Mazda 6 2014 -Body Shop Manual

Title Section

GENERAL INFORMATION 00

BODY

STRUCTURE

CONSTRUCTION 80A

PANEL REPLACEMENT

80B

WATER-PROOF AND RUST

PREVENTIVE

80C

DIMENSIONS 80D

PLASTIC BODY PARTS

80E

CONSTRUCTION

STANDARD VALVES

80F

CONTENTS

2014-present

Bodyshop

Manual

FOREWORD

This bodyshop manual is intended for

use by technicians of Authorized Mazda

Dealers to help them service and repair

Mazda vehicles. It can also be useful to

owners and operators of Mazda vehicles in

performing limited repair and maintenance

on Mazda vehicles.

For proper repair and maintenance, a

thorough familiarization with this manual is

important, and it should always be kept in a

handy place for quick and easy reference.

All the contents of this manual, including

drawings and specifications, are the latest

available at the time of printing.

As modifications affecting repair or

maintenance occur, relevant information

supplementary to this volume will be made

available at Mazda dealers. This manual

should be kept up-to-date.

Mazda Motor Corporation reserves the

right to alter the specifications and contents

of this manual without obligation or ad-

vance notice.

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.

PRINTED IN U.S.A., DECEMBER 2012

Form No. 3525–1U–12L

Part No. 9999–95–099F–14

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VEHICLE IDENTIFICATION NUMBERS (VIN)

