Bodyshop Manual

3419-1U-06C(INDEX).
fm 1 ページ２００６年３月２３日　木曜日　午前１１時１８分
2007-2012 CONTENTS
Mazda CX-7 Title Section
Bodyshop GENERAL INFORMATION 00
Manual CONSTRUCTION 80A
PANEL REPLACEMENT 80B

BODY WATER-PROOF AND RUST
FOREWORD
STRUCTURE PREVENTIVE 80C
This bodyshop manual is intended for DIMENSIONS 80D
use by technicians of Authorized Mazda
Dealers to help them service and repair
Mazda vehicles. It can also be useful to PLASTIC BODY PARTS 80E
owners and operators of Mazda vehicles in
performing limited repair and maintenance APPLICATION:
on Mazda vehicles. This manual is applicable to vehicles beginning
with the Vehicle Identification Numbers (VIN),
For proper repair and maintenance, a shown on the following page.
thorough familiarization with this manual is
important, and it should always be kept in a © 2006 Mazda Motor Corporation
handy place for quick and easy reference. PRINTED IN U.S.A., MARCH 2006
Form No. 3419–1U–06C
All the contents of this manual, including Part No. 9999–95–093F–07
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
3419-1U-06C(INDEX).fm 2 ページ２００６年３月２３日　木曜日　午前１１時１８分
VEHICLE IDENTIFICATION NUMBERS (VIN)
JM3 ER29L✻7# 100001—

JM3 ER293✻7# 100001—
3419-1U-06C(00-00).fm 1 ページ２００６年３月２２日　水曜日　午後４時１４分
GENERAL INFORMATION 00
SECTION
00-00
Toc of SCT INFORMATION . . . . 00-00

GENERAL
Toc of SCT
00-00 GENERAL INFORMATION
VEHICLE IDENTIFICATION NUMBER Selection of Cut-and-join Locations . . . 00-00–10
(VIN) CODE . . . . . . . . . . . . . . . . . . . . . . 00-00–2 Removal of Associated Parts . . . . . . . . 00-00–10
VEHICLE IDENTIFICATION NUMBERS Rough Cutting of Damaged Panel . . . . 00-00–10
(VIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-00–2 INSTALLATION PREPARATIONS. . . . . . 00-00–10
HOW TO USE THIS MANUAL . . . . . . . . . 00-00–3 Rough Cutting of New Parts. . . . . . . . . 00-00–10
Efficient Replacement of Body Panels . 00-00–3 Determination of Welding Method . . . . 00-00–11
Symbols of Panel Replacement . . . . . . 00-00–4 Making Holes for CO2 Arc Welding . . . 00-00–11
Body Dimensions Application of Weld-through Primer . . . 00-00–11
(Flat-plane Dimensions) . . . . . . . . . . . 00-00–4 EFFICIENT INSTALLATION OF
Body Dimensions BODY PANELS . . . . . . . . . . . . . . . . . . . 00-00–12
(Straight-line Dimensions). . . . . . . . . . 00-00–6 Checking Preweld Measurements
Symbols of Body Dimensions . . . . . . . . 00-00–7 And Watching . . . . . . . . . . . . . . . . . . . 00-00–12
SERVICE PRECAUTIONS . . . . . . . . . . . . 00-00–8 Welding Notes . . . . . . . . . . . . . . . . . . . 00-00–12
Arrangement of Workshop . . . . . . . . . . 00-00–8 Spot Welding Notes . . . . . . . . . . . . . . . 00-00–12
Safety Precautions . . . . . . . . . . . . . . . . 00-00–8 Checking Weld Strength. . . . . . . . . . . . 00-00–13
Vehicle Protection . . . . . . . . . . . . . . . . . 00-00–8 ANTICORROSION, SOUND INSULATION,
Remove Dangerous Articles . . . . . . . . . 00-00–8 AND VIBRATION INSULATION . . . . . . 00-00–14
Use of Pulling Equipment . . . . . . . . . . . 00-00–9 Body Sealing . . . . . . . . . . . . . . . . . . . . 00-00–14
Prevent Short Circuits . . . . . . . . . . . . . . 00-00–9 Application of Undercoating . . . . . . . . . 00-00–14
EFFICIENT REMOVAL OF Application of Rust Inhibitor . . . . . . . . . 00-00–14
BODY PANELS. . . . . . . . . . . . . . . . . . . . 00-00–9 Application of Floor Silencer. . . . . . . . . 00-00–14
Body Measurements . . . . . . . . . . . . . . . 00-00–9 ABBREVIATION . . . . . . . . . . . . . . . . . . . 00-00–15
Prevention of Body Deformation . . . . . . 00-00–10
End of Toc
BM: GENERAL INFORMATION
00-00–1
GENERAL INFORMATION
VEHICLE IDENTIFICATION NUMBER (VIN) CODE
id000000600800
J M3ER 293 *7 # 12 3 4 5 6
Serial No.
0= Hiroshima
Plant 1= Hofu
Model year 7= 2007
Check digit *= 0 to 9, X
L= 2.3 L (California (L3 WITH TC))

Engine 3= 2.3 L (Federal/CANADA (L3 WITH TC))
9= Wagon, Gross vehicle weight class C

Body, Gross vehicle weight class (1814 2267 kg)
Resraint system 2= with Curtain and Side air bags
Carline, Series ER= Mazda CX-7
World manufacturer identification JM3= Mazda/Multi-purpose vehicle category/U.S.A.
acxuuw00002316
End Of Sie
VEHICLE IDENTIFICATION NUMBERS (VIN)
id000000600100
JM3 ER29L*7# 100001—
JM3 ER293*7# 100001—
End Of Sie
00-00–2
GENERAL INFORMATION
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. 00-00
• 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
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 17 weld locations indicated by (A), from the room side.
Shows a cross location

Shows a dimensions BRAZE WELDING
A A
250mm
{9.84in} Shows a insulator
CUT-AND-JOINT LOCATION
ROUGH CUT LOCATION 17
(A)17
4
30mm
{1.18in} 5
5
Shows welding region

Shows number of weld
7 1 A-A
Shows a cross
acxuub00000031
00-00–3
GENERAL INFORMATION
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 SYMBOL MEANING

Spot welding Continuous MIG welding (Cut-and-join location)
CO2 arc welding (plug welding) Braze welding
CO2 spot welding Rough cut location
acxuub00000032
Body Dimensions (Flat-plane Dimensions)

• Flat-plane dimensions are the dimensions measured by projecting certain reference points onto a plane
surface.
FRONT FENDER INSTALLATION NUT
810 {31.89}
FLAT-PLANE DIMENSIONS
acxuub00000033
• 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.
00-00–4
GENERAL INFORMATION
Example
Shows vehicle section
When there are no specific indications, all of

UNDERBODY FLAT-PLANE DIMENSIONS units are in millimeters (mm).
00-00
The dimensions on the left
and right in regard to the center Shows outline drawing mm {in}
of the vehicle are different.
{19.05}
484
{17.91}
478
455
1,106 {43.54}
1,073 {37.91}
1,164 {45.83}
650 {25.59}
650 {25.59}
605 {23.82}
760 {29.92}
650 {25.59}
RH LH
{40.00}
1,016
{18.46}
{21.37}
469
485
543
Shows dimension
A B C D E F G H I J K L
Shows point
symbol
1,084 {42.84}
{25.98}
{41.06}
{26.22}
Shows hypothetical
{27.05}
{25.75}
{22.80}
{18.86}
{17.17}
{17.17}
{17.52}
{20.16}
1,043
660
666
687
654
579
479
436
436
445
512
standard line
182 93 144 120 140 68

420 1,030 760 379
{16.54} {7.17} {3.66} {5.67} {4.72} {40.55} {5.51} {29.92} {2.68} {14.92}
Hole diameter Hole diameter

Point Point
Designation or bolt or nut Designation or bolt or nut
symbol symbol
size mm {in} size mm {in}
Crossmember No,1 standard F Front frame rear standard hole φ 18 {0.62} Shows
A φ 16 {0.62}
hole G Rear side frame standard hole φ 16 {0.62} slot
B Front side frame standard hole φ 16 {0.62} 17 × 29.5
H Link bracket
Front suspension mounting {0.66×1.16}
C φ 80 {3.14}
block surface hole center I Rear suspension housing φ 12 {0.47}
Front suspension mounting J Rear side frame standard hole φ 16 {0.62}
D M14 {0.55}
bolt K Rear suspension housing φ 31 {1.22}
E Front frame rear standard hole φ 16 {0.62} L Rear side frame standard hole φ 12 {0.47}
Shows bolt size Shows hole diameter

acxuub00000034
00-00–5
GENERAL INFORMATION
Body Dimensions (Straight-line Dimensions)
• Straight-line dimensions are the actual dimensions between two standard points.
FRONT FENDER INSTALLATION NUT
817 {32.17}
STRAIGHT-LINE DIMENSIONS
acxuub00000035
• When there are no specific indications, the standard points and dimensions are symmetrical in regard to the
center of the vehicle.
00-00–6
GENERAL INFORMATION
Example
ROOM STRAIGHT-LINE DIMENSIONS (1)
Shows vehicle section Shows point

symbol Shows outline drawing 00-00
A
Shows dimension
B
1,128
{44.41} F
1,263
1,067 {49.72}
{42.01} H
Shows dimension location
No indication are shown 1,048
{41.26} I
within the outline drawing. 1,398
{55.04}
C
1,406
799 {55.35}
{31.46} G
851
{33.50}
Shows point indication

Shows details of the standard Without apostrophe:RH
Shows position and shape of the points With apostrophe:LH
point location
A B C D E,E'
Fr
Fr
Fr Fr Fr
F G H I
Fr
Fr Fr Fr

Point Point
symbol
size mm {in}
symbol
size mm {in}
Shows hole diameter
A Front pillar inner designation φ 16 {0.62} F Trim installation hole φ 18 {0.71}
G Harness installation hole φ 16 {0.62}
B Front pillar inner designation φ 17 {0.67} 17 × 29.5
H Chaker bracket installation hole Shows
{0.66×1.16}
C Harness installation hole φ 31 {1.22} slot
I Chaker bracket installation hole φ 12 {0.47}
D Front floor pan designation M14 {0.55}
E Adjuster installation hole φ 16 {0.62}
Shows bolt size

acxuub00000149
Symbols of Body Dimensions

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

Center of circular hole (arrow only) Bolt tip
Center elliptical hole Center of rectangular-shaped hole
Notch Edge of rectangular-shaped hole

Panel seam, bead, etc.
acxuub00000037
End Of Sie
00-00–7
GENERAL INFORMATION
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. Welding Ear Weldlng Cotton
glasses protectors gloves gloves
Dust mask Safety glasses Safety shoes

Face shield
acxuub00000038
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.
acxuub00000063
Remove Dangerous Articles

