  • Page 22 BODY STRUCTURE [CONSTRUCTION] Ultra high- High- Thickness Rust proof Part Name tension tension steel (mm) {in} steel steel Rear deck panel 0.80 {0.031} Rear deck 0.70 {0.028} Convertible Top* 0.95 {0.037} Trunk lid panel Power Retractable 0.65 {0.026} Hardtop Floor reinforcement 1.00 {0.039} Front B frame 1.60 {0.063}...
  • Page 23 BODY STRUCTURE [CONSTRUCTION] ADOPTION OF ULTRA HIGH-TENSION STEEL[CONSTRUCTION] id098007785600 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 25 BODY STRUCTURE [PANEL REPLACEMENT] 09-80B BODY STRUCTURE [PANEL REPLACEMENT] SHROUD UPPER PANEL REMOVAL FRONT FRAME COMPONENT [PANEL REPLACEMENT]... 09-80B–3 (FRONT) INSTALLATION[PANEL SHROUD UPPER PANEL INSTALLATION REPLACEMENT] ....09-80B–30 [PANEL REPLACEMENT].
  • Page 26 BODY STRUCTURE [PANEL REPLACEMENT] CORNER PLATE REMOVAL END PLATE REMOVAL [PANEL REPLACEMENT] ... 09-80B–66 [PANEL REPLACEMENT]... 09-80B–77 CORNER PLATE INSTALLATION END PLATE INSTALLATION [PANEL REPLACEMENT] .
  • Page 27: Shroud Upper Panel Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] SHROUD UPPER PANEL REMOVAL[PANEL REPLACEMENT] id098008800400 1. Remove the shroud upper panel. 09-80B SHROUD UPPER PANEL D5U0980B040 End Of Sie 09-80B–3...
  • Page 28: Shroud Upper Panel Installation[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] SHROUD UPPER PANEL INSTALLATION[PANEL REPLACEMENT] id098008603000 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2. Drill holes for plug welds before installing new parts. 3. After temporarily installing new parts, make sure the related parts fit properly. SHROUD UPPER PANEL D5U0980B041 End Of Sie...
  • Page 29: Shroud Lower Panel Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] SHROUD LOWER PANEL REMOVAL[PANEL REPLACEMENT] id098008603100 1. Remove the shroud lower panel. Note • When removing the hood lock bracket and the condenser bracket separately, drill the 7 locations indicated by (A) and the 6 locations indicated by (B). 09-80B HOOD LOCK BRACKET (A) 7...
  • Page 30: Shroud Lower Panel Installtion[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] SHROUD LOWER PANEL INSTALLTION[PANEL REPLACEMENT] id098008603200 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2. Drill holes for plug welds before installing new parts. 3. After temporarily installing new parts, make sure the related parts fit properly. Note •...
  • Page 31: 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. Drill holes for plug welds before installing new parts. 3. After temporarily installing new parts, make sure the related parts fit properly. 09-80B FRONT BUMPER BRACKET D5U0980B045...
  • Page 32: 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 D5U0980B044 End Of Sie CROSSMEMBER No.1 REMOVAL[PANEL REPLACEMENT] BM: CROSSMEMBER No.1 id098008603500 1. Remove the crossmember No.1. 09-80B–8...
  • Page 33 BODY STRUCTURE [PANEL REPLACEMENT] 09-80B CROSSMEMBER No.1 D5U0980B046 09-80B–9...
  • Page 34 BODY STRUCTURE [PANEL REPLACEMENT] 2. Remove the crossmember No.1 side bracket. CROSSMEMBER No.1 SIDE BRACKET CROSSMEMBER No.1 SIDE BRACKET D5U0980B052 End Of Sie 09-80B–10...
  • Page 35: Crossmember No.1 Installation[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] CROSSMEMBER No.1 INSTALLATION[PANEL REPLACEMENT] id098008603600 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2. Drill holes for plug welds before installing new parts. 3. After temporarily installing new parts, make sure the related parts fit properly. 4.
  • Page 36 BODY STRUCTURE [PANEL REPLACEMENT] 5. Install the crossmember No.1. CROSSMEMBER No.1 D5U0980B047 End Of Sie BM: COWL SIDE REINFORCEMENT 09-80B–12...
  • Page 37: Cowl Side Reinforcement Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] COWL SIDE REINFORCEMENT REMOVAL[PANEL REPLACEMENT] id098008741700 1. Remove the cowl side reinforcement. Caution • Be careful not to damage the windshield when drilling the 2 locations indicated by (A). 09-80B (A)2 COWL SIDE REINFORCEMENT D5U0980B048 End Of Sie 09-80B–13...
  • Page 38: 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 plug welds before installing new parts. 3. After temporarily installing new parts, make sure the related parts fit properly. COWL SIDE REINFORCEMENT D5U0980B049 End Of Sie...
  • Page 39: Apron Reinforcement

