Body

3424-1U-06L(INDEX).
fm 1 ページ２００６年１２月１９日　火曜日　午後３時３２分
2007-present CONTENTS
Mazda CX-9 Title Section
Bodyshop GENERAL INFORMATION 00
Manual CONSTRUCTION 80A
PANEL REPLACEMENT 80B

WATER-PROOF AND RUST 80C
FOREWORD
BODY PREVENTIVE
This bodyshop manual is intended for STRUCTURE
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
CONSTRUCTION 80F
on Mazda vehicles. STANDARD VALUES
For proper repair and maintenance, a APPLICATION:

thorough familiarization with this manual is This manual is applicable to vehicles beginning
important, and it should always be kept in a with the Vehicle Identification Numbers (VIN),
handy place for quick and easy reference. shown on the following page.
All the contents of this manual, including © 2006 Mazda Motor Corporation
drawings and specifications, are the latest PRINTED IN U.S.A., DECEMBER 2006
available at the time of printing. Form No. 3424–1U–06L
As modifications affecting repair or Part No. 9999–95–007F–07
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 ad-
vance 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
3424-1U-06L(INDEX).fm 2 ページ２００６年１２月１９日　火曜日　午後３時３２分
VEHICLE IDENTIFICATION NUMBERS (VIN)
JM3 TB28C✻7# 100001—

JM3 TB28Y✻7# 100001—
JM3 TB38C✻7# 100001—
JM3 TB38Y✻7# 100001—
2007 Mazda CX-9 Bodyshop Manual (3424–1U–06L)
GENERAL INFORMATION 00SECTION

00-00
Toc of SCT INFORMATION . . . . 00-00

GENERAL
Toc of SCT
00-00 GENERAL INFORMATION
VEHICLE IDENTIFICATION Removal of Associated Parts . . . . . . . . 00-00–10
NUMBER (VIN) CODE . . . . . . . . . . . . . . 00-00–2 Rough Cutting of
VEHICLE IDENTIFICATION Damaged Panel . . . . . . . . . . . . . . . . . 00-00–10
NUMBERS (VIN). . . . . . . . . . . . . . . . . . 00-00–2–1 EFFICIENT INSTALLATION OF
HOW TO USE THIS MANUAL . . . . . . . . . 00-00–3 BODY PANELS . . . . . . . . . . . . . . . . . . . 00-00–11
Efficient Replacement of Checking Preweld Measurements
Body Panels . . . . . . . . . . . . . . . . . . . . 00-00–3 And Watching . . . . . . . . . . . . . . . . . . . 00-00–11
Symbols of Panel Replacement . . . . . . 00-00–3 Welding Notes . . . . . . . . . . . . . . . . . . . 00-00–11
Body Dimensions Spot Welding Notes . . . . . . . . . . . . . . . 00-00–11
(Flat-plane Dimensions) . . . . . . . . . . . 00-00–4 Checking Weld Strength. . . . . . . . . . . . 00-00–12
Body Dimensions INSTALLATION PREPARATIONS. . . . . . 00-00–13
(Straight-line Dimensions). . . . . . . . . . 00-00–6 Rough Cutting of New Parts. . . . . . . . . 00-00–13
Symbols of Body Dimensions . . . . . . . . 00-00–7 Determination of Welding Method . . . . 00-00–13
SERVICE PRECAUTIONS . . . . . . . . . . . . 00-00–8 Making Holes for CO2 Arc
Arrangement of Workshop . . . . . . . . . . 00-00–8 Welding . . . . . . . . . . . . . . . . . . . . . . . 00-00–13
Safety Precautions . . . . . . . . . . . . . . . . 00-00–8 Application of Weld-through
Vehicle Protection . . . . . . . . . . . . . . . . . 00-00–8 Primer. . . . . . . . . . . . . . . . . . . . . . . . . 00-00–13
Remove Dangerous Articles . . . . . . . . . 00-00–8 ANTICORROSION,
Use of Pulling Equipment . . . . . . . . . . . 00-00–9 SOUND INSULATION, AND
Prevent Short Circuits . . . . . . . . . . . . . . 00-00–9 VIBRATION INSULATION . . . . . . . . . . . 00-00–14
EFFICIENT REMOVAL OF Body Sealing . . . . . . . . . . . . . . . . . . . . 00-00–14
BODY PANELS. . . . . . . . . . . . . . . . . . . . 00-00–10 Application of Undercoating . . . . . . . . . 00-00–14
Body Measurements . . . . . . . . . . . . . . . 00-00–10 Application of Rust Inhibitor . . . . . . . . . 00-00–14
Prevention of Body Deformation . . . . . . 00-00–10 Application of Floor Silencer. . . . . . . . . 00-00–14
Selection of Cut-and-join ABBREVIATION . . . . . . . . . . . . . . . . . . . 00-00–15
Locations. . . . . . . . . . . . . . . . . . . . . . . 00-00–10
End of Toc
BM: GENERAL INFORMATION
Revised 6/2008 (Ref. No. R113/08) 00-00–1

2007 Mazda CX-7 Bodyshop Manual (3419–1U–06C)
GENERAL INFORMATION
VEHICLE IDENTIFICATION NUMBER (VIN) CODE
id000000600800
2007 Model Year
J M3 TB28C* 7# 12 3 4 5 6
Serial No.
0= Hiroshima
Plant 1= Hofu
Model year 7= 2007
Check digit *= 0 to 9, X
C= 3.5 L, MZI-3.5 (California)

Engine Y= 3.5 L, MZI-3.5 (Federal/CANADA)
Body 8= Multi-purpose vehicle (Wagon)
3= AWD
Chassis type 2= 2WD
Carline, Series TB= Mazda CX-9
World manufacturer identification JM3= Mazda (Multi-purpose vehicle category)
ac9uuw00001184
2008 Model Year
J M3 TB28A* 8# 12 3 4 5 6
Serial No.
0= Hiroshima
Plant 1= Hofu
Model year 8= 2008
V= 3.7 L, MZI-3.7 (California)

Engine A= 3.7 L, MZI-3.7 (Federal/CANADA)
3= AWD
Chassis type 2= 2WD
ac9uuw00002814
End Of Sie
00-00–2 Revised 6/2008 (Ref. No. R113/08)

2007 Mazda CX-9 Bodyshop Manual (3424–1U–06L)
GENERAL INFORMATION
00-00
VEHICLE IDENTIFICATION NUMBER (VIN) CODE GENERAL INFORMATION
2009 Model Year
J M3 TB 2 8 A * 9 # 12 3 4 5 6
Serial No.
0= Hiroshima
Plant 1= Hofu
00-00
Model year 9= 2009
V= 3.7 L, MZI-3.7 (California)

Engine A= 3.7 L, MZI-3.7 (Federal/CANADA)
3= AWD
Gross vehicle weight class E (2722—3175 kg)
2= 2WD
Chassis type, Gross vehicle weight class Gross vehicle weight class D (2268—2722 kg)

ac9uuw00002873
End Of Sie
VEHICLE IDENTIFICATION NUMBERS (VIN)
id000000600100
2007 Model Year
JM3 TB28C*7# 100001—
JM3 TB28Y*7# 100001—
JM3 TB38C*7# 100001—
JM3 TB38Y*7# 100001—
2008 Model Year

JM3 TB28A*8# 100001—
JM3 TB28V*8# 100001—
JM3 TB38A*8# 100001—
JM3 TB38V*8# 100001—
2009 Model Year

JM3 TB28A*9# 100001—
JM3 TB28V*9# 100001—
JM3 TB38A*9# 100001—
JM3 TB38V*9# 100001—
End Of Sie
Revised 6/2008 (Ref. No. R113/08) 00-00-2–1

2007 Mazda CX-7 Bodyshop Manual (3419–1U–06C)
GENERAL INFORMATION
THIS PAGE INTENTIONALLY

LEFT BLANK
00-00-2–2
3424-1U-06H(00-00).fm 3 ページ２００６年１２月１９日　火曜日　午後３時１６分
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
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
00-00–3
GENERAL INFORMATION
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
UNDERBODY FLAT-PLANE DIMENSIONS

00-00
The dimensions on the left
and right in regard to the center Shows outline drawing
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}
When there are no specific indications, all of

units are in millimeters (mm). mm {in}
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

ac9uub00000034
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}
D
When there are no specific indications, all of
units are in millimeters (mm).
mm {in}
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}
Shows bolt size
E Adjuster installation hole φ 16 {0.62}
ac9uub00000035
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
00-00–9
GENERAL INFORMATION
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
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
00-00–10
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. 00-00
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 3 mm Repair weld

