Mazda 2009 6 User manual

Title Section
GENERAL INFORMATION 00
BODY
STRUCTURE
CONSTRUCTION 80A
PANEL REPLACEMENT 80B
WATER-PROOFANDRUST
PREVENTIVE
80C
DIMENSIONS 80D
PLASTIC BODY PARTS 80E
CONSTRUCTION
STANDARD VALVES
80F
CONTENTS
2009-2013
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 North American Operations
reserves the right to alter the specifications
and contents of this manual without obliga-
tion or advance notice.
Allrightsreserved.Nopartofthisbookmay
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 North American Operations
HIROSHIMA, JAPAN
APPLICATION:
This manual is applicable to vehicles beginning
with the Vehicle Identification Numbers (VIN),
shown on the following page.
© 2009 Mazda North American Operations
PRINTED IN U.S.A., JULY 2009
Form No. 3442–1U–09G
Part No. 9999–95–099F–09
3442-1U-09G(INDEX).fm 1 ページ ２００９年７月２９日 水曜日 午後１時３１分

VEHICLE IDENTIFICATION NUMBERS (VIN)
2009 MY
1YV HP80A✻95 M00001—
1YV HP80H✻95 M00001—
1YV HP81A✻95 M00001—
1YV HP81B✻95 M00001—
1YV HP81H✻95 M00001—
1YV HP82A✻95 M00001—
1YV HP82B✻95 M00001—
1YV HP82H✻95 M00001—
2010 MY
1YV HZ8AA✻A5 M00001—
1YV HZ8AH✻A5 M00001—
1YV HZ8BA✻A5 M00001—
1YV HZ8BB✻A5 M00001—
1YV HZ8BH✻A5 M00001—
1YV HZ8CA✻A5 M00001—
1YV HZ8CB✻A5 M00001—
1YV HZ8CH✻A5 M00001—
3442-1U-09G(INDEX).fm 2 ページ ２００９年７月２９日 水曜日 午後１時３１分

