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Mazda6
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
miantenance 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
APPLICATION:
This manual is applicable to vehicles
beginning with the Vehicle Identification
Numbers (VIN) shown on the following
page.
CONTENTS
Title
GENERAL INFORMATION
CONSTRUCTION
PANEL REPLACEMENT
WATER-PROOF AND RUST PREVENTIVE
TREATMENT
DIMENSIONS
PLASTIC BODY PARTS
PRIMARY COLOR MIXTURE CHART FOR
BODY COLORS
© 2002 Mazda Motor Corporation
PRINTED IN THE NETHERLANDS, March 2002
3360–1E–02C
Section
I
II
III
IV
V
VI
VII

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   Summary of Contents for Mazda 2002 6

  • Page 1

    DIMENSIONS use by technicians of Authorized Mazda PLASTIC BODY PARTS Dealers to help them service and repair Mazda vehicles. It can also be useful to PRIMARY COLOR MIXTURE CHART FOR owners and operators of Mazda vehicles in BODY COLORS performing limited repair and maintenance on Mazda vehicles.

  • Page 2

    VEHICLE IDENTIFICATION NUMBERS (VIN) European (L.H.D.) specs. JMZ GG1232✻ ✻ ✻ ✻ # 100001— JMZ GG1432✻ ✻ ✻ ✻ # 100001— JMZ GG1282✻ ✻ ✻ ✻ # 100001— JMZ GG1482✻ ✻ ✻ ✻ # 100001— JMZ GG12F2✻ ✻ ✻ ✻ # 100001— JMZ GG14F2✻...

  • Page 3

    The contents of this manual, including drawings and specifications, are the latest available at the time of printing, and Mazda Motor Corporation reserves the right to change the vehicle designs and alter the contents of this manual without notice and without incurring obligation.

  • Page 4: Table Of Contents

    G ENERAL INFORMATION HOW TO USE THIS MANUAL ........ I-2 HOW TO READ EFFICIENT REPLACEMENT OF BODY PANELS..........I-2 HOW TO READ BODY DIMINSIONS....I-3 SERVICE PRECAUTIONS ........I-5 SERVICE PRECAUTIONS ........I-5 EFFICIENT REPLACEMENT OF BODY PANELS..............I-7 EFFICIENT REMOVAL OF BODY PANELS..I-7 INSTALLATION PREPARATIONS .......

  • Page 5: How To Use This Manual

    HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL HOW TO READ EFFICIENT REPLACEMENT OF BODY PANELS A6E201000001B01 • 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: How To Read Body Diminsions

    HOW TO USE THIS MANUAL HOW TO READ BODY DIMINSIONS A6E201000001B02 Body Dimensions (Flat-plane Dimensions) • Flat-plane dimensions are the dimensions measured by projecting certain reference points onto a plane surface. • When there are no specific indications, the standard points and dimensions are symmetrical in regard to the center of the vehicle.

  • Page 7

    HOW TO USE THIS MANUAL Body Dimensions (Straight-line Dimensions) • Straight-line dimensions are the actual dimensions between two standard points. • When there are no specific indications, the standard points and dimensions are symmetrical in regard to the center of the vehicle. MZZ2010B004 Symbols of Body Dimensions •...

  • Page 8: Service Precautions

    SERVICE PRECAUTIONS SERVICE PRECAUTIONS SERVICE PRECAUTIONS A6E203600025B01 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 9

    SERVICE PRECAUTIONS Use of Pulling Equipment • When using pulling equipment, keep away from the pulling area and use safety wires to prevent accidents. MZZ2036B004 Prevent Short Circuits • Turn the ignition switch to the LOCK position. • Disconnect the buttery cables. MZZ2036B005 •...

  • Page 10: Efficient Replacement Of Body Panels

    EFFICIENT REPLACEMENT OF BODY PANELS EFFICIENT REPLACEMENT OF BODY PANELS EFFICIENT REMOVAL OF BODY PANELS A6E203800026B01 Body Measurements • Before removal or rough-cutting, first measure the body at and around the damaged area against the standard reference dimension specifications. If there is deformation, use frame repair equipment to make a rough correction.

  • Page 11: Installation Preparations

    EFFICIENT REPLACEMENT OF BODY PANELS 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 the damaged panel.

  • Page 12: Efficient Installation Of Body Panels

    EFFICIENT REPLACEMENT OF BODY PANELS 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}) Board thickness (ø) Hole diameter (ø) 0.60—0.90 {0.02—0.03} 5 {0.19} 0.91—1.20 {0.04—0.05}...

  • Page 13

    EFFICIENT REPLACEMENT OF BODY PANELS Welding Notes • For the number of weld points, welding should be performed in accordance with the following reference standards. MZZ2038B005 Spot Welding Notes • The shape of the spot welder tip is D=(2×t)+3. If the upper panel thickness is different from that of the under panel, adjust to the thinner one.

  • Page 14

    EFFICIENT REPLACEMENT OF BODY PANELS Checking Weld Strength • Installation locations of the engine, chassis, and seat belts are designated as important safety locations for weld strength. Check weld strength by driving a chisel between the panels at every fourth or fifth weld spot, and every tenth regular weld location.

