2012-2014 Mazda Mazda5 Service & Repair Manual

Title Section GENERAL INFORMATION 00 BODY STRUCTURE BODY STRUCTURE 80A PANEL REPLACEMENT 80B WATER-PROOF AND RUST PREVENTIVE 80C DIMENSIONS 80D PLASTIC BODY PARTS 80E CONSTRUCTION STANDARD VALVES 80F CONTENTS 2012-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. 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. © 2010 Mazda Motor Corporation PRINTED IN U.S.A., OCTOBER 2010 Form No. 3494–1U–10J Part No. 9999–95–030F–12

VEHICLE IDENTIFICATION NUMBERS (VIN) JM1 CW2✻L✻C# 100001—

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 2012 Model Year . . . . . . . . . . . . . . . . . . 00-00–2 VEHICLE IDENTIFICATION NUMBERS (VIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-00–2 2012 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 Side Air Bag Sensor Handling. . . . . . . . 00-00–9 Pre-tensioner Seat Belt Inspection . . . . 00-00–9 Lap 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 . . . . . . . . . . . . . . . . . . . . 00-00–11 Body Measurements . . . . . . . . . . . . . . 00-00–11 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 . . . . 00-00–12 EFFICIENT INSTALLATION OF BODY PANELS . . . . . . . . . . . . . . . . . . . 00-00–12 Checking Preweld Measurements And Watching . . . . . . . . . . . . . . . . . . . . . . 00-00–12 Welding Notes . . . . . . . . . . . . . . . . . . . 00-00–13 Spot Welding Notes . . . . . . . . . . . . . . . 00-00–13 Checking Weld Strength. . . . . . . . . . . . 00-00–14 INSTALLATION PREPARATIONS. . . . . . 00-00–15 Rough Cutting of New Parts . . . . . . . . . 00-00–15 Determination of Welding Method . . . . 00-00–15 Making Holes for CO 2 Arc Welding . . . 00-00–15 Application of Weld-through Primer . . . 00-00–16 ANTICORROSION, SOUND INSULATION, AND VIBRATION INSULATION . . . . . . 00-00–16 Body Sealing . . . . . . . . . . . . . . . . . . . . 00-00–16 Application of Undercoating . . . . . . . . . 00-00–16 Application of Rust Inhibitor . . . . . . . . . 00-00–17 Application of Dumping Sheet . . . . . . . 00-00–17 ABBREVIATION . . . . . . . . . . . . . . . . . . . 00-00–17 BODY COLORS . . . . . . . . . . . . . . . . . . . . 00-00–17 Color Code and Color Name . . . . . . . . 00-00–17 Verification of Primary Color Mixture for Body Color . . . . . . . . . . . . . . . . . . . . . 00-00–17 IDENTIFICATION NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . 00-00–18 Vehicle Identification Number (VIN) . . . 00-00–18 Engine Identification Number . . . . . . . . 00-00–18 End of Toc BM: GENERAL INFORMATION

GENERAL INFORMATION 00-00–2 VEHICLE IDENTIFICATION NUMBER (VIN) CODE id000000600800 2012 Model Year End Of Sie VEHICLE IDENTIFICATION NUMBERS (VIN) id000000600100 2012 Model Year JM1 CW2*L*C# 100001— End Of Sie J M 1 C W 2 W L 0 C 0 1 2 3 4 5 6 Plant Serial No. 0= Hiroshima 1= Hofu Body style A, B, C, D, E, W= Wagon World manufacturer identification Model year Engine Carline and Series CW= Mazda5 JM1= Mazda/Passenger car/USA L= 2.5 L (MZR 2.5) USA/Canada/Mexico 2= with Side Air bags, Front Wheel Drive Check digit 0 to 9, X C= 2012 Restraint system and Axle configuration am5uuw0000360

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 (A)17 17 4 5 7 1 5 acxuub00000031 SYMBOL MEANING Spot welding CO 2 arc welding (plug welding) CO 2 spot welding SYMBOL MEANING Continuous MIG welding (Cut-and-join location) Braze welding Rough cut location acxuub00000032

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 am5ezb0000017

GENERAL INFORMATION 00-00–5 00-00 Example Shows vehicle section Shows outline drawing Shows dimension Shows point symbol 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 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 Rear side frame standard hole Shows bolt size Shows hole diameter mm {in} UNDERBODY FLAT-PLANE DIMENSIONS 16 {0.62} 16 {0.62} 16 {0.62} M14 {0.55} 80 {3.14} 16 {0.62} 31 {1.22} 12 {0.47} Rear suspension housing L 12 {0.47} 16 {0.62} 18 {0.62} 17 29.5 {0.66 1.16} A B C D E F G H I J K L 182 93 144 120 {7.17} {3.66} {5.67} {4.72} 140 68 {5.51} {2.68} LH RH 1,016 {40.00} 469 {18.46} 455 {17.91} 1,106 {43.54} 760 {29.92} 605 {23.82} 650 {25.59} 650 {25.59} 650 {25.59} 1,164 {45.83} 543 {21.37} 484 {19.05} 1,073 {37.91} 485 {19.1} 478 {18.8} The dimensions on the left and right in regard to the center of the vehicle are different. Shows hypothetical standard line When there are no specific indications, all of units are in millimeters (mm). Shows slot Designation Point symbol Hole diameter or bolt or nut size mm {in} Designation Point symbol Hole diameter or bolt or nut size mm {in} 687 {27.05} 654 {25.75} 1,084 {42.84} 579 {22.80} 479 {18.86} 436 {17.17} 436 {17.17} 445 {17.52} 512 {20.16} 660 {25.98} 1,043 {41.06} 666 {26.22} 420 {16.54} 1,030 {40.55} 760 {29.92} 379 {14.92} am5ezb0000017

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 {32.17} FRONT FENDER INSTALLATION NUT STRAIGHT-LINE DIMENSIONS am5ezb0000017

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 A B C H D I E F G A F G B H I C D E,E' Fr Fr Fr Fr Fr Fr Fr Fr Fr Front pillar inner designation Front pillar inner designation Front floor pan designation Adjuster installation hole Trim installation hole Harness installation hole Chaker bracket installation hole Chaker bracket installation hole A B C D E F G H I 16 {0.62} 18 {0.71} 16 {0.62} Harness installation hole Designation Shows bolt size Shows hole diameter Shows slot 16 {0.62} M14 {0.55} 31 {1.22} 17 {0.67} 12 {0.47} 1,128 {44.41} 1,263 {49.72} 1,048 {41.26} 1,406 {55.35} 851 {33.50} 1,067 {42.01} 799 {31.46} 1,398 {55.04} Point symbol Hole diameter or bolt or nut size mm {in} Designation Point symbol Hole diameter or bolt or nut size mm {in} 17 29.5 {0.66 1.16} ROOM STRAIGHT-LINE DIMENSIONS (1) Shows vehicle section Shows dimension location Shows outline drawing Shows position and shape of the points Shows dimension mm {in} No indication are shown within the outline drawing. Shows point symbol When there are no specific indications, all of units are in millimeters (mm). Shows point indication Without apostrophe:RH With apostrophe:LH Shows details of the standard point location am5ezb0000017 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 acxuub00000037

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 to 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 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 to 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 am3uuw0000368 GOOD NO GOOD am3uuw0000368 NO GOOD GOOD am3uuw0000369

2012-2014 Mazda Mazda5 Service & Repair Manual

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