    BODY STRUCTURE [PANEL REPLACEMENT] APRON REINFORCEMENT COMPONENT REMOVAL[PANEL REPLACEMENT] id098008604700 1. Drill the 15 locations indicated by (A) and 13 locations indicated by (B), then remove the apron reinforcement component. Note • When removing the apron reinforcement (upper) separately, drill the 13 locations indicated by (B) and the 9 locations indicated by (C).
  • Page 40: Apron Reinforcement Component Installation[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] APRON REINFORCEMENT COMPONENT INSTALLATION[PANEL REPLACEMENT] id098008604800 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2. Drill holes for plug welds before installing new parts. 3. After temporarily installing new parts, make sure the related parts fit properly. APRON REINFORCEMENT COMPONENT APRON REINFORCEMENT COMPONENT D5U0980B051...
  • Page 41: 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) 09-80B D5U0980B054 End Of Sie 09-80B–17...
  • Page 42: 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 plug welds before installing new parts. 3. After temporarily installing new parts, make sure the related parts fit properly. APRON REINFORCEMENT (LOWER) D5U0980B055 End Of Sie...
  • Page 43: Front Side Frame Rear Reinforcement Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] FRONT SIDE FRAME REAR REINFORCEMENT REMOVAL[PANEL REPLACEMENT] id098008606500 1. Remove the front side frame rear reinforcement. 09-80B DRIVER'S SIDE:7 PASSENGER'S SIDE:8 FRONT SIDE FRAME REAR REINFORCEMENT D5U0980B056 End Of Sie 09-80B–19...
  • Page 44: Front Side Frame Rear Reinforcement Installation[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] FRONT SIDE FRAME REAR REINFORCEMENT INSTALLATION[PANEL REPLACEMENT] id098008606600 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2. Drill holes for plug welds before installing new parts. 3. After temporarily installing new parts, make sure the related parts fit properly. DRIVER'S SIDE:7 PASSENGER'S SIDE:8 FRONT SIDE FRAME REAR...
  • Page 45: Front Side Frame (Outer) Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] FRONT SIDE FRAME (OUTER) REMOVAL[PANEL REPLACEMENT] id098008606100 1. Remove the front side frame (outer). 09-80B FRONT SIDE FRAME (OUTER) D5U0980B058 End Of Sie 09-80B–21...
  • Page 46: Front Side Frame (Outer) Installation[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] FRONT SIDE FRAME (OUTER) INSTALLATION[PANEL REPLACEMENT] id098008606200 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2. Drill holes for plug welds before installing new parts. 3. After temporarily installing new parts, make sure the related parts fit properly. FRONT SIDE FRAME (OUTER) D5U0980B059 End Of Sie...
  • Page 47: Front Side Frame Component Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] FRONT SIDE FRAME COMPONENT REMOVAL[PANEL REPLACEMENT] id098008741900 1. Remove the front side frame component. 09-80B FRONT SIDE FRAME COMPONENT D5U0980B060 End Of Sie 09-80B–23...
  • Page 48: 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 plug welds before installing new parts. 3. After temporarily installing new parts, make sure the related parts fit properly. FRONT SIDE FRAME COMPONENT D5U0980B061 End Of Sie...
  • Page 49: Front Side Frame (Partial Cutting) Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] FRONT SIDE FRAME (PARTIAL CUTTING) REMOVAL[PANEL REPLACEMENT] id098008742100 1. Rough cut and remove the damaged part of the front side frame. 09-80B CUT-AND-JOIN LOCATION ROUGH CUT LOCATION 70mm {2.76in} 45mm {1.77in} FRONT SIDE FRAME D5U0980B068 End Of Sie 09-80B–25...