  • Page 15: After-installation Rust Proofing, Noise And Vibration Insulating

    EFFICIENT REPLACEMENT OF BODY PANELS AFTER-INSTALLATION RUST PROOFING, NOISE AND VIBRATION INSULATING A6E203800026B04 Body Sealing • Apply body sealer where necessary. • For locations where application of body sealer is difficult after installation, apply it before installation. MZJ2038B016 Application of Undercoating •...

  • Page 16

    EFFICIENT REPLACEMENT OF BODY PANELS ABBREVIATION Five-door hatchback Front Rear Right Left Metallic Mica End Of Sie I–13...

  • Page 17

    C ONSTRUCTION CONSTRUCTION ........... II-2 CONSTRUCTION ..........II-2 II–1...

  • Page 18

    CONSTRUCTION CONSTRUCTION CONSTRUCTION A6E981007000B01 SEDAN A6J9810B001 II–2...

  • Page 19

    CONSTRUCTION :Applied -:Not applied High- Rust High- Rust Thickness Thickness Part Name tension proof Part Name tension proof (mm) {in} (mm) {in} steel steel steel steel 25 Roof rail inner 1.2{0.047} Bonnet 0.7{0.028} 0.65 Front bumper bracket 2.9{0.114} 26 Rear pillar inner {0.026} 1.6{0.063} Front side...

  • Page 20

    CONSTRUCTION A6J9810B002 II–4...

  • Page 21

    CONSTRUCTION x:Applied -:Not applied High- Rust High- Rust Thickness Thickness Part Name tension proof Part Name tension proof (mm) {in} (mm) {in} steel steel steel steel 25 Roof rail inner 1.2{0.047} Bonnet 0.7{0.028} 0.65 Front bumper bracket 2.9{0.114} 26 Rear pillar inner {0.026} 1.6{0.063} Front side...

  • Page 22

    P ANEL REPLACEMENT I I I PANEL REPLACEMENT........III-2 SHROUD UPPER REINFORCEMENT REMOVAL............III-2 SHROUD UPPER RAINFORCEMENT INSTALLATION..........III-3 COWL SIDE REINFORCEMENT AND COWL UPPER PLATE REMOVAL ....III-4 COWL SIDE REINFORCEMENT AND COWL UPPER PLATE INSTALLATION ..III-5 APRON REINFORCEMENT ASSEMBLY REMOVAL............

  • Page 23: Panel Replacement

    PANEL REPLACEMENT PANEL REPLACEMENT SHROUD UPPER REINFORCEMENT REMOVAL A6E981253152B01 1. Remove the shroud upper reinforcement. A6E9812B001 End Of Sie III–2...

  • Page 24: Shroud Upper Rainforcement Installation

    PANEL REPLACEMENT SHROUD UPPER RAINFORCEMENT INSTALLATION A6E981253152B02 1. Drill holes for plug welds before installing new parts. 2. After trial-fitting new parts, make sure the related parts fit properly. A6E9812B002 End Of Sie III–3...

  • Page 25: Cowl Side Reinforcement And Cowl Upper Plate Removal

    PANEL REPLACEMENT COWL SIDE REINFORCEMENT AND COWL UPPER PLATE REMOVAL A6E981253290B01 1. Remove the cowl side reinforcement. Note • The weld locations (B) in the figure indicate the same locations. Caution • Be careful not to damage the windshield when drilling the location indicated by (A). 2.

  • Page 26: Cowl Side Reinforcement And Cowl Upper Plate Installation

    PANEL REPLACEMENT COWL SIDE REINFORCEMENT AND COWL UPPER PLATE INSTALLATION A6E981253290B02 1. When installing new parts, position each part so that the section measurement aligns to the body dimension. 2. Drill holes for plug welds before installing new parts. 3. After trial-fitting new parts, make sure the related parts fit properly. A6E9812B004 End Of Sie III–5...

  • Page 27: Apron Reinforcement Assembly Removal

    PANEL REPLACEMENT APRON REINFORCEMENT ASSEMBLY REMOVAL A6E981253260B01 1. Rough cut the apron reinforcement upper. 2. Remove the apron reinforcement assembly. A6E9812B005 End Of Sie III–6...

  • Page 28: Apron Reinforcement Assembly Installation

    PANEL REPLACEMENT APRON REINFORCEMENT ASSEMBLY INSTALLATION A6E981253260B02 1. When installing new parts, position each part so that the section measurement aligns to the body dimension. 2. Drill holes for plug welds before installing new parts. 3. Install in the following order: apron reinforcement lower,apron reinforcement rear, and apron reinforcement upper.

  • Page 29: Wheel Apron Panel Assembly Removal

    PANEL REPLACEMENT WHEEL APRON PANEL ASSEMBLY REMOVAL A6E981253210B01 1. Drill the 26 weld locations indicated by (A), and 7 weld locations indicated by (B), remove the wheel apron panel assembly. Note • If removing the wheel apron panel front and the suspension housing separately as separate parts, drill 7 locations indicated by (B) and drill 6 locations indicated by (C).

  • Page 30: Wheel Apron Panel Assembly Installation

    PANEL REPLACEMENT WHEEL APRON PANEL ASSEMBLY INSTALLATION A6E981253210B02 1. When installing new parts, position each part so that the section measurement aligns to the body dimension. 2. Drill holes for plug welds before installing new parts. 3. After trial-fitting new parts, make sure the related parts fit properly. Note •...

