Mazda 2007 MX-5 Miata User manual

Title Section
GENERAL INFORMATION 00
BODY
STRUCTURE
CONSTRUCTION 80A
PANEL REPLACEMENT 80B
WATER-PROOF AND RUST
PREVENTIVE
80C
DIMENSIONS 80D
PLASTIC BODY PARTS 80E
CONTENTS
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
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
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VEHICLE IDENTIFICATION NUMBERS (VIN)
JM1 NC15F✻7# 100001—
JM1 NC16F✻7# 100001—
JM1 NC25F✻7# 100001—
JM1 NC26F✻7# 100001—
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00
GENERAL INFORMATION
00-00–1
SECTION
00-00
To c o f S C T
GENERAL INFORMATION . . . . 00-00
To c o f S C T
00-00 GENERAL INFORMATION
VEHICLE IDENTIFICATION NUMBER
(VIN) CODE . . . . . . . . . . . . . . . . . . . . . . 00-00–2
VEHICLE IDENTIFICATION NUMBER
(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 . . . . . . . . 00-00–8
SERVICE PRECAUTIONS . . . . . . . . . . . . 00-00–8
Arrangement of Workshop . . . . . . . . . . 00-00–8
Safety Precautions . . . . . . . . . . . . . . . . 00-00–8
Vehicle Protection . . . . . . . . . . . . . . . . . 00-00–8
Remove Dangerous Articles . . . . . . . . . 00-00–9
Use of Pulling Equipment . . . . . . . . . . . 00-00–9
Prevent Short Circuits . . . . . . . . . . . . . . 00-00–9
EFFICIENT REMOVAL OF BODY
PANELS . . . . . . . . . . . . . . . . . . . . . . . . . 00-00–10
Body Measurements . . . . . . . . . . . . . . . 00-00–10
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 . . . . 00-00–11
INSTALLATION PREPARATIONS. . . . . . 00-00–11
Rough Cutting of New Parts. . . . . . . . . 00-00–11
Determination of Welding
Method . . . . . . . . . . . . . . . . . . . . . . . . 00-00–11
Making Holes for CO2Arc
Welding . . . . . . . . . . . . . . . . . . . . . . . 00-00–12
Application of Weld-through
Primer. . . . . . . . . . . . . . . . . . . . . . . . . 00-00–12
EFFICIENT INSTALLATION OF
BODY PANELS . . . . . . . . . . . . . . . . . . . 00-00–12
Checking Preweld Measurements And
Watching . . . . . . . . . . . . . . . . . . . . . . 00-00–12
Welding Notes . . . . . . . . . . . . . . . . . . . 00-00–13
Spot Welding Notes . . . . . . . . . . . . . . . 00-00–13
Checking Weld Strength. . . . . . . . . . . . 00-00–14
ANTICORROSION, SOUND INSULATION, AND
VIBRATION INSULATION . . . . . . . . . . . 00-00–15
Body Sealing . . . . . . . . . . . . . . . . . . . . 00-00–15
Application of Undercoating . . . . . . . . . 00-00–15
Application of Rust Inhibitor . . . . . . . . . 00-00–15
Application of Damping Sheet . . . . . . . 00-00–16
ABBREVIATION . . . . . . . . . . . . . . . . . . . 00-00–16
End of Toc
NG: GENERAL INFORMATION
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GENERAL INFORMATION
00-00–2
VEHICLE IDENTIFICATION NUMBER (VIN) CODE id000000100200
End Of Sie
VEHICLE IDENTIFICATION NUMBER (VIN) id000000100300
JM1 NC15F*7# 100001—
JM1 NC16F*7# 100001—
JM1 NC25F*7# 100001—
JM1 NC26F*7# 100001—
End Of Sie
BM: GENERAL INFORMATION
J M 1 N C 1 5 F * 7 # 1 2 3 4 5 6
Serial No.
0= Hiroshima
JM1= Mazda/Passenger car
*= 0 to 9, X
Plant
Check digit
Restraint system
Body
Carline, series
1= Hofu
Model year
Engine F= 2.0 L (LF)
NC= Mazda MX-5
World manufacturer identification
5= 2-door Open, Convertible Top
6= 2-door Open, Power Retractable Hardtop
7= 2007
1= without Side air bag
2= with Side air bag
amxuub0000001
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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
DPE2010B001
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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.
