Mazda 3 2004 2009 User Manual

2004-2009

CONTENTS

Mazda3 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.

Title Section

GENERAL INFORMATION 00

CONSTRUCTION 80A

PANEL REPLACEMENT

BODY STRUCTURE

WATER-PROOF AND RUST PREVENTIVE TREATMENT

DIMENSIONS 80D

PLASTIC BODY PARTS

APPLICATION:

This manual is applicable to vehicles beginning with the Vehicle Identification Numbers (VIN), shown on the following page.

PRINTED IN U.S.A., OCTOBER 2003 Form No. 3386–1U–03J Part No. 9999–95–036F–04

80B

80C

80E

Mazda 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.

North American Operations

Mazda Motor Corporation

HIROSHIMA, JAPAN

VEHICLE IDENTIFICATION NUMBERS (VIN)

JM1 BK123✻4# 100001— JM1 BK223✻4# 100001— JM1 BK323✻4# 100001— JM1 BK12F✻4# 100001— JM1 BK22F✻4# 100001— JM1 BK32F✻4# 100001— JM1 BK143✻4# 100001— JM1 BK243✻4# 100001— JM1 BK343✻4# 100001—

GENERAL INFORMATION

Toc of SCT

GENERAL INFORMATION . . . . 00-00

Toc of SCT

00–00 GENERAL INFORMATION

SECTION

00–00

HOW TO USE THIS MANUAL . . . . . . . . . 00–00–2

Efficient Replacem ent of

Body Panels . . . . . . . . . . . . . . . . . . . . 00–00–2

Symbols of Panel Replac ement . . . . . . 00–00–2

Body Dimensions

(Flat-plane Dimensions ) . . . . . . . . . . . 00–00–3

Body Dimensions

(Straight-line Dimensi ons ). . . . . . . . . . 00–00–4

Symbols of Body Dimensions. . . . . . . . 00–00–4

SERVICE PRECAUTIONS . . . . . . . . . . . . 00–00–5

Arrangement of Workshop . . . . . . . . . . 00–00–5

Safety Precaution s . . . . . . . . . . . . . . . . 00–00–5

Vehicle Protection . . . . . . . . . . . . . . . . . 00–00–5

Remove Dangerous Articles . . . . . . . . . 00–00–5

Use of Pulling Equipment . . . . . . . . . . . 00–00–5

Prevent Short Circuits. . . . . . . . . . . . . . 00–00–6

EFFICIENT REMOVAL OF

BODY PANELS . . . . . . . . . . . . . . . . . . . 00–00–6

Body Measurements . . . . . . . . . . . . . . . 00–00–6

Prevention of Body Deformatio n . . . . . . 00–00–6

Selection of Cut-and-join Locations . . . 00–00–7

Removal of Associated Parts . . . . . . . . 00–00–7

End of Toc

Rough Cutting of Damaged Panel . . . . 00–00–7

INSTALLATION PREPARATIONS . . . . . 00–00–7

Rough Cutting of New Parts . . . . . . . . . 00–00–7

Determination of Welding Method . . . . 00–00–7

Making Holes for CO2 Arc Welding . . . 00–00–8 Application of Weld-throu gh Prime r . . . 00–00–8

EFFICIENT INSTALLATION OF

BODY PANELS . . . . . . . . . . . . . . . . . . . 00–00–8

Checking Preweld Measurements

And Watching. . . . . . . . . . . . . . . . . . . 00–00–8

Welding Notes . . . . . . . . . . . . . . . . . . . 00–00–9

Spot Welding Notes . . . . . . . . . . . . . . . 00–00–9

Checking Weld Strength. . . . . . . . . . . . 00–00–10

ANTICORROSION, SOUND

INSULATION, AND VIBRATION

INSULATION . . . . . . . . . . . . . . . . . . . . . 00–00–11

Body Sealing . . . . . . . . . . . . . . . . . . . . 00–00–11

Application of Undercoating . . . . . . . . . 00–00–11

Application of Rust Inhibitor . . . . . . . . . 00–00–11

Application of Floor Silencer. . . . . . . . . 00–00–12

ABBREVIATION . . . . . . . . . . . . . . . . . . . 00–00–12

00–00–1

GENERAL INFORMATION

HOW TO USE THIS MANUAL

C3U000000000B01

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

Caution

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.