• Remove the fuel tank before using an open flame
in that area. Plug connection piping to prevent
fuel leakage.
acxuub00000064
00-00–8
GENERAL INFORMATION
Use of Pulling Equipment
• When using pulling equipment, keep away from
the pulling area and use safety wires to prevent
accidents.
00-00
Safety wires
acxuub00000041
Prevent Short Circuits

• Turn the ignition switch to the LOCK position.
• Disconnect the battery cables. Battery cable
acxuub00000042
• Securely connect the welding machine ground

near the welding area.
End Of Sie
Ground
acxuub00000043
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.
acxuub00000065
00-00–9
GENERAL INFORMATION
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.
acxuub00000066
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.
acxuub00000067
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
Rough cut location Cut-and-join location

acxuub00000047
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 30-50mm{1.18-1.97in} 30-50mm{1.18-1.97in}
parts. Over lap Over lap
Body side rough cut location

New part rough cut location
acxuub00000048
00-00–10
GENERAL INFORMATION
Determination of Welding Method
• If the total thickness at the area to be welded is 3 mm {0.12 in} or more, use a CO2 gas shielded-arc welder to
make the plug welds.
00-00
3mm
{0.12in}or more
acxuub00000049
Making Holes for CO2 Arc Welding

• For places that cannot be spot welded, make a hole for CO2 arc welding using a punch or drill as follows.
(mm {in})
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}
• 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.
φ10mm{0.39in}
30° 30°
Outer panel
Middle panel
Inner panel
acxuub00000050
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
acxuub00000068
00-00–11
GENERAL INFORMATION
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.
acxuub00000069
Welding Notes
• For the number of weld points, welding should be Spot welding
performed in accordance with the following Original weld Repair weld
reference standards.
Original number of
welds x 1.3 or more
CO2 arc welding If 3mm Repair weld

Original spot weld {0.12in} or more
Original number of welds

or more
acxuub00000053
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
70 - 120°
the under panel, adjust to the thinner one.
D t
acxuub00000054
• 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.
acxuub00000070
00-00–12
GENERAL INFORMATION
• Before spot welding, make a trial weld using the
same material as the body panel to check the Test piece method
weld strength.
00-00
Nugget diameter
:4/5 of tip
acxuub00000071
Checking Weld Strength

• Installation locations of the engine, chassis, and
seat belts are designated as important safety Chisel dimensions
locations for weld strength. Check weld strength
by driving a chisel between the panels at every 25mm 20°
fourth or fifth weld spot, and every tenth regular {0.98in}
weld location.
8mm{0.31in}
Weld location
Within 5mm
{0.20in}
Within 5mm
{0.20in}
acxuub00000057
• Drive the chisel between the panels according to

the number of panels as shown below. Two panels Weld location
• 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.
One location
• Restore the shape of the checked area.
End Of Sie Three panels
Weld location
Two location
Four panels
Weld location
Three location
acxuub00000058
00-00–13
GENERAL INFORMATION
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.
acxuub00000059
Application of Undercoating
• Apply an undercoat to the required location of the body.
acxuub00000060
Application of Rust Inhibitor

• Apply rust inhibitor (wax, oil, etc.) to the back of the welded areas.
acxuub00000061
Application of Floor Silencer

• Apply floor silencer by heating with an infrared ray lamp.
End Of Sie
acxuub00000062
00-00–14
GENERAL INFORMATION
ABBREVIATION
id000000600700
CM Control module
Ctr Center
DSC Dynamic stability control 00-00
Fr Front
HU Hydraulic unit
LH Left
M Metallic
MC Mica
RH Right
Rr Rear
End Of Sie
00-00–15
3419-1U-06C(09-80A).fm 1 ページ２００６年３月２２日　水曜日　午後６時２０分
BODY & ACCESSORIES 09

SECTION
09-80A
Toc
BODYof SCT
STRUCTURE BODY STRUCTURE
[CONSTRUCTION] . . . . . . . . . 09-80A [DIMENSIONS] . . . . . . . . . . . 09-80D
BODY STRUCTURE BODY STRUCTURE
[PANEL REPLACEMENT] . . . 09-80B [PLASTIC BODY PARTS] . . . 09-80E
BODY STRUCTURE
[WATER-PROOF AND RUST
PREVENTIVE]. . . . . . . . . . . . . 09-80C
Toc of SCT
09-80A BODY STRUCTURE [CONSTRUCTION]
BODY COMPONENTS Characteristics of Ultra High-Tensile
CONSTRUCTION[CONSTRUCTION] . . 09-80A–2 Steel Plates . . . . . . . . . . . . . . . . . . . . 09-80A–5
ULTRA HIGH-TENSION STEEL Range of Use and Cautions
[CONSTRUCTION] . . . . . . . . . . . . . . . . . 09-80A–5 for Service . . . . . . . . . . . . . . . . . . . . . 09-80A–5
End of Toc
BM: CONSTRUCTION
09-80A–1
BODY STRUCTURE [CONSTRUCTION]

BODY COMPONENTS CONSTRUCTION[CONSTRUCTION]
id098007739700
37
20
36
19 35 38 39
34
33
32 30
31 29 40
41
1 18 27
25
26 42
21
17
28
7 8 43
44
5
9 22
4 6 45
2 10 23
3 24
11 12
46
14
13
15
16
47
54
58
50 59
55
53 57
49
48
52 56
51
acxuub00000025
09-80A–2

x:Applied
-:Not applied
Ultra high- High- Thickness
Rust proof
No. Part Name tension tension
steel mm {in}
steel steel
1 Hood - x x 0.70 {0.028}
2 Front bumper bracket - x x 2.00 {0.079}
Front x - x 1.80 {0.071} 09-80A
3 Front side frame (inner)
Rear - x x 2.30 {0.091}
4 Shroud side panel - - x 1.60 {0.063}
5 Shroud side member - - x 1.20 {0.047}
RH - - x 1.00 {0.039}
6 Apron panel (front)
LH - - x 0.65 {0.026}
7 Engine mount bracket No.3 - - x 1.40 {0.055}
8 Front suspension housing (upper) - x x 2.60 {0.102}
9 Apron panel (lower)) - - x 0.85 {0.033}
10 Apron reinforcement (lower) - x x 0.85 {0.033}
11 Apron reinforcement (upper) - x x 1.40 {0.055}
12 Cowl side reinforcement - - x 1.20 {0.047}
Front x - x 1.80 {0.071}
13 Front side frame (outer) Center x - x 2.60 {0.102}
Rear - x x 2.30 {0.091}
14 Front frame rear - x x 2.90 {0.114}
15 Torque box - x x 1.40 {0.055}
16 Front fender panel - - x 0.85 {0.033}
17 Dash lower member - - x 1.20 {0.047}
18 Dash lower panel - - x 0.80 {0.031}
19 Cowl panel - - x 0.70 {0.028}
20 Wiper bracket - - x 1.60 {0.063}
21 Hinge pillar (inner) - x x 1.00 {0.039}
22 Hinge pillar reinforcement x - - 1.60 {0.063}
23 Side sill (inner) - x x 1.40 {0.055}
24 Side sill reinforcement x - - 1.20 {0.047}
25 Front pillar (inner) x - - 1.40 {0.055}
26 Front pillar reinforcement x - - 1.60 {0.063}
27 Center pillar (inner) x - - 1.20 {0.047}
Upper x - - 1.60 {0.063}
28 Center pillar reinforcement (outer) Center x - - 1.80 {0.071}
Lower x - - 1.20 {0.047}
29 Roof rail (inner) x - - 1.20 {0.047}
30 Roof rail reinforcement - x - 1.60 {0.063}
31 Front header - - - 0.80 {0.031}
32 Roof reinforcement - - - 0.55 {0.022}
33 Roof reinforcement x - - 1.20 {0.047}
Upper - - - 0.50 {0.020}
36 Rear header
Lower - - - 0.75 {0.030}
37 Roof panel - - - 0.85 {0.033}
38 Rear pillar reinforcement - - - 0.70 {0.028}
39 Rear pillar (outer) - - x 0.70 {0.028}
40 Corner junction - - - 1.00 {0.039}
41 Corner plate - - x 1.00 {0.039}
42 Wheel house (inner) - - x 0.85 {0.033}
43 Rear pillar (inner) - - x 0.65 {0.026}
44 Rear suspension housing reinforcement - - - 0.90 {0.035}
09-80A–3

Ultra high- High- Thickness
Rust proof
No. Part Name tension tension
steel mm {in}
steel steel
45 Side frame outer - - x 0.70 {0.028}
46 Rear door panel - x x 0.70 {0.028}
47 Front door panel - x x 0.70 {0.028}
48 Crossmember No.2 - x - 1.20 {0.047}
49 Seat bracket - x - 1.20 {0.047}
50 Front floor pan - - x 0.65 {0.026}
51 Front B frame - x x 2.30 {0.090}
52 Tunnel reinforcement - x x 1.40 {0.055}
53 Crossmember No.3 - x x 1.40 {0.055}
54 Trunk floor pan - - x 0.65 {0.026}
55 Crossmember No.4 - x x 1.20 {0.047}
56 Rear side frame x - x 1.80 {0.071}
57 Rear bumper bracket - x x 3.20 {0.126}
58 Crossmember No.5 - - - 0.70 {0.028}
59 Rear end panel - - x 1.20 {0.047}
End Of Sie
09-80A–4

ULTRA HIGH-TENSION STEEL[CONSTRUCTION]
id098007745600
Characteristics of Ultra High-Tensile Steel Plates
• Ultra high-tensile steel plates have enhanced tensile strength compared to previous high-tensile steel plates.
• Because the strength is maintained even though the plates are thin-walled, the ultra high-tensile steel plates
are used for the frames and the main frame parts which form the cabin, reducing the weight of the vehicle.
• Enhanced shock absorption has improved the safety.
Range of Use and Cautions for Service 09-80A

• Because the ultra high-tensile steel is hard and it may be difficult to reform, when extracting the damaged part
using a frame repair machine, perform the work verifying that other parts are not affected.
• When drilling welded parts, use a well-ground drill bit.
• After welding, inspect the weld strength. If adhesion is poor, perform CO2 arc welding (plug welding).
ROOF REINFORCEMENT *1
CENTER PILLAR (INNER)*1
ROOF RAIL (INNER,REAR) *1 CENTER PILLAR
REINFORCEMENT (UPPER) *1
FRONT PILLAR (INNER) *1
FRONT PILLAR
REINFORCEMENT (INNER)*1
CENTER PILLAR
REINFORCEMENT (CENTER) *2
CENTER PILLAR
REINFORCEMENT *2
CENTER PILLAR
SIDE SILL HINGE PILLAR REINFORCEMENT (LOWER) *1
REINFORCEMENT (UPPER) *1 REINFORCEMENT *1
SIDE SILL REINFORCEMENT *2
FRONT PILLAR
REINFORCEMENT *1
acxuub00000026
09-80A–5
REAR FRAME
REINFORCEMENT *1
FIXING
REINFORCEMENT *1
REAR FRAME
CROSSMEMBER No.3 GUSSET *1
REINFORCEMENT (FRONT)*1
REAR SIDE
FRAME (REAR) *1
CROSSMEMBER No.3
REINFORCEMENT *1
SIDE SILL
REINFORCEMENT *1
FRONT SIDE FRAME