  • Page 31: Front Side Frame Removal

    PANEL REPLACEMENT FRONT SIDE FRAME REMOVAL A6E981253300B01 1. Remove the member side. 2. Drill the 1 weld locations indicated by (A), from the room side. 3. Drill the remaining weld locations and remove the front side frame by pulling it. A6E9812B009 End Of Sie III–10...

  • Page 32: Front Side Frame Installation

    PANEL REPLACEMENT FRONT SIDE FRAME INSTALLATION A6E981253300B02 1. When installing new parts, position each part so that the section measurement aligns to the body dimension. 2. Drill holes for plug welds before installing new parts. 3. After trial-fitting new parts, make sure the related parts fit properly. A6E9812B010 End Of Sie III–11...

  • Page 33: Front Pillar Removal

    PANEL REPLACEMENT FRONT PILLAR REMOVAL A6E981274090B01 1. Rough cut area (A), drill the 35 weld locations indicated by (B), then remove the lower part of the front pillar outer. 2. Rough cut area (C), drill the 20 weld locations indicated by (D), and 2 weld locations indicated by (E), then remove the front pillar.

  • Page 34

    PANEL REPLACEMENT A6E9812B012 End Of Sie III–13...

  • Page 35: Front Pillar Installation

    PANEL REPLACEMENT FRONT PILLAR INSTALLATION A6E981274090B02 1. When joining the new and old parts, temporarily install and fit the new part in position, measure each dimension according to the body dimension, then adjust the position to align it to the standard dimensions. 2.

  • Page 36

    PANEL REPLACEMENT A6E9812B014 End Of Sie III–15...

  • Page 37: Center Pillar Removal

    PANEL REPLACEMENT CENTER PILLAR REMOVAL A6E981270350B01 1. Rough cut area (A), drill the 44 weld locations indicated by (B), then remove the lower part of the center pillar outer. 2. Rough cut area (C), drill the 20 weld locations indicated by (D), then remove the center pillar outer. 3.

  • Page 38: Center Pillar Installation

    PANEL REPLACEMENT CENTER PILLAR INSTALLATION A6E981270350B02 1. When joining the new and old parts, temporarily install and fit the new part in position, measure each dimension according to the body dimension, then adjust the position to align it to the standard dimensions. 2.

  • Page 39: Rear Fender Panel Removal

    PANEL REPLACEMENT REAR FENDER PANEL REMOVAL A6E981274100B01 SEDAN Caution • Avoid cutting with a blowtorch or similar tools as the insulator (shaded area) is flammable. 1. The rear fender panel and the rear pillar inner are joined with glue at the wheel arch line. Use a chisel or other to separate the rear fender panel from the rear pillar inner, then remove the rear fender panel.

  • Page 40

    PANEL REPLACEMENT Caution • Avoid cutting with a blowtorch or similar tools as the insulator (shaded area) is flammable. 1. The rear fender panel and the rear pillar inner are joined with glue at the wheel arch line. Use a chisel or other to separate the rear fender panel from the rear pillar inner, then remove the rear fender panel.

  • Page 41: Rear Fender Panel Installation

    PANEL REPLACEMENT REAR FENDER PANEL INSTALLATION A6E981274100B02 SEDAN 1. When joining the new and old parts, temporarily install and fit the new part in position, measure each dimension according to the body dimension, then adjust the position to align it to the standard dimensions. 2.

  • Page 42

    PANEL REPLACEMENT 1. When joining the new and old parts, temporarily install and fit the new part in position, measure each dimension according to the body dimension, then adjust the position to align it to the standard dimensions. 2. Drill holes for plug welds before installing new parts. 3.

  • Page 43: Side Sill Panel Removal

    PANEL REPLACEMENT SIDE SILL PANEL REMOVAL A6E981270270B01 1. Remove the side sill panel. 2. Drill the 3 weld locations indicated by (A), from the room side. 3. Remove the side sill reinforcement. A6E9812B021 End Of Sie III–22...

  • Page 44: Side Sill Panel Installation

    PANEL REPLACEMENT SIDE SILL PANEL INSTALLATION A6E981270270B02 1. When joining the new and old parts, temporarily install and fit the new part in position, measure each dimension according to the body dimension, then adjust the position to align it to the standard dimensions. 2.

  • Page 45: Rear End Panel Removal

    PANEL REPLACEMENT REAR END PANEL REMOVAL A6E981270750B01 SEDAN 1. Remove the rear end panel. A6E9812B023 III–24...

  • Page 46

    PANEL REPLACEMENT 1. Drill the 2 weld locations indicated by (A), from the room side. 2. Remove the rear end panel. A6E9812B025 End Of Sie III–25...

  • Page 47: Rear End Panel Installation

    PANEL REPLACEMENT REAR END PANEL INSTALLATION A6E981270750B02 SEDAN 1. When installing new parts, position each part so that the section measurement aligns to the body dimension. 2. Drill holes for plug welds before installing new parts. 3. After trial-fitting new parts, make sure the related parts fit properly. A6E9812B024 III–26...

  • Page 48

    PANEL REPLACEMENT 1. When installing new parts, position each part so that the section measurement aligns to the body dimension. 2. Drill holes for plug welds before installing new parts. 3. After trial-fitting new parts, make sure the related parts fit properly. A6E9812B026 End Of Sie III–27...