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

or more
ac9uub00000037
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
ac9uub00000041
• 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
00-00–11
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.
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 25 mm 20°
fourth or fifth weld spot, and every tenth regular {0.98 in}
weld location.
8 mm {0.31 in}
Weld location
Within 5 mm
{0.20 in}
Within 5 mm
{0.20 in}
ac9uub00000036
• 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
00-00–12
GENERAL INFORMATION
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—50 mm{1.18—1.97 in} 30—50 mm{1.18—1.97 in} 00-00
parts. Over lap Over lap
Body side rough cut location

New part rough cut location
ac9uub00000038
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. 3 mm
{0.12 in}or more
ac9uub00000039
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—
φ10 mm {0.39 in}
4 plates are put together. Also, weld the plates
together tightly so that gaps do not develop. 30° 30°
Outer panel
Middle panel
Inner panel
ac9uub00000040
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
00-00–13
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
Fr Front
LH Left Hand
RH Right Hand 00-00
Rr Rear
End Of Sie
00-00–15
3424-1U-06H(09-80A).fm 1 ページ２００６年１２月１９日　火曜日　午後３時１９分
BODY & ACCESSORIES 09SECTION
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 BODY STRUCTURE
[WATER-PROOF AND [CONSTRUCTION
RUST PREVENTIVE] . . . . . . . 09-80C STANDARD VALUES] . . . . . . 09-80F
Toc of SCT
09-80A BODY STRUCTURE [CONSTRUCTION]
BODY COMPONENTS CONSTRUCTION Characteristics of Ultra High-Tensile
[CONSTRUCTION] . . . . . . . . . . . . . . . . . 09-80A–2 Steel Plates . . . . . . . . . . . . . . . . . . . . 09-80A–5
ULTRA HIGH-TENSION STEEL Range of Use and
[CONSTRUCTION] . . . . . . . . . . . . . . . . . 09-80A–5 Cautions for Service . . . . . . . . . . . . . . 09-80A–5
End of Toc
BM: CONSTRUCTION
09-80A–1
BODY STRUCTURE [CONSTRUCTION]

BODY COMPONENTS CONSTRUCTION [CONSTRUCTION]
id098007739700
38
20 37
19 29
36 30
34 35
33 40
32
39
31
27
1 44 42
25
28 43
26 41
21
18
45
23
17
8
7
5 22
2 6
4 10 24
11
46
13
3 9 12
48
14
15
47
16 68
63
56
69
67
53 65
52 50 66
62 64
61
60 59
57
58
54 55
49
51
ac9uub00000026
09-80A–2

.
x:Applied
-:Not applied
Ultra high- High-
Rust proof Thickness
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} 09-80A
Front x - x 1.80 {0.071}
3 Front side frame (inner)
Rear - x x 2.30 {0.091}
4 Shroud side panel - - x 1.60 {0.063}
5 Shroud upper member - - x 1.20 {0.047}
RH - - x 1.00 {0.039}
6 Wheel 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 2.90 {0.114}
9 B frame reinforcement (outer) x - x 1.60 {0.063}
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 x 1.00 {0.039}
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 1.20 {0.047}
16 Front fender panel - - x 0.85 {0.033}
17 Dash lower member - - x 1.20 {0.047}
18 Dash lower panel - - x 1.20 {0.047}
19 Cowl panel - - x 1.00 {0.039}
20 Wiper bracket - - x 1.80 {0.071}
21 Hinge pillar (inner) - x x 1.20 {0.047}
22 Hinge pillar reinforcement x - x 1.80 {0.071}
Front - x x 1.40 {0.055}
23 Side sill panel (inner) Center - x x 1.40 {0.055}
Rear - - x 2.00 {0.079}
24 Side sill reinforcement x - - 1.20 {0.047}
25 Front pillar (inner) x - - 1.60 {0.063}
26 Front pillar reinforcement x - - 1.60 {0.063}
27 Center pillar (inner) - x - 1.20 {0.047}
Upper x - - 1.40 {0.055}
28 Center pillar reinforcement 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 - - - 1.20 {0.047}
32 Roof reinforcement - - - 0.55 {0.022}
33 Roof reinforcement x - - 1.20 {0.047}
Upper - - - 0.60 {0.024}
37 Rear header
Lower - - - 0.75 {0.030}
38 Roof panel - - - 0.75 {0.030}
39 Rear pillar reinforcement - - - 0.65 {0.026}
40 Rear pillar (outer) - - x 0.70 {0.028}
41 Corner junction - - x 1.00 {0.039}
09-80A–3

Ultra high- High-
Rust proof Thickness
No. Part Name tension tension
steel (mm) {in}
steel steel
42 Corner plate - - x 0.65 {0.026}
43 Wheel house (inner) - - x 1.20 {0.047}
44 Rear pillar (inner) - - x 0.65 {0.026}
45 Rear suspension housing reinforcement - - - 1.00 {0.039}
46 Side frame (outer) - - x 0.70 {0.028}
47 Front door panel - x x 0.70 {0.028}
48 Rear door panel - x x 0.70 {0.028}
49 Crossmember No.2 - - x 2.00 {0.079}
50 Front floor pan - - x 0.65 {0.026}
Front - x x 2.60 {0.102}
51 Front B frame
Rear x - x 1.80 {0.071}
52 Tunnel reinforcement - - - 1.20 {0.047}
53 Change reinforcement - - - 1.20 {0.047}
54 Front frame rear reinforcement - x - 2.00 {0.079}
55 Crossmember No.3 - x x 1.60 {0.063}
56 Trunk floor pan - - x 0.65 {0.026}
58 Rear side frame (rear) x - x 1.60 {0.063}
59 Rear bumper bracket x - x 2.00 {0.079}
61 Crossmember No.6 - - x 1.20 {0.047}
63 Crossmember No.8 - - x 1.20 {0.047}
64 Crossmember No.9 - - x 1.40 {0.055}
65 Floor side panel - - x 0.70 {0.028}
66 Seat anchor bracket - x x 1.80 {0.071}
67 Brace bracket - - - 1.80 {0.071}
Side - - - 1.20 {0.047}
68 Rear end member
Center - - - 0.90 {0.035}
69 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
B PILLAR
ROOF RAIL (INNER,REAR)*1 REINFORCEMENT (UPPER)*1
FRONT PILLAR (INNER)*1
B PILLAR
REINFORCEMENT (CENTER)*2
FRONT PILLAR REINFORCEMENT*1
SIDE SILL REINFORCEMENT*2
HINGE PILLAR REINFORCEMENT*1

ac9uub00000032
09-80A–5
FIXING REINFORCEMENT*1
REAR SIDE FRAME*1 BUMPER BRACKET*1
FRONT B FRAME (REAR)*1
TORQUE BOX No.2*1
SIDE SILL REINFORCEMENT*1
REAR
SIDE FRAME (REAR)*1
B FRAME REINFORCEMENT (OUTER)*1

FRONT FRAME (INNER,FRONT)*1
FRONT FRAME (OUTER,CENTER)*1
FRONT FRAME (OUTER,FRONT)*1

ac9uub00000033
*1 : Indicates tensile strength of 590 MPa.
*2 : Indicates tensile strength of 780 MPa.
End Of Sie
09-80A–6
3424-1U-06H(09-80B).fm 1 ページ２００６年１２月１９日　火曜日　午後３時２０分
BODY STRUCTURE [PANEL REPLACEMENT]