(INNER,FRONT) *1
REAR FRAME GUSSET

REINFORCEMENT *1
REAR SIDE
FRAME (FRONT)*1
REAR FRAME
REINFORCEMENT (FRONT)*1
CROSSMEMBER No.3 (REAR)*3
TORQUE BOX C *1 TUNNEL PANEL (REAR)*1
CROSSMEMBER No.3
FRONT SIDE FRAME REINFORCEMENT (LOWER) *1
(OUTER,CENTER) *1
FRONT SIDE FRAME

(OUTER,FRONT)*1
acxuub00000027
*1 : Indicates tensile strength of 590 MPa.
End Of Sie
09-80A–6
3419-1U-06C(09-80B).fm 1 ページ２００６年３月２４日　金曜日　午後４時４７分
BODY STRUCTURE [PANEL REPLACEMENT]

09-80B BODY STRUCTURE [PANEL REPLACEMENT]
FRONT BUMPER BRACKET REMOVAL FRONT SIDE FRAME
[PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–2 (PARTIAL CUTTING) REMOVAL
FRONT BUMPER BRACKET [PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–24
INSTALLATION RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-80B–24
[PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–3 LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-80B–25
TIEDOWN REINFORCEMENT REMOVAL FRONT SIDE FRAME
[PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–4 (PARTIAL CUTTING) INSTALLATION
TIEDOWN REINFORCEMENT [PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–26 09-80B
INSTALLATION RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-80B–26
[PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–5 LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-80B–31
SHROUD UPPER PANEL REMOVAL TORQUE BOX REMOVAL
[PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–6 [PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–36
SHROUD UPPER PANEL TORQUE BOX INSTALLATION
INSTALLATION [PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–38
[PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–7 FRONT FRAME (REAR) REMOVAL
COWL SIDE REINFORCEMENT [PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–40
REMOVAL FRONT FRAME (REAR) INSTALLATION
COWL SIDE REINFORCEMENT FRONT PILLAR REMOVAL
[PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–9 FRONT PILLAR INSTALLATION
WIPER BRACKET COMPONENT [PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–46
REMOVAL CENTER PILLAR REMOVAL
WIPER BRACKET COMPONENT CENTER PILLAR INSTALLATION
[PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–11 SIDE SILL PANEL REMOVAL
APRON REINFORCEMENT (UPPER) [PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–57
REMOVAL[PANEL REPLACEMENT] . . 09-80B–12 SIDE SILL PANEL INSTALLATION
APRON REINFORCEMENT (UPPER) [PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–59
INSTALLATION REAR FENDER PANEL REMOVAL
APRON REINFORCEMENT (LOWER) REAR FENDER PANEL INSTALLATION
REMOVAL[PANEL REPLACEMENT] . . 09-80B–14 [PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–64
APRON REINFORCEMENT (LOWER) REAR END PANEL REMOVAL
[PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–15 REAR END PANEL INSTALLATION
WHEEL APRON PANEL (FRONT) [PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–68
REMOVAL[PANEL REPLACEMENT] . . 09-80B–16 REAR PILLAR (OUTER) REMOVAL
WHEEL APRON PANEL (FRONT) [PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–69
INSTALLATION REAR PILLAR (OUTER) INSTALLATION
WHEEL APRON COMPONENT REAR FLOOR PAN REMOVAL
REMOVAL[PANEL REPLACEMENT] . . 09-80B–18 [PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–75
WHEEL APRON COMPONENT REAR FLOOR PAN INSTALLATION
[PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–19 REAR SIDE FRAME REMOVAL
FRONT SIDE FRAME COMPONENT [PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–81
REMOVAL[PANEL REPLACEMENT] . . 09-80B–20 REAR SIDE FRAME INSTALLATION
FRONT SIDE FRAME COMPONENT INSTALLATION [PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–82
[PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–22 ROOF PANEL REMOVAL
[PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–83
ROOF PANEL INSTALLATION
[PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–84
End of Toc
BM: BUMPER BRACKET
09-80B–1

FRONT BUMPER BRACKET REMOVAL[PANEL REPLACEMENT]
id098008743100
1. Remove the front bumper bracket.
FRONT BUMPER
BRACKET
BOLT
acxuub00000072
End Of Sie
09-80B–2

FRONT BUMPER BRACKET INSTALLATION[PANEL REPLACEMENT]
id098008743200
1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions.
2. Tighten the bolts at section (A) to the specified torque and install the front bumper bracket.
Tightening torque
15.7—22.6 N·m {161—230 kgf·cm, 139—200 in·lbf}
09-80B
FRONT BUMPER
BRACKET
(A) BOLT
acxuub00000073
End Of Sie
09-80B–3

TIEDOWN REINFORCEMENT REMOVAL[PANEL REPLACEMENT]
id098008800200
1. Remove the tiedown reinforcement.
TIEDOWN REINFORCEMENT
acxuub00000074
End Of Sie
09-80B–4

TIEDOWN REINFORCEMENT INSTALLATION[PANEL REPLACEMENT]
id098008800300
2. Drill holes for the plug welding before installing the new parts.
3. After temporarily installing new parts, make sure the related parts fit properly.
09-80B
acxuub00000075
End Of Sie
BM: SHROUD PANEL
09-80B–5

SHROUD UPPER PANEL REMOVAL[PANEL REPLACEMENT]
id098008800400
1. Remove the shroud upper panel.
Note
• When removing the shroud upper panel and the shroud side panel separately, drill the 3 locations
indicated by (A).
SHROUD UPPER PANEL
(A)3
SHROUD SIDE PANEL
acxuub00000076
End Of Sie
09-80B–6

SHROUD UPPER PANEL INSTALLATION[PANEL REPLACEMENT]
id098008800500
09-80B
SHROUD UPPER PANEL
SHROUD SIDE PANEL
acxuub00000077
End Of Sie
BM: COWL SIDE REINFORCEMENT
09-80B–7

COWL SIDE REINFORCEMENT REMOVAL[PANEL REPLACEMENT]
id098008741700
1. Remove the cowl side reinforcement.
COWL SIDE REINFORCEMENT
acxuub00000078
End Of Sie
09-80B–8

COWL SIDE REINFORCEMENT INSTALLATION[PANEL REPLACEMENT]
id098008741800
09-80B
COWL SIDE REINFORCEMENT
acxuub00000079
End Of Sie
BM: WIPER BRACKET
09-80B–9

WIPER BRACKET COMPONENT REMOVAL[PANEL REPLACEMENT]
id098008750000
1. Remove the wiper bracket.
WIPER BRACKET
2
2
acxuub00000080
End Of Sie
09-80B–10

WIPER BRACKET COMPONENT INSTALLATION[PANEL REPLACEMENT]
id098008750100
09-80B
WIPER BRACKET
2
2
acxuub00000081
End Of Sie
BM: APRON REINFORCEMENT
09-80B–11

APRON REINFORCEMENT (UPPER) REMOVAL[PANEL REPLACEMENT]
id098008800000
1. Drill the 1 location indicated by (A) from the bottom, as they cannot be seen from the outer side.
2. Remove the apron reinforcement (upper).
7
APRON REINFORCEMENT (UPPER)
(A)1
acxuub00000082
End Of Sie
09-80B–12

APRON REINFORCEMENT (UPPER) INSTALLATION[PANEL REPLACEMENT]
id098008800100
09-80B
7
APRON REINFORCEMENT (UPPER)
acxuub00000083
End Of Sie
09-80B–13

APRON REINFORCEMENT (LOWER) REMOVAL[PANEL REPLACEMENT]
id098008741300
1. Remove the apron reinforcement (lower).
4
5
APRON REINFORCEMENT (LOWER)
acxuub00000084
End Of Sie
09-80B–14

APRON REINFORCEMENT (LOWER) INSTALLATION[PANEL REPLACEMENT]
id098008741400
09-80B
4
5
APRON REINFORCEMENT (LOWER)
acxuub00000085
End Of Sie
BM: WHEEL APRON PANEL
09-80B–15

WHEEL APRON PANEL (FRONT) REMOVAL[PANEL REPLACEMENT]
id098008741100
1. Remove the wheel apron panel (front).
WHEEL APRON PANEL

FRONT (RH)
12
WHEEL APRON PANEL FRONT (LH)
11
acxuub00000086
End Of Sie
09-80B–16

WHEEL APRON PANEL (FRONT) INSTALLATION[PANEL REPLACEMENT]
id098008741200
4. Weld the 20 locations indicated by (A) and install the engine mount bracket.
5. Install the wheel apron panel (front).
WHEEL APRON PANEL

FRONT (RH)
09-80B
(A)5 5
(A)4 (A)6
WHEEL APRON PANEL FRONT (LH)
(A)5
12
ENGINE MOUNT BRACKET 5
11
acxuub00000087
End Of Sie
09-80B–17

WHEEL APRON COMPONENT REMOVAL[PANEL REPLACEMENT]
id098008746000
1. Remove the wheel apron component.
WHEEL APRON COMPONENT
RH : 22
LH : 21 2
acxuub00000088
End Of Sie
09-80B–18

WHEEL APRON COMPONENT INSTALLATION[PANEL REPLACEMENT]
id098008746100
09-80B
RH : 22
LH : 21 2
acxuub00000089
End Of Sie
BM: FRONT SIDE FRAME
09-80B–19

FRONT SIDE FRAME COMPONENT REMOVAL[PANEL REPLACEMENT]
id098008741900
1. Rough cut area (A), drill the 14 locations indicated by (B).
A-A
FRONT SIDE FRAME COMPONENT
(B)5
A
(A)ROUGH CUT LOCATION
(B)3
acxuub00000090
09-80B–20

2. Drill the 2 locations indicated by (C), and remove the front side frame component.
Note
• The 2 weld locations indicated by (C) cannot be seen from the interior.
(C)2
09-80B
(B)2
(B)4
acxuub00000091
End Of Sie
09-80B–21

FRONT SIDE FRAME COMPONENT INSTALLATION[PANEL REPLACEMENT]
id098008742000
3. To prepare for installation, drill 2 through holes at the locations indicated by (A).
4. Weld the 2 locations indicated by (B) from the interior.
(A)2
(B)2
acxuub00000092
09-80B–22

6. Weld the remaining weld locations and install the front side frame component.
09-80B
acxuub00000093
End Of Sie
09-80B–23

