Mazda 2007 CX-7 User manual

Title Section
GENERAL INFORMATION 00
BODY
STRUCTURE
CONSTRUCTION 80A
PANEL REPLACEMENT 80B
WATER-PROOFANDRUST
PREVENTIVE
80C
DIMENSIONS 80D
PLASTIC BODY PARTS 80E
CONTENTS
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 ina
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
righttoalterthespecificationsand contents
of this manual without obligation or
advance notice.
Allrights reserved. No partofthis 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.
© 2006 Mazda Motor Corporation
PRINTED IN U.S.A., MARCH 2006
Form No. 3419–1U–06C
Part No. 9999–95–093F–07
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VEHICLE IDENTIFICATION NUMBERS (VIN)
JM3 ER29L✻7# 100001—
JM3 ER293✻7# 100001—
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00
GENERAL INFORMATION
00-00–1
SECTION
00-00
Toc of SCT
GENERAL INFORMATION . . . .00-00
Toc of SCT
00-00 GENERAL INFORMATION
VEHICLE IDENTIFICATION NUMBER
(VIN) CODE . . . . . . . . . . . . . . . . . . . . . .00-00–2
VEHICLE IDENTIFICATION NUMBERS
(VIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-00–2
HOW TO USE THIS MANUAL . . . . . . . . .00-00–3
Efficient Replacement of Body Panels .00-00–3
Symbols of Panel Replacement . . . . . .00-00–4
Body Dimensions
(Flat-plane Dimensions) . . . . . . . . . . .00-00–4
Body Dimensions
(Straight-line Dimensions). . . . . . . . . .00-00–6
Symbols of Body Dimensions. . . . . . . .00-00–7
SERVICE PRECAUTIONS . . . . . . . . . . . .00-00–8
Arrangement of Workshop . . . . . . . . . .00-00–8
Safety Precautions . . . . . . . . . . . . . . . .00-00–8
Vehicle Protection . . . . . . . . . . . . . . . . .00-00–8
Remove Dangerous Articles . . . . . . . . .00-00–8
Use of Pulling Equipment . . . . . . . . . . .00-00–9
Prevent Short Circuits. . . . . . . . . . . . . .00-00–9
EFFICIENT REMOVAL OF
BODY PANELS. . . . . . . . . . . . . . . . . . . .00-00–9
Body Measurements. . . . . . . . . . . . . . .00-00–9
Prevention of Body Deformation . . . . . .00-00–10
Selection of Cut-and-join Locations . . . 00-00–10
Removal of Associated Parts. . . . . . . . 00-00–10
Rough Cutting of Damaged Panel . . . . 00-00–10
INSTALLATION PREPARATIONS. . . . . . 00-00–10
Rough Cutting of New Parts. . . . . . . . . 00-00–10
Determination of Welding Method . . . . 00-00–11
Making Holes for CO2Arc Welding . . . 00-00–11
Application of Weld-through Primer . . . 00-00–11
EFFICIENT INSTALLATION OF
BODY PANELS . . . . . . . . . . . . . . . . . . . 00-00–12
Checking Preweld Measurements
And Watching. . . . . . . . . . . . . . . . . . . 00-00–12
Welding Notes . . . . . . . . . . . . . . . . . . . 00-00–12
Spot Welding Notes . . . . . . . . . . . . . . . 00-00–12
Checking Weld Strength. . . . . . . . . . . . 00-00–13
ANTICORROSION, SOUND INSULATION,
AND VIBRATION INSULATION . . . . . . 00-00–14
Body Sealing . . . . . . . . . . . . . . . . . . . . 00-00–14
Application of Undercoating . . . . . . . . . 00-00–14
Application of Rust Inhibitor . . . . . . . . . 00-00–14
Application of Floor Silencer. . . . . . . . . 00-00–14
ABBREVIATION . . . . . . . . . . . . . . . . . . . 00-00–15
End of Toc
BM: GENERAL INFORMATION
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GENERAL INFORMATION
00-00–2
VEHICLE IDENTIFICATION NUMBER (VIN) CODE id000000600800
End Of Sie
VEHICLE IDENTIFICATION NUMBERS (VIN) id000000600100
JM3 ER29L*7# 100001—
JM3 ER293*7# 100001—
End Of Sie
J M 3 E R 2 9 3 * 7 # 1 2 3 4 5 6
Model year
Plant
Serial No.