09-80B BODY STRUCTURE [PANEL REPLACEMENT]
FRONT BUMPER BRACKET FRONT SIDE FRAME
REMOVAL (PARTIAL CUTTING) REMOVAL
[PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–2 [PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–24
FRONT BUMPER BRACKET RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-80B–24
INSTALLATION LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-80B–25
[PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–3 FRONT SIDE FRAME
TIEDOWN REINFORCEMENT (PARTIAL CUTTING) INSTALLATION
REMOVAL [PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–26
[PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–4 RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-80B–26 09-80B
TIEDOWN REINFORCEMENT LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-80B–30
INSTALLATION FRONT FRAME (REAR) REMOVAL
SHROUD UPPER PANEL REMOVAL FRONT FRAME (REAR)
[PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–6 INSTALLATION
SHROUD UPPER PANEL [PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–36
INSTALLATION FRONT PILLAR REMOVAL
COWL SIDE REINFORCEMENT FRONT PILLAR INSTALLATION
[PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–8 CENTER PILLAR REMOVAL
COWL SIDE REINFORCEMENT [PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–46
INSTALLATION CENTER PILLAR INSTALLATION
WIPER BRACKET COMPONENT SIDE SILL PANEL REMOVAL
[PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–10 SIDE SILL PANEL INSTALLATION
WIPER BRACKET COMPONENT [PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–54
INSTALLATION REAR FENDER PANEL REMOVAL
APRON REINFORCEMENT REAR FENDER PANEL
(UPPER) REMOVAL INSTALLATION
APRON REINFORCEMENT REAR END PANEL REMOVAL
(UPPER) INSTALLATION [PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–60
[PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–13 REAR END PANEL INSTALLATION
APRON REINFORCEMENT [PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–61
(LOWER) REMOVAL REAR PILLAR (OUTER) REMOVAL
APRON REINFORCEMENT REAR PILLAR (OUTER)
(LOWER) INSTALLATION INSTALLATION
WHEEL APRON PANEL CROSSMEMBER NO.8 REMOVAL
(FRONT) REMOVAL [PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–64
[PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–16 CROSSMEMBER NO.8 INSTALLATION
WHEEL APRON PANEL [PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–65
(FRONT) INSTALLATION FLOOR SIDE PANEL REMOVAL
WHEEL APRON COMPONENT FLOOR SIDE PANEL INSTALLATION
[PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–18 REAR FLOOR PAN REMOVAL
WHEEL APRON COMPONENT [PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–68
INSTALLATION REAR FLOOR PAN INSTALLATION
FRONT SIDE FRAME COMPONENT REAR SIDE FRAME REMOVAL
[PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–20 REAR SIDE FRAME INSTALLATION
FRONT SIDE FRAME COMPONENT [PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–72
INSTALLATION ROOF PANEL REMOVAL
ROOF PANEL INSTALLATION
[PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–74
End of Toc
09-80B–1

FRONT BUMPER BRACKET REMOVAL [PANEL REPLACEMENT]
BM: BUMPER BRACKET
id098008743100
1. Remove the front bumper bracket.
FRONT BUMPER BRACKET
BOLT
ac9uub00000083
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
BOLT
ac9uub00000084
End Of Sie
09-80B–3

TIEDOWN REINFORCEMENT REMOVAL [PANEL REPLACEMENT]
id098008800200
1. Remove the tiedown reinforcement.
TIEDOWN REINFORCEMENT
2
am8rrb00000018
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
2
am8rrb00000019
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
ac9uub00000081
End Of Sie
09-80B–6

SHROUD UPPER PANEL INSTALLATION [PANEL REPLACEMENT]
id098008800500
09-80B
SHROUD UPPER PANEL
(A)3
SHROUD SIDE PANEL
ac9uub00000082
End Of Sie
BM: COWL SIDE REINFORCEMENT
09-80B–7

COWL SIDE REINFORCEMENT REMOVAL [PANEL REPLACEMENT]
id098008741700
1. Remove the cowl side reinforcement.
2
6
COWL SIDE REINFORCEMENT
12
ac9uub00000044
End Of Sie
09-80B–8

COWL SIDE REINFORCEMENT INSTALLATION [PANEL REPLACEMENT]
id098008741800
09-80B
2
6
12
ac9uub00000045
End Of Sie
BM: WIPER BRACKET
09-80B–9

WIPER BRACKET COMPONENT REMOVAL [PANEL REPLACEMENT]
id098008750000
1. Remove the wiper bracket component.
1
3
1
WIPER BRACKET
1
3
ac9uub00000042
End Of Sie
09-80B–10

WIPER BRACKET COMPONENT INSTALLATION [PANEL REPLACEMENT]
id098008750100
09-80B
1
3
1
WIPER BRACKET
1
3
ac9uub00000043
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).
LH:5
RH:6
APRON REINFORCEMENT (UPPER)
(A)1
3
3
1 4
APRON REINFORCEMENT
(UPPER)
ac9uub00000028
End Of Sie
09-80B–12

APRON REINFORCEMENT (UPPER) INSTALLATION [PANEL REPLACEMENT]
id098008800100
LH:5
RH:6 09-80B
APRON REINFORCEMENT (UPPER)
3
3
1 4
APRON REINFORCEMENT
(UPPER)
ac9uub00000029
End Of Sie
09-80B–13

APRON REINFORCEMENT (LOWER) REMOVAL [PANEL REPLACEMENT]
id098008741300
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 (lower).
APRON REINFORCEMENT (LOWER)
3
4
7
(A)1
3
ac9uub00000030
End Of Sie
09-80B–14

APRON REINFORCEMENT (LOWER) INSTALLATION [PANEL REPLACEMENT]
id098008741400
09-80B
3
2
APRON REINFORCEMENT (LOWER)
3
4
7
1
3
ac9uub00000031
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)
10
ac9uub00000085
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)6
WHEEL APRON PANEL

(FRONT, LH)
(A)4
(A)5
12
ENGINE MOUNT 5
BRACKET
10
ac9uub00000086
End Of Sie
09-80B–17

WHEEL APRON COMPONENT REMOVAL [PANEL REPLACEMENT]
id098008746000
1. Remove the wheel apron component.
WHEEL APRON COMPONENT
RH : 23
LH : 19 RH : 1
LH : 2
RH : 2
LH : 3
RH : 7
LH : 3
ac9uub00000087
End Of Sie
09-80B–18

WHEEL APRON COMPONENT INSTALLATION [PANEL REPLACEMENT]
id098008746100
09-80B
RH : 23
LH : 19 RH : 1
LH : 2
RH : 2
LH : 3
RH : 7
LH : 3
ac9uub00000088
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 21 locations indicated by (B).
A-A
FRONT SIDE FRAME COMPONENT
A
(B)2
(B)9
A
(A)ROUGH CUT
LOCATION (B)4
ac9uub00000091
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
am8rrb00000035
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
am8rrb00000036
09-80B–22

6. Weld the remaining weld locations and install the front side frame component.
2 09-80B
ac9uub00000092
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 19 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)8
{1.18in}
(B)3
FRONT SIDE FRAME (INNER, RH)
85mm
{3.35in}
(A) ROUGH CUT AND

ac9uub00000093
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 19 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)8
FRONT SIDE FRAME (INNER, LH)
(B)3
105mm
{4.13in}
(A) ROUGH CUT AND

ac9uub00000094
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.
09-80B–26

6. Install the front side frame (inner).
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
{2.76in}
85mm
{3.35in}
FRONT SIDE FRAME (INNER, RH)
CUT-AND-JOIN
LOCATION
am8rrb00000040
7. Install the suspension mount reinforcement.
09-80B–27

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

2
SUSPENSION MOUNT BOLT
L=20mm
{0.79in}
am8rrb00000099
09-80B–28

9. 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.
11. 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, RH)
L=70mm 8
{2.76in} 30mm
{1.18in}
3
(A)5
ac9uub00000095
09-80B–29

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.
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.
09-80B–30

6. Install the front side frame (inner).
25mm
{0.98in}
L=30mm x 2
100mm {3.94in}
{1.18in}
t=2.3mm
{0.09in}
09-80B
EXTRUSION
BEAD
EXTRUSION
BEAD
REINFORCEMENT
L=70mm x 2
{2.76in}
FRONT SIDE FRAME (INNER, LH)
105mm
{4.13in}
CUT-AND-JOIN
LOCATION
am8rrb00000043
7. Install the suspension mount reinforcement.
09-80B–31

8. Install the suspension mount bolt.
Tightening torque
1.0—5.0 N·m {11—50 kgf·cm, 8.9—44 in·lbf}
L=15mm
{0.59in}
SUSPENSION MOUNT REINFORCEMENT 2
SUSPENSION MOUNT BOLT
L=20mm
{0.79in}
am8rrb00000100
09-80B–32

9. Because the front side frame (outer) cannot be welded to the existing parts from the inside of the panel, drill 5
Caution
11. 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}
8 L=70mm
3 {2.76in}
(A)5
ac9uub00000096
End Of Sie
BM: FRONT FRAME REAR
09-80B–33

FRONT FRAME (REAR) REMOVAL [PANEL REPLACEMENT]
id098008742500
1. Drill the 36 locations indicated by (A), then remove the torque box.
(A)3
(A)8
(A)3
(A)3
TORQUE BOX
(A)7
(A)5
(A)3
TORQUE BOX
(A)2
(A)2
am8rrb00000101
2. Drill the 10 locations indicated by (B) from the interior.
09-80B–34