FRONT SIDE FRAME (PARTIAL CUTTING) REMOVAL[PANEL REPLACEMENT]
id098008742100
RH
Caution
• The rough cut area indicates the maximum size range of the installation position.
1. Rough cut area (A), drill the 18 locations indicated by (B), and then remove the front side frame.
(A) ROUGH CUT AND

CUT-AND-JOIN LOCATION
(B)8
FRONT SIDE FRAME (OUTER, RH)
30mm (B)7
{1.18in}
(B)3
FRONT SIDE FRAME (INNER, RH)
85mm
{3.35in}
(A) ROUGH CUT AND

acxuub00000110
09-80B–24

LH
Caution
• The rough cut area indicates the maximum size range of the installation position.
1. Rough cut area (A), drill the 18 locations indicated by (B), and then remove the front side frame.
09-80B
(A)ROUGH CUT AND

(B)8
FRONT SIDE FRAME (OUTER, LH)

50mm
{1.97in}
(B)7 (A) ROUGH CUT AND

(B)3
105mm
{4.13in}
FRONT SIDE FRAME (INNER, LH)
acxuub00000111
End Of Sie
09-80B–25

FRONT SIDE FRAME (PARTIAL CUTTING) INSTALLATION[PANEL REPLACEMENT]
id098008742200
RH
Caution
• The cut-and-joint area indicates the maximum size range of the installation position.
1. Make a reinforcement panel using the material from the front side frame (inner).
2. To cut and join the new and existing parts, cut the new part at the specified location shown in the figure, and
chamfer the joint surfaces of the new and existing parts.
4. When installing the new parts, trial-fit new and existing parts, and then measure and adjust the body to conform
with standard dimensions.
5. Trial-fit the new and existing parts, weld the existing parts and the reinforcement, and then butt weld the new
and existing parts.
Caution
• Press fit the reinforcement panel and the body side material, and then weld them.
• To prevent weld bead drop from the reinforcement panel, weld the reinforcement plate such that
the weld bead are longer than their widths.
6. Install the front side frame (inner).
09-80B–26
25mm
{0.98in}
L=30mm x 2
{1.18in}
100mm {3.94in}
t=2.3mm
{0.09in} EXTRUSION
BEAD
09-80B
EXTRUSION
BEAD
REINFORCEMENT
L=70mm x 2
15mm 10mm {2.76in}
{0.59in} {0.39in}
85mm
{3.35in}
FRONT SIDE FRAME (INNER, RH)
CUT-AND-JOIN
LOCATION
acxuub00000112
09-80B–27

7. Install the front side frame reinforcement.
FRONT SIDE FRAME REINFORCEMENT (RH)
L=50mm
{1.97in}
L=50mm
{1.97in}
acxuub00000094
8. Install the suspension mount reinforcement.

9. Install the suspension mount bolt.
Tightening torque
1.0—5.0 N·m {11—50 kgf·cm, 8.9—44 in·lbf}
09-80B–28
L=15mm
09-80B
{0.59in}
SUSPENSION MOUNT REINFORCEMENT

2
SUSPENSION MOUNT BOLT
L=20mm
{0.79in}
am8rrb00000041
09-80B–29

10. Because the front side frame (outer) cannot be welded to the existing parts from the inside of the panel, drill 5
plug weld holes at the locations indicated by (A) on the existing parts. Install the reinforcement and the existing
parts by plug welding from the outside, then butt weld the new and existing parts.
Caution
• Press fit the reinforcement panel and the body side material, and then plug weld them.
12. Install the front side frame (outer).
50mm
{1.97in}
100mm {3.94in}
t=2.3mm
{0.09in}
REINFORCEMENT
CUT-AND-JOIN
LOCATION
FRONT SIDE FRAME (OUTER, RH)
L=70mm 7
{2.76in} 30mm
{1.18in}
3
(A)5
acxuub00000113
09-80B–30

LH
Caution
• The cut-and-joint area indicates the maximum size range of the installation position.
1. Make a reinforcement panel using the material from the front side frame (inner).
4. When installing the new parts, trial-fit new and existing parts, and then measure and adjust the body to conform
with standard dimensions. 09-80B
and existing parts.
Caution
• To prevent weld bead drop from the reinforcement panel, weld the reinforcement plate such that
the weld bead are longer than their widths.
6. Install the front side frame (inner).
09-80B–31
25mm
{0.98in}
L=30mm x 2
100mm {3.94in}
{1.18in}
t=2.3mm
{0.09in}
EXTRUSION
BEAD
EXTRUSION
BEAD
REINFORCEMENT
L=70mm x 2
{2.76in} 10mm 15mm
{0.39in} {0.59in}
FRONT SIDE FRAME (INNER, LH)
105mm
{4.13in}
CUT-AND-JOIN
LOCATION
acxuub00000114
09-80B–32

7. Install the front side frame reinforcement.
FRONT SIDE FRAME REINFORCEMENT (LH)
09-80B
L=50mm
{1.97in}
L=50mm
{1.97in}
acxuub00000095
8. Install the suspension mount reinforcement.

9. Install the suspension mount bolt.
Tightening torque
1.0—5.0 N·m {11—50 kgf·cm, 8.9—44 in·lbf}
09-80B–33
L=15mm
{0.59in}
SUSPENSION MOUNT REINFORCEMENT 2
SUSPENSION MOUNT BOLT
L=20mm
{0.79in}
am8rrb00000044
09-80B–34

10. Because the front side frame (outer) cannot be welded to the existing parts from the inside of the panel, drill 5
Caution
12. Install the front side frame (outer).
50mm 09-80B
{1.97in}
100mm {3.94in}
t=2.3mm
{0.09in}
REINFORCEMENT
CUT-AND-JOIN
LOCATION
FRONT SIDE FRAME (OUTER, LH)
50mm
{1.97in}
7 L=70mm
3 {2.76in}
(A)5
acxuub00000150
End Of Sie
BM: TORQUE BOX
09-80B–35

TORQUE BOX REMOVAL[PANEL REPLACEMENT]
id098008607100
1. When removing the torque box, the nut plate may interfere and make removal difficult. Therefore, drill the 3
locations indicated by (A) and then open the nut plate outward.
2. Drill the 25 locations indicated by (B).
(B)1 (B)9
(B)2
(A)3
(B)3 TORQUE BOX
(B)5
(B)2
(B)3 TORQUE BOX
acxuub00000145
09-80B–36

3. Rough cut area (C), drill the 2 locations indicated by (D), then remove the torque box.
09-80B
(C)ROUGH CUT LOCATION
TORQUE BOX
(D)2
acxuub00000146
End Of Sie
09-80B–37

TORQUE BOX INSTALLATION[PANEL REPLACEMENT]
id098008607200
9
1
3 TORQUE BOX
3 TORQUE BOX
acxuub00000147
09-80B–38
09-80B
L=90mm
{3.54in}
TORQUE BOX
acxuub00000148
End Of Sie
BM: FRONT FRAME REAR
09-80B–39

FRONT FRAME (REAR) REMOVAL[PANEL REPLACEMENT]
id098008742500
1. Remove the front frame rear component.
10
13
FRONT FRAME REAR

COMPONENT
FRONT FRAME REAR

COMPONENT
17
4
3
5
3
acxuub00000137
End Of Sie
09-80B–40

FRONT FRAME (REAR) INSTALLATION[PANEL REPLACEMENT]
id098008742600
10
09-80B
13
FRONT FRAME REAR

COMPONENT
FRONT FRAME REAR

COMPONENT
17
4
3
5
3
acxuub00000138
End Of Sie
BM: FRONT PILLAR
09-80B–41

FRONT PILLAR REMOVAL[PANEL REPLACEMENT]
id098008744700
2. Drill the 1 locations indicated by (C) from the interior.
3. Remove the front pillar (outer).
(C)1
A-A
50mm {1.97in}
40mm {1.57in}
A
CUT-AND-JOIN
A LOCATION
(B)11 (A)ROUGH CUT

LOCATION
FRONT PILLAR
(OUTER)
(B)3
(B)18
acxuub00000096
09-80B–42
B-B
(B)10 09-80B
FRONT PILLAR (OUTER)
(B)25
(B)2
(A) ROUGH CUT

LOCATION
CUT-AND JOIN
LOCATION
(B)2
B
40mm 40mm
{1.57in} {1.57in}
(B)7
acxuub00000097
09-80B–43

4. Rough cut area (D).
5. Drill the 2 locations indicated by (E) from the interior.
6. Remove the front pillar reinforcement.
A-A B-B
125mm
{4.92in} CUT-AND JOIN
LOCATION
30mm (D) ROUGH CUT
{1.18in}
LOCATION
A
A
FRONT PILLAR
REINFORCEMENT
(E)2
(D) ROUGH CUT

LOCATION CUT-AND JOIN
LOCATION
110mm {4.33in}
40mm {1.57in}
acxuub00000098
09-80B–44

7. Rough cut area (F), drill the 3 locations indicated by (G), and then remove the front pillar (inner).
8. Remove the spot weld sealer using a disc grinder.
09-80B
190mm
{7.48in}
30mm {1.18in} CUT-AND JOIN

LOCATION
FRONT PILLAR (INNER) (F) ROUGH CUT

LOCATION
(G)2
(G)1
acxuub00000099
End Of Sie
09-80B–45

FRONT PILLAR INSTALLATION[PANEL REPLACEMENT]
id098008744800
3. Apply body sealer to the joints of old and new parts for waterproofing and rust protection.
4. Install the front pillar (inner).
190mm
{7.48in}
CUT-AND JOIN
LOCATION
FRONT PILLAR (INNER)
acxuub00000100
09-80B–46

5. Make a reinforcement panel using the material from the front pillar reinforcement.
6. Because the front pillar reinforcement cannot be welded to the existing parts from the inside of the panel, drill 2
Caution
7. Drill the 2 locations indicated by (B) from the interior.
09-80B
20mm
{0.79in}
30mm {1.18in}
125mm
{4.92in}
t=1.6mm (A)2
{0.06in}
CUT-AND JOIN
LOCATION
REINFORCEMENT
L=10mm
{0.39in}
FRONT PILLAR
REINFORCEMENT
(B)2
acxuub00000101
09-80B–47

8. Make a reinforcement panel using the material from the front pillar reinforcement.
9. Because the front pillar reinforcement cannot be welded to the existing parts from the inside of the panel, drill 3
plug weld holes at the locations indicated by (C) on the existing parts. Install the reinforcement and the existing
Caution
10. Install the front pillar reinforcement.
50mm
{1.97in}
80mm {3.15in}
t=1.2mm
{0.05in}
REINFORCEMENT
(C)3
FRONT PILLAR
REINFORCEMENT
L=60mm
{2.36in}
110mm
{4.33in}
CUT-AND JOIN
LOCATION
acxuub00000151
09-80B–48

12. Drill the 1 locations indicated by (D) from the interior.
13. Weld the 81 locations indicated by (E) and install the front pillar (outer).
(D)1
09-80B
50mm {1.97in}
CUT-AND-JOIN
LOCATION
(E)12
FRONT PILLAR
(OUTER)
(E)3
(E)18
acxuub00000102
09-80B–49
(E)10
FRONT PILLAR (OUTER)
(E)26
(E)2
CUT-AND JOIN
LOCATION
(E)2
40mm
{1.57in}
(E)8
acxuub00000103
End Of Sie
BM: CENTER PILLAR
09-80B–50

CENTER PILLAR REMOVAL[PANEL REPLACEMENT]
id098008743900
1. Rough cut area (A), drill the 57 locations indicated by (B), then remove the center pillar (outer).
A-A B-B C-C

09-80B
40mm {1.57in}
20mm {0.79in}
CUT-AND JOIN
LOCATION
A
A
(A)ROUGH CUT
CENTER PILLAR LOCATION
(OUTER)
(B)19
(B)21
(B)2
CUT-AND JOIN
CUT-AND JOIN
LOCATION (A) ROUGH CUT LOCATION
(A) ROUGH CUT
LOCATION LOCATION
B C
(B)1
B C
120mm 20mm 30mm 130mm
{4.72in} {0.79in} {1.18in} {5.12in}
(B)14
acxuub00000104
09-80B–51

2. Rough cut area (C), drill the 3 locations indicated by (D).
Caution
• Avoid cutting with a blow torch or similar tools as the insulator (shaded area) is flammable.
3. Drill the 3 locations indicated by (E) from the interior.