  • 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. 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 51 BODY STRUCTURE [PANEL REPLACEMENT] 5. Trial-fit the new and existing parts, weld the existing parts and the reinforcement, and then butt weld the new and existing parts. Caution • Press fit the reinforcement panel and the body side material, and then plug weld them. L=10mm x 2 {0.39in} 20mm...
  • Page 52: Front Frame Component (Front) Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] FRONT FRAME COMPONENT (FRONT) REMOVAL[PANEL REPLACEMENT] id098008606300 1. Drill the 2 locations indicated by (A). Note • To prevent damage to the front side frame rear reinforcement, grind it using a belt grinder from the front side.
  • Page 53 BODY STRUCTURE [PANEL REPLACEMENT] FRONT FRAME COMPONENT (FRONT) 09-80B D5U0980B141 End Of Sie 09-80B–29...
  • Page 54: Front Frame Component (Front) Installation[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] FRONT FRAME COMPONENT (FRONT) INSTALLATION[PANEL REPLACEMENT] id098008606400 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2. Drill holes for plug welds before installing new parts. 3. After temporarily installing new parts, make sure the related parts fit properly. Caution •...
  • Page 55 BODY STRUCTURE [PANEL REPLACEMENT] FRONT FRAME COMPONENT (FRONT) 09-80B D5U0980B143 End Of Sie 09-80B–31...
  • Page 56: Front Frame Component Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] FRONT FRAME COMPONENT REMOVAL[PANEL REPLACEMENT] id098008616400 1. Drill the 2 location indicated by (A) from the interior, as they cannot be seen from the outer side. 2. Remove the front frame component. (A)2 FRONT FRAME COMPONENT DRIVER'S SIDE:7 PASSENGER'S SIDE:8 D5U0980B062...
  • Page 57 BODY STRUCTURE [PANEL REPLACEMENT] FRONT FRAME COMPONENT 09-80B FRONT FRAME COMPONENT D5U0980B063 End Of Sie 09-80B–33...
  • Page 58: Front Frame Component Installation[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] FRONT FRAME COMPONENT INSTALLATION[PANEL REPLACEMENT] id098008616500 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2. Drill holes for plug welds before installing new parts. 3. After temporarily installing new parts, make sure the related parts fit properly. FRONT FRAME COMPONENT DRIVER'S SIDE:7 PASSENGER'S SIDE:8...
  • Page 59 BODY STRUCTURE [PANEL REPLACEMENT] FRONT FRAME COMPONENT 09-80B FRONT FRAME COMPONENT D5U0980B065 End Of Sie BM: TORQUE BOX 09-80B–35...
  • Page 60: Torque Box Component Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] TORQUE BOX COMPONENT REMOVAL[PANEL REPLACEMENT] id098008616800 1. Remove the torque box component. Note • When removing the torque box separately, drill the 24 locations indicated by (A). (A)10 (A)2 TORQUE BOX COMPONENT D5U0980B066 09-80B–36...
  • Page 61 BODY STRUCTURE [PANEL REPLACEMENT] 09-80B (A)2 TORQUE BOX COMPONENT (A)6 (A)3 (A)1 D5U0980B067 End Of Sie 09-80B–37...
  • Page 62: Torque Box Component Installation[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] TORQUE BOX COMPONENT INSTALLATION[PANEL REPLACEMENT] id098008616900 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2. Drill holes for plug welds before installing new parts. 3. After temporarily installing new parts, make sure the related parts fit properly. TORQUE BOX COMPONENT D5U0980B070 09-80B–38...
