Tài liệu hướng dẫn sửa chữa than xe trên xe Cx 5 body workshop manual_Sua chua than xe. Cung cấp các thông tin cần thiết cho Kỹ thuật viên tiến hành chẩn đoán, sửa chữa nhanh chóng, chính xác, hiệu quả
MAZDA CX5 BODYSHOP MANUAL VIEW CONTENTS PAGE BACK TO MODEL INDEX FOREWORD This wiring diagram incorporates the wiring schematics of the Mazda CX-5 and available optional equipment Actual vehicle wiring may vary slightly depending on optional equipment or local specifications, or both For proper repair and maintenance, a thorough familiarization with this manual is important, and it should always be kept in a handy place for quick and easy reference All the contents of this manual, including drawings and specifications, are the latest available at the time of printing As modifications affecting repair or maintenance occur, relevant information supplementary to this volume will be made available at Mazda dealers This manual should be kept up-to-date Ford Motor Company 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 WARNING Servicing a vehicle can be dangerous If you have not received service-related training, the risks of injury, property damage, and failure of servicing increase The recommended servicing procedures for the vehicle in this workshop manual were developed with Mazda-trained technicians in mind This manual may be useful to non-Mazda trained technicians, but a technician with our servicerelated training and experience will be at less risk when performing service operations However, all users of this manual are accepted at least to know general safety procedures This manual contains “Warnings” and “Cautions” applicable to risks not normally encountered in a general technician’s experience They should be followed to reduce the risk of injury and the risk that improper service or repair may damage the vehicle or render it unsafe It is also important to understand that the “Warnings” and “Cautions” are not exhaustive It is impossible to warn of all the hazardous consequences that might result from failure to follow the procedures The procedures recommended and described in this manual are effective methods of performing service and repair Some require tools specifically designed for a specific purpose Persons using procedures and tools which are not recommended by Mazda Motor Corporation must satisfy themselves thoroughly that neither personal safety nor safety of the vehicle will be jeopardized The contents of this manual, including drawings and specifications, are the latest available at the time of printing, and Mazda Motor Corporation reserves the right to change the vehicle designs and alter the contents of this manual without notice and without incurring obligation Parts should be replaced with genuine Mazda replacement parts or with parts which match the quality of genuine Mazda replacement parts Persons using replacement parts of lesser quality than that of genuine Mazda replacement parts must satisfy themselves thoroughly that neither personal safety nor safety of the vehicle will be jeopardized Mazda Motor Corporation is not responsible for any problems which may arise from the use of this manual The cause of such problems includes but is not limited to insufficient service related training, use of improper tools, use of replacement parts of lesser quality than that of genuine Mazda replacement parts, or not being aware of any revision of this manual © 2012 FMCSA Ford Motor Company of Southern