4. Remove the center pillar inner reinforcement.
A-A
B-B C-C
(D)3
110mm (C) ROUGH CUT AND

{4.33in} CUT-AND JOIN LOCATION
A
A
(E)3
CENTER PILLAR
REINFORCEMENT
(C)ROUGH CUT
LOCATION INSULATOR CUT-AND JOIN
(C)ROUGH CUT LOCATION
CUT-AND JOIN LOCATION
LOCATION
B C
C
150mm 20mm B 30mm 180mm
{5.90in} {0.79in} {1.18in} {7.09in}
acxuub00000105
09-80B–52

5. Rough cut area (F), drill the 2 locations indicated by (G), then remove the center pillar (inner).
190mm
{7.48in}
30mm CUT-AND JOIN

{1.18in} LOCATION 09-80B
(F) ROUGH CUT
LOCATION
CENTER PILLAR
(INNER)
(G)2
acxuub00000106
End Of Sie
09-80B–53

CENTER PILLAR INSTALLATION[PANEL REPLACEMENT]
id098008744000
1. Make a reinforcement panel using the material from the center pillar (inner).
2. When joining and cutting the new and existing parts, trial fit the new part, and then measure and adjust the
body as necessary to conform with standard dimensions.
and existing parts.
Caution
5. Install the center pillar (inner).
30mm
{1.18in}
50mm {1.97in}
t=1.2mm
{0.05in}
190mm
{7.48in}
REINFORCEMENT
CUT-AND JOIN
LOCATION
L=10mm x 4
{0.39in}
CENTER PILLAR
(INNER)
acxuub00000107
6. Make a reinforcement panel using the material from the center pillar reinforcement.
7. Because the center pillar reinforcement cannot be welded to the existing parts from the inside of the panel, drill
6 plug weld holes at the locations indicated by (A) on the existing parts. Install the reinforcement and the
existing parts by plug welding from the outside, then butt weld the new and existing parts.
Caution
09-80B–54

9. Weld the remaining weld locations, then install the center pillar reinforcement.
50mm
{1.97in}
3
110mm ROUGH CUT AND

80mm {3.15in}
{4.33in} CUT-AND JOIN LOCATION

t=1.2mm
{0.05in}
09-80B
REINFORCEMENT (B)3
CENTER PILLAR
REINFORCEMENT
CUT-AND JOIN
LOCATION
CUT-AND JOIN
LOCATION
(A)3 (A)3
150mm L=60mm L=60mm 180mm

{5.90in} {2.36in} {2.36in} {7.09in}
acxuub00000108
09-80B–55

11. Install the center pillar (outer).
40mm {1.57in}
CUT-AND JOIN
LOCATION
CENTER PILLAR
(OUTER)
21
22
2
CUT-AND JOIN CUT-AND JOIN

LOCATION LOCATION
120mm 130mm
{4.72in} {5.12in}
15
acxuub00000109
End Of Sie
BM: SIDE SILL PANEL
09-80B–56

SIDE SILL PANEL REMOVAL[PANEL REPLACEMENT]
id098008743700
1. Rough cut area (A), drill the 82 locations indicated by (B), and then remove the side sill (outer).
A-A B-B C-C
09-80B
80mm 140mm
{3.15in} {5.51in}
CUT-AND JOIN
30mm 30mm
{1.18in} LOCATION {1.18in} 100mm
{3.94in}
(A)ROUGH CUT CUT-AND JOIN
A A
LOCATION B B LOCATION 30mm
{1.18in}
(B)3 (A) ROUGH CUT
(B)23 LOCATION
C C
(B)13
(B)1 (B)20
(B)5
(B)36
SIDE SILL (OUTER)
(B)1
acxuub00000129
09-80B–57

2. Rough cut area (C).
Caution
• During rough cutting, be careful not to damage the hinge reinforcement and the center pillar
reinforcement (inner) indicated by dotted lines in the figure.
3. Drill the 5 locations indicated by (D) from the interior.

4. Remove the side sill reinforcement.
A-A B-B
(D)3
(D)2
240mm 270mm
{9.45in} {10.63in}
CUT-AND JOIN
LOCATION
30mm
{1.18in}
(C) ROUGH CUT B B (C)ROUGH CUT AND
A A LOCATION CUT-AND-JOIN
LOCATION
SIDE SILL REINFORCEMENT

acxuub00000130
End Of Sie
09-80B–58

SIDE SILL PANEL INSTALLATION[PANEL REPLACEMENT]
id098008743800
1. Make a reinforcement panel using the material from the side sill reinforcement.
4. Because the side sill reinforcement cannot be welded to the existing parts from the inside of the panel, drill 3
Caution
• Press fit the reinforcement panel and the body side material, and then plug weld them. 09-80B
6. Install the side sill reinforcement.
50mm
{1.97in}
70mm {2.76in}
t=1.6mm
{0.06in}
REINFORCEMENT
(B)3
(B)2
240mm 270mm
{9.45in}
{10.63in}
CUT-AND JOIN ROUGH CUT AND

LOCATION CUT-AND-JOIN
LOCATION
SIDE SILL REINFORCEMENT

(A)3
L=10mm x 2
{0.39in}
acxuub00000131
09-80B–59

8. Install the side sill (outer).
CUT-AND JOIN
LOCATION
80mm 140mm
{3.15in} {5.51in}
CUT-AND JOIN
LOCATION
100mm
{3.94in}
CUT-AND JOIN
LOCATION
4
24
14 1 21
6
SIDE SILL (OUTER) 36
acxuub00000132
End Of Sie
BM: REAR FENDER PANEL
09-80B–60

REAR FENDER PANEL REMOVAL[PANEL REPLACEMENT]
id098008744900
Caution
• Avoid cutting with a blow torch or similar tools as the insulator (shaded area) is flammable.
2. The rear fender panel and the rear pillar (inner) are joined with spot weld sealer at the tire arch line. Use a
chisel or similar tool to separate the rear fender panel from the rear pillar (inner), then remove the rear fender
panel.
3. Remove the rear fender panel. 09-80B
A-A B-B C-C
INSULATOR
CUT-AND JOIN
LOCATION
45mm {1.77in} (A) ROUGH CUT

40mm LOCATION
CUT-AND JOIN {1.57in}
LOCATION 40mm {1.57in}
140mm
{5.51in} B B
A A
(A) ROUGH CUT
LOCATION
(B)21
(B)10
(A) ROUGH CUT

INSULATOR LOCATION
CUT-AND JOIN
LOCATION REAR FENDER PANEL
(B)8
C
C
30mm 45mm
{1.18in} {1.77in} (B)1
(B)6
acxuub00000115
09-80B–61
REAR FENDER
PANEL
(B)6
(B)10
(B)3
(B)1
(B)7
acxuub00000116
09-80B–62

5. Remove the rear fender panel (lower).
09-80B
REAR FENDER (LOWER)
8
1
acxuub00000117
End Of Sie
09-80B–63

REAR FENDER PANEL INSTALLATION[PANEL REPLACEMENT]
id098008745000
3. Install the rear fender panel (lower).
REAR FENDER (LOWER)
8
1
acxuub00000118
4. Before installing new parts, apply spot weld sealer to the tire arch line.
09-80B–64

6. Install the rear fender panel.
09-80B
REAR FENDER
PANEL
10
acxuub00000119
09-80B–65
45mm {1.77in} CUT-AND JOIN

LOCATION
180mm
{7.09in}
CUT-AND JOIN
LOCATION
23
12
CUT-AND JOIN
LOCATION
REAR FENDER PANEL
30mm
{1.18in} 1
acxuub00000120
End Of Sie
BM: REAR END PANEL
09-80B–66

REAR END PANEL REMOVAL[PANEL REPLACEMENT]
id098008744500
1. Drill the 2 locations indicated by (A) from the interior.
2. Remove the rear end panel.
6 6
09-80B
(A)1 (A)1
REAR END PANEL
5 5
26
2
2
2
acxuub00000121
End Of Sie
09-80B–67

REAR END PANEL INSTALLATION[PANEL REPLACEMENT]
id098008744600
3. Apply spot weld sealer to the joints of old and new parts for waterproofing and rust protection.
6 6
1 1
REAR END PANEL
5 5
26
2
2
2
acxuub00000122
End Of Sie
BM: REAR PILLAR OUTER
09-80B–68

REAR PILLAR (OUTER) REMOVAL[PANEL REPLACEMENT]
id098008747200
Note
• When removing the rear pillar (outer) and corner plate separately, drill the 5 locations indicated by (C).
09-80B
210mm
{8.27in}
CUT-AND JOIN
LOCATION
30mm
{1.18in}
(A) ROUGH CUT

LOCATION
(B)9
REAR PILLAR
(OUTER)
(C)5
CORNER
PLATE
acxuub00000123
09-80B–69

2. Rough cut area (D), drill the 13 locations indicated by (E).
250mm
{9.84in}
CUT-AND JOIN
LOCATION
30mm
{1.18in}
(D) ROUGH CUT