3. Drill the remaining locations, then remove the front frame rear component.
FRONT FRAME REAR

COMPONENT
(B)4
09-80B
(B)6
7 4
7
4
4
8
FRONT FRAME REAR

COMPONENT
am8rrb00000102
End Of Sie
09-80B–35

FRONT FRAME (REAR) INSTALLATION [PANEL REPLACEMENT]
id098008742600
3. Install the front frame rear component.
FRONT FRAME REAR

COMPONENT
7 4
7
4
4
8
FRONT FRAME REAR

COMPONENT
am8rrb00000103
09-80B–36

5. Install the torque box.
09-80B
TORQUE BOX
3
TORQUE BOX
2
2
am8rrb00000104
End Of Sie
BM: FRONT PILLAR
09-80B–37

FRONT PILLAR REMOVAL [PANEL REPLACEMENT]
id098008744700
1. Rough cut area (A), drill the 90 locations indicated by (B), then remove the front pillar (outer).
2. Drill the 2 locations indicated by (C) from the interior.
Caution
• Avoid cutting with a blow torch or similar tools as the insulator (shaded area) is flammable.
FRONT PILLAR (OUTER)

90 mm {3.54 in}
30 mm {1.18 in}
FRONT PILLAR
(INNER)
(C)2 CUT-AND-JOIN
A LOCATION
(A)ROUHGT CUT
A
(B)14 LOCATION
(B)7
A-A
ac9uub00000046
09-80B–38

3. Chisel is Inserted from the connector hole, it moves in the direction of the arrow, and the insulator is separated
as shown in the figure.
Note
• Chisel is inserted because the laser welding is given as for the arrow part of the figure below and the
welding is separated.
09-80B
INSULATOR
(B)2
CHISEL
(B)33
(B)6
30 mm {1.18 in}
(B)2
20 mm {0.79 in}
INSULATOR
(B)26 CUT-AND-JOIN
LOCATION
(A)ROUHGT CUT
LOCATION
ac9uub00000047
4. Rough cut area (D).
Caution
5. Drill the 3 locations indicated by (E) from the interior.
09-80B–39

6. Remove the front pillar reinforcement.
A-A
130 mm {5.12 in}

20 mm {0.79 in}
INSULATOR
A
B-B
CUT-AND-JOIN
(D)ROUHGT CUT LOCATION
LOCATION
FRONT PILLAR
(INNER)
(E)3
30 mm {1.18 in}
40 mm {1.57 in}
B
CUT-AND-JOIN
LOCATION
(D)ROUHGT CUT
LOCATION
ac9uub00000048
7. Rough cut area (F), drill the 21 locations indicated by (G), and then remove the front pillar (inner).
8. Drill the 1 locations indicated by (H) from the interior.
09-80B–40

9. Remove the spot weld sealer using a disc grinder.
160 mm {6.30 in}
20 mm {0.79 in}
FRONT PILLAR
(INNER)
CUT-AND-JOIN 09-80B
LOCATION
(F)ROUHGT CUT
LOCATION
(G)5
FRONT PILLAR
(INNER)
(G)2 (H)1
(G)11
(G)3
ac9uub00000049
End Of Sie
09-80B–41

FRONT PILLAR INSTALLATION [PANEL REPLACEMENT]
id098008744800
1. Make a reinforcement panel using the material from the front pillar (inner).
4. Apply body sealer to the joints of old and new parts for waterproofing and rust protection.
and existing parts.
Caution
6. Weld the 14 locations indicated by (A) and install the front pillar (inner).
7. Weld the 1 location indicated by (B) from the interior.
160 mm {6.30 in}
FRONT PILLAR
(INNER)
CUT-AND-JOIN
LOCATION
FRONT PILLAR
(INNER)
(B)1
(A)11
(A)3
ac9uub00000050
8. Weld the 3 locations indicated by (C) from the interior.

9. Make a reinforcement panel using the material from the front pillar reinforcement.
10. Because the front pillar reinforcement cannot be welded to the existing parts from the inside of the panel, drill 6
Caution
09-80B–42

11. Install the front pillar reinforcement.
50mm
{1.97in}
80mm {3.15in}
t=1.2mm
{0.05in} 130 mm {5.12 in}
09-80B
REINFORCEMENT
CUT-AND-JOIN
LOCATION
HINGE PILLAR
(INNER)
(C)3
70 mm {2.76 in}
L=60mm
{2.36in}
CUT-AND-JOIN
(D)3
LOCATION
ac9uub00000051
09-80B–43

13. Weld the 96 locations indicated by (E) and install the front pillar (outer).
Note
• Spot weld sealer is spread on the arrow part of the figure.
(E)2
(E)36
(E)6
50 mm {1.97 in}
(E)2
(E)27 CUT-AND-JOIN
LOCATION
ac9uub00000052
09-80B–44

90 mm {3.54 in}
FRONT PILLAR
(INNER) 09-80B
(E)2
(E)14
(E)7
ac9uub00000053
End Of Sie
BM: CENTER PILLAR
09-80B–45

CENTER PILLAR REMOVAL [PANEL REPLACEMENT]
id098008743900
1. Rough cut area (A), drill the 89 locations indicated by (B), then remove the center pillar (outer).
Note
• The damage of the remaining parts is noted, center pillar (outer) is moved in the direction of the arrow of
the figure below, and the insulator is separated.
90 mm {3.54 in}
CUT-AND-JOIN
LOCATION
30 mm {1.18 in}
(A)ROUHGT CUT
LOCATION
CENTER PILLAR CENTER PILLAR (OUTER)

(OUTER) (B)2
(B)33 (B)35
(B)2
120 mm {4.72 in} 120 mm {4.72 in}
30 mm {1.18 in} 30 mm {1.18 in}
(A)ROUHGT CUT (B)17

CUT-AND-JOIN
LOCATION
LOCATION
CUT-AND-JOIN (A)ROUHGT CUT

LOCATION LOCATION
ac9uub00000054
2. Rough cut area (C), drill the 4 locations indicated by (D).
Caution
09-80B–46

3. Remove the center pillar inner reinforcement.
A-A
B-B C-C
09-80B
130 mm {5.12 in}

CUT-AND-JOIN
LOCATION
30 mm {1.18 in}
(C)ROUHGT CUT
LOCATION
A A
CENTER PILLAR REINFORCEMENT
SIDE SILL REINFORCEMENT

20 mm {0.79 in}
20 mm {0.79 in}
50 mm {1.97 in}
30 mm {1.18 in}
C
B (D)2 (D)2
B C
(C)ROUHGT CUT
LOCATION CUT-AND-JOIN
LOCATION
CUT-AND-JOIN (C)ROUHGT CUT
LOCATION LOCATION
ac9uub00000055
4. Rough cut area (E), drill the 2 locations indicated by (F).

5. Drill the 2 locations indicated by (G) from the interior.
09-80B–47

6. Remove the center pillar inner reinforcement.
170 mm {6.69 in}
CUT-AND-JOIN
LOCATION
30 mm {1.18 in}
(E)ROUHGT CUT
LOCATION
CENTER PILLAR (INNER)

CENTER PILLAR
(INNER)
(G)2
(F)1 (F)1
ac9uub00000056
End Of Sie
09-80B–48

CENTER PILLAR INSTALLATION [PANEL REPLACEMENT]
id098008744000
1. 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
09-80B
4. Weld the 2 locations indicated by (A) from the interior.
5. Install the center pillar (inner).
170 mm {6.69 in}
CUT-AND-JOIN
LOCATION
CENTER PILLAR (INNER) CENTER PILLAR (INNER)
(A)2
1 1
ac9uub00000057
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–49

8. Weld the remaining weld locations, then install the center pillar reinforcement.
130 mm {5.12 in}
50mm CUT-AND-JOIN
{1.97in}
LOCATION
80mm {3.15in}
t=1.2mm
{0.05in}
CENTER PILLAR REINFORCEMENT
REINFORCEMENT
70 mm {2.76 in}
50 mm {1.97 in}
(A)3
(A)3
2 2
L=60mm L=60mm
{2.36in} {2.36in}
CUT-AND-JOIN
LOCATION
ac9uub00000058
Note
09-80B–50

10. Install the center pillar (outer).
90 mm {3.54 in}
CUT-AND-JOIN
LOCATION
09-80B
(A)2
(A)35 (A)37
(A)2
150 mm {5.91 in} 150 mm {5.91 in}
(A)19
CUT-AND-JOIN
LOCATION
CUT-AND-JOIN
LOCATION
ac9uub00000059
End Of Sie
BM: SIDE SILL PANEL
09-80B–51

