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3360-1E-02C(INDEX).fm ページ ２００２年３月１３日 水曜日 午後８時３２分 Mazda6 Bodyshop Manual FOREWORD This bodyshop manual is intended for use by technicians of Authorized Mazda Dealers to help them service and repair Mazda vehicles It can also be useful to owners and operators of Mazda vehicles in performing limited repair and maintenance on Mazda vehicles CONTENTS Title Section GENERAL INFORMATION I CONSTRUCTION II PANEL REPLACEMENT III WATER-PROOF AND RUST PREVENTIVE TREATMENT IV DIMENSIONS V PLASTIC BODY PARTS VI PRIMARY COLOR MIXTURE CHART FOR BODY COLORS VII 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 miantenance occur, relevant information supplementary to this volume will be made available at Mazda dealers This manual should be kept up-to-date Mazda Motor Corporation reserves the right to alter the specifications and contents of this manual without obligation or advance notice All rights reserved No part of this book may be reproduced or used in any form or by any means, electronic or mechanical including photocopying and recording and the use of any kind of information storage and retrieval system-without permission in writing Mazda Motor Corporation HIROSHIMA, JAPAN APPLICATION: This manual is applicable to vehicles beginning with the Vehicle Identification Numbers (VIN) shown on the following page © 2002 Mazda Motor Corporation PRINTED IN THE NETHERLANDS, March 2002 3360–1E–02C 3360-1E-02C(WARNING).fm ページ ２００２年３月１３日 水曜日 午後８時３２分 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 service-related training and experience will be at less risk when performing service operations However, all users of this manual are expected to at least 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 3360-1E-02C(INDEX).fm ページ ２００２年３月１３日 水曜日 午後８時３２分 VEHICLE IDENTIFICATION NUMBERS (VIN) European (L.H.D.) specs ✻# 100001— JMZ GG1232✻ ✻# 100001— JMZ GG1282✻ ✻# 100001— JMZ GG12F2✻ ✻# 100001— JMZ GG12F5✻ U.K specs JMZ GG12820# JMZ GG12F20# JMZ GG12F50# JMZ GG14320# 100001— 100001— 100001— 100001— GCC specs ✻✻# JM7 GG32F✻✻ ✻✻ 100001— ✻✻# JM7 GG42F✻✻ ✻✻ 100001— JMZ JMZ JMZ JMZ ✻# GG1432✻ ✻# GG1482✻ ✻# GG14F2✻ ✻# GG14F5✻ 100001— 100001— 100001— 100001— JMZ GG14820# 100001— JMZ GG14F20# 100001— JMZ GG14F50# 100001— ✻✻# 100001— JM7 GG34F✻✻ ✻✻ ✻✻# JM7 GG44F✻✻ ✻✻ 100001— 3360-1E-02C.book ページ ２００２年３月１３日 水曜日 午後８時３分 GENERAL INFORMATION I I HOW TO USE THIS MANUAL I-2 HOW TO READ EFFICIENT REPLACEMENT OF BODY PANELS I-2 HOW TO READ BODY DIMINSIONS I-3 SERVICE PRECAUTIONS I-5 SERVICE PRECAUTIONS I-5 EFFICIENT REPLACEMENT OF BODY PANELS I-7 EFFICIENT REMOVAL OF BODY PANELS I-7 INSTALLATION PREPARATIONS I-8 EFFICIENT INSTALLATION OF BODY PANELS I-9 AFTER-INSTALLATION RUST PROOFING, NOISE AND VIBRATION INSULATING I-12 I–1 3360-1E-02C.book ページ ２００２年３月１３日 水曜日 午後８時３分 HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL HOW TO READ EFFICIENT REPLACEMENT OF BODY PANELS A6E201000001B01 • 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 positions and indicated by symbol • Some sections have notes concerning the operation being performed thoroughly read and understand the notes before carrying out any procedures MZZ2010B001 Symbols of Panel Replacement • The following symbols are used to indicate the type of weld that is used when replacing body panels MZZ2010B002 End Of Sie I–2 3360-1E-02C.book ページ ２００２年３月１３日 水曜日 午後８時３分 HOW TO USE THIS MANUAL HOW TO READ BODY DIMINSIONS A6E201000001B02 Body Dimensions (Flat-plane Dimensions) • Flat-plane dimensions are the dimensions measured by projecting certain reference points onto a plane surface • When there are no specific indications, the standard points and dimensions are symmetrical in regard to the center of the vehicle • The hypothetical lines may differ according to the vehicle model • The outline drawing shows the figure that projected vehicle from the upper side MZZ2010B003 I–3 I 3360-1E-02C.book ページ ２００２年３月１３日 水曜日 午後８時３分 HOW TO USE THIS MANUAL Body Dimensions (Straight-line Dimensions) • Straight-line dimensions are the actual dimensions between two standard points • When there are no specific indications, the standard points and dimensions are symmetrical in regard to the center of the vehicle MZZ2010B004 Symbols of Body Dimensions • The following symbols are used to indicate the standard points MZZ2010B005 End Of Sie I–4 3360-1E-02C.book ページ ２００２年３月１３日 水曜日 午後８時３分 SERVICE PRECAUTIONS SERVICE PRECAUTIONS SERVICE PRECAUTIONS I A6E203600025B01 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 MZZ2036B001 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 MZZ2036B002 Remove Dangerous Articles • Remove the fuel tank before using an open flame in that area Plug connection piping to prevent fuel leakage MZZ2036B003 I–5 3360-1E-02C.book ページ ２００２年３月１３日 水曜日 午後８時３分 SERVICE PRECAUTIONS Use of Pulling Equipment • When using pulling equipment, keep away from the pulling area and use safety wires to prevent accidents MZZ2036B004 Prevent Short Circuits • Turn the ignition switch to the LOCK position • Disconnect the buttery cables MZZ2036B005 • Securely connect the welding machine ground near the welding area MZZ2036B006 End Of Sie I–6 3360-1E-02C.book ページ ２００２年３月１３日 水曜日 午後８時３分 EFFICIENT REPLACEMENT OF BODY PANELS EFFICIENT REPLACEMENT OF BODY PANELS EFFICIENT REMOVAL OF BODY PANELS I A6E203800026B01 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 MZJ2038B001 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 MZJ2038B002 Selection of Cut-and-join Locations • For parts where complete replacement is not feasible, careful cutting and joining operations should be followed If the location to be cut is a flat area where there is no reinforcement, the selected cutting location should be where the welding distortion will be minimal MZJ2038B003 Remove of Associated Parts • Protect moldings, garnishes, and ornaments with tape when removing associated parts I–7