Mazda 5. Manual - part 81

BODY STRUCTURE [DIMENSIONS]

09–80D–15

09

End Of Sie

BODY STRUCTURE [PLASTIC BODY PARTS]

09–80E–1

09

09–80E

BODY STRUCTURE [PLASTIC BODY PARTS]

PLASTIC PARTS HEAT RESISTING 

TEMPERATURE  . . . . . . . . . . . . . . . . . .  09–80E–1

REPAIRABLE RANGE OF POLYPROPYLENE 

BUMPERS . . . . . . . . . . . . . . . . . . . . . . .  09–80E–1

POLYPROPYLENE BUMPER REPAIR . .  09–80E–3
PROCEDURE  . . . . . . . . . . . . . . . . . . . . .  09–80E–3

PLASTIC LIFTGATE. . . . . . . . . . . . . . . . . 09–80E–8
REPAIRABLE RANGE OF POLYCARBONATE; 

ABS-RESIN LIFTGATE  . . . . . . . . . . . . . 09–80E–9

REPAIR OF POLYCARBONATE; 

ABS-RESIN LIFTGATE  . . . . . . . . . . . . . 09–80E–11

End of Toc

PLASTIC PARTS HEAT RESISTING TEMPERATURE

DPE098050000B01

Note

• The application of temperatures higher than heat resisting temperatures may result in part deformation.

End Of Sie

REPAIRABLE RANGE OF POLYPROPYLENE BUMPERS

DPE098050000B02

The three types of damaged bumpers shown below are considered repairable. Although a bumper which has been 
damaged greater than this could also be repaired, it should be replaced with a new one because such repair would 
detract from the looks and quality of the bumper. In addition, such repair is not considered reasonable in terms of 
work time.

Part Name

Code

Material Name

Heat resisting

Temperature

°C{°F}

WINDSHIELD MOULDING

PVC

POLYVINYLCHLORIDE

95 {203}

COWL GRILLE

PP

POLYPROPYLENE

95 {203}

FRONT COMBINATION 
LIGHT

LENS

PC

POLYCARBONATE

130 {266}

HOUSING

PP

POLYPROPYLENE

90 {194}

RADIATOR GRILLE

PP

POLYPROPYLENE

95 {203}

FRONT BUMPER

PP

POLYPROPYLENE

100 {212}

SIDE TURN LIGHT

LENS

PMMA

ACRYLIC

75 {167}

HOUSING

PC-PBT

POLYCARBONATE-PBT

80 {176}

OUTSIDE MIRROR

ABS

ABS

100 {212}

SIDE STEP MOLDING

PP

POLYPROPYLENE

75 {167}

ROOF MOULDING

PVC

PVC

95 {203}

REAR BUMPER

PP

POLYPROPYLENE

100 {212}

REAR COMBINATION 
LIGHT

LENS

PMMA

ACRYLIC

80 {176}

HOUSING AAS

AAS

70 

{158}

OUTER HANDLE

LEVER

PC-PBT

POLYCARBONATE-PBT

80 {176}

BASE

PC-PET

POLYCARBONATE-PET

80 {176}

HIGH-MOUNT BRAKE 
LIGHT

LENS

PMMA

ACRYLIC

80 {176}

HOUSING

ABS

ABS

100 {212}

REAR SPOILER

PP

POLYPROPYLENE

90 {194}

PILLAR GARNISH

AES

AES

90 {194}

DOOR GARNISH

AES

AES

90 {194}

SHROUD PANEL

PP

POLYPROPYLENE

100 {212}

LIFTGATE

OUTER

PC-ABS

POLYCARBONATE-ABS

100 {212}

INNER

PP(GF40%) POLYPROPYLENE-GLASS FIBER

100 {212}

09–80E–2

BODY STRUCTURE [PLASTIC BODY PARTS]

Repairable Bumpers

1. A bumper with a hole less than 50 mm {1.97 in} in 

diameter.

2. A bumper with a crack less than 100 mm {3.94 in} 

in length.

3. A bumper with a crack less than 100 mm {3.94 in} 

in length that is less than half of the width of the 
bumper.

End Of Sie

YMU980PCM

YMU980PCN

LESS THAN HALF OF (A)  

(A)

YMU980PCP

BODY STRUCTURE [PLASTIC BODY PARTS]

09–80E–3

09

POLYPROPYLENE BUMPER REPAIR

DPE098050000B03

End Of Sie

PROCEDURE

DPE098050000B04

Repair of polypropylene bumpers having damage that has reached the surface of the polypropylene and are too 

Scratch on paint only

Hole or crack through surface

Crack more than 100 mm

{3.94in} long or completely

broken

Bumper
surface

Bumper
surface
not visible

visible

Remove paint

Smooth damaged area

Apply aluminium tape to

reverse side of bumper

Plastic weld damaged area 

Rough sand damage area

Degrease damaged area

Apply repair agent to 
damaged area and let dry

Sand damaged area
smooth

Sand dam-

aged area

Apply polypropylene primer to damaged 
area and let dry 

Spray primer surfacer on damaged area

and let dry

Spray primer surfacer on

bumper and let dry

Sand surface of bumper

Sand partial or complete surface of bumper 

Degrease bumper

Spray matching body color paint on bumper and let dry

Replace damaged

Bumper

Spray entire bumper

surface with
polypropylene primer

Apply polypropylene primer

to damaged area

YMU980PCQ