SIDE SILL PANEL REMOVAL [PANEL REPLACEMENT]
id098008743700
1. Rough cut area (A), drill the 129 locations indicated by (B), and then remove the side sill (outer).
Note
A-A B-B C-C
158 mm
CUT-AND-JOIN
{6.22 in}
LOCATION (A)ROUHGT CUT
(A)ROUHGT CUT LOCATION
215 mm LOCATION 30 mm
{8.46 in} C
{1.18 in}
(B)38 A A (B)35 C 345 mm
A A CUT-AND-JOIN
30 mm {13.58 in}
{1.16 in} 2 LOCATION
2 (A)ROUHGT CUT
LOCATION
SIDE SILL (OUTER) (B)50

30 mm
{1.18 in}
(B)4
(B)2
ac9uub00000060
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 3 locations indicated by (D) from the interior.
09-80B–52

4. Remove the side sill reinforcement.
HINGE PILLAR
(INNER)
(D)3
09-80B
CUT-AND-JOIN
LOCATION
CUT-AND-JOIN 30 mm (C)ROUHGT CUT
LOCATION {1.18 in} LOCATION
30 mm (A)ROUHGT CUT
{1.18 in} LOCATION
106 mm
{4.17 in} SIDE SILL REINFORCEMENT
70 mm
{2.76 in}
ac9uub00000061
End Of Sie
09-80B–53

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 6
Caution
5. Weld the 3 locations indicated by (B) from the interior.

6. Install the side sill reinforcement.
50mm
{1.97in}
HINGE PILLAR
(INNER)
70mm {2.76in}
(B)3
t=1.6mm
{0.06in}
REINFORCEMENT
CUT-AND-JOIN
(A)3 (A)3 LOCATION
CUT-AND-JOIN
LOCATION
L=10mm x 2
{0.39in} SIDE SILL REINFORCEMENT
L=10mm x 2
{0.39in}
ac9uub00000062
09-80B–54

8. Install the side sill (outer).
Note
CUT-AND-JOIN
LOCATION
09-80B
40 37
1
CUT-AND-JOIN
2 LOCATION
2
SIDE SILL (OUTER) 52
ac9uub00000063
End Of Sie
BM: REAR FENDER PANEL
09-80B–55

REAR FENDER PANEL REMOVAL [PANEL REPLACEMENT]
id098008744900
1. Rough cut area (A), drill the LH:103,RH:104 locations indicated by (B).
Caution
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.
Note
3. Remove the rear fender panel.
09-80B–56

(B)10
09-80B
A-A B-B C-C
(A)ROUHGT CUT
CUT-AND-JOIN
LOCATION
LOCATION
30 mm 86 mm
{1.18 in} {3.39 in}
CUT-AND-JOIN
LOCATION
A A (B)12 B B REAR FENDER PANEL
(A)ROUHGT CUT
LOCATION
(B)32
(B)7 (B)1
30 mm
{1.18 in}
C
(B)8
260 mm
{10.24 in}
C (B)3
(A)ROUHGT CUT
LOCATION
CUT-AND-JOIN
LOCATION (B)10
(B)12
(B)RH:7
LH:6
(B)2
ac9uub00000064
09-80B–57

End
REAROfFENDER
Sie PANEL INSTALLATION [PANEL REPLACEMENT]
id098008745000
3. Before installing new parts, apply spot weld sealer to the tire arch line.
Note
09-80B–58

5. Install the rear fender panel.
11
09-80B
CUT-AND-JOIN
LOCATION
CUT-AND-JOIN
LOCATION REAR FENDER PANEL
13
34
CUT-AND-JOIN
LOCATION 10
12
RH:7
LH:6
ac9uub00000065
09-80B–59

End
REAROfEND
Sie PANEL REMOVAL [PANEL REPLACEMENT]
id098008744500
1. Drill the 96 locations indicated by (A).
2. Remove the rear end panel component.
LH RH
(A)9
(A)9
(A)3 (A)3
(A)1 (A)1
REAR END PANEL
(A)12 (A)17 (A)11
(A)4
(A)26
ac9uub00000066
End Of Sie
09-80B–60

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.
LH RH
9 9 09-80B
3 3
1 1
REAR END PANEL
12 17 11
26
ac9uub00000067
End Of Sie
BM: REAR PILLAR OUTER
09-80B–61

REAR PILLAR (OUTER) REMOVAL [PANEL REPLACEMENT]
id098008747200
1. Rough cut area (A), drill the 18 locations indicated by (B).
Note
• When removing the rear pillar (outer) and the corner plate separately, drill the 5 locations indicated by (C).
Caution
60 mm CUT-AND-JOIN
{2.36 in} LOCATION
30 mm (A)ROUHGT CUT
{1.18 in} LOCATION
REAR PILLAR
(OUTER)
(B)18
(C)5
CORNER PLATE
ac9uub00000068
End Of Sie
09-80B–62

REAR PILLAR (OUTER) INSTALLATION [PANEL REPLACEMENT]
id098008747300
CUT-AND-JOIN 09-80B
REAR PILLAR (OUTER)
LOCATION
19
CORNER PLATE
ac9uub00000069
End Of Sie
BM: CROSSMEMBER No.8
09-80B–63

CROSSMEMBER NO.8 REMOVAL [PANEL REPLACEMENT]
id098008618500
Caution
• It is noted to damage floor side panel when crossmember no.8 is detached and not to transform it.
2. Remove the crossmember no.8.
(A)11
(A)3
(A)3
(A)4
CROSSMEMBER No.8 FLOOR SIDE PANEL (RH)

FLOOR SIDE PANEL (LH)
ac9uub00000070
End Of Sie
09-80B–64

CROSSMEMBER NO.8 INSTALLATION [PANEL REPLACEMENT]
id098008618600
09-80B
11
3
4
FLOOR SIDE PANEL (LH) CROSSMEMBER No.8 FLOOR SIDE PANEL (RH)
ac9uub00000071
End Of Sie
BM: FLOOR SIDE PANEL
09-80B–65

FLOOR SIDE PANEL REMOVAL [PANEL REPLACEMENT]
id098008618700
1. Remove the floor side panel.
6
10
8 6
1
FLOOR SIDE PANEL (RH)
ac9uub00000072
09-80B–66

End Of Sie
FLOOR SIDE PANEL INSTALLATION [PANEL REPLACEMENT]
id098008618800
09-80B
6
10
8 6
1
FLOOR SIDE PANEL (RH)
ac9uub00000089
09-80B–67

End
REAROfFLOOR
Sie PAN REMOVAL [PANEL REPLACEMENT]
id098008742700
2. Remove the rear floor pan.
(A)16
(A)8
(A)8
(A)18
(A)2 (A)2
(A)12 (A)5
(A)4
(A)11
(A)3 (A)3
REAR FLOOR PAN
ac9uub00000074
End Of Sie
09-80B–68

REAR FLOOR PAN INSTALLATION [PANEL REPLACEMENT]
id098008742800
3. Install the crossmember no.9.
2
09-80B
CROSSMEMBER No9
ac9uub00000080
09-80B–69

16
8
8
18
2
2
12 5
4
11
3
3
REAR FLOOR PAN 18
ac9uub00000075
End Of Sie
BM: REAR SIDE FRAME
09-80B–70

REAR SIDE FRAME REMOVAL [PANEL REPLACEMENT]
id098008801200
1. Remove the rear side frame.
2 09-80B
4
2
6
REAR SIDE FRAME
REAR SIDE FRAME
ac9uub00000076
End Of Sie
09-80B–71

REAR SIDE FRAME INSTALLATION [PANEL REPLACEMENT]
id098008801300
4
2
6
REAR SIDE FRAME
REAR SIDE FRAME
ac9uub00000090
End Of Sie
BM: ROOF PANEL
09-80B–72

ROOF PANEL REMOVAL [PANEL REPLACEMENT]
id098008744300
2. Remove the roof panel.
09-80B
(A)2
(A)33
(A)23
(A)21
ROOF PANEL
(A)33
(A)2
ac9uub00000078
End Of Sie
09-80B–73

ROOF PANEL INSTALLATION [PANEL REPLACEMENT]
id098008744400
2
33
23
21
ROOF PANEL
33
ac9uub00000079
End Of Sie
09-80B–74
3424-1U-06H(09-80C).fm 1 ページ２００６年１２月１９日　火曜日　午後３時２２分
BODY STRUCTURE [WATER-PROOF AND RUST PREVENTIVE]