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
2009 MY . . . . . . . . . . . . . . . . . . . . . . . . 00-00–2
2010 MY . . . . . . . . . . . . . . . . . . . . . . . . 00-00–3
VEHICLE IDENTIFICATION NUMBERS
(VIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-00–3
2009 MY . . . . . . . . . . . . . . . . . . . . . . . . 00-00–3
2010 MY . . . . . . . . . . . . . . . . . . . . . . . . 00-00–3
HOW TO USE THIS MANUAL . . . . . . . . .00-00–4
Efficient Replacement of
Body Panels . . . . . . . . . . . . . . . . . . . .00-00–4
Symbols of Panel Replacement . . . . . .00-00–4
Body Dimensions
(Flat-plane Dimensions) . . . . . . . . . . .00-00–5
Body Dimensions
(Straight-line Dimensions) . . . . . . . . .00-00–6
Symbols of Body Dimensions. . . . . . . .00-00–9
AIR BAG SYSTEM
SERVICE WARNINGS . . . . . . . . . . . . . .00-00–9
Air Bag Module Inspection . . . . . . . . . .00-00–9
Air Bag Module Handling . . . . . . . . . . .00-00–9
Side Air Bag Module Handling . . . . . . .00-00–10
SAS Control Module Handling . . . . . . .00-00–10
Side Air Bag Sensor Handling. . . . . . . .00-00–10
Pre-tensioner Seat Belt Inspection . . . .00-00–10
SERVICE PRECAUTIONS . . . . . . . . . . . .00-00–11
Arrangement of Workshop . . . . . . . . . .00-00–11
Safety Precautions . . . . . . . . . . . . . . . .00-00–11
Vehicle Protection . . . . . . . . . . . . . . . . .00-00–11
Remove Dangerous Articles . . . . . . . . .00-00–11
Use of Pulling Equipment . . . . . . . . . . .00-00–12
Prevent Short Circuits. . . . . . . . . . . . . .00-00–12
EFFICIENT REMOVAL OF
BODY PANELS . . . . . . . . . . . . . . . . . . . 00-00–12
Body Measurements . . . . . . . . . . . . . . 00-00–12
Prevention of Body Deformation. . . . . . 00-00–13
Selection of Cut-and-join Locations . . . 00-00–13
Removal of Associated Parts . . . . . . . . 00-00–13
Rough Cutting of Damaged Panel . . . . 00-00–13
EFFICIENT INSTALLATION OF
BODY PANELS . . . . . . . . . . . . . . . . . . . 00-00–13
Checking Preweld Measurements And
Watching . . . . . . . . . . . . . . . . . . . . . . 00-00–13
Welding Notes . . . . . . . . . . . . . . . . . . . 00-00–14
Spot Welding Notes . . . . . . . . . . . . . . . 00-00–14
Checking Weld Strength. . . . . . . . . . . . 00-00–15
INSTALLATION PREPARATIONS. . . . . . 00-00–16
Rough Cutting of New Parts. . . . . . . . . 00-00–16
Determination of Welding Method . . . . 00-00–16
Making Holes for CO2Arc Welding . . . 00-00–16
Application of Weld-through Primer . . . 00-00–17
ANTICORROSION, SOUND INSULATION,
AND VIBRATION INSULATION . . . . . . 00-00–17
Body Sealing . . . . . . . . . . . . . . . . . . . . 00-00–17
Application of Undercoating . . . . . . . . . 00-00–17
Application of Rust Inhibitor . . . . . . . . . 00-00–18
Application of Floor Silencer. . . . . . . . . 00-00–18
BODY COLORS. . . . . . . . . . . . . . . . . . . . 00-00–18
Color Code and Color Name . . . . . . . . 00-00–18
Verification of Primary Color Mixture for
Body Color . . . . . . . . . . . . . . . . . . . . . 00-00–18
ABBREVIATION . . . . . . . . . . . . . . . . . . . 00-00–18
IDENTIFICATION NUMBER
LOCATIONS . . . . . . . . . . . . . . . . . . . . . 00-00–19
Vehicle Identification Number (VIN) . . . 00-00–19
Engine Identification Number. . . . . . . . 00-00–19
End of Toc
BM: GENERAL INFORMATION
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GENERAL INFORMATION
00-00–2
VEHICLE IDENTIFICATION NUMBER (VIN) CODE id000000600800
2009 MY
1Y V H P 80 A * 9 5 M 0 0 0 0 1
H= With front, side and curtain air bag
M00001 to M99999
N00001 to N99999
1YV= Mazda passenger car, produced at AAI
5= AAI, Flat Rock, Michigan/U.S.A.
9= 2009
*= 0 to 9, X
A= L5 (2.5 L)(Made in Mexico) *1
H= L5 (2.5 L)(Made in Hiroshima)
B= MZI-3.7 (3.7 L)
0= Standard grade, Sedan
1= Base grade, Sedan
2= High grade, Sedan
8= Mazda6
P= Passenger car
World manufacturer identification
Air bag