Africa MAZDA CX5 BODYSHOP MANUAL TO MODEL INDEX BACK TO FOREWORD & FRONT PAGE CONTENTS Title Bodyshop Manual GENERAL INFORMATION BODY STRUCTURE APPLICATION: This manual is applicable to vehicles beginning with the Vehicle Identification Numbers (VIN) shown on the following page PANEL REPLACEMENT WATER-PROOF AND RUST PREVENTIVE DIMENSIONS PLASTIC BODY PARTS CONSTRUCTION STANDARD VALUES Section 00 80A 80B 80C 80D 80E 80F © 2012 Ford Motor Company of Southern Africa tomsn048@gmail.com MAZDA CX5 BODYSHOP MANUAL TO MODEL INDEX BACK TO MAIN INDEX GENERAL INFORMATION 00 SECTION Toc of SCT INFORMATION 00-00 GENERAL Toc of SCT MAZDA CX5 BODYSHOP MANUAL BACK TO CHAPTER INDEX TO MODEL INDEX GENERAL INFORMATION 00-00 GENERAL INFORMATION VEHICLE IDENTIFICATION NUMBER (VIN) CODE European (L.H.D U.K.) China specs Australian, General (R.H.D.) specs General (L.H.D.) specs VEHICLE IDENTIFICATION NUMBERS (VIN) European (L.H.D U.K.) specs Australian, General (R.H.D.) specs General (L.H.D.) specs HOW TO USE THIS MANUAL Efficient Replacement of Body Panels Symbols of Panel Replacement Body Dimensions (Flat-plane Dimensions) Body Dimensions (Straight-line Dimensions) Symbols of Body Dimensions AIR BAG SYSTEM SERVICE WARNINGS Air Bag Module Inspection Air Bag Module Handling Side Air Bag Module Handling SAS Control Module Handling Crash Zone Sensor Handling Side Air Bag Sensor Handling Pre-tensioner Seat Belt Inspection SERVICE PRECAUTIONS Arrangement of Workshop Safety Precautions Vehicle Protection Remove Dangerous Articles Use of Pulling Equipment 00-00–2 00-00–2 00-00–2 00-00–3 00-00–4 00-00–4 00-00–4 00-00–4 00-00–4 00-00–4 00-00–5 00-00–5 00-00–8 00-00–9 00-00–10 00-00–10 00-00–10 00-00–10 00-00–10 00-00–11 00-00–11 00-00–11 00-00–11 00-00–11 00-00–12 00-00–12 00-00–12 00-00–12 Prevent Short Circuits 00-00–12 EFFICIENT REMOVAL OF BODY PANELS 00-00–13 Body Measurements 00-00–13 Prevention of Body Deformation 00-00–13 Selection of Cut-and-join Locations 00-00–14 Removal of Associated Parts 00-00–14 Rough Cutting of Damaged Panel 00-00–14 EFFICIENT INSTALLATION OF BODY PANELS 00-00–14 Checking Preweld Measurements And Watching 00-00–14 Welding Notes 00-00–15 Spot Welding Notes 00-00–15 Checking Weld Strength 00-00–16 INSTALLATION PREPARATIONS 00-00–16 Rough Cutting of New Parts 00-00–16 Determination of Welding Method 00-00–17 Making Holes for Arc Welding 00-00–17 Application of Weld-through Primer 00-00–17 ANTICORROSION, SOUND INSULATION, AND VIBRATION INSULATION 00-00–18 Body Sealing 00-00–18 Application of Undercoating 00-00–18 Application of Rust Inhibitor 00-00–18 Application of Dumping Sheet 00-00–18 ABBREVIATION 00-00–19 BODY COLORS 00-00–19 Color Code and Color Name 00-00–19 Verification of Primary Color Mixture for Body Color 00-00–19 IDENTIFICATION NUMBER LOCATIONS 00-00–19 Vehicle Identification Number (VIN) 00-00–19 Engine Identification Type/Number 00-00–20 End of Toc BM: GENERAL INFORMATION 00-00–1 MAZDA CX5 BODYSHOP MANUAL BACK TO CHAPTER INDEX TO MODEL INDEX GENERAL INFORMATION VEHICLE IDENTIFICATION NUMBER (VIN) CODE id000000600800 European (L.H.D U.K.) China specs JMZKEC97600123456 Serial No Plant Dummy Transmission Engine Body 0= Hiroshima 1= Hofu 6= 6MT 8= 6EAT 1= 2.2 L (SKYACTIV-D 2.2 Low, Diesel) 2= 2.2 L (SKYACTIV-D 2.2 Hi, Diesel) 7= 2.0 L (SKYACTIV-G 2.0) 9= Station Wagon Drive axle/ Emission stage C= 2WD, Stage5 F= 2WD, Stage6 K= 4WD, Stage5 N= 4WD, Stage6 1= 2WD, Stage4 8= 4WD, Stage4 Car line, series