LOCATION
REAR PILLAR
REINFORCEMENT
(E)7
(E)6
acxuub00000124
09-80B–70

3. Remove the corner junction.
09-80B
2
6
CORNER
JUNCTION
acxuub00000125
End Of Sie
09-80B–71

REAR PILLAR (OUTER) INSTALLATION[PANEL REPLACEMENT]
id098008747300
1. When joining and cutting the new and existing parts, trial fit the new part in position, then measure and adjust
the body as necessary to conform with standard dimensions.
2. Drill holes for plug welds before installing new parts.
3. Install the corner junction.
2
6
CORNER
JUNCTION
acxuub00000126
09-80B–72

4. Install the rear pillar reinforcement.
09-80B
250mm
{9.84in}
CUT-AND JOIN
LOCATION
REAR PILLAR
REINFORCEMENT
9
acxuub00000127
09-80B–73

6. Install the rear pillar (outer).
Note
• When replacing the rear pillar (outer) and corner plate separately, weld the 5 locations indicated by (A).
CUT-AND JOIN
LOCATION
210mm
{8.27in}
10
REAR PILLAR
(OUTER)
(A)5
CORNER
PLATE
acxuub00000128
End Of Sie
BM: TRUNK FLOOR PAN
09-80B–74

REAR FLOOR PAN REMOVAL[PANEL REPLACEMENT]
id098008742700
1. Remove the crossmember No.5.
9 9
09-80B
18
18
CROSSMEMBER No.5
acxuub00000139
09-80B–75

2. Rough cut area (A).
Caution
• During rough cutting, be careful not to damage the crossmember No.4 indicated by dotted lines in
the figure.
3. Drill the remaining locations, then remove the rear floor pan.
CUT-AND JOIN
LOCATION
60mm {2.36in}
40mm {1.57in}
(A)ROUGH CUT
LOCATION
13 13
10 10
REAR FLOOR PAN
acxuub00000140
09-80B–76
09-80B
8
REAR FLOOR PAN
acxuub00000141
End Of Sie
09-80B–77

REAR FLOOR PAN INSTALLATION[PANEL REPLACEMENT]
id098008742800
1. When joining and cutting the new and existing parts, trial fit the new part in position, then measure and adjust
the body as necessary to conform with standard dimensions.
2. Cut area (A) on new part.
4. Apply spot sealer to the areas where both the overlapping ends of the new and existing parts will be welded.
Adhere the sections to be welded, and fillet weld along both seams at the locations indicated by (B).
Note
• Create a flange with flanging tool where new and existing parts are joined.
5. Weld the remaining weld locations, then install the rear floor pan.
(B)FILLET WELDING
NEW PARTS
EXISTING PARTS
CROSSMEMBER No.4
A-A
60mm {2.36in}
A
(A)CUT-AND JOIN
LOCATION
13 13
10 10
REAR FLOOR PAN
acxuub00000142
09-80B–78
09-80B
8
REAR FLOOR PAN
acxuub00000143
09-80B–79

7. Install the crossmember No.5.
9 9
18
18
CROSSMEMBER No.5
acxuub00000144
End Of Sie
BM: REAR SIDE FRAME
09-80B–80

REAR SIDE FRAME REMOVAL[PANEL REPLACEMENT]
id098008801200
1. Rough cut and remove the damaged part of the rear side frame.
09-80B
145mm
{5.71in}
CUT-AND JOIN
LOCATION
ROUGH CUT
LOCATION
REAR SIDE FRAME
acxuub00000133
End Of Sie
09-80B–81

REAR SIDE FRAME INSTALLATION[PANEL REPLACEMENT]
id098008801300
1. Make a reinforcement panel using the material from the rear side frame.
2. To cut-and-join the new and existing parts, cut at the locations for the new part indicated in the figure below and
bevel the locations where the new and existing parts are joined.
3. When installing the new parts, trial-fit new and existing parts, then measure and adjust the body to conform
with standard dimensions.
and existing parts.
Caution
30mm
{1.18in}
50mm {1.97in}
t=1.8mm
{0.07in}
REINFORCEMENT
L=10mm x 4
{0.39in}
L=10mm x 4
{0.39in}
145mm
{5.71in}
CUT-AND JOIN
LOCATION
L=10mm x 4
{0.39in}
REAR SIDE FRAME
acxuub00000134
End Of Sie
09-80B–82

ROOF PANEL REMOVAL[PANEL REPLACEMENT]
BM: ROOF PANEL
id098008744300
1. Remove the roof panel.
09-80B
22
19 25
22
ROOF PANEL
acxuub00000135
End Of Sie
09-80B–83

ROOF PANEL INSTALLATION[PANEL REPLACEMENT]
id098008744400
22
19 25
22
ROOF PANEL
acxuub00000136
End Of Sie
09-80B–84
3419-1U-06C(09-80C).fm 1 ページ２００６年３月２２日　水曜日　午後６時１５分
BODY STRUCTURE [WATER-PROOF AND RUST PREVENTIVE]

09-80C BODY STRUCTURE [WATER-PROOF AND RUST
PREVENTIVE]
BODY SEALING[WATER-PROOF AND RUST PREVENTIVE TREATMENT
RUST PREVENTIVE] . . . . . . . . . . . . . . 09-80C–2 [WATER-PROOF AND
UNDER COATING[WATER-PROOF AND RUST PREVENTIVE] . . . . . . . . . . . . . . . 09-80C–6
RUST PREVENTIVE] . . . . . . . . . . . . . . 09-80C–5 DUMPING SHEET REPLACEMENT
CHIPPING-RESISTANT COATING [WATER-PROOF AND
[WATER-PROOF AND RUST PREVENTIVE] . . . . . . . . . . . . . . . 09-80C–7
RUST PREVENTIVE] . . . . . . . . . . . . . . 09-80C–5
End of Toc 09-80C

BM: CONSTRUCTION
09-80C–1

BODY SEALING[WATER-PROOF AND RUST PREVENTIVE]
id098009739800
Sealant is applied to the parts where the panels meet and to the hemmed parts of the door panel and hood panel
to provide water proofing and rust proofing.
A-A B-B
LH
RH
acxuub00000018
09-80C–2
09-80C
acxuub00000019
09-80C–3
acxuub00000020
End Of Sie
09-80C–4
2007 Mazda CX-7 Bodyshop Manual (3419–1U–06C)
UNDER COATING[WATER-PROOF AND RUST PREVENTIVE]
id098009739900
The shaded areas indicated under body locations that are undercoated to prevent noise and rusting.End Of Sie
LH
09-80C
RH
acxuub00000154
CHIPPING-RESISTANT COATING[WATER-PROOF AND RUST PREVENTIVE]

id098009740000
The coating locations are indicated by the shaded areas.End Of Sie
acxuub00000022
Revised 9/2006 (Ref. No. R121/06) 09-80C–5

2007 Mazda CX-7 Bodyshop Manual (3419–1U–06C)
RUST PREVENTIVE TREATMENT[WATER-PROOF AND RUST PREVENTIVE]
id098009740100
acxuub00000023
End Of Sie
09-80C–6

DUMPING SHEET REPLACEMENT[WATER-PROOF AND RUST PREVENTIVE]
id098009745700
• After repairing the body, attach the dumping sheet to the location shown in the figure for noise insulation.
09-80C
acxuub00000024
09-80C–7
3419-1U-06C(09-80D).fm 1 ページ２００６年３月２３日　木曜日　午前９時５３分
BODY STRUCTURE [DIMENSIONS]

09-80D BODY STRUCTURE [DIMENSIONS]
UNDERBODY FLAT-PLANE CABIN SIDE FRAME STRAIGHT-LINE
DIMENSIONS[DIMENSIONS] . . . . . . . . 09-80D–2 DIMENSIONS[DIMENSIONS] . . . . . . . . 09-80D–7
UNDERBODY STRAIGHT-LINE ROOM STRAIGHT-LINE DIMENSIONS
DIMENSIONS[DIMENSIONS] . . . . . . . . 09-80D–3 (1)[DIMENSIONS]. . . . . . . . . . . . . . . . . . 09-80D–8
FRONT BODY STRAIGHT-LINE ROOM STRAIGHT-LINE DIMENSIONS
DIMENSIONS (1)[DIMENSIONS] . . . . . 09-80D–4 (2)[DIMENSIONS]. . . . . . . . . . . . . . . . . . 09-80D–10
FRONT BODY STRAIGHT-LINE ROOM STRAIGHT-LINE DIMENSIONS
DIMENSIONS (2)[DIMENSIONS] . . . . . 09-80D–5 (3)[DIMENSIONS]. . . . . . . . . . . . . . . . . . 09-80D–11
FRONT BODY STRAIGHT-LINE REAR BODY STRAIGHT-LINE
DIMENSIONS (3)[DIMENSIONS] . . . . . 09-80D–6 DIMENSIONS (1)[DIMENSIONS] . . . . . . 09-80D–12
End of Toc
09-80D
BM: UNDERBODY
09-80D–1

UNDERBODY FLAT-PLANE DIMENSIONS[DIMENSIONS]
id098010740400
• The following figures are bottom and side views.
mm {in}
{16.64}
423
{41.26}
LH
{38.66}
{39.69}
{47.09}
1,048
{36.73}
{33.23}
{16.93}
{24.02}
1,008
{33.27}
1,196
{38.90}
{38.43}
982
933
430
976
988
610
844
845
{16.63}
RH
422
A B C D E F G H I J K L
{44.84}
1,139
{27.76}
{27.20}
{26.26}
705
691
{22.09}
667
{20.28}
{20.47}
{20.55}
{22.32}
{18.39}
561
{17.83}
{17.40}
515
502
522
567
467
453
442
631 359 440 606 389 516 635

{24.84} {14.13} {17.32} {23.86} {15.31} {20.31} {25.00}
157 296 56 14
{6.18} {11.65} {2.20} {0.55}
acxuub00000001

Point Point
symbol symbol
size (mm {in}) size (mm {in})
A Front side frame datum hole φ14 {0.55} Tunnel reinforcement datum
G φ16 {0.63}
Front suspension mounting hole
B M14 {0.55}
bolt H Front B frame datum hole φ12 {0.47}
Front suspension mounting I Rear side frame datum hole φ16 {0.63}
C M14 {0.55}
bolt J Rear side frame datum hole φ20 {0.79}
Front suspension mounting Rear suspension mounting
D M14 {0.55} K φ55.6 {2.19}
bolt block
E Torque box datum hole φ16.5 {0.65} L Rear side frame datum hole φ25 {0.98}
F Front B frame datum hole φ16 {0.63}
End Of Sie
09-80D–2

UNDERBODY STRAIGHT-LINE DIMENSIONS[DIMENSIONS]
id098010740500
• The following figure is a bottom view.
mm {in}
2,551 1,170
{100.43} {46.06}
1,163
{45.79}
1,150
{45.28} 918 1,216
730 {36.14} {47.87}
1,476 {28.74} 994
LH
{58.11} 2,708 879 {39.13} 1,548