  • Page 49: Rear Fender Rain Rail And Corner Plate Removal

    PANEL REPLACEMENT REAR FENDER RAIN RAIL AND CORNER PLATE REMOVAL A6E981270440B01 SEDAN 1. Remove the rear fender rein rail and corner plate. Note • When removing the rear fender rain rail and the corner plate separately, drill 3 locations indicated by (A). A6E9812B027 III–28...

  • Page 50

    PANEL REPLACEMENT 1. Remove the rear fender rain rail and corner plate. Note • When removing the rear fender rain rail and the corner plate separately, drill 2 locations indicated by (A). A6E9812B029 End Of Sie III–29...

  • Page 51: Rear Fender Rain Rail And Corner Plate Installation

    PANEL REPLACEMENT REAR FENDER RAIN RAIL AND CORNER PLATE INSTALLATION A6E981270440B02 SEDAN 1. When installing new parts, position each part so that the section measurement aligns to the body dimension. 2. Drill holes for plug welds before installing new parts. 3.

  • Page 52

    PANEL REPLACEMENT 1. When joining the new and old parts, temporarily install and fit the new part in position, measure each dimension according to the body dimension, then adjust the position to align it to the standard dimensions. 2. After trial-fitting new parts, make sure the related parts fit properly. A6E9812B030 End Of Sie III–31...

  • Page 53: Rear Floor Pan Removal

    PANEL REPLACEMENT REAR FLOOR PAN REMOVAL A6E981253750B01 1. Remove the rear floor pan. A6E9812B035 End Of Sie III–32...

  • Page 54: Rear Floor Pan Installation

    PANEL REPLACEMENT REAR FLOOR PAN INSTALLATION A6E981253750B02 1. Drill holes for plug welds before installing new parts. 2. After trial-fitting new parts, make sure the related parts fit properly. A6E9812B036 End Of Sie III–33...

  • Page 55: Floor Side Panel Removal

    PANEL REPLACEMENT FLOOR SIDE PANEL REMOVAL A6E981253730B01 SEDAN 1. Remove the floor side panel. A6E9812B037 III–34...

  • Page 56

    PANEL REPLACEMENT 1. Remove the floor side panel. A6E9812B039 End Of Sie III–35...

  • Page 57: Floor Side Panel Installation

    PANEL REPLACEMENT FLOOR SIDE PANEL INSTALLATION A6E981253730B02 SEDAN 1. Drill holes for plug welds before installing new parts. 2. After trial-fitting new parts, make sure the related parts fit properly. A6E9812B038 III–36...

  • Page 58

    PANEL REPLACEMENT 1. Drill holes for plug welds before installing new parts. 2. After trial-fitting new parts, make sure the related parts fit properly. A6E9812B040 End Of Sie III–37...

  • Page 59: Rear Side Frame (partial Cutting) Removal

    PANEL REPLACEMENT REAR SIDE FRAME (PARTIAL CUTTING) REMOVAL A6E981253815B01 1. Rough cut and remove the damaged part of the rear side frame. A6E9812B041 End Of Sie III–38...

  • Page 60: Rear Side Frame (partial Cutting) Installation

    PANEL REPLACEMENT REAR SIDE FRAME (PARTIAL CUTTING) INSTALLATION A6E981253815B02 1. Cut the new and old parts at the cut-and-join location, and bevel the parts. 2. When installing new parts, position each part so that the section measurement aligns to the standard dimensions.

  • Page 61: Roof Panel Removal

    PANEL REPLACEMENT ROOF PANEL REMOVAL A6E981270600B01 SEDAN 1. Remove the roof panel. A6E9812B031 III–40...

  • Page 62

    PANEL REPLACEMENT 1. Remove the roof panel. A6E9812B033 End Of Sie III–41...

  • Page 63: Roof Panel Installation

    PANEL REPLACEMENT ROOF PANEL INSTALLATION A6E981270600B02 SEDAN 1. Drill holes for plug welds before installing new parts. 2. After trial-fitting new parts, make sure the related parts fit properly. A6E9812B032 III–42...

  • Page 64

    PANEL REPLACEMENT 1. Drill holes for plug welds before installing new parts. 2. After trial-fitting new parts, make sure the related parts fit properly. A6E9812B034 End Of Sie III–43...

  • Page 65

    WATER-PROOF AND RUST PREVENTIVE TREATMENT WATER-PROOF AND RUST PREVENTIVE TREATMENT ............IV-2 BODY SEALING ..........IV-2 UNDER COATING ..........IV-5 CHIPPING-RESISTANT COATING ....IV-6 RUST PREVENTIVE TREATMENT....IV-7 IV–1...

  • Page 66: Water-proof And Rust Preventive Treatment

    WATER-PROOF AND RUST PREVENTIVE TREATMENT WATER-PROOF AND RUST PREVENTIVE TREATMENT BODY SEALING A6E981407000B01 Sealant is applied to the parts where the panels meet and to the hemmed parts of the door panel and bonnet to provide waterproofing and rust proofing. A6E9814B001 IV–2...

  • Page 67

    WATER-PROOF AND RUST PREVENTIVE TREATMENT A6E9814B002 IV–3...

  • Page 68

    WATER-PROOF AND RUST PREVENTIVE TREATMENT A6E9814B003 End Of Sie IV–4...