KE= Mazda CX-5 World manufacturer identification JM7= Mazda (China specs.) JMZ= Mazda (European (L.H.D U.K.) specs.) ac5wzw0000457 Australian, General (R.H.D.) specs JM0KE107100123456 Serial No Dummy Dummy Minor change code Engine Dummy Body Carline and Series World manufacturer identification 2= 2.2 L (SKYACTIV-D 2.2 Hi, Diesel) 7= 2.0 L (SKYACTIV-G 2.0) 1= Closed body KE= Mazda CX-5 JM0= Mazda (Australian specs.) JM6= Mazda (General (R.H.D.) specs.) ac5wzw0000457 00-00–2 MAZDA CX5 BODYSHOP MANUAL BACK TO CHAPTER INDEX TO MODEL INDEX GENERAL INFORMATION General (L.H.D.) specs Except for Algeria J M K E W7 0D Serial No Plant Israel: Dummy Except Israel: Model year Israel: Except Israel: Transmission CheckDigit (*) code Engine Israel: Z D=2013 (J0b#1-) 8=6EAT to and X 7= 2.0 L (SKYACTIV-G 2.0) 9= Station Wagon Except Israel: Body W= Station Wagon C= 2WD stage5b/OBD-stage5+ K= 4WD stage5b/OBD-stage5+ Israel: Except Israel: 0=Hiroshima 1=Hofu Axle configuration, GVW Body Carline and Series Israel: 2= 2WD with Curtain & Side airbags 4= 4WD with Curtain & Side airbags KE= Mazda CX-5 JMZ= Mazda (General (L.H.D.) specs.) (for Israel) Except Israel: WMI JM8= Mazda (General (L.H.D.) specs.) (Except for Israel) ac5wzw0000457 Algeria only m KE1071 m 12 m Serial No Model change code Engine type 7= 2.0 L (SKYACTIV-G 2.0, with out i-stop) Body style 10= Closed body Vehicle type BL= Mazda CX-5 m :This mark is used only for Algerian model, in order to identify the manufacturer ac5wzw0000457 End Of Sie 00-00–3 MAZDA CX5 BODYSHOP MANUAL BACK TO CHAPTER INDEX TO MODEL INDEX GENERAL INFORMATION VEHICLE IDENTIFICATION NUMBERS (VIN) id000000600100 European (L.H.D U.K.) specs JMZ KE19760# 100001— JMZ KE19780# 100001— JMZ KE89780# 100001— JMZ KEC9760# 100001— JMZ KEF9160# 100001— JMZ KEF9180# 100001— JMZ KEK9760# 100001— JMZ KEK9780# 100001— JMZ KEN9160# 100001— JMZ KEN9180# 100001— JMZ KEN9260# 100001— JMZ KEN9280# 100001— JM7 KE197**# 100001— JM7 KE897**# 100001— ac5wzw0000457 Australian, General (R.H.D.) specs JM0 KE102100 100001— JM0 KE107100 100001— JM6 KE1071*0# 100001— ac5wzw0000458 General (L.H.D.) specs Except for Algeria JMZ KEC978*# 100001— JMZ KEK978*# 100001— JM8 KE2W7**# 100001— JM8 KE4W7**# 100001— ac5wzw0000458 Algeria only m KE1071 m 100001 m — m : This mark is used only for Algerian model, in order to identify the manufacturer ac5wzw0000458 End Of Sie HOW TO USE THIS MANUAL id000000600900 Efficient Replacement of Body Panels x 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 x The type of weld and position are indicated by symbols x Some sections have notes concerning the operation being performed Thoroughly read and understand the notes before carrying out any procedures 00-00–4 MAZDA CX5 BODYSHOP MANUAL BACK TO CHAPTER INDEX TO MODEL INDEX GENERAL INFORMATION 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 BRAZE WELDING Shows a dimensions A A 250mm {9.84in} Shows a insulator CUT-AND-JOINT LOCATION ROUGH CUT LOCATION 17 (A)17 30mm {1.18in} 5 Shows welding region Shows number of weld A-A Shows a cross acxuub00000031 Symbols of Panel Replacement x The following symbols are used to indicate the type of weld that is used when replacing body panels SYMBOL MEANING SYMBOL MEANING Spot welding Continuous arc welding (Cut-and-join location) Arc welding (plug welding) Brazing welding (oxyacetylene welding) Arc welding (spot welding) Rough cut location ac5wzb00000204 Body Dimensions (Flat-plane Dimensions) x Flat-plane