JM1 GJ1S3*E# 100001—

JM1 GJ1S5*E# 100001—

JM1 GJ1T3*E# 100001—

JM1 GJ1T5*E# 100001—

JM1 GJ1U3*E# 100001—

JM1 GJ1U5*E# 100001—

JM1 GJ1V3*E# 100001—

JM1 GJ1V5*E# 100001—

JM1 GJ1W3*E# 100001—

JM1 GJ1W5*E# 100001—

JM1 GJ1X3*E# 100001—

JM1 GJ1X5*E# 100001—

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00

GENERAL INFORMATION

00-00–1

SECTION

00-00

Toc of SCT

GENERAL INFORMATION . . . .00-00

Toc of SCT

00-00 GENERAL INFORMATION

VEHICLE IDENTIFICATION

NUMBER (VIN) CODE . . . . . . . . . . . . . .00-00–2

VEHICLE IDENTIFICATION NUMBERS

(VIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-00–2

2014 Model Year. . . . . . . . . . . . . . . . . .00-00–2

HOW TO USE THIS MANUAL . . . . . . . . .00-00–3

Efficient Replacement of

Body Panels . . . . . . . . . . . . . . . . . . . .00-00–3

Symbols of Panel Replacement . . . . . .00-00–3

Body Dimensions (Flat-plane

Dimensions) . . . . . . . . . . . . . . . . . . . .00-00–4

Body Dimensions (Straight-line

Dimensions) . . . . . . . . . . . . . . . . . . . .00-00–6

Symbols of Body Dimensions. . . . . . . .00-00–7

AIR BAG SYSTEM

SERVICE WARNINGS . . . . . . . . . . . . . .00-00–8

Air Bag Module Inspection . . . . . . . . . . 00-00–8

Air Bag Module Handling . . . . . . . . . . .00-00–8

Side Air Bag Module Handling . . . . . . .00-00–8

SAS Control Module Handling . . . . . . .00-00–9

Crash Zone Sensor Handling . . . . . . . .00-00–9

Side Air Bag Sensor Handling. . . . . . . .00-00–9

Pre-tensioner Seat Belt Inspection . . . .00-00–10

SERVICE PRECAUTIONS . . . . . . . . . . . . 00-00–10

Arrangement of Workshop . . . . . . . . . . 00-00–10

Safety Precautions . . . . . . . . . . . . . . . .00-00–10

Vehicle Protection . . . . . . . . . . . . . . . . .00-00–10

Remove Dangerous Articles . . . . . . . . . 00-00–10

Use of Pulling Equipment . . . . . . . . . . .00-00–11

Prevent Short Circuits. . . . . . . . . . . . . .00-00–11

EFFICIENT REMOVAL OF

BODY PANELS. . . . . . . . . . . . . . . . . . . . 00-00–12

Body Measurements. . . . . . . . . . . . . . .00-00–12

Prevention of Body Deformation. . . . . . 00-00–12

Selection of Cut-and-join Locations . . . 00-00–12

Removal of Associated Parts. . . . . . . . 00-00–12

Rough Cutting of Damaged Panel . . . . 00-00–13

EFFICIENT INSTALLATION OF

BODY PANELS . . . . . . . . . . . . . . . . . . . 00-00–13

Checking Preweld Measurements And

Watching . . . . . . . . . . . . . . . . . . . . . . 00-00–13

Welding Notes . . . . . . . . . . . . . . . . . . . 00-00–13

Spot Welding Notes . . . . . . . . . . . . . . . 00-00–14

Checking Weld Strength. . . . . . . . . . . . 00-00–15

INSTALLATION PREPARATIONS. . . . . . 00-00–16

Rough Cutting of New Parts. . . . . . . . . 00-00–16

Determination of Welding Method . . . . 00-00–16

Making Holes for Arc Welding . . . . . . . 00-00–16

Application of Weld-through Primer . . . 00-00–17

ANTICORROSION,

SOUND INSULATION,

AND VIBRATION INSULATION . . . . . . 00-00–17

Body Sealing . . . . . . . . . . . . . . . . . . . . 00-00–17

Application of Undercoating . . . . . . . . . 00-00–17

Application of Rust Inhibitor . . . . . . . . . 00-00–18

Application of Dumping Sheet . . . . . . . 00-00–18

ABBREVIATION . . . . . . . . . . . . . . . . . . . 00-00–18

IDENTIFICATION NUMBER

LOCATIONS . . . . . . . . . . . . . . . . . . . . . 00-00–19

Vehicle Identification Number (VIN) . . . 00-00–19

Engine Type/Number . . . . . . . . . . . . . . 00-00–19

BODY COLORS. . . . . . . . . . . . . . . . . . . . 00-00–19

Color Code and Color Name

. . . . . . . . 00-00–19

V

eri

fication of Primary Color Mixture for

Body Color . . . . . . . . . . . . . . . . . . . . . 00-00–19

End of Toc

BM: GENERAL INFORMATION

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GENERAL INFORMATION

00-00–2

VEHICLE IDENTIFICATION NUMBER (VIN) CODE

id000000600800

2014 Model Year

End Of Sie

VEHICLE IDENTIFICATION NUMBERS (VIN)

id000000600100

2014 Model Year

JM1 GJ1S3*E# 100001—

JM1 GJ1S5*E# 100001—

JM1 GJ1T3*E# 100001—

JM1 GJ1T5*E# 100001—

JM1 GJ1U3*E# 100001—

JM1 GJ1U5*E# 100001—

JM1 GJ1V3*E# 100001—

JM1 GJ1V5*E# 100001—

JM1 GJ1W3*E# 100001—

JM1 GJ1W5*E# 100001—

JM1 GJ1X3*E# 100001—

JM1 GJ1X5*E# 100001—

End Of Sie

J M 1 G J 1 S 2 0 E 1 1 2 3 4 5 6

Model year

Plant

Serial No.

Check digit

Engine

Body style S, T, U, V, W, X= Sedan

Carline, series

GJ= Mazda6

World manufacturer identification

0 to 9, X

3= 2.5 L (SKYACTIV-G 2.5, Mexico)

5= 2.5 L (SKYACTIV-G 2.5, U.S.A., Canada)

0= Hiroshima

1= Hofu

E= 2014

Restraint system, Axle configuration

JM1= Mazda/passenger car/USA

1= with side airbag, 2WD

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GENERAL INFORMATION

00-00–3

00-00

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.

• Some sections have notes concerning the operation being performed. Thoroughly read and understand the

notes before carrying out any procedures.

Example

Symbols of Panel Replacement

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

REAR FENDER PANEL REMOVAL

Shows operation section

Shows procedure, caution and note

BRAZE WELDING

Shows welding region

Shows a cross

Shows a insulator

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.