  • Page 63 BODY STRUCTURE [PANEL REPLACEMENT] 09-80B TORQUE BOX COMPONENT D5U0980B071 End Of Sie BM: FRONT PILLAR 09-80B–39...
  • Page 64: Front Pillar (Outer) Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] FRONT PILLAR (OUTER) REMOVAL[PANEL REPLACEMENT] id098008716600 1. Rough cut area (A), drill the 18 locations indicated by (B). Caution • During rough cutting, be careful not to damage the front pillar reinforcement indicated by dotted lines in the figure. 2.
  • Page 65: Front Pillar (Outer) Installation[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] FRONT PILLAR (OUTER) INSTALLATION[PANEL REPLACEMENT] id098008716700 1. To prepare for installation, cut area (A) on the new front header. 2. Grind the area (A) on the new front header with a disk grinder to finish the surface. FRONT HEADER 09-80B (A)ROUGH CUT LOCATION...
  • Page 66 BODY STRUCTURE [PANEL REPLACEMENT] CUT-AND-JOIN LOCATION FRONT HEADER (B)BOLT 545mm {21.46in} D5U0980B073 End Of Sie 09-80B–42...
  • Page 67: Hinge Pillar (Outer) Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] HINGE PILLAR (OUTER) REMOVAL[PANEL REPLACEMENT] id098008613500 1. Drill the 2 locations indicated by (A) from the interior. 2. Remove the hinge pillar (outer). 3. Remove the spot weld sealer using a disc grinder. 09-80B (A)2 HINGE PILLAR (OUTER) D5U0980B074 4.
  • Page 68 BODY STRUCTURE [PANEL REPLACEMENT] 5. Remove the spot weld sealer using a disc grinder. COWL SIDE PANEL D5U0980B075 09-80B–44...
  • Page 69 BODY STRUCTURE [PANEL REPLACEMENT] 6. Remove the front pillar reinforcement. 09-80B FRONT PILLAR REINFORCEMENT D5U0980B076 09-80B–45...
  • Page 70 BODY STRUCTURE [PANEL REPLACEMENT] 7. Remove the front pillar (inner). FRONT PILLAR (INNER) D5U0980B077 End Of Sie 09-80B–46...
  • Page 71: Hinge Pillar (Outer) Installation[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] HINGE PILLAR (OUTER) INSTALLATION[PANEL REPLACEMENT] id098008613600 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 72 BODY STRUCTURE [PANEL REPLACEMENT] 5. Install the front pillar reinforcement. FRONT PILLAR REINFORCEMENT D5U0980B079 6. Install the cowl side panel. 09-80B–48...
  • Page 73 BODY STRUCTURE [PANEL REPLACEMENT] 09-80B COWL SIDE PANEL D5U0980B080 09-80B–49...
  • Page 74 BODY STRUCTURE [PANEL REPLACEMENT] 7. Install the hinge pillar (outer). HINGE PILLAR (OUTER) D5U0980B081 End Of Sie BM: REAR FENDER PANEL 09-80B–50...
  • Page 75: Rear Fender Panel (Lower) Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] REAR FENDER PANEL (LOWER) REMOVAL[PANEL REPLACEMENT] id098008614300 1. Remove the rear fender panel (lower). 09-80B REAR FENDER PANEL (LOWER) D5U0980B083 End Of Sie 09-80B–51...
  • Page 76: Rear Fender Panel (Lower) Installation[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] REAR FENDER PANEL (LOWER) INSTALLATION[PANEL REPLACEMENT] id098008614400 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2. Drill holes for plug welds before installing new parts. 3. After temporarily installing new parts, make sure the related parts fit properly. REAR FENDER PANEL (LOWER) D5U0980B084 End Of Sie...
  • Page 77: Rear Fender Panel Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] REAR FENDER PANEL REMOVAL[PANEL REPLACEMENT] id098008744900 1. Drill the 65 locations (vehicle with convertible top)/64 locations (vehicle with power retractable hardtop) indicated by (A), 17 locations indicated by (B), and 2 locations (vehicle with convertible top only) indicated by (C), then remove the rear fender panel.
  • Page 78: Convertible Top