Car identifier
Carline, series
Grade, Body type
Engine type
Check digit
Model year
Plant
Serial No.
*1:Vehicles with the followingVIN are equipped with a Hiroshima-manufactured engine.
1YVHP81A095M47734
1YVHP81A095M47751
1YVHP81A095M47975
1YVHP81A095M48043
1YVHP81A095M48057
1YVHP81A095M48074
1YVHP81A095M48091
1YVHP81A095M48107
1YVHP81A195M48035
1YVHP81A195M48066
1YVHP81A195M48097
1YVHP81A195M48102
1YVHP81A295M47797
1YVHP81A295M47816
1YVHP81A295M47976
1YVHP81A295M48058
1YVHP81A295M48075
1YVHP81A295M48089
1YVHP81A295M48092
1YVHP81A295M48108
1YVHP81A295M48111
1YVHP81A395M47968
1YVHP81A395M48070
1YVHP81A395M48084
1YVHP81A395M48098
1YVHP81A395M48103
1YVHP81A395M48117
1YVHP81A495M47770
1YVHP81A495M47784
1YVHP81A495M48031
1YVHP81A495M48059
1YVHP81A495M48062
1YVHP81A495M48076
1YVHP81A495M48112
1YVHP81A595M47700
1YVHP81A595M47714
1YVHP81A595M47969
1YVHP81A595M48037
1YVHP81A595M48068
1YVHP81A595M48071
1YVHP81A595M48085
1YVHP81A595M48099
1YVHP81A595M48104
1YVHP81A595M48118
1YVHP81A695M47740
1YVHP81A695M47771
1YVHP81A695M48046
1YVHP81A695M48063
1YVHP81A695M48077
1YVHP81A695M48080
1YVHP81A695M48113
1YVHP81A795M47813
1YVHP81A795M47987
1YVHP81A795M48105
1YVHP81A895M48064
1YVHP81A895M48100
1YVHP81A995M47697
1YVHP81A995M47733
1YVHP81A995M48011
1YVHP81A995M48073
1YVHP81A995M48087
1YVHP81A995M48090
1YVHP81A995M48106
1YVHP81AX95M47966
1YVHP81AX95M48051
1YVHP81AX95M48065
1YVHP81AX95M48082
1YVHP81AX95M48096
1YVHP81AX95M48101
1YVHP81AX95M48115
1YVHP82A095M48185
1YVHP82A295M48186
1YVHP82A495M48187
1YVHP82A495M48190
1YVHP82A695M48188
1YVHP82A895M48189
1YVHP82A995M48184
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GENERAL INFORMATION
00-00–3
00-00
2010 MY
End Of Sie
VEHICLE IDENTIFICATION NUMBERS (VIN) id000000600100
2009 MY
1YV HP80A*95 M00001—
1YV HP80H*95 M00001—
1YV HP81A*95 M00001—
1YV HP81B*95 M00001—
1YV HP81H*95 M00001—
1YV HP82A*95 M00001—
1YV HP82B*95 M00001—
1YV HP82H*95 M00001—
2010 MY
1YV HZ8AA*A5 M00001—
1YV HZ8AH*A5 M00001—
1YV HZ8BA*A5 M00001—
1YV HZ8BB*A5 M00001—
1YV HZ8BH*A5 M00001—
1YV HZ8CA*A5 M00001—
1YV HZ8CB*A5 M00001—
1YV HZ8CH*A5 M00001—
End Of Sie
1Y V H Z 8A B * A 5 M 0 0 0 0 1
H= With front, side and curtain air bag
M00001 to M99999
N00001 to N99999
1YV= Mazda passenger car, produced at AAI
5= AAI, Flat Rock, Michigan/U.S.A.
A= 2010
*= 0 to 9, X
A= 2.5 L (L5) (Made in Mexico)
B= 3.7 L (MZI-3.7) (Made in Hiroshima)
H= 2.5 L (L5) (Made in Hiroshima)
A= Standard grade, Sedan
B= Base grade, Sedan
C= High grade, Sedan
8= Mazda6
Z= Passenger car
World manufacturer identification
Air bag
Car identifier
Carline, series
Grade, Body type
Engine type
Check digit
Model year
Plant
Serial No.
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GENERAL INFORMATION
00-00–4
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
Symbols of Panel Replacement
•The following 6 symbols are used to indicate the type of weld that is used when replacing body panels.
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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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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GENERAL INFORMATION
00-00–5
00-00
Body Dimensions (Flat-plane Dimensions)
•Flat-plane dimensions are the dimensions measured by projecting certain reference points onto a plane
surface.
810{31.89}
FLAT-PLANE DIMENSIONS
FRONT FENDER INSTALLATION NUT
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GENERAL INFORMATION
00-00–6
•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
Body Dimensions (Straight-line Dimensions)
•Straight-line dimensions are the actual dimensions between two standard points.
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
00-00–7
00-00
817
FRONT FENDER INSTALLATION NUT
STRAIGHT-LINE DIMENSIONS
{32.17}
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3442-1U-09G.book 7 ページ ２００９年７月２２日 水曜日 午前１１時７分