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
MZZ2010B002
810 {31.89}
FLAT-PLANE DIMENSIONS
FRONT FENDER INSTALLATION NUT
DPE2010B010
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GENERAL INFORMATION
00-00–5
00-00
•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
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
K
Rear 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
DPE2010B003
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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.
817
FRONT FENDER INSTALLATION NUT
STRAIGHT-LINE DIMENSIONS
{32.17}
DPE2010B011
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GENERAL INFORMATION
00-00–7
00-00
•When there are no specific indications, the standard points and dimensions are symmetrical in regard to the
center of the vehicle.
Example
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
f16
f17
f16
M14
f31 f12
f16
f18
17 ´ 29.5
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
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.
DPE2010B004
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GENERAL INFORMATION
00-00–8
Symbols of Body Dimensions
•The following 8 symbols are used to indicate the standard points.
End Of Sie
SOKYU_WM: GENERAL INFORMATION
SERVICE PRECAUTIONS id000000739200
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.
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
MZZ2010B016
Welding
glasses
Ear
protectors
Weldlng
gloves
Cotton
gloves
Dust mask Safety glasses
Face shield
Safety shoes
MZZ2036B001
MZZ2036B002
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GENERAL INFORMATION
00-00–9
00-00
Remove Dangerous Articles
•Remove the fuel tank before using an open flame
in that area. Plug connection piping to prevent
fuel leakage.
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.
Note
•When connecting the negative battery cable
to the battery, connect the negative battery
cable and the ground cable as shown in the
figure.
MZZ2036B003
Safety wires
MZZ2036B004
Battery cable
MZZ2036B005
GROUND CABLE
FRONT
BATTERY
NEGATIVE
CABLE
BATTERY
POSITIVE
CABLE
BATTERY
BOX
E5U117ZW5004
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GENERAL INFORMATION
00-00–10
•Securely connect the welding machine ground
near the welding area.
End Of Sie
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.
If there is deformation, use frame repair
equipment to make a rough correction.
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.
Ground
MZZ2036B006
MZJ2038B001
MZJ2038B002
MZJ2038B003
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GENERAL INFORMATION
00-00–11
00-00
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 id000000739400
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.
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.
Wiring harness
Rough cut location Cut-and-join location
MZZ2038B001
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}
MZZ2038B002
3mm
{0.12in}or more
MZZ2038B003
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GENERAL INFORMATION
00-00–12
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
EFFICIENT INSTALLATION OF BODY PANELS id000000739500
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.
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}
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°
MZZ2038B004
MZJ2038B008
MZJ2038B009
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GENERAL INFORMATION
00-00–13
00-00
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.
•Before spot welding, make a trial weld using the
same material as the body panel to check the
weld strength.
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
DPE2038B005
D
70 - 120°
t
MZZ2038B009
MZJ2038B012
Test piece method
Nugget diameter
:4/5 of tip
MZZ2038B006
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GENERAL INFORMATION
00-00–14
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
Chisel dimensions
25mm
{0.98in}
8mm{0.31in}
{0.20in}
{0.20in}
20°
Weld location
Within 5mm
Within 5mm
MZZ2038B007
Two panels Weld location
Three panels Weld location
One location
Two location
Four panels Weld location
Three location
MZZ2038B008
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GENERAL INFORMATION
00-00–15
00-00
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.
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.
CJJ2038B016
CJJ2038B017
CJJ2038B018
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GENERAL INFORMATION
00-00–16
Application of Damping Sheet
•Apply damping sheet by heating with an infrared ray lamp.
End Of Sie
SOKYU_NG: GENERAL INFORMATION
ABBREVIATION id000000000800
End Of Sie
CJJ2038B019
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
To c o f S C T
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
To c o f S C T
09-80A BODY STRUCTURE [CONSTRUCTION]
BODY COMPONENTS CONSTRUCTION
[CONSTRUCTION]. . . . . . . . . . . . . . . . . 09-80A–2
ADOPTION OF 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
.
9
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7
5
4
3
1
2
10
6
19
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17
15
16
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11
12
20
29
28
27
25
26
24
23
21
22
30
39
38
37
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34
33
31
32
40
49
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amxuub0000000
3426-1U-06F(09-80A).fm 2 ページ ２００６年６月２０日 火曜日 午後３時３７分