2014-2015 Mazda 6 2.5L Skyactiv-G i4 Service & Repair 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. 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. © 2012 Mazda Motor Corporation PRINTED IN U.S.A., DECEMBER 2012 Form No. 3525–1U–12L Part No. 9999–95–099F–14

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—

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 Verification of Primary Color Mixture for Body Color . . . . . . . . . . . . . . . . . . . . . 00-00–19 End of Toc BM: GENERAL INFORMATION

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 am6xuw0000649

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 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

2014-2015 Mazda 6 2.5L Skyactiv-G i4 Service & Repair Manual

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