    BODY STRUCTURE [PANEL REPLACEMENT] 3. Remove the spot weld sealer using a disc grinder. Convertible Top (A)11 REAR DECK PANEL (A)2 (C)2 (A)8 REAR FENDER PANEL amxuub0000000 09-80B–54...
  • Page 79: Power Retractable Hardtop

    BODY STRUCTURE [PANEL REPLACEMENT] Power Retractable Hardtop 09-80B (A)11 (A)1 (A)8 REAR FENDER PANEL amxuub00000004 End Of Sie 09-80B–55...
  • Page 80: Rear Fender Panel Installation[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] REAR FENDER PANEL INSTALLATION[PANEL REPLACEMENT] id098008745000 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 81: Convertible Top

    BODY STRUCTURE [PANEL REPLACEMENT] Convertible Top 09-80B REAR DECK PANEL REAR FENDER PANEL amxuub0000000 Power Retractable Hardtop Note • Spot weld the 3 locations indicated by (A) and assemble the rear fender and the corner plate before installing the rear fender to the vehicle. •...
  • Page 82 BODY STRUCTURE [PANEL REPLACEMENT] (C)11 (B)1 (A)3 CORNER PLATE REAR FENDER PANEL amxuub00000007 End Of Sie 09-80B–58...
  • Page 83: Side Sill Reinforcement (Front) Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] SIDE SILL REINFORCEMENT (FRONT) REMOVAL[PANEL REPLACEMENT] BM: SIDE SILL PANEL id098008616200 1. Rough cut and remove the damaged part of the side sill reinforcement (front). Caution • During rough cutting, be careful not to damage the front pillar reinforcement indicated by dotted lines in the figure.
  • Page 84: Side Sill Reinforcement (Front) Installation[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] SIDE SILL REINFORCEMENT (FRONT) INSTALLATION[PANEL REPLACEMENT] id098008616300 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 85: Side Sill Reinforcement (Center) Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] SIDE SILL REINFORCEMENT (CENTER) REMOVAL[PANEL REPLACEMENT] id098008609600 1. Rough cut at the locations shown in the figure to remove damaged parts. 2. Remove the side sill reinforcement (center). 09-80B ROUGH CUT LOCATION CUT-AND-JOIN LOCATION CUT-AND-JOIN LOCATION ROUGH CUT LOCATION 60mm 120mm...
  • Page 86: Side Sill Reinforcement (Center) Installation[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] SIDE SILL REINFORCEMENT (CENTER) INSTALLATION[PANEL REPLACEMENT] id098008609700 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 87: Side Sill Reinforcement Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] SIDE SILL REINFORCEMENT REMOVAL[PANEL REPLACEMENT] id098008609200 Caution • The side sill reinforcement removal procedure is based on the condition that the cowl side panel and the hinge pillar (outer) and the rear fender panel have been removed. 1.
  • Page 88: Side Sill Reinforcement Installation[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] SIDE SILL REINFORCEMENT INSTALLATION[PANEL REPLACEMENT] id098008609300 Caution • The side sill reinforcement installation procedure is based on the condition that the cowl side panel and the hinge pillar (outer) and the rear fender panel have been removed. 1.
  • Page 89: Rear End Panel Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] REAR END PANEL REMOVAL[PANEL REPLACEMENT] id098008744500 1. Remove the rear end panel. REAR END PANEL 09-80B D5U0980B095 End Of Sie 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.
  • Page 90: Corner Plate Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] CORNER PLATE REMOVAL[PANEL REPLACEMENT] id098008610400 1. Remove the corner plate. CORNER PLATE D5U0980B109 End Of Sie CORNER PLATE INSTALLATION[PANEL REPLACEMENT] id098008610500 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2.
  • Page 91: Rear Fender Rain Rail (Partial Cutting) Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] REAR FENDER RAIN RAIL (PARTIAL CUTTING) REMOVAL[PANEL REPLACEMENT] id098008610600 1. Rough cut at the locations shown in the figure to remove damaged parts. 2. Remove the rear fender rain rail and corner plate. CUT-AND-JOIN LOCATION ROUGH CUT LOCATION 09-80B 55mm {2.17in}...
  • Page 92: Rear Fender Rain Rail (Partial Cutting) Installation[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] REAR FENDER RAIN RAIL (PARTIAL CUTTING) INSTALLATION[PANEL REPLACEMENT] id098008610700 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 93: Rear Deck Panel Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] REAR DECK PANEL REMOVAL[PANEL REPLACEMENT] id098008610800 1. Remove the rear deck panel. Convertible Top 09-80B REAR DECK PANEL amxuub0000000 09-80B–69...
  • Page 94: Power Retractable Hardtop

    BODY STRUCTURE [PANEL REPLACEMENT] Power Retractable Hardtop REAR DECK PANEL amxuub00000010 End Of Sie 09-80B–70...
  • Page 95: Rear Deck Panel Installation[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] REAR DECK PANEL INSTALLATION[PANEL REPLACEMENT] id098008610900 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2. Drill holes for plug welds before installing new parts. 3. After temporarily installing new parts, make sure the related parts fit properly. Convertible Top 09-80B REAR DECK PANEL...
  • Page 96: Power Retractable Hardtop

    BODY STRUCTURE [PANEL REPLACEMENT] Power Retractable Hardtop REAR DECK PANEL amxuub00000012 End Of Sie 09-80B–72...
  • Page 97: Rear Fender Rain Rail Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] REAR FENDER RAIN RAIL REMOVAL[PANEL REPLACEMENT] id098008611000 1. Remove the rear fender rain rail. Convertible Top 09-80B REAR FENDER RAIN RAIL RH:3 LH:5 amxuub0000001 09-80B–73...
  • Page 98: Power Retractable Hardtop