1,010 835 {34.61}
{39.76} {106.61} {60.94}
{32.87} 1,129 09-80D
RH
778 {44.45}
{30.63}
491 640
{19.33} {25.20}
357 359 398
634 {14.06} {14.13} {15.67} 534 650
{24.96} {21.02} {25.59}
132
236 {5.20}
{9.29}
A B C D E F G H I J L
acxuub00000002
A,B C D,E F G
B E
Fr Fr
Fr Fr D Fr
A
H I J L
Fr Fr Fr Fr
acxuub00000003

Point Point
symbol symbol
A Front side frame datum hole φ14 {0.55} F Front B frame datum hole φ16 {0.63}
Front suspension mounting Tunnel reinforcement datum
B M14 {0.55} G φ16 {0.63}
bolt hole
Front suspension mounting H Front B frame datum hole φ12 {0.47}
C M14 {0.55}
bolt I Rear side frame datum hole φ16 {0.63}
Front suspension mounting J Rear side frame datum hole φ20 {0.79}
D M14 {0.55}
bolt
L Rear side frame datum hole φ25 {0.98}
E Torque box datum hole φ16.5 {0.65}
End Of Sie
BM: FRONT BODY
09-80D–3

FRONT BODY STRAIGHT-LINE DIMENSIONS (1)[DIMENSIONS]
id098010740600
mm {in}
A 1,216 A'
{47.87}
1,625
843 {63.98}
{33.19}
B B'
1,588
{62.52}
1,464
{57.64}
1,229
{48.39}
957
920 {37.68}
C {36.22} C'
D 855 D'
{33.66} E'
E
acxuub00000004
A B C D E
Fr Fr Fr
Fr Fr
acxuub00000005

Point Point
symbol symbol
A Roof seamless location - D Shroud side panel datum hole φ15 {0.59}
B Front pillar projection location - Front bumper bracket datum
E φ10 {0.39}
C Shroud side stay datum hole φ7 {0.28} hole
End Of Sie
09-80D–4

id098010740700
mm {in}
B
C
1,432
{56.38}
1,151
{45.31} 1,309
{51.54} 09-80D
D
A'
1,467 1,320
{57.76} {51.97} B' 255
{10.04}
1,258
{49.53} 1,380
{54.33}
C'
E 235
1,228 {9.25}
{48.35} 609
{23.98}
1,044 D'
{41.10}
1,014
{39.92}
E'
acxuub00000006
A B C D E
Fr Fr Fr Fr Fr
acxuub00000007

Point Point
symbol symbol
A Hood hinge installation hole φ14 {0.55} Shroud side member datum
D φ7 {0.28}
Suspension housing upper hole
B φ11 {0.43}
datum hole E Front side frame datum hole φ14 {0.55}
Apron reinforcement upper
C φ12 {0.47}
datum hole
End Of Sie
09-80D–5

id098010740800
mm {in}
C
1,500
{59.06}
D A
1,474
642 1,380 {58.03} B'
{25.28}
{54.33}
F C' 385
1,335 {15.16}
908 1,219 {52.56}
{35.75} {47.99} D' 242
{9.53}
1,108
{43.62}
E
E'
acxuub00000008
A B C D E
Fr Fr Fr
Fr Fr
Fr
acxuub00000009

Point Point
symbol symbol
Dash member upper datum Apron reinforcement upper
A φ8 {0.31} C φ12 {0.47}
hole datum hole
B Hood hinge installation hole φ14 {0.55}
09-80D–6

Point Point
symbol symbol
Shroud side member datum E Front side frame datum hole φ16 {0.63}
D φ7 {0.28}
hole Engine mount bracket datum
F φ16 {0.63}
hole
End Of Sie
CABIN SIDE FRAME STRAIGHT-LINE DIMENSIONS[DIMENSIONS]
BM: CABIN SIDE FRAME
id098010743600
mm {in}
G 607 I
{23.90}
09-80D
917
{36.10}
1,136
1,031 {44.72} 1,711
E {40.59} {67.36}
B 1,125
{44.29} 1,189
1,105 K
1,194 {43.25} {46.81} J
{47.01} 580 1,552
1,067 {42.01} {22.83} {61.10}
1,156 F
{45.51} 396 711
A C {15.59} {27.99}
D H
acxuub00000028
A B C D E
Fr Fr Fr Fr Fr
F G H I J
Fr Fr Fr Fr Fr
K
Fr
acxuub00000029

Point Point
symbol symbol
Front side frame outer datum φ12 × 12 Front door hinge installation
A B φ12 {0.47}
slot {0.47 × 0.47} hole
Front door hinge installation
C φ12 {0.47}
hole
09-80D–7

Point Point
symbol symbol
D Side frame outer notch - I Side frame outer datum hole φ8.2 {0.32}
E Side frame outer datum hole φ12 {0.47} J Side frame outer datum hole φ4.5 {0.18}
F Side frame outer datum hole φ12 {0.47} Front side frame outer datum φ8 × 6.1
K
G Side frame outer notch - slot {0.31 × 0.24}
H Side frame outer notch -
End Of Sie
ROOM STRAIGHT-LINE DIMENSIONS (1)[DIMENSIONS]
BM: ROOM
id098010743300
mm {in}
A F
B 1,129
{44.45}
1,195 C
{47.05} 1,315 G
1,006 {51.77}
{39.61}
I-I'
1,102
{43.39}
1,538 D
{60.55} 864 H
{34.02} 797
{31.38}
acxuub00000010
09-80D–8
A B C D E
Fr Fr Fr Fr Fr
F G H I
09-80D
Fr Fr Fr Fr
acxuub00000011

Point Point
symbol symbol
A Front pillar inner datum hole φ6 {0.24} F Center pillar inner datum hole φ16 {0.63}
B Front pillar inner datum hole φ7 {0.28} G Center pillar inner datum hole φ10 {0.39}
Front pillar inner reinforcement 26 × 6
C φ10 {0.39} H Center pillar inner square hole
datum hole {1.02 × 0.24}
D Hinge pillar inner datum hole φ8.6 {0.34} I Side frame installation hole φ12 {0.47}
Instrument panel bracket φ12 × 18
E
datum slot {0.47 × 0.71}
End Of Sie
09-80D–9

id098010743400
mm{in}
A
E
1,150
{45.28}
1,438
B {56.61} F
H-H'
931
{36.65}
1,408
{55.43}
1,564
{61.57}
C G
729 1,101
{28.70} {43.35}
acxuub00000012
,
A B C D,D E
,
D
Fr Fr Fr Fr Fr
F G H
Fr Fr Fr
acxuub00000013

Point Point
symbol symbol
A Center pillar inner datum hole φ16 {0.63} E Rear pillar inner datum hole φ7 {0.28}
B Center pillar inner datum hole φ10 {0.39} F Rear seat bracket datum hole φ5 {0.20}
26 × 6 G Rear pillar inner datum hole φ7 {0.28}
C Center pillar inner square hole
{1.02 × 0.24} H Side frame outer datum hole φ12 {0.47}
Parking brake bracket datum
D,D’ φ10 {0.39}
hole
End Of Sie
09-80D–10

id098010746200
mm{in}
E
B
972 F
{38.27}
1,080
{42.52} 970
{38.19}
09-80D
938
{36.93}
G
H-H'
849
{33.43}
1,596
{62.83}
C
837
{32.95} D
acxuub00000014
A B C D E
Fr
Fr Fr Fr Fr
F G H
Fr Fr Fr
acxuub00000015

Point Point
symbol symbol
A Rear pillar inner datum hole φ7 {0.28} E Rear pillar inner datum hole φ6 {0.24}
B Rear seat bracket datum hole φ5 {0.20} F Corner junction datum hole φ8.6 {0.34}
C Rear pillar inner datum hole φ7 {0.28} 28 × 8
G Rear end member square hole
φ7.2 × 10 {1.10 × 0.31}
D Crossmember No.5 datum slot
{0.28 × 0.39} H Side frame outer datum hole φ13 {0.51}
09-80D–11

End Of Sie
REAR BODY STRAIGHT-LINE DIMENSIONS (1)[DIMENSIONS]

BM: REAR BODY
id098010746300
mm {in}
A' A
725
{28.54}
1,030 B
B' {40.55}
1,399
{55.08} 581
{22.87}
1,168 953
{45.98} {37.52}
1,573
C' {61.93} C
1,431 304
{56.34} {11.97}
1,242
D' {48.90} D
E' 629 E
{24.76}
461
979 {18.15}
{38.54}
600
{23.62}
F' F
acxuub00000016
A B C D E
Fr
Fr Fr Fr Fr
,
F F
Fr Fr
acxuub00000017

Point Point
symbol symbol
A Liftgate hinge installation hole φ12 {0.47} 8 × 6.1
D Rear end panel square hole
B Rear pillar outer datum hole φ10 {0.39} {0.31 × 0.24}
φ8 × 16 28 × 8
C Corner plate datum slot E Rear end member square hole
{0.31 × 0.63} {1.10 × 0.31}
09-80D–12

Point Point
symbol symbol
F Rear end panel datum hole φ12 {0.47} φ12 × 18
F’ Rear end panel datum slot
{0.47 × 0.71}
End Of Sie
09-80D
09-80D–13
3419-1U-06C(09-80E).fm 1 ページ２００６年３月２２日　水曜日　午後６時２８分
BODY STRUCTURE [PLASTIC BODY PARTS]

09-80E BODY STRUCTURE [PLASTIC BODY PARTS]
PLASTIC PARTS HEAT RESISTING Repairable Bumpers . . . . . . . . . . . . . . . 09-80E–2
TEMPERATURE POLYPROPYLENE BUMPER
[PLASTIC BODY PARTS] . . . . . . . . . . . 09-80E–1 REPAIR[PLASTIC BODY PARTS] . . . . . 09-80E–3
REPAIRABLE RANGE OF PROCEDURE[PLASTIC BODY PARTS] . 09-80E–4
POLYPROPYLENE BUMPERS
[PLASTIC BODY PARTS] . . . . . . . . . . . 09-80E–2
End of Toc
PLASTIC PARTS HEAT RESISTING TEMPERATURE[PLASTIC BODY PARTS]
BM: PLASTIC BODY PARTS
id098011740200
Heat resisting
Part Name Code Material Name
Temperature(°C {°F})
WINDSHIELD MOULDING PVC POLYVINYLCHLORIDE 95 {203}
COWL GRILLE PP POLYPROPYLENE 95 {203}
FRONT COMBINATION LENS PC POLYCARBONATE 130 {266} 09-80E
LIGHT HOUSING PP POLYPROPYLENE 90 {194}
RADIATOR GRILLE PP POLYPROPYLENE 95 {203}
FRONT BUMPER PP POLYPROPYLENE 100 {212}
PANEL AAS AAS 100 {212}
OUTSIDE MIRROR
VISOR AAS AAS 100 {212}
SIDE STEP MOLDING PP POLYPROPYLENE 75 {167}
SIDE GARNISH AES AES 90 {194}
REAR COMBINATION LENS PMMA ACRYLIC 80 {176}
LIGHT HOUSING AAS AAS 70 {158}
REAR BUMPER PP POLYPROPYLENE 100 {212}
ROOF MOULDING PVC POLYVINYLCHLORIDE 95 {203}
LENS PC POLYCARBONATE 80 {176}
REFLECTOR
HOUSING PC POLYCARBONATE 80 {176}
COLOR LEVER PC-PBT POLYCARBONATE-PBT 138 {248}
S BASE PC-PET POLYCARBONATE-PET 140 {252}
OUTER HANDLE EXCEP LEVER PC-ABS POLYCARBONATE-ABS 125 {225}
T
COLOR BASE PC-ABS POLYCARBONATE-ABS 125 {225}
S
HIGH-MOUNT BRAKE LENS PMMA ACRYLIC 100 {212}
LIGHT HOUSING ABS ABS 94 {201}
SHROUD PANEL PP POLYPROPYLENE 100 {212}
REAR SPOILER ABS ABS 90 {194}
Note
• The application of temperatures higher than heat resisting temperatures may result in part deformation.
End Of Sie
BM: BUMPER
09-80E–1