Drill the 17 weld locations indicated by (A), from the room side.

Caution

NOTE

CUT-AND-JOINT LOCATION

ROUGH CUT LOCATION

Shows a dimensions

{9.84in}

250mm

A-A

30mm

{1.18in}

Shows number of weld

Shows a cross location

A

(A)17

17

4

5

7

1

5

acxuub00000031

SYMBOL

MEANING

Spot welding

Arc welding (plug welding)

Arc welding (spot welding)

SYMBOL

MEANING

Continuous arc welding (Cut-and-join location)

Brazing welding (oxyacetylene welding)

Rough cut location

ac5wzb00000204

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GENERAL INFORMATION

00-00–4

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 schematic diagram shows the vehicle as it is projected from the underbody.

810

{31.89}

FLAT-PLANE DIMENSIONS

FRONT FENDER INSTALLATION NUT

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GENERAL INFORMATION

00-00–5

00-00

Example

Shows vehicle section

When there are no specific indications, all of

units are in millimeters (mm).

Shows outline drawing

Shows dimension

The dimensions on the left

and right in regard to the center

of the vehicle are different.

Shows hypothetical

standard line

Shows point

symbol

Point

symbol

Designation

Hole diameter

or bolt or nut

size mm {in}

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

Rear side frame standard hole

Link bracket

Rear suspension housing

A

B

C

D

E

F

G

H

I

J

K

Rear side frame standard hole

Shows bolt size

Shows hole diameter

Shows

slot

mm {in}

UNDERBODY FLAT-PLANE DIMENSIONS

φ 16 {0.62}

M14 {0.55}

φ 80 {3.14}

Point

symbol

Designation

Hole diameter

or bolt or nut

size mm {in}

φ 16 {0.62}

φ 31 {1.22}

φ 12 {0.47}

Rear suspension housing

L

φ 12 {0.47}

φ 16 {0.62}

φ 18 {0.62}

17 × 29.5

{0.66×1.16}

ABCDE F G H I J KL

1,016

{40.00}

687

{27.05}

420

182 93 144 120

{7.17} {3.66} {5.67} {4.72}

1,030

140

760

68

{5.51} {2.68}

379

{16.54}

{40.55}

{29.92} {14.92}

{25.75}

654

1,084 {42.84}

579

{22.80}

479

{18.86}

436

{17.17}

445

512

660

1,043

666

{17.52}

{20.16}

{25.98}

{41.06}

{26.22}

1,106 {43.54}

1,164

543

485

484

{21.37}

{19.05}

478

1,073 {37.91}

455

{17.91}

469

{18.46}

760

605

650

{29.92}

{23.82}

{25.59}

650

{45.83}

{25.59}

LH

RH

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GENERAL INFORMATION

00-00–6

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.

817

FRONT FENDER INSTALLATION NUT

STRAIGHT-LINE DIMENSIONS

{32.17}

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GENERAL INFORMATION

00-00–7

00-00

Example

Symbols of Body Dimensions

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

End Of Sie

1,128

{44.41}

A

B

C

H

D

I

E

F

G

1,398

{55.04}

1,406

{55.35}

{42.01}

1,067

799

{31.46}

1,263

{49.72}

1,048

{41.26}

{33.50}

A

F

G

B

H

I

C

D

E,E'

Fr

Fr Fr

FrFr

Fr

Front pillar inner designation

Front floor pan designation

Adjuster installation hole

Trim installation hole

Harness installation hole

Chaker bracket installation hole

A

B

C

D

E

F

G

H

I

φ 16 {0.62}

φ 18 {0.71}

φ 16 {0.62}

Harness installation hole

Point

symbol

Designation

Hole diameter

or bolt or nut

size mm {in}

Point

symbol

Designation

Hole diameter

or bolt or nut

size mm {in}

Shows bolt size

Shows hole diameter

Shows

slot

851

φ 16 {0.62}

M14 {0.55}

φ 31 {1.22}

φ 17 {0.67}

17 × 29.5

{0.66×1.16}

φ 12 {0.47}

ROOM STRAIGHT-LINE DIMENSIONS (1)

Shows vehicle section

Shows dimension location

Shows outline drawing

Shows point

symbol

Shows point indication

Without apostrophe:RH

With apostrophe:LH

Shows details of the standard

point location

Shows position and shape of the points

Shows dimension

No indication are shown

within the outline drawing.