    BODY STRUCTURE [PANEL REPLACEMENT] Power Retractable Hardtop REAR FENDER RAIN RAIL amxuub00000014 End Of Sie 09-80B–74...
  • Page 99: Rear Fender Rain Rail Installation[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] REAR FENDER RAIN RAIL INSTALLATION[PANEL REPLACEMENT] id098008611100 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2. Drill holes for plug welds before installing new parts. 3. After temporarily installing new parts, make sure the related parts fit properly. Convertible Top 09-80B REAR FENDER RAIN RAIL...
  • Page 100 BODY STRUCTURE [PANEL REPLACEMENT] Power Retractable Hardtop REAR FENDER RAIN RAIL REAR FENDER GUSSET amxuub00000016 End Of Sie 09-80B–76...
  • Page 101: End Plate Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] END PLATE REMOVAL[PANEL REPLACEMENT] id098008611200 1. Remove the bolt locations indicated by (A). 2. Remove the end plate. 09-80B (A)BOLT END PLATE D5U0980B103 End Of Sie 09-80B–77...
  • Page 102: End Plate Installation[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] END PLATE INSTALLATION[PANEL REPLACEMENT] id098008611300 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2. Drill holes for plug welds before installing new parts. 3. After temporarily installing new parts, make sure the related parts fit properly. 4.
  • Page 103 BODY STRUCTURE [PANEL REPLACEMENT] 09-80B (A)BOLT END PLATE D5U0980B104 End Of Sie 09-80B–79...
  • Page 104: Corner Junction Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] CORNER JUNCTION REMOVAL[PANEL REPLACEMENT] id098008611400 1. Remove the corner junction. CORNER JUNCTION D5U0980B105 End Of Sie 09-80B–80...
  • Page 105: Corner Junction Installation[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] CORNER JUNCTION INSTALLATION[PANEL REPLACEMENT] id098008611500 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2. Drill holes for plug welds before installing new parts. 3. After temporarily installing new parts, make sure the related parts fit properly. 09-80B CORNER JUNCTION D5U0980B106...
  • Page 106: Wheel House (Inner) Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] WHEEL HOUSE (INNER) REMOVAL[PANEL REPLACEMENT] id098008611600 1. Remove the wheel house (inner). 2. Remove the spot weld sealer using a disc grinder. WHEEL HOUSE (INNER) D5U0980B107 End Of Sie 09-80B–82...
  • Page 107: Wheel House (Inner) Installation[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] WHEEL HOUSE (INNER) INSTALLATION[PANEL REPLACEMENT] id098008611700 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2. Drill holes for plug welds before installing new parts. 3. Before installing new parts, apply spot weld sealer to the wheel arch line. 4.
  • Page 108: Rear Floor Pan Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] REAR FLOOR PAN REMOVAL[PANEL REPLACEMENT] id098008742700 1. Rough cut area (A). Caution • During rough cutting, be careful not to damage the crossmember No.4 indicated by dotted lines in the figure. 2. Remove the rear floor pan. (A)ROUGH CUT LOCATION REAR FLOOR PAN CROSSMEMBER No.4...
  • Page 109 BODY STRUCTURE [PANEL REPLACEMENT] 09-80B D5U0980B112 End Of Sie 09-80B–85...
  • Page 110: 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 111 BODY STRUCTURE [PANEL REPLACEMENT] 09-80B D5U0980B114 End Of Sie BM: REAR SIDE FRAME 09-80B–87...
  • Page 112: Rear Side Frame (Partial Cutting) Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] REAR SIDE FRAME (PARTIAL CUTTING) REMOVAL[PANEL REPLACEMENT] id098008742900 1. Rough cut and remove the damaged part of the rear side frame. 30mm {1.18in} 30mm {1.18in} REAR SIDE FRAME CUT-AND-JOIN LOCATION ROUGH CUT LOCATION D5U0980B115 End Of Sie REAR SIDE FRAME (PARTIAL CUTTING) INSTALLATION[PANEL REPLACEMENT] id098008743000 Caution...
  • Page 113 BODY STRUCTURE [PANEL REPLACEMENT] 5. Trial-fit the new and existing parts, weld the existing parts and the reinforcement, and then butt weld the new and existing parts. Caution • Press fit the reinforcement panel and the body side material, and then plug weld them. L=10mm x 2 {0.39in} 40mm...
  • Page 114: Front Header Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] FRONT HEADER REMOVAL[PANEL REPLACEMENT] id098008612700 1. Rough cut and remove the damaged part of the front header. Caution • During rough cutting, be careful not to damage the front pillar reinforcement indicated by dotted lines in the figure. FRONT HEADER FRONT HEADER ROUGH CUT LOCATION...
  • Page 115: Front Header Installation[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] FRONT HEADER INSTALLATION[PANEL REPLACEMENT] id098008612800 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. Drill holes for plug welds before installing new parts. 3.
  • Page 117 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 RUST UNDER COATING[WATER-PROOF AND PREVENTIVE] .
  • Page 118: 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. D5U0980B120 09-80C–2...
  • Page 119 BODY STRUCTURE [WATER-PROOF AND RUST PREVENTIVE] 09-80C D5U0980B126 09-80C–3...
  • Page 120 BODY STRUCTURE [WATER-PROOF AND RUST PREVENTIVE] D5U0980B121 09-80C–4...
  • Page 121 BODY STRUCTURE [WATER-PROOF AND RUST PREVENTIVE] 09-80C D5U0980B122 End Of Sie 09-80C–5...
  • Page 122: Under Coating[Water-Proof And Rust Preventive]