dimensions are the dimensions measured by projecting certain reference points onto a plane 00-00–5 MAZDA CX5 BODYSHOP MANUAL BACK TO CHAPTER INDEX TO MODEL INDEX GENERAL INFORMATION surface FRONT FENDER INSTALLATION NUT 810 {31.89} FLAT-PLANE DIMENSIONS acxuub00000033 x When there are no specific indications, the standard points and dimensions are symmetrical in regard to the center of the vehicle x The hypothetical lines may differ according to the vehicle model x The schematic diagram shows the vehicle as it is projected from the underbody 00-00–6 MAZDA CX5 BODYSHOP MANUAL BACK TO CHAPTER INDEX TO MODEL INDEX GENERAL INFORMATION Example Shows vehicle section UNDERBODY FLAT-PLANE DIMENSIONS 478 485 650 {25.59} 1,164 {45.83} 543 484 {21.37} {19.05} 1,073 {37.91} Shows outline drawing 650 {25.59} 650 {25.59} 605 {23.82} 469 455 {18.46} {17.91} 1,106 {43.54} 760 {29.92} 1,016 {40.00} RH LH The dimensions on the left and right in regard to the center of the vehicle are different Shows dimension A B C D E F G H I J K L 420 {16.54} 182 93 144 120 {7.17} {3.66} {5.67} {4.72} 140 1,030 {40.55} 760 {29.92} {5.51} 68 {2.68} When there are no specific indications, all of units are in millimeters (mm) Point symbol A B C D E Designation Crossmember No,1 standard hole Front side frame standard hole Front suspension mounting block surface hole center Front suspension mounting bolt Front frame rear standard hole Hole diameter or bolt or nut size mm {in} Point symbol φ 16 {0.62} F G φ 16 {0.62} φ 80 {3.14} M14 {0.55} φ 16 {0.62} Designation Front frame rear standard hole Rear side frame standard hole H Link bracket I J K L Rear suspension housing Rear side frame standard hole Rear suspension housing Rear side frame standard hole Shows bolt size 666 {26.22} 660 {25.98} 1,043 {41.06} 512 {20.16} 445 {17.52} 436 {17.17} 436 {17.17} 1,084 {42.84} 579 {22.80} 479 {18.86} 654 {25.75} Shows hypothetical standard line 687 {27.05} Shows point symbol 379 {14.92} mm {in} Hole diameter or bolt or nut size mm {in} φ 18 {0.62} φ 16 {0.62} 17 × 29.5 {0.66×1.16} φ 12 {0.47} φ 16 {0.62} φ 31 {1.22} φ 12 {0.47} Shows slot Shows hole diameter ac9uub00000034 00-00–7 MAZDA CX5 BODYSHOP MANUAL BACK TO CHAPTER INDEX TO MODEL INDEX BODY STRUCTURE [DIMENSIONS] Point sym bol D E F G H I Designation Rear seat installation hole Rear pillar inner datum hole C-pillar trim installation hole Trunk side trim installation hole Rear pillar inner datum hole Rear door striker installation hole Hole diameter or bolt or nut size mm {in} I14 {0.55} I7 {0.3} I10 {0.39} I8.6 {0.34} I8.6 {0.34} I13 {0.51} End Of Sie ROOM STRAIGHT-LINE DIMENSIONS (3) [DIMENSIONS] id098010746200 B C 1,013 {39.88} 1,030 {40.55} D 1,048 {41.26} E 950 {37.4} A ac5wzb00000302 A B C D E E' A' A E ac5wzb00000176 Point sym Designation bol A Rear seat installation hole 09-80D–12 Hole diameter or bolt or nut size mm {in} I14 {0.55} Point sym Designation bol B D-pillar trim installation hole Hole diameter or bolt or nut size mm {in} I8.6 {0.34} MAZDA CX5 BODYSHOP MANUAL BACK TO CHAPTER INDEX TO MODEL INDEX BODY STRUCTURE [DIMENSIONS] Point sym bol Hole diameter or bolt or nut size mm {in} Designation Liftgate stay damper installation hole Trunk side trim installation hole Liftgate striker installation hole C D E I7 {0.3} I8.6 {0.34} I14 {0.55} End Of Sie REAR BODY STRAIGHT-LINE DIMENSIONS (1) [DIMENSIONS] BM: REAR BODY A' 198 {7.80} B' id098010746300 A 725 {28.5} 907 {35.7} 1,080 {42.52} 476 {18.7} B 