GENERAL INFORMATION
00-00–8
•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
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.
When there are no specific indications, all of
units are in millimeters (mm).
mm {in}
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GENERAL INFORMATION
00-00–9
00-00
Symbols of Body Dimensions
•The following 8 symbols are used to indicate the standard points.
End Of Sie
AIR BAG SYSTEM SERVICE WARNINGS id000000920000
Air Bag Module Inspection
•Inspecting an air bag module using a tester can operate (deploy) the air bag module, which may cause
serious injury. Do not use a tester to inspect an air bag module. Always use the on-board diagnostic
function to diagnose the air bag module for malfunctions.
Air Bag Module Handling
•Before removing the air bag module or disconnecting the air bag module connector, always switch the
ignition to off, disconnect the negative battery cable, and then wait for 1 min or more to allow the
backup power supply of the SAS control module to deplete its stored power.
•Handling a live (undeployed) air bag module
that is pointed toward your body could result
in serious injury if the air bag module were to
accidentally operate (deploy). When carrying
a live (undeployed) air bag module, point the
deployment surface away from your body to
lessen the chance of injury in case it operates
(deploys).
•A live (undeployed) air bag module placed
with its deployment surface to ground is
dangerous. If the air bag module were to
accidentally operate (deploy), it could cause
serious injury. Always place a live
(undeployed) air bag module with its
deployment surface up.
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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NO GOOD
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GOOD NO GOOD
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NO GOOD
GOOD
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GENERAL INFORMATION
00-00–10
Side Air Bag Module Handling
•Before removing the side air bag module or disconnecting the side air bag module connector, always
switch the ignition to off, disconnect the negative battery cable, and then wait for 1 min or more to
allow the backup power supply of the SAS control module to deplete its stored power.
•When a side air bag module operates (deploys) due to a collision, the interior of the seat back (pad,
frame, trim) may become damaged. If a side air bag does not operate (deploy) normally from a seat
back that has been reused, a serious accident may result. After a side air bag has operated (deployed),
always replace both the side air bag module and the seat back (pad, frame, trim) with new parts. After
servicing, verify that the seat operates normally and that the wiring harness is not caught.
SAS Control Module Handling
•Removing the SAS control module or disconnecting the SAS control module connector with the
ignition switch at the ON position can activate the sensor in the SAS control module and operate
(deploy) the air bags and pre-tensioner seat belts, which may cause serious injury. Before removing the
SAS control module or disconnecting the SAS control module connector, always switch the ignition to
off, disconnect the negative battery cable, and then wait for 1 min or more to allow the backup power
supply of the SAS control module to deplete its stored power.
•Connecting the SAS control module connector with the SAS control module not securely fixed to the
vehicle is dangerous. The sensor in the SAS control module could send an electrical signal to the air
bag modules and pre-tensioner seat belts. This will operate (deploy) the air bags and pre-tensioner
seat belts, which may result in serious injury. Therefore, before connecting the connector, securely fix
the SAS control module to the vehicle.
•Because a sensor is built into the SAS control module, once the air bags and pre-tensioner seat belts
have operated (deployed) due to a collision or other causes, the SAS control module must be replaced
with a new one even if the used one does not have any visible external damage or deformation. The
used SAS control module may have been damaged internally, which may cause improper operation. If
the SAS control module is reused, the air bags and pre-tensioner seat belts may not operate (deploy)
normally, which could result in a serious accident. Always replace the SAS control module with a new
one. The SAS control module cannot be bench-checked or self-checked.
Side Air Bag Sensor Handling
•Removing the side air bag sensor or disconnecting the side air bag sensor connector with the ignition
switch at the ON position can activate the side air bag sensor and operate (deploy) the side air bag,
which may cause serious injury. Before removing the side air bag sensor or disconnecting the side air
bag sensor connector, always switch the ignition to off, disconnect the negative battery cable, and then
wait for 1 min or more to allow the backup power supply of the SAS control module to deplete its stored
power.
•If the side air bag sensor is subjected to shock or the sensor is disassembled, the side air bag may
accidentally operate (deploy) and cause injury, or the system may fail to operate normally and cause a
serious accident. Do not subject the side air bag sensor to shock or disassemble the sensor.
•Because a sensor is built into the side air bag sensor, once the air bag has operated (deployed) due to
a collision or other causes, the side air bag sensor must be replaced with a new one even if the used
one does not have any visible external damage or deformation. If the side air bag sensor is reused, the
side air bag may not operate (deploy) normally, which could result in a serious accident. Always
replace the side air bag sensor with a new one. The side air bag sensor cannot be bench-checked or
self-checked.
Pre-tensioner Seat Belt Inspection
•Inspecting a pre-tensioner seat belt using a
tester can operate (deploy) the pre-tensioner
seat belt, which may cause serious injury. Do
not use a tester to inspect a pre-tensioner
seat belt. Always use the on-board diagnostic
function to diagnose the pre-tensioner seat
belt for malfunctions.
End Of Sie
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3442-1U-09G.book 10 ページ ２００９年７月２２日 水曜日 午前１１時７分

