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.

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

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

am6xuw0000286

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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.

am6xuw0000287

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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

(A)17

acxuub00000031

SYMBOL MEANING

Spot welding

arc welding (plug welding)

spot welding

SYMBOL MEANING

Continuous MIG welding (Cut-and-join location)

Braze welding

Rough cut location

acxuub00000032

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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

acxuub00000033

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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

Rear side frame standard hole

Link bracket

Rear suspension housing

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}

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

{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

{29.92}

{23.82}

{25.59}

650

{45.83}

{25.59}

ac9uub00000034

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GENERAL INFORMATION

00-00–7

00-00

817

FRONT FENDER INSTALLATION NUT

STRAIGHT-LINE DIMENSIONS

{32.17}

acxuub00000035

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}

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}

CDE,E'

Fr Fr

FrFr Fr

Front pillar inner designation

Front floor pan designation

Adjuster installation hole

Trim installation hole

Harness installation hole

Chaker bracket installation hole

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}

am3uub0000007

3442-1U-09G.book 8 ページ２００９年７月２２日　水曜日　午前１１時７分

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