1,323 {52.09} 1,087 {42.80} 1,097 {43.19} 1,406 {55.35} C' 1,425 {56.10} 294 {11.6} E 996 {39.2} E' D' C 1,053 {41.46} D 1,381 {54.37} 389 {15.3} F' 1,160 {45.67} G' 154 {6.06} F G 864 {34.0} 972 {38.3} 1,067 {42.01} H' H ac5wzb00000303 A, B C A D B E F F' F G, H G H ac5wzb00000304 Point sym Designation bol A Liftgate hinge installation hole Liftgate stay damper installation B hole Rear combination light installation C slot D Rear bumper installation bolt Hole diameter or bolt or nut size mm {in} I12 {0.47} I10 {0.39} I10 {0.39} M6 Point sym Designation bol E Brace bracket datum hole F Liftgate striker installation hole Rear bumper reinforcement G installation bolt Rear bumper reinforcement H installation bolt Hole diameter or bolt or nut size mm {in} I10 {0.39} I14 {0.55} M10 M10 09-80D–13 MAZDA CX5 BODYSHOP MANUAL BACK TO CHAPTER INDEX TO MODEL INDEX BODY STRUCTURE [PLASTIC BODY PARTS] 09-80E BODY STRUCTURE [PLASTIC BODY PARTS] PLASTIC PARTS HEAT RESISTING TEMPERATURE [PLASTIC BODY PARTS] 09-80E–1 REPAIRABLE RANGE OF POLYPROPYLENE BUMPERS [PLASTIC BODY PARTS] 09-80E–1 Repairable Bumpers 09-80E–2 POLYPROPYLENE BUMPER REPAIR [PLASTIC BODY PARTS] 09-80E–3 PROCEDURE [PLASTIC BODY PARTS] 09-80E–4 MAZDA CX5 BODYSHOP MANUAL BACK TO CHAPTER INDEX TO MODEL INDEX BODY STRUCTURE [PLASTIC BODY PARTS] End of Toc PLASTIC PARTS HEAT RESISTING TEMPERATURE [PLASTIC BODY PARTS] BM: PLASTIC BODY PARTS Part Name Windshield molding Cowl grille Front combination light Lens Housing Front bumper Front side turn light Out side mirror Lens Housing Panel Visor Outer cover Front door garnish Rear door garnish Side garnish Front Rear Rear over fender Roof molding Rear bumper Rear combination light High-mount brake light Rear Spoiler Shroud panel Lens Housing Lens Housing Code PVC PP PC PP PP PMMA PC-PBT ABS AAS AAS AAS AAS PP PP PP AC PP PMMA AAS PMMA ABS PP PP Material Name POLYVINYLCHLORIDE POLYPROPYLENE POLYCARBONATE POLYPROPYLENE POLYPROPYLENE ACRYLIC POLYCARBONATE-PBT ABS AAS AAS AAS AAS POLYPROPYLENE POLYPROPYLENE POLYPROPYLENE ACS POLYPROPYLENE ACRYLIC AAS ACRYLIC ABS POLYPROPYLENE POLYPROPYLENE id098011740200 Heat resisting TemperatureqC{qF} 95 {203} 95 {203} 130 {266} 90 {194} 100 {212} 75 {167} 80 {176} 90 {194} 100 {212} 100 {212} 100 {212} 100 {212} 90 {194} 90 {194} 90 {194} 90 {194} 100 {212} 80 {176} 70 {158} 80 {176} 100 {212} 90 {194} 100 {212} Note x The application of temperatures higher than heat resisting temperatures may result in part deformation End Of Sie REPAIRABLE RANGE OF POLYPROPYLENE BUMPERS [PLASTIC BODY PARTS] BM: BUMPER 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 09-80E–1 MAZDA CX5 BODYSHOP MANUAL BACK TO CHAPTER INDEX TO MODEL INDEX BODY STRUCTURE [PLASTIC BODY PARTS] Repairable Bumpers A bumper with a hole less than 50 mm {1.97 in} in diameter am8rrb00000046 A bumper with a crack less than 100 mm {3.94 in} in length am8rrb00000047 A bumper with a crack less than 100 mm {3.94 in} in length that is less than half of the width of the bumper (A) End Of Sie LESS THAN HALF OF (A) am8rrb00000048 09-80E–2 MAZDA CX5 BODYSHOP MANUAL BACK TO CHAPTER INDEX TO MODEL INDEX BODY STRUCTURE [PLASTIC BODY PARTS] POLYPROPYLENE BUMPER REPAIR [PLASTIC BODY PARTS] Scratch on paint only Bumper surface not visible Hole or crack through surface Bumper surface visible id098011600200 Crack more than 100 mm {3.94 in} long or completely broken Remove paint Smooth damaged area Apply aluminium tape to reverse side of bumper