When there are no specific indications, all of

units are in millimeters (mm).

mm {in}

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SYMBOL

MEANING

SYMBOL

MEANING

Center of circular hole

Center elliptical hole

Notch

Panel seam, bead, etc.

Bolt tip

(arrow only)

Center of rectangular-shaped hole

Edge of rectangular-shaped hole

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GENERAL INFORMATION

00-00–8

AIR BAG SYSTEM SERVICE WARNINGS

id000000920000

Air Bag Module Inspection

• Inspecting an air bag module using a tester can operate (deploy) the air bag module, which may cause

serious injury. Do not use a tester to inspect an air bag module. Always use the on-board diagnostic

function to diagnose the air bag module for malfunctions.

Air Bag Module Handling

• Before removing the air bag module or disconnecting the air bag module connector, always switch the

ignition off, disconnect the negative battery cable, and then wait for 1 min or more to allow the backup

power supply of the SAS control module to deplete its stored power.

• Handling a live (undeployed) air bag module

that is pointed toward your body could result

in serious injury if the air bag module were to

accidentally operate (deploy). When carrying

a live (undeployed) air bag module, point the

deployment surface away from your body to

lessen the chance of injury in case it operates

(deploys).

• A live (undeployed) air bag module placed

with its deployment surface to the ground is

dangerous. If the air bag module were to

accidentally operate (deploy), it could cause

serious injury. Always place a live

(undeployed) air bag module with its

deployment surface up.

Side Air Bag Module Handling

• Before removing the side air bag module or disconnecting the side air bag module connector, always

switch the ignition off, disconnect the negative battery cable, and then wait for 1 min or more to allow

the backup power supply of the SAS control module to deplete its stored power.

• When a side air bag module operates (deploys) due to a collision, the interior of the seat back (pad,

frame, trim) may become damaged. If a side air bag does not operate (deploy) normally from a seat

back that has been reused, a serious accident may result. After a side air bag has operated (deployed),

always replace both the side air bag module and the seat back (pad, frame, trim) with new parts. After

servicing, verify that the seat operates normally and that the wiring harness is not caught.

NO GOOD

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GOOD

NO GOOD

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NO GOOD

GOOD

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GENERAL INFORMATION

00-00–9

00-00

SAS Control Module Handling

• When connecting or disconnecting the SAS control module connector, a person charged with static

electricity could accidentally operate (deploy) each air bag module. Before connecting or

disconnecting the SAS control module connector, discharge any charged static electricity from your

body.

• Removing the SAS control module or disconnecting the SAS control module connector with the

ignition ON can activate the sensor in the SAS control module and operate (deploy) the air bags and

pre-tensioner seat belts, which may cause serious injury. Before removing the SAS control module or

disconnecting the SAS control module connector, always switch the ignition off, disconnect the

negative battery cable, and then wait for 1 min or more to allow the backup power supply of the SAS

control module to deplete its stored power.

• Connecting the SAS control module connector with the SAS control module not securely fixed to the

vehicle is dangerous. The sensor in the SAS control module could send an electrical signal to the air

bag modules and pre-tensioner seat belts. This will operate (deploy) the air bags and pre-tensioner

seat belts, which may result in serious injury. Therefore, before connecting the connector, securely fix

the SAS control module to the vehicle.

• Because a sensor is built into the SAS control module, once the air bags and pre-tensioner seat belts

have operated (deployed) due to a collision or other causes, the SAS control module must be replaced

with a new one even if the used one does not have any visible external damage or deformation. The

used SAS control module may have been damaged internally, which may cause improper operation. If

the SAS control module is reused, the air bags and pre-tensioner seat belts may not operate (deploy)

normally, which could result in a serious accident. Always replace the SAS control module with a new

one. The SAS control module cannot be bench-checked or self-checked.