GENERAL INFORMATION
00-00–11
00-00
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 WELDING
GLOVES COTTON
GLOVES
DUST SAFETY
FACE SHIELD
SAFETY
MASK GLASSES SHOES
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3442-1U-09G.book 11 ページ ２００９年７月２２日 水曜日 午前１１時７分

GENERAL INFORMATION
00-00–12
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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3442-1U-09G.book 12 ページ ２００９年７月２２日 水曜日 午前１１時７分

GENERAL INFORMATION
00-00–13
00-00
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 {1.2—1.9 in} and then rough-cut the
damaged panel.
End Of Sie
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.
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Wiring harness
Rough cut location Cut-and-join location
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3442-1U-09G.book 13 ページ ２００９年７月２２日 水曜日 午前１１時７分

GENERAL INFORMATION
00-00–14
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 3 mm
{0.12 in} 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
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D
70—120°
t
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TEST PIECE METHOD
NUGGET DIAMETER
:4/5 OF TIP
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3442-1U-09G.book 14 ページ ２００９年７月２２日 水曜日 午前１１時７分

GENERAL INFORMATION
00-00–15
00-00
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
25 mm
{0.98 in}
8 mm {0.31 in}
{0.20 in}
{0.20 in}
20°
WELD LOCATION
WITHIN 5 mm
WITHIN 5 mm
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TWO PANELS WELD LOCATION
THREE PANELS
ONE LOCATION
TWO LOCATION
FOUR PANELS
THREE LOCATION
WELD LOCATION
WELD LOCATION
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3442-1U-09G.book 15 ページ ２００９年７月２２日 水曜日 午前１１時７分

GENERAL INFORMATION
00-00–16
INSTALLATION PREPARATIONS id000000600400
Rough Cutting of New Parts
•For cut-and-join areas, allow for an overlap of 30—50 mm {1.2—1.9 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.
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.
OVER LAP
BODY SIDE ROUGH CUT LOCATION
NEW PART ROUGH CUT LOCATION
30—50 mm{1.2—1.9 in} 30—50 mm{1.2—1.9 in}
OVER LAP
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3 mm
{0.1 in} OR MORE
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Panel thickness (φ) Hole diameter (φ)
0.60—0.90 {0.024—0.035} 5.0 {0.20}
0.91—1.20 {0.036—0.047} 6.0 {0.24}
1.21—1.80 {0.0477—
0.0708} 8.0 {0.31}
1.81—4.50 {0.072—0.177} 10.0 {0.394}
φ 10.0 mm {0.394 in}
OUTER PANEL
MIDDLE PANEL
INNER PANEL
30°30°
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3442-1U-09G.book 16 ページ ２００９年７月２２日 水曜日 午前１１時７分

GENERAL INFORMATION
00-00–17
00-00
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
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.
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3442-1U-09G.book 17 ページ ２００９年７月２２日 水曜日 午前１１時７分

GENERAL INFORMATION
00-00–18
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
WM: GENERAL INFORMATION
BODY COLORS id000000788800
Color Code and Color Name
Verification of Primary Color Mixture for Body Color
Confirm the primary color mixture for the body color at the paint manufacturer URL.
End Of Sie
BM: GENERAL INFORMATION
ABBREVIATION id000000600700
End Of Sie
WM: GENERAL INFORMATION
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Color Code Color Name
A2N High performance white
NN Ebony black
36W LT. ice blue MC
36Y Sangaria red MC
37B Kona blue MC
37C Black cherry MC
37D Comet gray MC
38H Brilliant silver MC
Fr Front
LH Left Hand
RH Right Hand
Rr Rear
3442-1U-09G.book 18 ページ ２００９年７月２２日 水曜日 午前１１時７分