0= Hiroshima
1= Hofu
7= 2007
Engine
Body, Gross vehicle weight class 9= Wagon, Gross vehicle weight class C
(1814 2267 kg)
Carline, Series ER= Mazda CX-7
JM3= Mazda/Multi-purpose vehicle category/U.S.A.
World manufacturer identification
Check digit *= 0 to 9, X
L= 2.3 L (California (L3 WITH TC))
3= 2.3 L (Federal/CANADA (L3 WITH TC))
Resraint system 2= with Curtain and Side air bags
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GENERAL INFORMATION
00-00–3
00-00
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.
•The type of weld and position are indicated by symbols.
•Some sections have notes concerning the operation being performed. Thoroughly read and understand the
notes before carrying out any procedures.
Example
REAR FENDER PANEL REMOVAL Shows operation section Shows procedure, caution and note
BRAZE WELDING
Shows welding region
Shows a cross
Shows a insulator
Avoid cutting with a flame as the insulator (shaded) is flammable.
1.The rear fender panel and wheel house are joined with glue at the wheel arch line.
Drill the 17 weld locations indicated by (A), from the room side.
Caution
NOTE
CUT-AND-JOINT LOCATION
ROUGH CUT LOCATION
Shows a dimensions
{9.84in}
250mm
A-A
30mm
{1.18in}
Shows number of weld
Shows a cross location
AA
(A)17
17
4
5
71
5
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GENERAL INFORMATION
00-00–4
Symbols of Panel Replacement
•The following 6 symbols are used to indicate the type of weld that is used when replacing body panels.
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.
•The hypothetical lines may differ according to the vehicle model.
•The schematic diagram shows the vehicle as it is projected from the underbody.
SYMBOL MEANING
Spot welding
CO
2
arc welding (plug welding)
CO
2
spot welding
SYMBOL MEANING
Continuous MIG welding (Cut-and-join location)
Braze welding
Rough cut location
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810{31.89}
FLAT-PLANE DIMENSIONS
FRONT FENDER INSTALLATION NUT
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GENERAL INFORMATION
00-00–5
00-00
Example
Shows vehicle section
When there are no specific indications, all of
units are in millimeters (mm).
Shows outline drawing
Shows dimension
The dimensions on the left
and right in regard to the center
of the vehicle are different.
Shows hypothetical
standard line
Shows point
symbol
Point
symbol Designation Hole diameter
or bolt or nut
size mm {in}
Crossmember No,1 standard
hole
Front side frame standard hole
Front suspension mounting
block surface hole center
Front suspension mounting
bolt
Front frame rear standard hole
Front frame rear standard hole
Rear side frame standard hole
Link bracket
Rear suspension housing
A
B
C
D
E
F
G
H
I
J
KRear side frame standard hole
Rear side frame standard hole
Shows bolt size Shows hole diameter
Shows
slot
mm {in}
UNDERBODY FLAT-PLANE DIMENSIONS
φ 16 {0.62}
φ 16 {0.62}
φ 16 {0.62}
M14 {0.55}
φ 80 {3.14}
Point
symbol Designation Hole diameter
or bolt or nut
size mm {in}
φ 16 {0.62}
φ 31 {1.22}
φ 12 {0.47}
Rear suspension housing
Lφ 12 {0.47}
φ 16 {0.62}
φ 18 {0.62}
17 × 29.5
{0.66×1.16}
ABCDE F G H I J KL
1,016
{40.00}
687 {27.05}
420 182 93 144 120
{7.17} {3.66} {5.67} {4.72} 1,030 140 760 68
{5.51} {2.68} 379
{16.54} {40.55} {29.92} {14.92}
{25.75} 654
1,084 {42.84}
579 {22.80} 479 {18.86} 436 436 {17.17} {17.17} 445 512
660 1,043 666
{17.52} {20.16}
{25.98} {41.06} {26.22}
1,106 {43.54}
1,164
543
485
484
{21.37} {19.05}
478
1,073 {37.91}
455
{17.91}
469
{18.46}
760
605
650 650
{29.92}
{23.82}
{25.59} {25.59}
650
{45.83}
{25.59}
LH
RH
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GENERAL INFORMATION
00-00–6
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.
