Mazda 5. Manual - part 65

BODY STRUCTURE [PANEL REPLACEMENT]

09–80B–23

09

End Of Sie

FRONT SIDE FRAME (PARTIAL CUTTING) REMOVAL

DPE098053300B03

1. Rough cut and remove the damaged part of the front side frame.

3

4

9

10

FRONT SIDE FRAME COMPONENT

DPE0980B065

09–80B–24

BODY STRUCTURE [PANEL REPLACEMENT]

End Of Sie

FRONT SIDE FRAME (PARTIAL CUTTING) INSTALLATION

DPE098053300B04

Caution

• The cut-and-joint area indicates the maximum size range of the installation position.

1. Make a reinforcement panel using the material from the front side frame.
2. To cut and join the new and existing parts, cut the new part at the specified location shown in the figure, and 

chamfer the joint surfaces of the new and existing parts.

3. When installing the new parts, trial-fit new and existing parts, and then measure and adjust the body to conform 

with standard dimensions.

130mm
{5.12in}

40mm

{1.57in}

5

6

240mm

{9.45in}

40mm

{1.57in}

FRONT SIDE FRAME

ROUGH CUT 
LOCATION (INNER)

ROUGH CUT 
LOCATION (OUTER)

CUT-AND-JOIN 
LOCATION (OUTER)

CUT-AND-JOIN 
LOCATION (INNER)

DPE0980B074

BODY STRUCTURE [PANEL REPLACEMENT]

09–80B–25

09

4. To install the inner, trial-fit the new and existing parts, weld the existing parts and the reinforcement, and then 

butt weld the new and existing parts.

5. Because the outer cannot be welded to the existing parts from the inside of the frame, drill 2 plug weld holes at 

the locations indicated by (A) on the existing parts. Install the reinforcement and the existing parts by plug 
welding from the outside of the frame, then butt weld the new and existing parts.

Caution

• Press fit the reinforcement panel and the body side material, and then plug weld them.

6. Grind the area where the inner and outer are butt welded with a disc grinder to finish the surface.

REINFORCEMENT

REINFORCEMENT

65mm

30mm

OUTER:t=2.0mm

INNER:t=2.0mm

L=10mm x 2

L=10mm x 6

{0.39in}

{0.39in}

{0.08in}

{0.08in}

{1.18in} 

{2.56in}

240mm

{9.45in}

CUT-AND-JOIN 
LOCATION (INNER)

FRONT SIDE FRAME

FRONT SIDE FRAME 
(INNER)

NEW FRONT SIDE FRAME (INNER)

DPE0980B075

09–80B–26

BODY STRUCTURE [PANEL REPLACEMENT]

End Of Sie

TORQUE BOX REMOVAL

DPE098053381B01

1. Drill the 2 locations indicated by (A) from the interior.
2. Remove the torque box.

130mm

{5.12in}

{0.39in}

(A)2

5

6

L=10mm x 2

FRONT SIDE FRAME (OUTER)

NEW FRONT SIDE FRAME (OUTER)

CUT-AND-JOIN 
LOCATION (OUTER)

REINFORCEMENT

DPE0980B076