Crash Zone Sensor Handling

• Removing the crash zone sensor or disconnecting the crash zone sensor connector with the ignition

ON can activate the crash zone sensor and operate (deploy) the air bags and pre-tensioner seat belts,

which may cause serious injury. Before removing the crash zone sensor or disconnecting the crash

zone sensor connector, always switch the ignition off, disconnect the negative battery cable, and then

wait for 1 min or more to allow the backup power supply of the SAS control module to deplete its stored

power.

• If the crash zone sensor is subjected to shock or the sensor is disassembled, the air bags and pre-

tensioner seat belts may accidentally operate (deploy) and cause injury, or the system may fail to

operate normally and cause a serious accident. Do not subject the crash zone sensor to shock or

disassemble the sensor.

• Because a sensor is built into the crash zone sensor, once the air bags and pre-tensioner seat belts

have operated (deployed) due to a collision or other causes, the crash zone sensor must be replaced

with a new one even if the used one does not have any visible external damage or deformation. If the

crash zone sensor is reused, the air bags and pre-tensioner seat belts may not operate (deploy)

normally, which could result in a serious accident. Always replace the crash zone sensor with a new

one. The crash zone sensor cannot be bench-checked or self-checked.

Side Air Bag Sensor Handling

• Removing the side air bag sensor or disconnecting the side air bag sensor connector with the ignition

ON can activate the side air bag sensor and operate (deploy) the side air bag, which may cause serious

injury. Before removing the side air bag sensor or disconnecting the side air bag sensor connector,

always switch the ignition off, disconnect the negative battery cable, and then wait for 1 min or more to

allow the backup power supply of the SAS control module to deplete its stored power.

• If the side air bag sensor is subjected to shock or the sensor is disassembled, the side air bag may

accidentally operate (deploy) and cause injury, or the system may fail to operate normally and cause a

serious accident. Do not subject the side air bag sensor to shock or disassemble the sensor.

• Because a sensor is built into the side air bag sensor, once the air bag has operated (deployed) due to

a collision or other causes, the side air bag sensor must be replaced with a new one even if the used

one does not have any visible external damage or deformation. If the side air bag sensor is reused, the

side air bag may not operate (deploy) normally, which could result in a serious accident. Always

replace the side air bag sensor with a new one. The side air bag sensor cannot be bench-checked or

self-checked.

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GENERAL INFORMATION

00-00–10

Pre-tensioner Seat Belt Inspection

• Inspecting a pre-tensioner seat belt using a

tester can operate (deploy) the pre-tensioner

seat belt, which may cause serious injury. Do

not use a tester to inspect a pre-tensioner

seat belt. Always use the on-board diagnostic

function to diagnose the pre-tensioner seat

belt for malfunctions.

End Of Sie

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.

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.

Remove Dangerous Articles

• Remove the fuel tank before using an open flame

in that area. Plug connection piping to prevent

fuel leakage.

NO GOOD

ac5uuw00001455

WELDING

GLASSES

EAR

PROTECTORS

WELDING

GLOVES

COTTON

GLOVES

DUST SAFETY

FACE SHIELD

SAFETY

MASK GLASSES

SHOES

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GENERAL INFORMATION

00-00–11

00-00

Use of Pulling Equipment

• When using pulling equipment, keep away from

the pulling area and use safety wires to prevent

accidents.

Prevent Short Circuits

• Switch the ignition to off.

• Disconnect the battery cables.

• Securely connect the welding machine ground

near the welding area.

End Of Sie

SAFETY WIRES

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Battery cable

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GROUND

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GENERAL INFORMATION

00-00–12

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.

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.

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.

Removal of Associated Parts

• Protect moldings, garnishes, and ornaments with tape when removing associated parts.

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GENERAL INFORMATION

00-00–13

00-00

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 {1.2—1.9 in} and then rough-cut the

damaged panel.