09-80C BODY STRUCTURE [WATER-PROOF AND RUST
PREVENTIVE]
BODY SEALING RUST PREVENTIVE TREATMENT
[WATER-PROOF AND [WATER-PROOF AND
RUST PREVENTIVE] . . . . . . . . . . . . . . 09-80C–2 RUST PREVENTIVE] . . . . . . . . . . . . . . . 09-80C–6
UNDER COATING DUMPING SHEET REPLACEMENT
[WATER-PROOF AND [WATER-PROOF AND
RUST PREVENTIVE] . . . . . . . . . . . . . . 09-80C–5 RUST PREVENTIVE] . . . . . . . . . . . . . . . 09-80C–7
End of Toc
BM: WATER-PROOF AND RUST PREVENTIVE
09-80C
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 bonnet panel
to provide water proofing and rust proofing.
B
A
A-A B-B
ac9uub00000020
09-80C–2
09-80C
ac9uub00000021
09-80C–3
ac9uub00000022
End Of Sie
09-80C–4

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
RH
09-80C
ac9uub00000023
09-80C–5

RUST PREVENTIVE TREATMENT [WATER-PROOF AND RUST PREVENTIVE]
id098009740100
ac9uub00000024
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
ac9uub00000025
End Of Sie
09-80C–7
3424-1U-06H(09-80D).fm 1 ページ２００６年１２月１９日　火曜日　午後３時２４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–8
UNDERBODY STRAIGHT-LINE ROOM STRAIGHT-LINE
DIMENSIONS [DIMENSIONS] . . . . . . . 09-80D–3 DIMENSIONS (1) [DIMENSIONS] . . . . . 09-80D–10
FRONT BODY STRAIGHT-LINE ROOM STRAIGHT-LINE
DIMENSIONS (1) [DIMENSIONS]. . . . . 09-80D–4 DIMENSIONS (2) [DIMENSIONS] . . . . . 09-80D–12
FRONT BODY STRAIGHT-LINE ROOM STRAIGHT-LINE
FRONT BODY STRAIGHT-LINE REAR BODY STRAIGHT-LINE
End of Toc
09-80D
BM: UNDERBODY
09-80D–1

UNDERBODY FLAT-PLANE DIMENSIONS [DIMENSIONS]
id098010740400
• The following figures are bottom and side views.
1,066 {41.97}
1,040 {40.94}
1,010 {39.76}
1,000 {39.37}
949 {37.36}
844 {33.23}
840 {33.07}
988 {38.90}
933 {36.73}
976 {38.43}
LH
{24.02}
610
RH
A B C D E F G H I J K
666 {26.22}
689 {27.13}
RH:538 {21.18}
LH:537 {21.14}
562 {22.13}
691 {27.20}
515 {20.28}
561 {22.09}
486 {19.13}
423 {17.44}
467 {18.39}
453 {17.83}
631 RH:940 {37.01} 673 788

{24.84} LH:910 {35.83} {26.50} {31.02}
157 296 359 RH:175 {6.89} 375
{6.18} {11.65} {14.13} LH:205 {8.07} {14.76}
56
mm {in}
{2.20}
ac9uub00000003

Point Point
symbol symbol
A Front side frame datum hole φ14 {0.55} RH:φ14 {0.55}
G Front B frame datum hole
Front suspension mounting LH:φ10 {0.39}
B M14 {0.55}
bolt H Rear side frame datum hole φ16 {0.63}
Front suspension mounting Rear suspension mounting
C M14 {0.55} I M14 {0.55}
bolt bolt
Front suspension mounting Rear suspension installation
D M14 {0.55} J φ12 {0.47}
bolt hole
E Torque box datum hole φ16.5 {0.65} K Rear side frame datum hole φ14 {0.55}
F Front B frame datum hole φ16.2 {0.64}
09-80D–2

End Of Sie STRAIGHT-LINE DIMENSIONS [DIMENSIONS]
UNDERBODY
id098010740500
• The following figure is a bottom view.
236 RH:178 {7.01}

{9.29} RH:1,554 {61.18}
LH:1,581 {62.24} LH:208 {8.19}
677 I' 1,180 K'
A' B' 366 G' H'
634 C' 359 F' RH:945 {37.20} {26.65} {46.46}
E'
{14.41} {14.13} RH:1,298 {51.10}
{24.96} LH:915 {36.02}
835 LH:1,315 {51.77}
1,150 D' 835 RH:2,255 {88.78}
{32.87}
{45.28} {32.87} LH:2,281 {89.80}
RH:992 {39.06}
LH
1,010 730
1,226 {28.74} 916 LH:995 {39.17}
{39.76} {48.27}
1,245 {36.06}
RH
960 RH:1,278 {50.31} 1,450 1,572 2,110

{49.02} 1,212
{37.80} LH:1,301 {51.22} {57.09} {61.89} {83.07}
{47.72}
D
C E F 09-80D
A 357 132 G H I K
B {14.06} {5.20} RH:2,018 {79.45}
1,519
{59.80} LH:2,048 {80.63}
mm {in}
ac9uub00000001
A,B C D,E D F G,H
B H
G
A E
I K
ac9uub00000002

Point Point
symbol symbol
A Front side frame datum hole φ14 {0.55} F Front B frame datum hole φ16.2 {0.64}
Front suspension mounting RH:φ14 {0.55}
B M14 {0.55} G Front B frame datum hole
bolt LH:φ10 {0.39}
Front suspension mounting H Rear side frame datum hole φ16 {0.63}
C M14 {0.55}
bolt Rear suspension mounting
I M14 {0.55}
Front suspension mounting bolt
D M14 {0.55}
bolt K Rear side frame datum hole φ14 {0.55}
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
A A'
1,225
{48.23}
796 1,620
{31.34} {63.78}
B B'
1,626
{64.02}
C C'
1,464
RH:1,248 {49.13} {57.64}
322 {12.68} LH:1,247 {49.09} RH:491 {19.33}
D D' LH:490 {19.29}
993
RH:181 {7.13} {39.09}
939 {36.97}
LH:180 {7.09}
855
E {33.66} E'
mm {in}
ac9uub00000004
A B C D,E
ampjjb00000006

Point Point
symbol symbol
A Roof seamless location - 10 × 14
D Shroud side panel datum slot
B Front pillar projection location - {0.39 × 0.55}
C Shroud side stay datum hole φ7 {0.28} 10 × 14
E Bumper bracket datum slot
{0.39 ×0.55}
End Of Sie
09-80D–4

FRONT BODY STRAIGHT-LINE DIMENSIONS (2) [DIMENSIONS]
id098010740700
1,508
119 {4.69} {59.37} 1,495
A 1,349
1,474 {58.86}
{53.11}
{58.03} A' 09-80D
497
{19.57} C
D
426
B 1,187 {46.73}
{16.77} 174
1,319 {51.93} {6.85}
1,314 {51.73} C'
1,493 B'
{58.78}
D'
1,264 882
{49.76} 474 {34.72}
{18.66}
1,588
E {62.52}
1,044
{41.10}
E'
mm {in}
ac9uub00000005
A B,C D E
C
ac9uub00000006

Point Point
symbol symbol
A Hood hinge installation hole φ14 {0.55} D Front fender installation hole φ7 {0.28}
Front suspension housing Bumper reinforcement
B φ11 {0.43} E φ14 {0.55}
(upper) datum hole installation hole
Apron reinforcement (upper) 12 × 18
C
datum slot {0.47 × 0.71}
09-80D–5

End Of BODY
FRONT Sie STRAIGHT-LINE DIMENSIONS (3) [DIMENSIONS]
id098010740800
B 536
C {21.10}
540 523
{21.26} A {20.59}
A' B'
708 527
D
{27.87} {20.75} C'
701
964 {27.60}
642 {37.95}
{25.28} D'
1,266
{49.84}
F 952
954 {37.48}
{37.56}
E 1,155
{45.47}
E'
mm {in}
ac9uub00000007
A B C D E
ac9uub00000008
09-80D–6

Point Point
symbol symbol
Dash upper menber datum D Front fender installation hole φ7 {0.28}
A φ10 {0.39}
hole Front side frame (inner) datum
E φ14 {0.55}
B Hood hinge installation hole φ14 {0.55} hole
Apron reinforcement (upper) 12 × 18 Wheel apron panel (front)
C F φ16 {0.63}
datum slot {0.47 × 0.71} datum hole
End Of Sie
BM: CABIN SIDE FRAME
09-80D
09-80D–7