  • Page 69: Under Coating

    WATER-PROOF AND RUST PREVENTIVE TREATMENT UNDER COATING A6E981407000B02 The shaded areas indicated underbody locations that are undercoated to prevent noise and rusting. European(L.H.D. U.K.)specs A6E9814B004 GCC specs A6E9814B009 IV–5...

  • Page 70: Chipping-resistant Coating

    WATER-PROOF AND RUST PREVENTIVE TREATMENT End Of Sie CHIPPING-RESISTANT COATING A6E981407000B04 The coating locations are indicated by the shaded areas. SEDAN OVER SPRAY ALLOWED URETHANE PAINT PVC PAINT A6E9814B105 OVER SPRAY ALLOWED URETHANE PAINT PVC PAINT A6E9814B106 End Of Sie IV–6...

  • Page 71: Rust Preventive Treatment

    WATER-PROOF AND RUST PREVENTIVE TREATMENT RUST PREVENTIVE TREATMENT A6E981407000B03 The coating locations are indicated by the shaded areas. SEDAN A6E9814B007 IV–7...

  • Page 72

    WATER-PROOF AND RUST PREVENTIVE TREATMENT A6E9814B008 End Of Sie IV–8...

  • Page 73

    D IMENSIONS DIMENSIONS ............V-2 UNDERBODY FLAT-PLANE DIMENSIONS..V-2 UNDERBODY STRAIGHT-LINE DIMENSIONS ........... V-3 FRONT BODY STRAIGHT-LINE DIMENSIONS (1) ..........V-4 FRONT BODY STRAIGHT-LINE DIMENSIONS (2) ..........V-5 CABIN SIDE FRAME STRAIGHT-LINE DIMENSIONS ........... V-6 ROOM STRAIGHT-LINE DIMENSIONS (1) ..V-8 ROOM STRAIGHT-LINE DIMENSIONS (2) ..

  • Page 74: Dimensions

    DIMENSIONS DIMENSIONS UNDERBODY FLAT-PLANE DIMENSIONS A6E981653010B01 A6E9816B001 Hole diameter Hole diameter Point Point Designation or bolt or nut Designation or bolt or nut symbol symbol size mm {in} size mm {in} 14 × 20 Front side frame standard hole ø16 {0.63} Front B frame standard hole {0.55 ×...

  • Page 75: Underbody Straight-line Dimensions

    DIMENSIONS UNDERBODY STRAIGHT-LINE DIMENSIONS A6E981653010B02 A6E9816B002 A6E9816B003 Measured Measured Dimensions mm {in} Dimensions mm {in} location location 149 {5.87} 1,150 {45.28} 993 {39.09} 1,205 {47.44} RH:152 {5.98}, LH:153 {6.02} 1,461 {57.52} RH:991 {39.02}, LH:1,001 {39.41} 479 {18.86} RH:924 {36.38}, LH:923 {36.34} 1,112 {43.78} RH:1,293 {50.91}, LH:1,286 {50.63} 395 {15.55}...

  • Page 76: Front Body Straight-line Dimensions (1

    DIMENSIONS FRONT BODY STRAIGHT-LINE DIMENSIONS (1) A6E981653020B01 A6E9816B004 A6E9816B005 Measured Measured Dimensions mm {in} Dimensions mm {in} location location 1,023 {40.28} 1,085 {42.72} 749 {29.49} 1,070 {42.13} 1,458 {57.40} 1,084 {42.68} 1,529 {60.20} 1,070 {42.13} 1,070 {42.13} End Of Sie V–4...

  • Page 77: Front Body Straight-line Dimensions (2

    DIMENSIONS FRONT BODY STRAIGHT-LINE DIMENSIONS (2) A6E981653020B02 A6E9816B006 A6E9816B007 Measured Measured Dimensions mm {in} Dimensions mm {in} location location 1,480 {58.27} 1,221 {48.07} 959 {37.76} 363 {14.29} 1,481 {58.31} 1,455 {57.28} 1,340 {52.76} 451 {17.76} 452 {17.80} 1,220 {48.03} 1,538 {60.55} 1,608 {63.31} 418 {16.46} 777 {30.59}...

  • Page 78: Cabin Side Frame Straight-line Dimensions

    DIMENSIONS CABIN SIDE FRAME STRAIGHT-LINE DIMENSIONS A6E981670010B01 SEDAN A6E9816B008 A6E9816B009 Measured Measured Dimensions mm {in} Dimensions mm {in} location location 692 {27.24} 1,093 {43.03} 747 {29.41} 662 {26.06} 998 {39.29} 943 {37.13} 968 {38.11} 979 {38.54} 451 {17.76} 864 {34.02} 1,349 {53.11} 921 {36.26} 1,144 {45.04}...

  • Page 79

    DIMENSIONS A6E9816B010 A6E9816B011 Measured Measured Dimensions mm {in} Dimensions mm {in} location location 692 {27.24} 1,093 {43.03} 747 {29.41} 908 {35.75} 998 {39.29} 943 {37.13} 968 {38.11} 979 {38.54} 451 {17.76} 1,050 {41.34} 1,349 {53.11} 921 {36.26} 1,144 {45.04} 683 {26.89} 1,144 {45.04} 1,231 {48.46} 1,501 {59.09}...