End Of Sie

EFFICIENT INSTALLATION OF BODY PANELS

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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.

Welding Notes

• For the number of weld points, welding should be

performed in accordance with the following

reference standards.

Wiring harness

Rough cut location

Cut-and-join location

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SPOT WELDING

ORIGINAL WELD

IF 3 mm

{0.12 in} OR MORE

ORIGINAL NUMBER OF

WELDS x 1.3 OR MORE

CO

2

ARC WELDING

ORIGINAL SPOT WELD

REPAIR WELD

ORIGINAL NUMBER OF

WELDS OR MORE

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GENERAL INFORMATION

00-00–14

Spot Welding Notes

• The shape of the spot welder tip is D=(2×t)+3. If

the upper panel thickness is different from that of

the under panel, adjust to the thinner one.

• Because the weld strength is affected by the

shape of the spot welder tip, the optimum

condition of the tip should always be maintained.

• Spot welds should be made at points other than

the originally welded points.

• Before spot welding, make a trial weld using the

same material as the body panel to check the

weld strength.

D

70

—120°

t

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TEST PIECE METHOD

NUGGET DIAMETER

:4/5 OF TIP

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GENERAL INFORMATION

00-00–15

00-00

Checking Weld Strength

• Installation locations of the engine, chassis, and

seat belts are designated as important safety

locations for weld strength. Check weld strength

by driving a chisel between the panels at every

fourth or fifth weld spot, and every tenth regular

weld location.

• Drive the chisel between the panels according to

the number of panels as shown below.

• To determine weld strength, drive the chisel

between the panel and check whether the panels

come apart. If the panels come apart, make

another weld near the original weld.

• Restore the shape of the checked area.

End Of Sie

CHISEL DIMENSIONS

25 mm

{0.98 in}

8 mm {0.31 in}

{0.20 in}

20°

WELD LOCATION

WITHIN 5 mm

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TWO PANELS

WELD LOCATION

THREE PANELS

ONE LOCATION

TWO LOCATION

FOUR PANELS

THREE LOCATION

WELD LOCATION

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GENERAL INFORMATION

00-00–16

INSTALLATION PREPARATIONS

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Rough Cutting of New Parts

• For cut-and-join areas, allow for an overlap of 30—50 mm {1.2—1.9 in} with the remaining area on the body

side and then rough-cut the new parts.

Determination of Welding Method

• If the total thickness at the area to be welded is 3 mm {0.12 in} or more, use a gas shielded-arc welder to make

the plug welds.

Making Holes for Arc Welding

• For places that cannot be spot welded, make a hole for arc welding using a punch or drill as follows.

(mm {in})

• Grind the shaded section indicated in the diagram below and create a hole in the part where the 3—4 plates

are put together. Also, weld the plates together tightly so that gaps do not develop.

OVER LAP

BODY SIDE ROUGH CUT LOCATION

NEW PART ROUGH CUT LOCATION

30—50 mm{1.2—1.9 in}

30

—50 mm{1.2—1.9 in}

OVER LAP

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3 mm

{0.1 in} OR MORE

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Panel thickness (φ) Hole diameter (φ)

0.60—0.90 {0.024—0.035} 5.0 {0.20}

0.91—1.20 {0.036—0.047} 6.0 {0.24}

1.21—1.80 {0.0477—

0.0708}

8.0 {0.31}

1.81—4.50 {0.072—0.177} 10.0 {0.394}

φ

10.0 mm {0.394 in}

OUTER PANEL

MIDDLE PANEL

INNER PANEL

30°

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GENERAL INFORMATION

00-00–17

00-00

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

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.

Application of Undercoating

• Apply an undercoat to the required location of the body.

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GENERAL INFORMATION

00-00–18

Application of Rust Inhibitor

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

Application of Dumping Sheet

• Apply dumping sheet by heating with an infrared ray lamp.

End Of Sie

ABBREVIATION

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End Of Sie

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Fr Front

LH Left Hand

RH Right Hand

Rr Rear

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Mazda 6 2014 -Body Shop Manual

Mazda 6 2014 -Body Shop Manual

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