817
FRONT FENDER INSTALLATION NUT
STRAIGHT-LINE DIMENSIONS
{32.17}
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GENERAL INFORMATION
00-00–7
00-00
Example
Symbols of Body Dimensions
•The following 8 symbols are used to indicate the standard points.
End Of Sie
1,128
{44.41}
A
B
C
H
D
I
E
F
G
1,398
{55.04}
1,406
{55.35}
{42.01}
1,067
799
{31.46}
1,263
{49.72}
1,048
{41.26}
{33.50}
A
FG
B
HI
CDE,E'
Fr
Fr Fr
FrFr Fr
Fr
Fr
Fr
Front pillar inner designation
Front pillar inner designation
Front floor pan designation
Adjuster installation hole
Trim installation hole
Harness installation hole
Chaker bracket installation hole
Chaker bracket installation hole
A
B
C
D
E
F
G
H
I
φ 16 {0.62} φ 18 {0.71}
φ 16 {0.62}
Harness installation hole
Point
symbol Designation Hole diameter
or bolt or nut
size mm {in}
Point
symbol Designation Hole diameter
or bolt or nut
size mm {in}
Shows bolt size
Shows hole diameter
Shows
slot
851
φ 16 {0.62}
M14 {0.55}
φ 31 {1.22}
φ 17 {0.67} 17 × 29.5
{0.66×1.16}
φ 12 {0.47}
ROOM STRAIGHT-LINE DIMENSIONS (1)
Shows vehicle section
Shows dimension location
Shows outline drawing
Shows point
symbol
Shows point indication
Without apostrophe:RH
With apostrophe:LH
Shows details of the standard
point location Shows position and shape of the points
Shows dimension
No indication are shown
within the outline drawing.
acxuub00000149
SYMBOL MEANING SYMBOL MEANING
Center of circular hole
Center elliptical hole
Notch
Panel seam, bead, etc.
Bolt tip
(arrow only) Center of rectangular-shaped hole
Edge of rectangular-shaped hole
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GENERAL INFORMATION
00-00–8
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.
Vehicle Protection
•Use seat covers and floor covers.
•Use heat-resistant protective covers to protect glass areas and seats from heat or sparks during welding.
•Protect items such as moldings, garnishes, and
ornaments with tape when welding.
Remove Dangerous Articles
•Remove the fuel tank before using an open flame
in that area. Plug connection piping to prevent
fuel leakage.
Welding
glasses Ear
protectors Weldlng
gloves Cotton
gloves
Dust mask Safety glasses
Face shield
Safety shoes
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GENERAL INFORMATION
00-00–9
00-00
Use of Pulling Equipment
•When using pulling equipment, keep away from
the pulling area and use safety wires to prevent
accidents.
Prevent Short Circuits
•Turn the ignition switch to the LOCK position.
•Disconnect the battery cables.
•Securely connect the welding machine ground
near the welding area.
End Of Sie
EFFICIENT REMOVAL OF BODY PANELS id000000600300
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.
Safety wires
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Battery cable
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Ground
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GENERAL INFORMATION
00-00–10
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.
Selection of Cut-and-join Locations
•For parts where complete replacement is not
feasible, careful cutting and joining operations
should be followed. If the location to be cut is a
flat area where there is no reinforcement, the
selected cutting location should be where the
welding distortion will be minimal.
Removal of Associated Parts
•Protect moldings, garnishes, and ornaments with tape when removing associated parts.
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.
End Of Sie
INSTALLATION PREPARATIONS id000000600400
Rough Cutting of New Parts
•For cut-and-join areas, allow for an overlap of
30—50 mm {1.18—1.97 in} with the remaining
area on the body side and then rough-cut the new
parts.
acxuub00000066
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Wiring harness
Rough cut location Cut-and-join location
acxuub00000047
Over lap Over lap
Body side rough cut location
New part rough cut location
30-50mm{1.18-1.97in} 30-50mm{1.18-1.97in}
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GENERAL INFORMATION
00-00–11
00-00
Determination of Welding Method
•If the total thickness at the area to be welded is 3 mm {0.12 in} or more, use a CO2gas shielded-arc welder to
make the plug welds.
Making Holes for CO2Arc Welding
•For places that cannot be spot welded, make a hole for CO2arc welding using a punch or drill as follows.
(mm {in})
•Grind the shaded section indicated in the diagram below and create a hole in the part where the 3—4 plates
are put together. Also, weld the plates together tightly so that gaps do not develop.