CABIN SIDE FRAME STRAIGHT-LINE DIMENSIONS [DIMENSIONS]
id098010743600
E H J
1,153 1,395 979

{45.39} {54.92} {38.54}
F
1,163 1,881
B L
{74.06} 1,956
1,148 {45.79} 1,233
1,202 {48.54} K {77.01}
{45.20}
{47.32}
1,097 1,057
A 1,162 G
{43.19} {41.61}
{45.75} C
D I
mm {in}
ac9uub00000009
E H 825 J
{32.48}
1,050
{41.34}
1,372 1,127
1,389 {54.02} F {44.37}
{54.69} L
2,521 B 1,324
600 K
{99.25} 917 {52.13}
660 {36.10} {23.62}
{25.98}
A G
C
D I
mm {in}
ac9uub00000010
09-80D–8
A B C D E,H
E H
F G I J K
09-80D
ac9uub00000011

Point Point
symbol symbol
Front side frame (outer) datum 12 x 18 Rear door hinge installation
A G φ12 {0.47}
slot {0.47 x 0.71} hole
Front door hinge installation Side frame (outer) projection
B φ12 {0.47} H -
hole location
Front door hinge installation I Side frame (outer) notch -
C φ12 {0.47}
hole J Side frame (outer) datum hole φ8 {0.31}
D Side frame (outer) notch - Rear door switch installation
K φ4.5 {0.18}
Side frame (outer) projection hole
E -
location 9x9
L Side frame (outer) square hole
Rear door hinge installation {0.35 x 0.35}
F φ12 {0.47}
hole
End Of Sie
BM: ROOM
09-80D–9

ROOM STRAIGHT-LINE DIMENSIONS (1) [DIMENSIONS]
id098010743300
A
F
B
1,221
{48.07}
G
1,278
{50.31}
C
1,203
{47.36}
1,192
{46.93} I-I'
1,045
{41.14}
D
1,646
{64.80}
1,018
{40.08} H
708
{27.87}
E
E'
mm {in}
ac9uub00000012
A B C D E
F G H I
ac9uub00000013
09-80D–10

Point Point
symbol symbol
Curtain air bag installation 12 x 18
A φ7 {0.28} F Center pillar (inner) datum slot
hole {0.47 x 0.71}
B Front pillar (inner) datum hole φ7 {0.28} G B pillar trim installation hole φ10.2{0.40}
C Hinge pillar (inner) datum hole φ10 {0.39} Center pillar (inner) datum
H φ7 {0.28}
D Front side trim installation hole φ8.6 {0.34} hole
Checker bracket installation
E
Heater bracket installation
φ11 {0.43} I φ10 {0.39}
hole hole
End Of Sie
09-80D
09-80D–11

id098010743400
A 1,246
{49.06}
B
1,238
{48.74}
H-H'
1,108
{43.62}
1,120 G
{44.09}
762
{30.00}
1,045
{41.14}
1,664
{65.51}
D
D'
mm {in}
ac9uub00000014
09-80D–12
A B C D E
F G H
09-80D
ac9uub00000015

Point Point
symbol symbol
12 x 18 E C pillar trim installation hole φ7{0.28}
A Center pillar (inner) datum slot
{0.47 x 0.71} F C pillar trim installation hole φ8.6 {0.34}
B B pillar trim installation hole φ10.2 {0.40} 7 x 10
G Rear pillar (inner) datum slot
Center pillar (inner) datum {0.28 x 0.39}
C φ7{0.28}
hole Front door striker installation
H φ13 {0.51}
D Seat installation hole φ16 {0.63} hole
End Of Sie
09-80D–13

id098010746200
E
A
F
1,268
{49.92} 1,088
{42.83}
960
{37.80}
H-H'
1,066 G
{41.97}
1,667 678
{65.63} {26.69}
C
1,052
{41.42}
D
mm {in}
ac9uub00000016
A B C D E
F G H
ac9uub00000017

Point Point
symbol symbol
A C pillar trim installation hole φ7 {0.28} E Rear speaker installation hole φ6.8 {0.27}
B C pillar trim installation hole φ8.6 {0.34} F Rear pillar (inner) datum hole φ6 {0.24}
7 x 10 Trunk end trim installation 8 x 28
C Rear pillar (inner) datum slot G
{0.28 x 0.39} square hole {0.31 x 1.10}
D Seat installation hole φ14 {0.55} Rear door striker installation
H φ13 {0.51}
hole
09-80D–14

End
REAROfBODY
Sie STRAIGHT-LINE DIMENSIONS (1) [DIMENSIONS]
id098010746300
A' A
735
{28.94}
213 925
{8.39} {36.42}
1,104 B
B'
{43.46}
966
{38.03} 1,067
{42.01} 1,455
{57.28} 1,342
1,406
808 1,330 {52.83} 09-80D
{55.35}
{31.81} {52.36}
638
{25.12}
1,550 C
C' {61.02}
1,503 204
{59.17} {8.03}
1,430 D
D' {56.30}
500
{19.69} 1,256
{49.45} 410 {16.14}
E
E' 858
{33.78}
1,270 {50.00}
1,010
{39.76} F
F'
mm {in}
ac9uub00000018
A,B A C D E F
F'
ac9uub00000019

Point Point
symbol symbol
A Liftgate hinge installation hole φ12 {0.47} Trunk end trim installation 8 x 28
E
B Stay damper installation hole φ7 {0.28} square hole {0.31 x 1.10}
C Corner plate datum hole φ8.5 {0.33} F Rear end panel datum hole φ12
Rear bumper installation 9x9 12 x 18
D F’ Rear end panel datum slot
square hole {0.35 x 0.35} {0.47 x 0.71}
09-80D–15
3424-1U-06H(09-80E).fm 1 ページ２００６年１２月１９日　火曜日　午後３時２６分
BODY STRUCTURE [PLASTIC BODY PARTS]

09-80E BODY STRUCTURE [PLASTIC BODY PARTS]
PLASTIC PARTS HEAT Repairable Bumpers . . . . . . . . . . . . . . . 09-80E–2
RESISTING TEMPERATURE POLYPROPYLENE BUMPER REPAIR
[PLASTIC BODY PARTS] . . . . . . . . . . . 09-80E–1 [PLASTIC BODY PARTS]. . . . . . . . . . . . 09-80E–3
REPAIRABLE RANGE OF PROCEDURE
POLYPROPYLENE BUMPERS [PLASTIC BODY PARTS]. . . . . . . . . . . . 09-80E–4
[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}
09-80E
LENS PC POLYCARBONATE 130 {266}
FRONT COMBINATION LIGHT
HOUSING PP POLYPROPYLENE 100 {212}
RADIATOR GRILLE ABS ABS 90 {194}
FRONT BUMPER PP POLYPROPYLENE 100 {212}
FRONT OVER FENDER PP POLYPROPYLENE 100 {212}
WITHOUT PANEL ABS ABS 90 {194}
TURN UNDER PANEL AAS AAS 100 {212}
LIGHT VISOR AAS AAS 100 {212}
OUTSIDE MIRROR
WITH PANEL ABS ABS 90 {194}
TURN UNDER PANEL AAS AAS 100 {212}
LIGHT VISOR AAS AAS 100 {212}
FRONT SIDE GARNISH PP POLYPROPYLENE 100 {212}
SIDE STEP MOLDING PP POLYPROPYLENE 100 {212}
REAR SIDE GARNISH PP POLYPROPYLENE 100 {212}
ROOF MOULDING AES AES 90 {194}
REAR DOOR GARNISH AES AES 90 {194}
REAR OVER FENDER PP POLYPROPYLENE 100 {212}
LENS PMMA ACRYLIC 100 {212}
REAR COMBINATION LIGHT
HOUSING AAS AAS 100 {212}
LIFTGATE GARNISH ABS ABS 90 {194}
REAR BUMPER PP OLYPROPYLENE 100 {212}
REFLECTOR
HOUSING AES AES 90 {194}
BASE PC-PET POLYCARBONATE-PET 123 {253}
COLORS
LEVER PC-PBT POLYCARBONATE-PBT 115 {239}
OUTER HANDLE
BASE PC-ABS POLYCARBONATE-ABS 110 {230}
EXCEPT COLORS
LEVER PC-ABS POLYCARBONATE-ABS 110 {230}
HIGH-MOUNT BRAKE LIGHT
HOUSING ABS ABS 94 {201}
REAR SPOILER PC-PET POLYCARBONATE-PET 140 {284}
SHROUD PANEL PP POLYPROPYLENE 100 {212}
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
3424-1U-06H(09-80F).fm 1 ページ２００６年１２月１９日　火曜日　午後３時２７分
BODY STRUCTURE [CONSTRUCTION STANDARD VALUES]