  • Page 80: Room Straight-line Dimensions (1

    DIMENSIONS ROOM STRAIGHT-LINE DIMENSIONS (1) A6E981670001B01 A6E9816B012 A6E9816B013 Measured Measured Dimensions mm {in} Dimensions mm {in} location location 1,024 {40.31} 1,010 {39.76} 1,098 {43.23} 767 {30.20} 920 {36.22} H-H’ 1,487 {58.54} 1,175 {46.26} End Of Sie V–8...

  • Page 81: Room Straight-line Dimensions (2

    DIMENSIONS ROOM STRAIGHT-LINE DIMENSIONS (2) A6E981670001B02 SEDAN A6E9816B014 A6E9816B015 Measured Measured Dimensions mm {in} Dimensions mm {in} location location RH:1,141 {44.92}, LH:1,104 {43.46} RH:1.079 {42.48}, LH:1,030 {40.55} RH:996 {39.21}, LH:946 {37.24} RH:833 {32.80}, LH:767 {30.20} RH:952 {37.48}, LH:897 {35.31} I-I’ 1,584 {62.36} RH:1,193 {46.97}, LH:1,157 {45.55} J-J’...

  • Page 82

    DIMENSIONS A6E9816B016 A6E9816B017 Measured Measured Dimensions mm {in} Dimensions mm {in} location location RH:1,141 {44.92}, LH:1,104 {43.46} RH:833 {32.80}, LH:767 {30.20} RH:996 {39.21}, LH:946 {37.24} RH:1,402 {55.20}, LH:1,374 {54.09} RH:952 {37.48}, LH:897 {35.31} RH:1,671 {65.79}, LH:1,657 {65.24} RH:1,204 {47.40}, LH:1,166 {45.91} J-J’...

  • Page 83: Rear Body Straight-line Dimensions

    DIMENSIONS REAR BODY STRAIGHT-LINE DIMENSIONS A6E981670002B01 SEDAN A6E9816B018 A6E9816B019 Measured Measured Dimensions mm {in} Dimensions mm {in} location location 1,013 {39.88} 680 {26.77} 1,273 {50.12} 1,402 {55.20} 826 {32.52} 1,388 {54.65} 928 {36.54} 452 {17.80} 969 {38.15} 1,228 {48.35} 555 {21.85} V–11...

  • Page 84

    DIMENSIONS A6E9816B020 A6E9816B021 Measured Measured Dimensions mm {in} Dimensions mm {in} location location 700 {27.56} 1,402 {55.20} 1,436 {56.54} 1,388 {54.65} 1,260 {49.61} 452 {17.80} 680 {26.77} 1,228 {48.35} End Of Sie V–12...

  • Page 85

    P LASTIC BODY PARTS PLASTIC BODY PARTS ........VI-2 PLASTIC PARTS HEAT RESISTING TEMPERATURE ..........VI-2 REPAIRABLE RANGE OF POLYPROPYLENE BUMPERS.......VI-3 POLYPROPYLENE BUMPER REPAIR....VI-4 PROCEDURE ............. VI-5 VI–1...

  • Page 86: Plastic Body Parts

    PLASTIC BODY PARTS PLASTIC BODY PARTS PLASTIC PARTS HEAT RESISTING TEMPERATURE A6E981850000B01 Heat resisting Part Name Code Material Name TemperatureC°{F°} WINDSHIELD MOULDING POLYVINYLCHLORIDE 95 {203} COWL GRILLE POLYPROPYLENE 95 {203} LENS POLYCARBONATE 130 {266} FRONT COMBINATION LIGHT HOUSING 120 {248} GRILLE 90 {194} RADIATOR GRILLE...

  • Page 87: Repairable Range Of Polypropylene Bumpers

    PLASTIC BODY PARTS REPAIRABLE RANGE OF POLYPROPYLENE BUMPERS A6E981850010B01 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 88: Polypropylene Bumper Repair

    PLASTIC BODY PARTS POLYPROPYLENE BUMPER REPAIR A6E981850010B02 YMU980PCQ End Of Sie VI–4...

  • Page 89: Procedure

    PLASTIC BODY PARTS PROCEDURE A6E981850010B03 Repair of polypropylene bumpers having damage that has reached the surface of the polypropylene and are too serious to be restored by painting only. ZUA9818B001 1. Cut the rough edges around the damage with a knife to make it smooth. Sand the area with a sander to make an angle of about 45°.

  • Page 90

    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. ZUA9818B003 • For repair of a hole, degrease the area on both sides of the bumper and apply aluminium tape on the reverse side of the damage area.

  • Page 91

    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. 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 92

    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. YMU980PD0 8.

  • Page 93

    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.

  • Page 94

    P RIMARY COLOR MIXTURE CHART FOR V I I BODY COLORS PRIMARY COLOR MIXTURE CHART FOR BODY COLORS ..........VII-2 PRIMARY COLOR MIXTURE CHART FOR BODY COLORS..........VII-2 VII–1...

  • Page 95

    PRIMARY COLOR MIXTURE CHART FOR BODY COLORS PRIMARY COLOR MIXTURE CHART FOR BODY COLORS PRIMARY COLOR MIXTURE CHART FOR BODY COLORS A6E982089000B01 • This is the primary color mixture chart for body colors. • Please use the paint available in your country. •...