NOTE

Drill the 24 weld locations indicated by (A), from the room side.

Shows a dimensions

250mm

{9.84in}

CUT-AND-JOINT LOCATION

ROUGH CUT LOCATION

Shows operation section

Shows procedure, caution and note

Shows a cross location

BRAZE WELDING

ROUGH CUT LOCATION

30mm

{1.18in}

CUT-AND-JOINT LOCATION

(A)24

Shows a insulator

BOTTOM SIDE 1

Shows number of weld

Shows welding region

Shows a cross

A-A

B-B

Symbols of Panel Replacement

• The following 6 symbols are used to indicate the type of weld that is used when replacing body panels.

SYMBOL

MEANING

Spot welding

arc welding (plug welding)

spot welding

SYMBOL

MEANING

Continuous MIG welding (Cut-and-join location)

Braze welding

Rough cut location

MZZ2010B001

MZZ2010B002

00–00–2

GENERAL INFORMATION

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.

Example

00–00

UNDERBODY FLAT-PLANE DIMENSIONS

1,030 {40.55}

Shows dimension

The dimensions on the left and right in regard to the center of the vehicle are different.

Shows hypothetical standard line

Shows vehicle section

495

{19.48}

918 {38.14}

1,162 {45.78}

485

{19.09}

619

{24.38}

185

{7.28}

725

{28.55}

{19.27}

489

1,211

{2.19}

{47.68}

{12.40}

609

315

527

{24.00}

690 {27.17}

{20.75}

425

{16.73}

Shows outline drawing

800 {31.50}

487

{19.19}

1,240

{48.82}

When there are no specific indications, all of units are in millimeters (mm).

mm {in}

1,220 {48.03}

587

{3.86}

547

{23.11}

{12.62}

{21.54}

320

1,089 {42.87}

624

{24.56}

716

{28.21}

1,060 {41.73}

Shows point symbol

700

{27.58}

Point symbol

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

Designation

Hole diameter

or bolt or nut size mm {in}

φ 16 {0.62}

φ 80 {3.14}

M14 {0.55}

φ 16 {0.62}

Shows bolt size

Point symbol

Front frame rear standard hole Rear side frame standard hole

Link bracket

Rear suspension housing

Rear side frame standard hole

Designation

Hole diameter

or bolt or nut

size mm {in}

φ 18 {0.62} φ 16 {0.62}

17 × 29.5

{0.66×1.16}

φ 12 {0.47}

φ 16 {0.62}

Shows hole diameter

00–00–3

Shows slot

MZZ2010B003

GENERAL INFORMATION

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.

Example

ROOM STRAIGHT-LINE DIMENSIONS (2)

Shows vehicle section

Shows details of the standard point location

F-F

Shows dimension location

Shows point symbol

Shows point indication Without apostrophe:RH

With apostrophe:LH

Shows position and shape of the points

B-B

G-G

C-C

H-H

Shows outline drawing

D-D

I - I

E. E

E-E

Measured

location

1 2 3 4 5 6 7

Dimension mm {in}

1,184 {46.61} 1,064 {41.89}

919 {36.18} 690 {27.17}

1,185 {46.65}

901 {35,47} 607 {23.90}

Shows dimension

No indication are shown within the outline drawing.

Symbols of Body Dimensions

• The following 8 symbols are used to indicate the standard points.

SYMBOL

Center of circular hole

MEANING

SYMBOL

(arrow only)

Center elliptical hole

Notch

Panel seam, bead, etc.