Plastic weld damaged area Rough sand damage area Replace damaged Bumper Spray entire bumper surface with polypropylene primer Degrease damaged area Apply polypropylene primer to damaged area Apply repair agent to damaged area and let dry Sand damaged area Sand damaged area smooth Apply polypropylene primer to damaged area and let dry Spray primer surfacer on damaged area and let dry Sand partial or complete surface of bumper Spray primer surfacer on bumper and let dry Sand surface of bumper Degrease bumper Spray matching body color paint on bumper and let dry am2uub0000000 End Of Sie 09-80E–3 MAZDA CX5 BODYSHOP MANUAL BACK TO CHAPTER INDEX TO MODEL INDEX BODY STRUCTURE [PLASTIC BODY PARTS] 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 SEC A-A SEC D-D SEC B-B, SEC C-C Top coat layer Primer layer Primer surface layer Polypropylene layer am2uub0000001 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° SEC D-D SEC A-A, SEC B-B, SEC C-C Cut with knife Cut with knife Polypropylene surface Sand Sand 45 Angle necessary for deposit of polypropylene welding rog am2uub0000001 Weld the damaged area 09-80E–4 MAZDA CX5 BODYSHOP MANUAL BACK TO CHAPTER INDEX TO MODEL INDEX BODY STRUCTURE [PLASTIC BODY PARTS] x For repair of a cracked area, melt the crack together with a heat gun and a melting attachment Heat gun Melt together SEC B-B, SEC C-C painted surface Attachment for melting Section after melting Polypropylene surface am2uub0000001 x For repair of a hole, degrease the area on both sides of the bumper and apply aluminium tape on the reverse side of the damage area Melt the polypropylene welding rod with a heat gun and deposit it the cracked area SEC A-A Degrease Aluminium tape am2uub0000001 Polypropylene welding rod SEC B-B, SEC C-C, SEC D-D Polypropylene welding rod Melt this area Melted area am2uub0000001 Note x Heat the shaded area to melt it x 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 x Hold the heat gun 10—20 mm {0.39—0.79 in} from the part being welded x Do not move the welding rod until the welded parts cool Polypropylene welding Polypropylene welding rod SEC A-A Paint Surface Top view Aluminium tape am2uub0000001 09-80E–5 MAZDA CX5 BODYSHOP MANUAL BACK TO CHAPTER INDEX TO MODEL INDEX BODY STRUCTURE [PLASTIC BODY PARTS] 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 am2uub0000001 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 am2uub0000001 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 x When mixing the main and stiffening agents, take care not to allow bubbles to form x The repair agent hardens quickly (about minutes); proceed with the work immediately after mixing the agents x Allow about 30 minutes to dry (20 °C {68 °F}) before sanding Repair agent Do not mix air Weld Polypropylene surface am2uub0000001 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 Sand the area with #180—240 sandpaper Note x If excessive force is applied to the area when sanding, the surface will be damaged x If fuzz remains around the repaired area, melt it with a heat gun 09-80E–6 MAZDA CX5 BODYSHOP MANUAL BACK TO CHAPTER INDEX TO MODEL INDEX BODY STRUCTURE [PLASTIC BODY PARTS] am2uub0000001 Degrease the painted surface 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 am2uub0000002 Use the primer within 16 hours after it is mixed Note x 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 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 Softener Note x 