REPAIRABLE RANGE OF POLYPROPYLENE BUMPERS[PLASTIC BODY PARTS]
id098011600100
The three types of damaged bumpers shown below are considered repairable. Although a bumper which has been
damaged greater than this could also be repaired, it should be replaced with a new one because such repair would
detract from the looks and quality of the bumper. In addition, such repair is not considered reasonable in terms of
work time.
Repairable Bumpers
1. A bumper with a hole less than 50 mm {1.97 in} in
diameter.
am8rrb00000046
2. A bumper with a crack less than 100 mm {3.94 in}

in length.
am8rrb00000047
3. A bumper with a crack less than 100 mm {3.94 in}

in length that is less than half of the width of the
(A)
bumper.
End Of Sie
LESS THAN HALF OF (A)

am8rrb00000048
09-80E–2

POLYPROPYLENE BUMPER REPAIR[PLASTIC BODY PARTS]
id098011600200
Scratch on paint only Hole or crack through surface Crack more than 100 mm
{3.94in} long or completely
broken
Bumper Bumper Remove paint

surface surface
not visible visible
Smooth damaged area
09-80E
Apply aluminium tape to
reverse side of bumper
Plastic weld damaged area Replace damaged

Bumper
Spray entire bumper
Rough sand damage area surface with
polypropylene primer
Degrease damaged area
Apply polypropylene primer

to damaged area
Apply repair agent to

damaged area and let dry
Sand dam- Sand damaged area

aged area smooth
Apply polypropylene primer to damaged

area and let dry
Spray primer surfacer on damaged area Spray primer surfacer on

and let dry bumper and let dry
Sand partial or complete surface of bumper Sand surface of bumper
Degrease bumper
Spray matching body color paint on bumper and let dry
am8rrb00000049
End Of Sie
09-80E–3

PROCEDURE[PLASTIC BODY PARTS]
id098011600300
Repair of polypropylene bumpers having damage that has reached the surface of the polypropylene and are too
serious to be restored by painting only.
Hole Flaw
Crack
A B C D
A B C D
A-A Section 1 B-B, D-D Section

Section
C-C
2
3
4
1 Top coat layer 2 Primer surface layer

3 Primer layer 4 Polypropylene layer
am8rrb00000050
1. Cut the rough edges around the damage with a knife to make it smooth. Sand the area with a sander to make
an angle of about 45°.
A-A, B-B, C-C Section D-D Section
Cut with knife
Cut with knife
Polypropylene surface
Sand
Sand
45°
Angle necessary for deposit of polypropylene welding rog

am8rrb00000051
09-80E–4

2. Weld the damaged area.
• For repair of a cracked area, melt the crack together with a heat gun and a melting attachment.
Heat gun
B-B,C-C Section Melt together
painted surface
Attachment for
melting Polypropylene surface Section after melting
am8rrb00000052
• For repair of a hole, degrease the area on

both sides of the bumper and apply aluminium
A-A Section
tape on the reverse side of the damage area. Degrease
3. Melt the polypropylene welding rod with a heat
gun and deposit it the cracked area. 09-80E
Aluminium tape
am8rrb00000053
Polypropylene welding rod

B-B,C-C,D-D Section
Melt this area
Melted area
am8rrb00000054
Note
• Heat the shaded area to melt it.
• Take care not to overly melt welding rod. If the part is welded with the welding rod melted like jelly, the
welding strength will be reduced.
• Hold the heat gun 10—20 mm {0.39—0.79 in} from the part being welded.
• Do not move the welding rod until the welded parts cool.
Polypropylene welding
A-A Section
Paint
Surface
Top view
Aluminium tape
am8rrb00000055
09-80E–5

4. Sand the surface of the polypropylene gradually as it is easily melted by the abrasion heat. Sand the area to
which repair agent will be applied.
Sand gradually
Sand repair area
Paint
am8rrb00000056
5. Uniformly apply polypropylene primer with a brush to an area larger than the repaired area. Allow to dry about
10 minutes at 20 °C {68 °F}.
Larger than repaired area
Polypropylene primer
am8rrb00000057
6. Mix the main agent and the stiffening agent in a ratio of one to one. Apply the mixed repair agent to the
damaged area.
Note
• When mixing the main and stiffening agents, take care not to allow bubbles to form.
• The repair agent hardens quickly (about 5 minutes); proceed with the work immediately after mixing the
agents.
• Allow about 30 minutes to dry (20 °C {68 °F}) before sanding.
Repair agent
Do not mix air
Weld
Polypropylene surface
am8rrb00000058
The repair agent is a two part epoxy adhesive.

When the repair agent hardens, it will provide a good finish with the same flexibility as the polypropylens.
The repair agent for a urethane bumper is also a two part adhesive compound. However, this is different from
that for a polypropylene bumper. If the incorrect repair agent is used, the repair will be faulty.
09-80E–6

7. Sand the area with #180—240 sandpaper.
Note
• If excessive force is applied to the area when sanding, the surface will be damaged.
• If fuzz remains around the repaired area, melt it with a heat gun.
09-80E
am8rrb00000062
8. Degrease the painted surface.

9. Mix the primer and the hardener at a ratio of one to one. Apply the primer to the repaired area and the surface
of the bumper with a brush or spray.
polypropylene primer Primer hardener
1 1
am8rrb00000060
Use the primer within 16 hours after it is mixed.
Note
• Polypropylene primer will dissolve even after drying if it is wiped with solvent. Use only water to clean
around the primer.
10. Allow the part to dry.
09-80E–7

11. Add the softener to the urethane primer surfacer and spray it on the repaired area.
a. Mixing method
Urethane primer surfacer + Softener ..... Mixture A
Mixture A + hardener ..... Mixture B
Dilute mixture B with thinner to spray on bumper
b. Viscosity
14—16 seconds/viscosimeter 20 °C {68 °F} Urethane primer surfacer Hardner
Note Softener
• Mix the solutions at the specified ratio.
c. Spray pressure
300—400 kPa {3—4 kg/cm2, 43—57 psi}
d. Standard film thickness
30—40 µ
e. Spray method
Spot-spray primer surfacer on bumper three
of four times Mixture A 100 30
12. Air drying 20 °C {68 °F} — 8 hours minimum.
Forced drying 60 °C {140 °F} — 1 hour
13. Lightly sand the complete surface of the bumper
with #400—#600 sandpaper. Do not expose the Mixture B 4 1
surface of the polypropylene. (Wet or dry sanding
is acceptable.) am8rrb00000061
14. Wipe the complete surface of the bumper with
degreasing agent. Quickly wipe the surface with a
clean rag to degrease it.
15. Apply a matching coat of body color to the polypropylene bumper.
Note
• Be sure to use only urethane primer for a urethane bumper and polypropylene primer for a polypropylene
bumper. Other paints for repairing a polypropylene bumper are the same as those for the urethane
bumper.
16. Air drying 20 °C {68 °F} — 8 hours minimum.

Forced drying 60 °C {140 °F} — 1 hour
Note
• Let the part air dry when possible as forced drying could cause bubbles in the top coat.
End Of Sie
09-80E–8

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3419-1U-06C(INDEX).

Bodyshop GENERAL INFORMATION 00

Manual CONSTRUCTION 80A

PANEL REPLACEMENT 80B

Mazda Motor Corporation reserves the

All rights reserved. No part of this book may

Mazda Motor Corporation

VEHICLE IDENTIFICATION NUMBERS (VIN)

JM3 ER29L✻7# 100001—

Toc of SCT INFORMATION . . . . 00-00

Model year 7= 2007

L= 2.3 L (California (L3 WITH TC))

9= Wagon, Gross vehicle weight class C

Resraint system 2= with Curtain and Side air bags

Carline, Series ER= Mazda CX-7

World manufacturer identification JM3= Mazda/Multi-purpose vehicle category/U.S.A.

REAR FENDER PANEL REMOVAL

Shows a cross location

ROUGH CUT LOCATION 17

Shows welding region

SYMBOL MEANING SYMBOL MEANING

Body Dimensions (Flat-plane Dimensions)

When there are no specific indications, all of

182 93 144 120 140 68

Hole diameter Hole diameter

Shows bolt size Shows hole diameter

Shows vehicle section Shows point

Shows point indication

Hole diameter Hole diameter

Shows bolt size

Symbols of Body Dimensions

SYMBOL MEANING SYMBOL MEANING

Notch Edge of rectangular-shaped hole

Dust mask Safety glasses Safety shoes

Remove Dangerous Articles

Prevent Short Circuits

• Securely connect the welding machine ground

EFFICIENT REMOVAL OF BODY PANELS

Selection of Cut-and-join Locations

Removal of Associated Parts

Rough Cutting of Damaged Panel

Rough cut location Cut-and-join location

Body side rough cut location

Making Holes for CO2 Arc Welding

Application of Weld-through Primer

CO2 arc welding If 3mm Repair weld

Original number of welds

Spot Welding Notes

• Because the weld strength is affected by the

Checking Weld Strength

• Drive the chisel between the panels according to

Application of Rust Inhibitor

Application of Floor Silencer

BODY & ACCESSORIES 09

BODY STRUCTURE [CONSTRUCTION]

BODY STRUCTURE [CONSTRUCTION]

BODY STRUCTURE [CONSTRUCTION]

BODY STRUCTURE [CONSTRUCTION]

Range of Use and Cautions for Service 09-80A

FRONT PILLAR (INNER) *1

BODY STRUCTURE [CONSTRUCTION]

FRONT SIDE FRAME

REAR FRAME GUSSET

CROSSMEMBER No.3 (REAR)*3

TORQUE BOX C 1 TUNNEL PANEL (REAR)1