Measured

location

9 10 11

B-B' C-C' D-D'

Dimension mm {in}

1,642 {64.65} 1,463 {57.60} 1,667 {65.63} 1,672 {65.83} 1,037 {40.83} 1,290 {50.79} 1,208 {47.56}

MZZ2010B004

MEANING

Bolt tip

Center of rectangular-shaped hole

Edge of rectangular-shaped hole

End Of Sie

00–00–4

MZZ2010B016

GENERAL INFORMATION

SERVICE PRECAUTIONS

C3U000000000B02

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.

Welding glasses

Dust mask Safety glasses

Ear protectors

Weldlng gloves

Face shield

Cotton gloves

Safety shoes

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.

00–00

MZZ2036B001

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.

MZZ2036B002

MZZ2036B003

Safety wires

MZZ2036B004

00–00–5

GENERAL INFORMATION

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

Battery cable

MZZ2036B005

EFFICIENT REMOVAL OF BODY PANELS

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.

Ground

MZZ2036B006

C3U000000000B03

MZJ2038B001

00–00–6

MZJ2038B002

GENERAL INFORMATION

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.

MZJ2038B003

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

Wiring harness

00–00

Rough cut location

INSTALLATION PREPARATIONS

Cut-and-join location

MZZ2038B001

C3U000000000B04

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.

30-50mm{1.18-1.97in}

Over lap

Body side rough cut location

New part rough cut location

30-50mm{1.18-1.97in}

Over lap

MZZ2038B002

Determination of Welding Method

• If the total thickness at the area to be welded is 3 mm {0.12 in} or more, use a CO

gas shielded-arc welder to

make the plug welds.

3mm {0.12in}or more

MZZ2038B003

00–00–7

GENERAL INFORMATION

Making Holes for CO2 Arc Welding

• For places that cannot be spot welded, make a hole for CO

(mm {in})

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}

• 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.

arc welding using a punch or drill as follows.

10mm{0.39in}

30°

Outer panel

Middie panel

Inner panel

MZZ2038B004

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

MZJ2038B008

EFFICIENT INSTALLATION OF BODY PANELS

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.

C3U000000000B05

00–00–8

MZJ2038B009

GENERAL INFORMATION

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.

Spot welding Original weld Pitch: 50mm{1.97in}

arc welding

Original spot weld

Repair weld Pitch: within 35mm{1.38in}

Original number of welds x 1.3 or more

If 3mm {0.12in} or more

Original number of welds or more

70 - 120°

Repair weld

MZZ2038B005

00–00

• 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.

MZZ2038B009

MZJ2038B012

Test piece method

Nagget diameter :4/5 of tip

MZZ2038B006

00–00–9

GENERAL INFORMATION

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}

Within 5mm

{0.20in}

Two panels

Three panels

20°

8mm{0.31in}

Weld location

Within 5mm

{0.20in}

MZZ2038B007

Weld location

One location

Weld location

Four panels

Two location

Weld location

Three location

MZZ2038B008

00–00–10

GENERAL INFORMATION

ANTICORROSION, SOUND INSULATION, AND VIBRATION INSULATION

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.

C3U000000000B06

00–00

YMU980PAR

Application of Rust Inhibitor

• Apply rust inhibitor (wax, oil, etc.) to the back of the welded areas.

YMU980PAS

YMU980PAT

00–00–11

GENERAL INFORMATION

Application of Floor Silencer

• Apply floor silencer by heating with an infrared ray lamp.