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 P e Spray method Spot-spray primer surfacer on bumper three or four times 12 Air drying 20 °C {68 °F} — hours minimum Forced drying 60 °C {140 °F} — hour 13 Lightly sand the complete surface of the bumper with #400—#600 sandpaper Do not expose the surface of the polypropylene (Wet or dry sanding is acceptable.) Hardner Mixture A 100 Mixture B 30 am2uub0000002 09-80E–7 MAZDA CX5 BODYSHOP MANUAL BACK TO CHAPTER INDEX TO MODEL INDEX BODY STRUCTURE [PLASTIC BODY PARTS] 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 x 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} — hours minimum Forced drying 60 °C {140 °F} — hour Note x Let the part air dry when possible as forced drying could cause bubbles in the top coat End Of Sie 09-80E–8 BACK TO CHAPTER INDEX MAZDA CX5 BODYSHOP MANUAL TO MODEL INDEX BODY STRUCTURE [CONSTRUCTION STANDARD VALUES] 09-80F BODY STRUCTURE [CONSTRUCTION STANDARD VALUES] CONSTRUCTION STANDARD VALUES [CONSTRUCTION STANDARD VALUES] 09-80F–1 End of Toc Front view 09-80F–1 Rear view 09-80F–2 MAZDA CX5 BODYSHOP MANUAL BACK TO CHAPTER INDEX TO MODEL INDEX BODY STRUCTURE [CONSTRUCTION STANDARD VALUES] BM: CONSTRUCTION STANDARD VALUES CONSTRUCTION STANDARD VALUES [CONSTRUCTION STANDARD VALUES] id0980c0740300 Front view G E E A A H D D B F F C C B H ac5wzb00000191 A B C D E H G F 12 10 13 11 ac5wzb00000305 Standar Maximu Minimu Side by Measure d values m values m values differenc No ment (mm (mm (mm e (mm part {in}) {in}) {in}) {in}) 5.0 7.0 3.0 2.0 A {0.20} {0.27} {0.12} {0.079} 4.5 6.0 3.0 B {0.18} {0.24} {0.12} Standar Maximu Minimu Side by Measure d values m values m values differenc No ment (mm (mm (mm e (mm part {in}) {in}) {in}) {in}) 4.5 6.4 2.6 2.5 {0.18} {0.25} {0.10} {0.098} C 1.0 2.8 -0.8 {0.039} {0.11} {-0.03} 1.8 3.2 0.4 1.4 D {0.055} {0.13} {0.002} {0.055} 09-80F–1 MAZDA CX5 BODYSHOP MANUAL BACK TO CHAPTER INDEX TO MODEL INDEX BODY STRUCTURE [CONSTRUCTION STANDARD VALUES] No E F G H Standar Maximu Minimu Side by Measure d values m values m values differenc ment (mm (mm (mm e (mm part {in}) {in}) {in}) {in}) 3.7 4.9 2.5 1.2 {0.15} {0.19} {0.098} {0.047} 0.5 1.8 {0.02} {0.071} 0.5 1.2 0.2 {0.02} {0.047} {0.008} 1.6 -1.6 {0.063} {-0.063} 1.6 -1.6 10 {0.063} {-0.063} 1.5 -1.5 11 {0.059} {-0.059} 3.5 4.5 2.5 1.0 12 {0.14} {0.18} {0.098} {0.039} 1.0 -1.0 13 {0.039} {-0.039} Rear view A A B B C E E I C I J J D D H G G F H F ac5wzb00000333 A B C D E I H G F J 14 12 10 11 15 13 ac5wzb00000306 09-80F–2 MAZDA CX5 BODYSHOP MANUAL BACK TO CHAPTER INDEX TO MODEL INDEX BODY STRUCTURE [CONSTRUCTION STANDARD VALUES] No A B C D E F Standar Maximu Minimu Side by Measure d values m values m values differenc ment (mm (mm (mm e (mm part {in}) {in}) {in}) {in}) 6.0 7.0 5.0 1.2 {0.24} {0.28} {0.20} {0.047} -1.0 -2.0 {-0.039} {-0.079} 4.3 6.8 1.8 2.5 {0.17} {0.27} {0.071} {0.047} 1.8 3.0 0.6 {0.071} {0.12} {0.02} 1.8 3.3 0.3 {0.071} {0.13} {0.01} 4.5 6.5 2.5 1.5 {0.18} {0.26} {0.098} {0.059} 1.8 -1.8 {0.071} {-0.071} 4.0 6.5 1.5 2.5 {0.16} {0.26} {0.059} {0.098} No G H I J Standar Maximu Minimu Side by Measure d values m values m values differenc ment (mm (mm (mm e (mm part {in}) {in}) {in}) {in}) 6.0 8.0 4.0 2.0 {0.24} {0.31} {0.16} {0.079} 0.5 1.8 10 {0.02} {0.071} 0.5 1.5 -0.2 11 {0.02} {0.059} {-0.008} 3.5 4.5 2.5 1.0 12 {0.14} {0.18} {0.098} {0.039} 1.0 -1.0 13 {0.039} {-0.039} 3.5 4.5 2.5 1.0 14 {0.14} {0.18} {0.098} {0.039} 1.0 -1.0 15 {0.039} {-0.039} End Of Sie 09-80F–3