    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. D5U0980B123 09-80C–6...
  • Page 123: Rust Preventive Treatment[Water-Proof And Rust Preventive]

    BODY STRUCTURE [WATER-PROOF AND RUST PREVENTIVE] RUST PREVENTIVE TREATMENT[WATER-PROOF AND RUST PREVENTIVE] id098009740100 09-80C D5U0980B124 End Of Sie 09-80C–7...
  • Page 124: Dumping Sheet Replacement[Water-Proof And Rust Preventive]

    BODY STRUCTURE [WATER-PROOF AND RUST PREVENTIVE] DUMPING SHEET REPLACEMENT[WATER-PROOF AND RUST PREVENTIVE] id098009745700 D5U0980B125 End Of Sie 09-80C–8...
  • Page 125 BODY STRUCTURE [DIMENSIONS] 09-80D BODY STRUCTURE [DIMENSIONS] UNDERBODY FLAT-PLANE CABIN SIDE FRAME DIMENSIONS[DIMENSIONS] ..09-80D–2 STRAIGHT-LINE DIMENSIONS UNDERBODY FRONT STRAIGHT-LINE [DIMENSIONS] ....09-80D–9 DIMENSIONS[DIMENSIONS] .
  • Page 126: Underbody Flat-Plane Dimensions[Dimensions]

    BODY STRUCTURE [DIMENSIONS] UNDERBODY FLAT-PLANE DIMENSIONS[DIMENSIONS] id098010740400 • The following figures are bottom and side views. {in} {4.53} {10.35} {15.55} {20.67} {12.01} {12.76} {6.89} {10.43} {9.25} {11.22} {5.75} {11.10} D5U0980B001 Hole diameter Hole diameter Point Point Designation or bolt or nut Designation or bolt or nut symbol...
  • Page 127: Underbody Front 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} Rear crossmember mounting ø16 x 20 M14 {0.55} Rear side frame datum slot bolt {0.63 x 0.79} End Of Sie...
  • Page 128: Underbody Rear 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} Engine mounting bolt M14 {0.55} ø16 x 20 Front frame rear datum slot Engine mounting bolt M14 {0.55} {0.63 x 0.79}...
  • Page 129 BODY STRUCTURE [DIMENSIONS] 09-80D D5U0980B023 Hole diameter Hole diameter Point Point Designation or bolt or nut Designation or bolt or nut symbol symbol size mm {in} size mm {in} Front B frame datum hole ø12 {0.47} Rear crossmember mounting M14 {0.55} bolt ø12 x 18 Front B frame datum slot...
  • Page 130: Front Body Straight-Line Dimensions (1)[Dimensions]

    BODY STRUCTURE [DIMENSIONS] FRONT BODY STRAIGHT-LINE DIMENSIONS (1)[DIMENSIONS] id098010740600 {in} {38.74} 1,330 {52.36} {22.05} 1,478 {58.19} {23.90} 1088 {20.12} {42.83} 1,520 {59.84} 1,286 {50.63} 1,006 {39.61} {21.38} {4.92} {37.13} {17.20} {34.17} D5U0980B004 G,G' D5U0980B005 Hole diameter Hole diameter Point Point Designation or bolt or nut Designation...
  • Page 131: Front Body Straight-Line Dimensions (2)[Dimensions]