End Of Sie

ABBREVIATION

CM Control module Ctr Center DSC Dynamic stability control Fr Front HU Hydraulic unit LH Left M Metallic MC Mica RH Right Rr Rear

YMU980PAU

C3U000000000B07

End Of Sie

00–00–12

BODY & ACCESSORIES

Toc of SCT

CONSTRUCTION . . . . . . . . . . . 09-80A

PANEL REPLACEMENT . . . . .09-80B

WATER-PROOF AND RUST

PREVENTIVE TREATMENT. . 09-80C

Toc of SCT

09–80A BODY STRUCTURE [CONSTRUCTION]

DIMENSIONS . . . . . . . . . . . . . . 09-80D

PLASTIC BODY PARTS . . . . . 09-80E

SECTION

09–80A

BODY COMPONENTS CONSTRUCTION09–80A–2

4SD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09–80A–2

End of Toc

5HB . . . . . . . . . . . . . . . . . . . . . . . . . . . 09–80A–5

09–80A–1

BODY STRUCTURE [CONSTRUCTION]

BODY COMPONENTS CONSTRUCTION

4SD

C3U098007000B01

B3U0980B041

09–80A–2

BODY STRUCTURE [CONSTRUCTION]

x:Applied

-:Not applied

No. Part Name High- tension steel Rust proof steel

1 Hood - x 0.70 {0.028} 2 Front bumper bracket x x 2.90 {0.114} 3 Front side frame (inner) x x 1.60 {0.063} 4 Front side frame (outer) x x 1.60 {0.063} 5 Apron reinforcement (lower) - x 0.70 {0.028} 6 Apron reinforcement (upper) - x 1.00 {0.039} 7 Shroud side panel x x 1.00 {0.039} 8 Suspension housing - x 2.60 {0.102}

9 Front fender panel x x 0.65 {0.026} 10 Side member deck - x 1.80 {0.071} 11 Front frame rear reinforcement x x 0.80 {0.031} 12 Front frame (rear) x x 1.80 {0.071} 13 Torque box - x 1.60 {0.063} 14 Dash lower member x x 1.40 {0.055} 15 Dash lower panel x 0.80 {0.031} 16 Wiper bracket - x 1.40 {0.055} 17 Dash upper panel - x 0.85 {0.033} 18 Cowl panel - x 0.80 {0.031} 19 Cowl side reinforcement - x 0.70 {0.028} 20 Hinge pillar (inner) x x 1.60 {0.063}

Front pillar (inner)

Center pillar (inner)

22 Center pillar reinforcement (inner) x - 1.80 {0.071} 23 Roof rail (inner, rear) x - 1.00 {0.039}

Front pillar reinforcement

Center pillar reinforcement

25 Side sill reinforcement x - 1.40 {0.055} 26 Wheel house (inner) - x 0.70 {0.028} 27 Rear pillar (inner) - x 0.65 {0.026} 28 Rear fender lower panel - x 0.70 {0.028} 29 Front header - - 0.65 {0.026} 30 Roof reinforcement (front) - - 0.55 {0.021} 31 Roof reinforcement center - - 1.00 {0.039} 32 Roof reinforcement (rear) - - 1.00 {0.039} 33 Rear header - - 0.70 {0.028} 34 Roof panel - - 0.70 {0.028} 35 Package tray - - 0.60 {0.024} 36 Rear fender rain rail - x 0.70 {0.028} 37 Corner plate - x 0.70 {0.028} 38 Trunk lid panel x x 0.70 {0.028} 39 Side panel (outer) - x 0.70 {0.028} 40 Rear door - x 0.65 {0.026} 41 Front door - x 0.70 {0.028} 42 Side sill (inner) x x 1.40 {0.055} 43 Front B frame x x 0.90 {0.035}

LH x - 1.40 {0.055} RH x - 1.60 {0.063}

Upper

Center x - 1.20 {0.047} Lower x - 1.00 {0.039}

Upper x - 1.80 {0.071} Lower x - 1.80 {0.071} Upper x - 1.40 {0.055} Lower x - 1.20 {0.047}

LH x - 1.60 {0.063} RH x - 1.80 {0.071}

Thickness

(mm) {in}

09–80A

09–80A–3

BODY STRUCTURE [CONSTRUCTION]