Application of Weld-through Primer
•For treatment against corrosion, remove the paint grease, and other material from the portion of new part and
body to be welded, and apply weld-through primer.
End Of Sie
3mm
{0.12in}or more
acxuub00000049
Panel thickness (φ) Hole diameter (φ)
0.60—0.90 {0.02—0.03} 5 {0.19}
0.91—1.20 {0.04—0.05} 6 {0.23}
1.21—1.80 {0.051—0.07} 8 {0.31}
1.81—4.50 {0.071—0.17} 10 {0.39}
φ 10mm{0.39in}
Outer panel
Middle panel
Inner panel
30°30°
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GENERAL INFORMATION
00-00–12
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.
Welding Notes
•For the number of weld points, welding should be
performed in accordance with the following
reference standards.
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.
•Because the weld strength is affected by the
shape of the spot welder tip, the optimum
condition of the tip should always be maintained.
•Spot welds should be made at points other than
the originally welded points.
acxuub00000069
Spot welding
Original weld
If 3mm
{0.12in} or more
Original number of
welds x 1.3 or more
CO2arc welding
Original spot weld Repair weld
Repair weld
Original number of welds
or more
acxuub00000053
D
70 - 120°
t
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GENERAL INFORMATION
00-00–13
00-00
•Before spot welding, make a trial weld using the
same material as the body panel to check the
weld strength.
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.
•Drive the chisel between the panels according to
the number of panels as shown below.
•To determine weld strength, drive the chisel
between the panel and check whether the panels
come apart. If the panels come apart, make
another weld near the original weld.
•Restore the shape of the checked area.
End Of Sie
Test piece method
Nugget diameter
:4/5 of tip
acxuub00000071
Chisel dimensions
25mm
{0.98in}
8mm{0.31in}
{0.20in}
{0.20in}
20°
Weld location
Within 5mm
Within 5mm
acxuub00000057
Two panels Weld location
Three panels Weld location
One location
Two location
Four panels Weld location
Three location
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GENERAL INFORMATION
00-00–14
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.
Application of Undercoating
•Apply an undercoat to the required location of the body.
Application of Rust Inhibitor
•Apply rust inhibitor (wax, oil, etc.) to the back of the welded areas.
Application of Floor Silencer
•Apply floor silencer by heating with an infrared ray lamp.
End Of Sie
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GENERAL INFORMATION
00-00–15
00-00
ABBREVIATION id000000600700
End Of Sie
CM Control module
Ctr Center
DSC Dynamic stability control
Fr Front
HU Hydraulic unit
LH Left
M Metallic
MC Mica
RH Right
Rr Rear
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09-80A–1
09
BODY & ACCESSORIES
SECTION
09-80A
Toc of SCT
BODY STRUCTURE
[CONSTRUCTION]. . . . . . . . .09-80A
BODY STRUCTURE
[PANEL REPLACEMENT] . . .09-80B
BODY STRUCTURE
[WATER-PROOF AND RUST
PREVENTIVE]. . . . . . . . . . . . .09-80C
BODY STRUCTURE
[DIMENSIONS] . . . . . . . . . . . 09-80D
BODY STRUCTURE
[PLASTIC BODY PARTS] . . . 09-80E
Toc of SCT
09-80A BODY STRUCTURE [CONSTRUCTION]
BODY COMPONENTS
CONSTRUCTION[CONSTRUCTION] . .09-80A–2
ULTRA HIGH-TENSION STEEL
[CONSTRUCTION]. . . . . . . . . . . . . . . . .09-80A–5
Characteristics of Ultra High-Tensile
Steel Plates . . . . . . . . . . . . . . . . . . . . 09-80A–5
Range of Use and Cautions
for Service . . . . . . . . . . . . . . . . . . . . . 09-80A–5
End of Toc
BM: CONSTRUCTION
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BODY STRUCTURE [CONSTRUCTION]
09-80A–2
BODY COMPONENTS CONSTRUCTION[CONSTRUCTION] id098007739700
.
1
3
2
5
4
9
8
7
10
6
13
11 12
14
15
16
19
18
17
20
28
27
26
24
25
23
22
21
29
30
37
36
34
33
32
31
38 39
43
45
41
47
50
49
48
51
57
56
55
52
54
58 59
42
46
44
53
35
40
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