    BODY STRUCTURE [DIMENSIONS] End Of Sie FRONT BODY STRAIGHT-LINE DIMENSIONS (2)[DIMENSIONS] id098010740700 {in} {19.49} 09-80D {12.87} 1,451 1,398 {57.13} {55.04} 1,330 {52.36} {35.91} 1,232 1,548 {60.94} 1,138 {48.50} {44.80} 1,086 {42.76} 1,508 {59.37} {32.36} {11.22} {14.45} {35.31} 1,327 {52.24} D5U0980B006 D5U0980B007 Hole diameter Hole diameter...
  • Page 132: Front Body Straight-Line Dimensions (3)[Dimensions]

    BODY STRUCTURE [DIMENSIONS] FRONT BODY STRAIGHT-LINE DIMENSIONS (3)[DIMENSIONS] id098010740800 {in} {35.31} {37.99} {31.69} {17.56} {39.06} 1,042 {41.02} {15.24} 1,232 {48.50} 1,013 {39.88} {37.68} D5U0980B008 D5U0980B009 09-80D–8...
  • Page 133: 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} Front header notch Suspension mounting ø8.2 {0.32} reinforcement datum hole Wiper installation hole ø7 {0.28} Front fender installation hole ø10 {0.39}...
  • Page 134: Room Straight-Line Dimensions (1)[Dimensions]

    BODY STRUCTURE [DIMENSIONS] ROOM STRAIGHT-LINE DIMENSIONS (1)[DIMENSIONS] id098010743300 {in} {35.16} RH:893 {34.49} LH:876 RH:908 {35.75} LH:888 {34.96} RH:956 {37.64} LH:934 {36.77} G-G' {38.54} 1,503 {59.17} RH:979 LH:956 {37.64} {31.65} RH:804 LH:777 {30.59} D5U0980B012 D5U0980B013 Hole diameter Hole diameter Point Point Designation or bolt or nut Designation...
  • Page 135: Room Straight-Line Dimensions (2)[Dimensions]

    BODY STRUCTURE [DIMENSIONS] ROOM STRAIGHT-LINE DIMENSIONS (2)[DIMENSIONS] id098010743400 {in} {30.16} {47.52} RH:1,207 LH:1,189 {46.81} {35.43} RH:900 {34.53} LH:877 RH:1,178 {46.38} 1,236 RH:995 {39.17} LH:1,162 {45.75} {48.66} LH:971 {38.23} RH:763 {30.04} LH:740 {29.13} 09-80D RH:774 {30.47} LH:746 {29.37} D5U0980B014 D5U0980B015 Hole diameter Hole diameter Point Point...
  • Page 136: Room Straight-Line Dimensions (3)[Dimensions]

    BODY STRUCTURE [DIMENSIONS] End Of Sie ROOM STRAIGHT-LINE DIMENSIONS (3)[DIMENSIONS] id098010746200 {in} {29.29} 1,264 {49.76} 1,366 {53.78} 1,533 {60.35} 1,127 {44.37} 1,410 {55.51} D5U0980B016 D5U0980B017 Hole diameter Hole diameter Point Point Designation or bolt or nut Designation or bolt or nut symbol symbol size mm {in}...
  • Page 137: Rear Body Straight-Line Dimensions[Dimensions]

    BODY STRUCTURE [DIMENSIONS] REAR BODY STRAIGHT-LINE DIMENSIONS[DIMENSIONS] id098010748200 {in} {32.13} 1,072 {42.20} {10.63} 1,320 {51.97} {9.72} {35.12} {31.54} {9.06} 09-80D D5U0980B018 D5U0980B019 Hole diameter Hole diameter Point Point Designation or bolt or nut Designation or bolt or nut symbol symbol size mm {in} size mm {in} ø8 x 12...
  • Page 139 BODY STRUCTURE [PLASTIC BODY PARTS] 09-80E BODY STRUCTURE [PLASTIC BODY PARTS] PLASTIC PARTS HEAT RESISTING Repairable Bumpers ....09-80E–2 TEMPERATURE POLYPROPYLENE BUMPER REPAIR [PLASTIC BODY PARTS] ... 09-80E–1 [PLASTIC BODY PARTS].
  • Page 140 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 141 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 Remove paint Bumper surface surface not visible visible Smooth damaged area 09-80E Apply aluminium tape to reverse side of bumper...
  • Page 142 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 143 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 Section after melting Polypropylene surface melting ZUA9818B003...
  • Page 144 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 YMU980PCX 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 145 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 YMU980PD0 8.
  • Page 146 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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