  • Page 96

    PRIMARY COLOR MIXTURE CHART FOR BODY COLORS KIND OF PAINT POLYXITHANE/POLYURETHANE AUTOBASE COLOR LABEL AUTOBASE AUTOCRYL COLOR NAME PLUS CODE CC/CC CC/CC CC/CC INGREDIENTS g{oz} g{oz} g{oz} SILVER DOLLAR 333DC 479.9 {16.93} METALLIC COARSE DARK RED OXIDE 493.8 {17.42} TRANSPARENT SPARKLING SILVER LIGHT GRAY 526.2 {18.56}...

  • Page 97

    PRIMARY COLOR MIXTURE CHART FOR BODY COLORS KIND OF PAINT POLYXITHANE/POLYURETHANE AUTOBASE COLOR LABEL AUTOBASE AUTOCRYL COLOR NAME PLUS CODE CC/CC CC/CC CC/CC INGREDIENTS g{oz} g{oz} g{oz} FIRST COAT Q110 WHITE 851.9 {30.05} BRIGHT YELLOW Q437 852.8 {30.08} OXIDE Q160 MIXING BLACK 854.0 {30.12} Q065 BINDER 1,109.1 {39.12}...

  • Page 98

    PRIMARY COLOR MIXTURE CHART FOR BODY COLORS V I I – 4 P RIMARY COLOR MIXTURE CHART FOR BODY COLORS PRIMARY COLOR MIXTURE CHART FOR BODY COLORS KIND OF PAINT POLYXITHANE/POLYURETHANE AUTOBASE COLOR LABEL AUTOBASE AUTOCRYL COLOR NAME PLUS CODE CC/CC CC/CC CC/CC...

  • Page 99

    PRIMARY COLOR MIXTURE CHART FOR BODY COLORS KIND OF PAINT POLYXITHANE/POLYURETHANE AUTOBASE COLOR LABEL AUTOBASE AUTOCRYL COLOR NAME PLUS CODE CC/CC CC/CC CC/CC INGREDIENTS g{oz} g{oz} g{oz} Q065 BINDER 224.9 {7.93} Q911 WHITE PEARL 432.7 {15.26} (Slight coarseness) Q911 SILVER EFFECT 606.6 {21.40} Q140 DEEP BLACK 763.6 {26.93}...

  • Page 100

    PRIMARY COLOR MIXTURE CHART FOR BODY COLORS V I I P RIMARY COLOR MIXTURE CHART FOR BODY COLORS PRIMARY COLOR MIXTURE CHART FOR BODY COLORS E.l.du pont de nemours &Co.(lnc.) • Please confirm the newest formula at the following URL. http://www.dupont.com/finishes/eu KIND OF PAINT POLYXITHANE/POLYURETHANE...

  • Page 101

    PRIMARY COLOR MIXTURE CHART FOR BODY COLORS KIND OF PAINT POLYXITHANE/POLYURETHANE COLOR LABEL CRONAR CRONAR COLOR NAME CODE CENTARI 6000 CENTARI 600 CENTARI 500 INGREDIENTS g{oz} g{oz} g{oz} SNOWFLAKE WHITE H.S. 655.7 {23.13} WHITE PEARL AB150 B/C BALANCER 1,186.9 {41.87} COLOR BASE SILVER CRYSTAL M8819...

  • Page 102

    PRIMARY COLOR MIXTURE CHART FOR BODY COLORS V I I – 6 P RIMARY COLOR MIXTURE CHART FOR BODY COLORS PRIMARY COLOR MIXTURE CHART FOR BODY COLORS KIND OF PAINT POLYXITHANE/POLYURETHANE AUTOBASE COLOR LABEL AUTOBASE AUTOCRYL COLOR NAME PLUS CODE CC/CC CC/CC CC/CC...

  • Page 103

    PRIMARY COLOR MIXTURE CHART FOR BODY COLORS V I I P RIMARY COLOR MIXTURE CHART FOR BODY COLORS PRIMARY COLOR MIXTURE CHART FOR BODY COLORS STANDOX • Please confirm the newest formula at the following URL. http://www.standox.com KIND OF PAINT POLYURETHANE COLOR LABEL...

  • Page 104

    PRIMARY COLOR MIXTURE CHART FOR BODY COLORS KIND OF PAINT POLYURETHANE COLOR LABEL STANDOX COLOR NAME CODE CC/CC MIXING No. g{oz} 477.5 {16.84} 716.3 {25.27} 823.7 {29.05} TITANIUM GRAY M 888.2 {31.33} 912.1 {32.17} 924.0 {32.59} 933.6 {32.93} 505.1 {17.82} 926.0 {32.66} SILVER CONTRAIL M 932.3 {32.89}...

  • Page 105

    PRIMARY COLOR MIXTURE CHART FOR BODY COLORS SPIES HACKER • Please confirm the newest formula at the following URL. http://www.spieshecker.com KIND OF PAINT POLYURETHANE COLOR COLOR NAME LABEL PERMACRON CODE INGREDIENTS g{oz} MB 544 528.2 {18.63} MB 536 717.7 {25.32} CLASSIC RED CLE MB 529 903.5 {31.87}...

  • Page 106

    PRIMARY COLOR MIXTURE CHART FOR BODY COLORS KIND OF PAINT POLYURETHANE COLOR COLOR NAME LABEL PERMACRON CODE INGREDIENTS g{oz} MB 558 487.5 {17.20} MB 513 717.7 {25.32} MB 502 825.3 {29.11} TITANIUM GRAY M MB 552 890.0 {31.39} MB 520 913.9 {32.24} MB 799 925.8 {32.66}...