09-80F BODY STRUCTURE [CONSTRUCTION STANDARD
VALUES]
CONSTRUCTION STANDARD VALUES FRONT VIEW . . . . . . . . . . . . . . . . . . . . 09-80F–2
[CONSTRUCTION REAR VIEW . . . . . . . . . . . . . . . . . . . . . 09-80F–4
STANDARD VALUES] . . . . . . . . . . . . . . 09-80F–2
End of Toc
BM: CONSTRUCTION STANDARD VALUES
09-80F
09-80F–1

CONSTRUCTION STANDARD VALUES [CONSTRUCTION STANDARD VALUES]
id0980c0740300
FRONT VIEW
I L L
I
H K
K
G G
J J
D D
A FF B
A
C E
C E
acxjjb00000099
A B 3 C D E
1
7
2 5
4
6
8
F G H I 18
9 11 12 13 14 16
19
10
17
15
J K L
22 24
21 20
23 25
ac9uub00000097
Side by Side by
Standar Maximu Minimu Standar Maximu Minimu
Measure side Measure side
d values m values m values d values m values m values
No. ment differenc No. ment differenc
(mm) (mm) (mm) (mm) (mm) (mm)
part e (mm) part e (mm)
{in} {in} {in} {in} {in} {in}
{in} {in}
4.50 6.00 3.00 2.00 0.00 1.00
1 7 0 -
{0.18} {0.24} {0.12} {0.08} {0.00} {0.04}
A E
2.59 4.09 1.09 0.50 1.20 -0.20
2 - 8 -
{0.10} {0.16} {0.04} {0.02} {0.05} {0.01}
1.20 2.60 -0.20 4.50 1.50 3.00
3 - 9 -
{0.05} {0.10} {0.01} {0.18} {0.06} {0.12}
B F
0.58 1.98 -0.82 {- 2.02 3.52 0.52
4 - 10 -
{0.02} {0.08} 0.03} {0.08} {0.14} {0.02}
1.20 2.40 0.00 2.00 4.30 5.50 3.1
C 5 11 -
{0.05} {0.09} {0.00} {0.08} {0.17} {0.22} {0.12}
G
4.00 5.50 2.50 4.00 5.20 2.80 1.00
D 6 - 12
{0.16} {0.22} {0.10} {0.16} {0.21} {0.11} {0.04}
09-80F–2

Side by Side by
{in} {in}
0.00 1.00 -1.00 {- 3.50 4.50 2.50 1.00
13 - 20
{0.00} {0.04} 0.04} {0.14} {0.18} {0.10} {0.04}
J
0.00 1.00 -1.00 {- 0.00 1.00 -1.00 {-
14 - 21 -
{0.00} {0.04} 0.04} {0.00} {0.04} 0.04}
0.00 1.50 -1.50 {- 3.50 4.50 2.50 1.00
H 15 - 22
{0.00} {0.06} 0.06} {0.14} {0.18} {0.10} {0.04}
K
0.00 1.50 -1.50 {- 0.00 1.00 -1.00 {-
16 - 23 -
{0.00} {0.06} 0.06} {0.00} {0.04} 0.04}
2.00 3.20 0.80 1.20 4.50 6.00 3.00 1.50
17 24
{0.08} {0.13} {0.03} {0.05} {0.18} {0.24} {0.12} {0.06}
L
4.40 6.10 2.70 2.30 0.00 1.50
18 25 - -
{0.17} {0.24} {0.11} {0.09} {0.00} {0.06}
I
0.60 2.60 -1.40 {-
19 -
{0.02} {0.10} 0.06}
09-80F
09-80F–3

REAR VIEW
A A B B
E D D
C C E
F
H H
F G G
I
I
K K J
N
J M
M
L
L
ac9uub00000098
A B C D E
1 3 7 9
2 4 8
6
5
F G H I J
11
12 14 17
10 16
13 18
15
K L M N
21 22
24
25
23
20
26
19
acxjjb00000102
Side by Side by
{in} {in}
6.00 7.00 5.00 1.20 4.90 6.70 3.10 1.80
1 7
{0.24} {0.28} {0.20} {0.05} {0.19} {0.26} {0.12} {0.07}
A D
-1.00 {- 0.00 -2.00 2.00 3.80 0.20
2 - 8 -
0.04} {0.00} {0.08} {0.08} {0.15} {0.01}
6.00 7.00 5.00 0.00 0.50
3 - E 9 - -
{0.24} {0.28} {0.20} {0.00} {0.02}
B
1.00 2.00 0.00 0.00 0.50
4 - F 10 - -
{0.04} {0.08} {0.00} {0.00} {0.02}
4.30 6.80 1.80 2.00 3.50 4.50 1.00
5 11 -
{0.17} {0.27} {0.07} {0.08} {0.14} {0.18} {0.04}
C G
2.50 5.10 -0.10 {- 0.00 1.00 -1.00 {-
6 - 12 -
{0.10} {0.20} 0.004} {0.00} {0.04} 0.04}
09-80F–4

Side by Side by
{in} {in}
4.00 5.20 2.80 6.00 8.00 4.00 2.00
13 - L 21
{0.16} {0.21} {0.11} {0.24} {0.32} {0.16} {0.08}
H
1.00 2.20 -0.20 {- 0.00 1.00
14 - 22 - -
{0.039} {0.09} 0.01} {0.00} {0.04}
M
1.20 2.20 0.20 0.50 1.20 -0.20 {-
15 - 23 -
{0.058} {0.09} {0.01} {0.02} {0.05} 0.01}
I
2.30 4.30 0.30 0.00 2.10 -2.10 {-
16 - 24 -
{0.09} {0.17} {0.01} {0.00} {0.08} 0.08}
1.20 2.50 0.10 2.00 4.00 0.00
17 - N 25 -
{0.05} {0.10} {0.004} {0.08} {0.16} {0.00}
J
2.99 4.49 1.49 0.50 12.50 -0.50 {-
18 - 26 -
{0.12} {0.18} {0.06} {0.02} {0.06} 0.02}
4.00 6.50 1.50 2.00
19
{0.16} {0.26} {0.06} {0.08}
K
-1.50 {- 0.50 -3.50 {-
20 - 09-80F
0.06} {0.02} 0.14}
End Of Sie
09-80F–5

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3424-1U-06L(INDEX).

Bodyshop GENERAL INFORMATION 00

Manual CONSTRUCTION 80A

PANEL REPLACEMENT 80B

For proper repair and maintenance, a APPLICATION:

Mazda Motor Corporation reserves the

All rights reserved. No part of this book may

Mazda Motor Corporation

VEHICLE IDENTIFICATION NUMBERS (VIN)

JM3 TB28C✻7# 100001—

GENERAL INFORMATION 00SECTION

Toc of SCT INFORMATION . . . . 00-00

Revised 6/2008 (Ref. No. R113/08) 00-00–1

Model year 7= 2007

C= 3.5 L, MZI-3.5 (California)

Body 8= Multi-purpose vehicle (Wagon)

Carline, Series TB= Mazda CX-9

World manufacturer identification JM3= Mazda (Multi-purpose vehicle category)

2008 Model Year

Model year 8= 2008

V= 3.7 L, MZI-3.7 (California)

Body 8= Multi-purpose vehicle (Wagon)

Carline, Series TB= Mazda CX-9

World manufacturer identification JM3= Mazda (Multi-purpose vehicle category)

00-00–2 Revised 6/2008 (Ref. No. R113/08)

2009 Model Year

Model year 9= 2009

V= 3.7 L, MZI-3.7 (California)

Body 8= Multi-purpose vehicle (Wagon)

Carline, Series TB= Mazda CX-9

World manufacturer identification JM3= Mazda (Multi-purpose vehicle category)

2008 Model Year

2009 Model Year

Revised 6/2008 (Ref. No. R113/08) 00-00-2–1

THIS PAGE INTENTIONALLY

REAR FENDER PANEL REMOVAL

Shows a cross location

ROUGH CUT LOCATION 17

Shows welding region

Symbols of Panel Replacement

SYMBOL MEANING SYMBOL MEANING

UNDERBODY FLAT-PLANE DIMENSIONS

182 93 144 120 140 68

When there are no specific indications, all of

Hole diameter Hole diameter

Shows bolt size Shows hole diameter

Shows vehicle section Shows point

Hole diameter Hole diameter

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

Prevention of Body Deformation

Selection of Cut-and-join Locations

Removal of Associated Parts

Rough Cutting of Damaged Panel

Rough cut location Cut-and-join location

CO2 arc welding If 3 mm Repair weld

Original number of welds

Spot Welding Notes

REAR SIDE FRAME1 BUMPER BRACKET1