No. Part Name High- tension steel Rust proof steel

44 Crossmember No.2 x - 1.20 {0.047} 45 Front floor pan - x 0.70 {0.028} 46 Crossmember No.3 x x 1.60 {0.063} 47 Crossmember No.4 gusset - x 1.40 {0.055}

Front x x 2.00 {0.079}

48 Rear side frame

49 Crossmember No.3 (front) - x 1.60 {0.063} 50 Suspension housing - x 0.75 {0.030} 51 Rear floor pan - x 2.00 {0.079} 52 Rear end member - - 0.60 {0.024} 53 Rear end panel - x 0.60 {0.024}

Center x x 2.60 {0.102} Rear x x 1.80 {0.071}

Thickness

(mm) {in}

09–80A–4

5HB

BODY STRUCTURE [CONSTRUCTION]

09–80A

B3U0980B043

09–80A–5

BODY STRUCTURE [CONSTRUCTION]

x:Applied

-:Not applied

No. Part Name High- tension steel Rust proof steel

1 Hood x x 0.70 {0.028} 2 Front bumper bracket x x 2.90 {0.114} 3 Front side frame (inner) x x 1.60 {0.063} 4 Front side frame (outer) x x 1.60 {0.063} 5 Apron reinforcement (lower) - x 0.70 {0.028} 6 Apron reinforcement (upper) - x 1.00 {0.039} 7 Shroud side panel x x 1.00 {0.039} 8 Suspension housing - x 2.60 {0.102}

Front pillar (inner)

Center pillar (inner)

22 Center pillar reinforcement (inner) x - 1.80 {0.071} 23 Roof rail (inner, rear) x - 1.00 {0.039}

Front pillar reinforcement

Center pillar reinforcement

25 Side sill reinforcement x - 1.40 {0.055} 26 Wheel house (inner) - x 0.70 {0.028} 27 Rear pillar (inner) - x 0.65 {0.026} 28 Rear pillar (outer) - x 0.70 {0.028} 29 Corner plate - x 0.70 {0.028} 30 Rear side panel - - 0.70 {0.028} 31 Rear pillar reinforcement - - 0.70 {0.028} 32 Rear fender lower panel - x 0.70 {0.028} 33 Front header - - 0.65 {0.026} 34 Roof reinforcement (front) - - 0.55 {0.021} 35 Roof reinforcement center (front) - - 1.00 {0.039} 36 Roof reinforcement center (rear) - - 0.75 {0.030} 37 Roof reinforcement (rear) - - 0.55 {0.021} 38 Rear header - - 0.75 {0.030} 39 Roof panel - - 0.75 {0.030} 40 Liftgate panel - x 0.70 {0.028} 41 Side panel (outer) - x 0.70 {0.028} 42 Rear door - x 0.65 {0.026} 43 Front door x x 0.70 {0.028}

LH x - 1.40 {0.055} RH x - 1.60 {0.063}

Upper

Center x - 1.20 {0.047} Lower x - 1.00 {0.039}

Upper x - 1.80 {0.071} Lower x - 1.80 {0.071} Upper x - 1.40 {0.055} Lower x - 1.20 {0.047}

LH x - 1.60 {0.063} RH x - 1.80 {0.071}

Thickness

(mm) {in}

09–80A–6

BODY STRUCTURE [CONSTRUCTION]

No. Part Name High- tension steel Rust proof steel

44 Side sill (inner) x x 1.40 {0.055} 45 Front B frame x x 0.90 {0.035} 46 Crossmember No.2 x - 1.20 {0.047} 47 Front floor pan - x 0.70 {0.028} 48 Crossmember No.3 x x 1.60 {0.063} 49 Crossmember No.4 gusset - x 1.40 {0.055}

Front x x 2.00 {0.079}

50 Rear side frame

51 Crossmember No.3 (front) - x 1.60 {0.063} 52 Rear floor pan - x 0.75 {0.030} 53 Suspension housing - x 2.00 {0.079} 54 Rear end member - - 1.20 {0.047} 55 Rear end panel - x 0.60 {0.024}