  • Page 107

    PRIMARY COLOR MIXTURE CHART FOR BODY COLORS Nexa Autocolor • Please confirm the newest formula at the following URL. http://www.iciautocolor.com KIND OF PAINT POLYURETHANE COLOR LABEL AUTOCOLOR COLOR NAME CODE INGREDIENTS g{oz} g{oz} P425-941 461.9 {16.29} 2,309.5 {81.46} P429-976 558.5 {19.70} 2,792.5 {98.50} CLASSIC RED CLE P425-900...

  • Page 108

    PRIMARY COLOR MIXTURE CHART FOR BODY COLORS KIND OF PAINT POLYURETHANE COLOR LABEL AUTOCOLOR COLOR NAME CODE INGREDIENTS g{oz} g{oz} P420-930 202.4 {7.14} 1,012.0 {35.70} P420-920 271.8 {9.59} 1,359.0 {47.94} P425-922 333.5 {11.76} 1,667.5 {58.82} STRATO BLUE MC P425-948 383.6 {13.53} 1,918.0 {67.65} P426-PP64 453.0 {15.98}...

  • Page 109

    PRIMARY COLOR MIXTURE CHART FOR BODY COLORS PPG INDUSTRIES • Please confirm the newest formula at the following URL. http://www.ppg.com/gridppg/ KIND OF PAINT POLYURETHANE COLOR LABEL DELTRON COLOR NAME CODE INGREDIENTS NOTE g{oz} 670.0 {23.63} 875.0 {30.86} CLASSIC RED CLE 953.0 {33.62} 957.9 {33.79} 1,237.9 {43.66}...

  • Page 110

    PRIMARY COLOR MIXTURE CHART FOR BODY COLORS KIND OF PAINT POLYURETHANE COLOR LABEL DELTRON COLOR NAME CODE INGREDIENTS NOTE g{oz} 936.0 {33.02} 943.5 {33.28} 949.5 {33.49} SILVER CONTRAIL M 953.5 {33.63} 956.7 {33.75} 959.2 {33.83} 960.2 {33.87} 598.1 {21.10} VELOCITY RED MC 888.1 {31.33} COLOR BASE 951.5 {33.56}...

  • Page 111

    PRIMARY COLOR MIXTURE CHART FOR BODY COLORS DIAMONT • Please confirm the newest formula at the following URL. http://www.rmpaint.net/ KIND OF PAINT POLYURETHANE COLOR LABEL SOLO DE COLOR NAME DIAMONT BASE CODE DIAMONT BASE g{oz} INGREDIENTS g{oz} BC 020 REDUCER(THINNER) 88.0 {3.10} BC 832 RED 2...

  • Page 112

    PRIMARY COLOR MIXTURE CHART FOR BODY COLORS KIND OF PAINT POLYURETHANE COLOR LABEL SOLO DE COLOR NAME DIAMONT BASE CODE DIAMONT BASE g{oz} INGREDIENTS g{oz} GROUND COAT BC 020 REDUCER(THINNER) 88.0 {3.10} BC 621 ORGANIC YELLOW 2 500.1 {17.64} BC 190 WHITE 857.0 {30.23} BC 615...

  • Page 113

    PRIMARY COLOR MIXTURE CHART FOR BODY COLORS KIND OF PAINT POLYURETHANE COLOR LABEL SOLO DE COLOR NAME DIAMONT BASE CODE DIAMONT BASE g{oz} INGREDIENTS g{oz} BC 020 REDUCER(THINNER) 88.0 {3.10} MEDIURM SHINY BC 175 639.4 {22.55} ALUMIUIUM BC 200 CARBON BLACK 1 739.5 {26.08} BC 115 RUSSET PEARL...

  • Page 114

    PRIMARY COLOR MIXTURE CHART FOR BODY COLORS GLASURIT • Please confirm the newest formula at the following URL. http://www.glasurit.com/ KIND OF PAINT POLYURETHANE COLOR GLASSOMAX GLASSODUR COLOR NAME LABEL CODE BASE COAT PUR TOP COAT 21- INGREDIENTS g{oz} g{oz} 352-91 173.8 {6.13} A 352 646.0 {22.79}...

  • Page 115

    PRIMARY COLOR MIXTURE CHART FOR BODY COLORS KIND OF PAINT POLYURETHANE COLOR GLASSOMAX GLASSODUR COLOR NAME LABEL CODE BASE COAT PUR TOP COAT 21- INGREDIENTS g{oz} g{oz} GROUND COAT 352-91 173.8 {6.13} A 143 540.1 {19.05} M 25 857.1 {30.23} M 146 969.4 {34.19} M 306...

  • Page 116

    PRIMARY COLOR MIXTURE CHART FOR BODY COLORS KIND OF PAINT POLYURETHANE COLOR GLASSOMAX GLASSODUR COLOR NAME LABEL CODE BASE COAT PUR TOP COAT 21- INGREDIENTS g{oz} g{oz} 352-91 173.8 {6.13} M 99/22 663.8 {23.41} M 800 737.9 {26.03} M 99/20 777.0 {27.41} TITANIUM GRAY M A 926...

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