Center x x 2.60 {0.102} Rear x x 1.80 {0.071}

Thickness

(mm) {in}

End Of Sie

09–80A

09–80A–7

BODY STRUCTURE [PANEL REPLACEMENT]

09–80B BODY STRUCTURE [PANEL REPLACEMENT]

FRONT BUMPER BRACKET

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . 09–80B–2

FRONT BUMPER BRACKET

INSTALLATION. . . . . . . . . . . . . . . . . . . 09–80B–3

SHROUD SIDE PANEL REMOVAL . . . . 09–80B–4

SHROUD SIDE PANEL

INSTALLATION. . . . . . . . . . . . . . . . . . . 09–80B–5

COWL SIDE REINFORCEMENT

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . 09–80B–6

COWL SIDE REINFORCEMENT

INSTALLATION. . . . . . . . . . . . . . . . . . . 09–80B–7

APRON REINFORCEMENT (LOWER)

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . 09–80B–8

APRON REINFORCEMENT (LOWER)

INSTALLATION. . . . . . . . . . . . . . . . . . . 09–80B–9

APRON REINFORCEMENT (PARTIAL

CUTTING) REMOVAL . . . . . . . . . . . . . . 09–80B–10

APRON REINFORCEMENT (PARTIAL

CUTTING) INSTALLATION. . . . . . . . . . 09–80B–12

WHEEL APRON PANEL (FRONT)

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . 09–80B–14

WHEEL APRON PANEL (FRONT)

INSTALLATION. . . . . . . . . . . . . . . . . . . 09–80B–15

FRONT SIDE FRAME COMPONENT

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . 09–80B–15

FRONT SIDE FRAME COMPONENT

INSTALLATION. . . . . . . . . . . . . . . . . . . 09–80B–19

FRONT SIDE FRAME (PARTIAL

CUTTING) REMOVAL . . . . . . . . . . . . . . 09–80B–22

FRONT SIDE FRAME (PARTIAL

CUTTING) INSTALLATION. . . . . . . . . . 09–80B–22

TORQUE BOX REMOVAL . . . . . . . . . . . 09–80B–25

TORQUE BOX INSTALLATION . . . . . . . 09–80B–26

FRONT FRAME (REAR) REMOVAL . . . 09–80B–27 FRONT FRAME (REAR)

INSTALLATION. . . . . . . . . . . . . . . . . . . 09–80B–28

FRONT PILLAR REMOVAL . . . . . . . . . . 09–80B–28

FRONT PILLAR INSTALLATION . . . . . . 09–80B–32

CENTER PILLAR REMOVAL . . . . . . . . . 09–80B–35

CENTER PILLAR INSTALLATION . . . . . 09–80B–37

REAR FENDER PANEL REMOVAL . . . . 09–80B–40

4SD . . . . . . . . . . . . . . . . . . . . . . . . . . . 09–80B–40

5HB . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09–80B–41

REAR FENDER PANEL

INSTALLATION . . . . . . . . . . . . . . . . . . . 09–80B–42

4SD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09–80B–42

5HB . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09–80B–43

REAR FENDER LOWER PANEL

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . 09–80B–44

4SD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09–80B–44

5HB . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09–80B–45

REAR FENDER LOWER PANEL

INSTALLATION . . . . . . . . . . . . . . . . . . . 09–80B–46

4SD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09–80B–46

5HB . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09–80B–47

SIDE SILL PANEL REMOVAL. . . . . . . . . 09–80B–48

SIDE SILL PANEL INSTALLATION. . . . .09–80B–49

REAR END PANEL REMOVAL . . . . . . . . 09–80B–50

4SD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09–80B–50

5HB . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09–80B–51

REAR END PANEL INSTALLATION . . . . 09–80B–52

4SD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09–80B–52

5HB . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09–80B–53

REAR FENDER RAIN RAIL AND

CORNER PLATE REMOVAL . . . . . . . . . 09–80B–54

4SD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09–80B–54

5HB . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09–80B–55

REAR FENDER RAIN RAIL AND

CORNER PLATE INSTALLATION . . . . 09–80B–56

4SD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09–80B–56

5HB . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09–80B–57

REAR FLOOR PAN REMOVAL . . . . . . . . 09–80B–58

REAR FLOOR PAN INSTALLATION. . . . 09–80B–60

REAR SIDE FRAME (PARTIAL CUTTING)

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . 09–80B–62

REAR SIDE FRAME (PARTIAL CUTTING)

INSTALLATION . . . . . . . . . . . . . . . . . . . 09–80B–63

ROOF PANEL REMOVAL . . . . . . . . . . . . 09–80B–64

4SD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09–80B–64

5HB . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09–80B–65

ROOF PANEL INSTALLATION . . . . . . . . 09–80B–66

4SD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09–80B–66

5HB . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09–80B–67

09–80B

End of Toc

09–80B–1

BODY STRUCTURE [PANEL REPLACEMENT]

FRONT BUMPER BRACKET REMOVAL

1. Remove the front bumper bracket.

Caution

•••• Only the procedure for the left side is described. The shape for the right side is different.

FRONT BUMPER BRACKET

C3U098053896B01

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09–80B–2

B3E0980B047

BODY STRUCTURE [PANEL REPLACEMENT]

FRONT BUMPER BRACKET INSTALLATION

C3U098053896B02

1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions.

2. After temporarily installing new parts, make sure the related parts fit properly.

FRONT BUMPER BRACKET

09–80B

End Of Sie

B3E0980B048

09–80B–3

BODY STRUCTURE [PANEL REPLACEMENT]

SHROUD SIDE PANEL REMOVAL

1. Remove the shroud side panel.

C3U098053140B01

SHROUD SIDE PANEL LH

End Of Sie

09–80B–4

SHROUD SIDE PANEL RH

B3E0980B049

BODY STRUCTURE [PANEL REPLACEMENT]

SHROUD SIDE PANEL INSTALLATION

C3U098053140B02

1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions.

2. Drill holes for plug welds before installing new parts.

3. After temporarily installing new parts, make sure the related parts fit properly.

09–80B

SHROUD SIDE PANEL LH

End Of Sie

SHROUD SIDE PANEL RH

B3E0980B050

09–80B–5

BODY STRUCTURE [PANEL REPLACEMENT]

COWL SIDE REINFORCEMENT REMOVAL

1. Remove the cowl side reinforcement.

Caution

•••• Be careful not to damage the windshield when drilling the 2 locations indicated by (A).

(A)2

C3U098053290B01

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COWL SIDE REINFORCEMENT

B3E0980B051

09–80B–6

BODY STRUCTURE [PANEL REPLACEMENT]

COWL SIDE REINFORCEMENT INSTALLATION

C3U098053290B02

1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions.

2. Drill holes for plug welds before installing new parts.

3. After temporarily installing new parts, make sure the related parts fit properly.

09–80B

End Of Sie

COWL SIDE REINFORCEMENT

B3E0980B052

09–80B–7

BODY STRUCTURE [PANEL REPLACEMENT]

APRON REINFORCEMENT (LOWER) REMOVAL

1. Remove the apron reinforcement (lower).

C3U098053260B01

APRON REINFORCEMENT (LOWER)

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B3E0980B053

09–80B–8

BODY STRUCTURE [PANEL REPLACEMENT]

APRON REINFORCEMENT (LOWER) INSTALLATION

C3U098053260B02

1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions.

2. Drill holes for plug welds before installing new parts.

3. After temporarily installing new parts, make sure the related parts fit properly.

APRON REINFORCEMENT (LOWER)

09–80B

End Of Sie

B3E0980B054

09–80B–9

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