Title Section

GENERAL INFORMATION 00
BODY
STRUCTURE
CONSTRUCTION 80A
PANEL REPLACEMENT 80B
WATER-PROOF AND RUST
PREVENTIVE TREATMENT
80C
DIMENSIONS 80D
PLASTIC BODY PARTS 80E
CONTENTS
2004 Mazda RX-8 Bodyshop Manual(33791U03D)
2004-2011
RX-8
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 advance 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.
2003 Mazda Motor Corporation
PRINTED IN JAPAN, APRIL 2003
Form No. 33791U03D
3379-10-03D(INDEX).fm 1
Revised 3/2008 (Ref. No. R045/08)
2004 Mazda RX-8 Bodyshop Manual(33791U03D)
VEHICLE IDENTIFICATION NUMBERS (VIN)
JM1 FE172*9# 400001
JM1 FE174*9# 400001
JM1 FE17M*9# 400001
JM1 FE17P*9# 400001
3379-10-03D(INDEX).fm 2
00
GENERAL INFORMATION
00001
SECTION
0000
Toc of SCT
GENERAL INFORMATION. . . . 00-00
Toc of SCT
0000 GENERAL INFORMATION
HOW TO USE THIS MANUAL . . . . . . . . . 00002
Efficient Replacement of
Body Panels . . . . . . . . . . . . . . . . . . . . 00002
Symbols of Panel Replacement . . . . . . 00002
Body Dimensions
(Flat-plane Dimensions) . . . . . . . . . . . 00003
Body Dimensions
(Straight-line Dimensions). . . . . . . . . . 00004
Symbols of Body Dimensions . . . . . . . . 00004
SERVICE PRECAUTIONS . . . . . . . . . . . . 00005
Arrangement of Workshop . . . . . . . . . . 00005
Vehicle Protection . . . . . . . . . . . . . . . . . 00005
Use of Pulling Equipment . . . . . . . . . . . 00005
Safety Precautions . . . . . . . . . . . . . . . . 00006
Prevent Short Circuits . . . . . . . . . . . . . . 00006
Remove Dangerous Articles . . . . . . . . . 00007
EFFICIENT REMOVAL OF
BODY PANELS . . . . . . . . . . . . . . . . . . . 00007
Body Measurements . . . . . . . . . . . . . . . 00007
Prevention of Body Deformation. . . . . . 00008
Selection of Cut-and-join Locations . . . 00008
Removal of Associated Parts . . . . . . . . 00008
Rough Cutting of Damaged Panel . . . . 00009
INSTALLATION PREPARATIONS . . . . . 00009
Application of Weld-through Primer . . . 00009
Determination of Welding Method . . . . 000010
Making Holes for CO2 Arc Welding . . . 000010
Rough Cutting of New Parts. . . . . . . . . 000010
EFFICIENT INSTALLATION OF
BODY PANELS . . . . . . . . . . . . . . . . . . . 000011
Checking Preweld Measurements And
Watching . . . . . . . . . . . . . . . . . . . . . . 000011
Welding Notes . . . . . . . . . . . . . . . . . . . 000011
Spot Welding Notes . . . . . . . . . . . . . . . 000012
Checking Weld Strength. . . . . . . . . . . . 000013
ANTICORROSION, SOUND INSULATION,
AND VIBRATION INSULATION . . . . . . 000014
Body Sealing . . . . . . . . . . . . . . . . . . . . 000014
Application of Undercoating . . . . . . . . . 000014
Application of Rust Inhibitor . . . . . . . . . 000014
Application of Floor Silencer. . . . . . . . . 000014
ABBREVIATION . . . . . . . . . . . . . . . . . . . 000015
End of Toc
GENERAL INFORMATION
00002
HOW TO USE THIS MANUAL
CHU000000001B01
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
CUT-AND-JOIN LOCATION
CUT-AND-JOIN LOCATION
ROUGH CUT LOCATION
ROUGH CUT LOCATION
Shows number of weld
Shows welding region
Shows a cross
Shows a insulator
Shows a dimensions
Shows a cross location
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 24 weld locations indicated by (A), from the room side.
Caution
NOTE
BOTTOM SIDE 1
{9.84 in}
250 mm
(A) 24
19
17
A-A
A A
B-B
30 mm
B B
{1.18in}
8
4
MZZ2010B001
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
MZZ2010B002
GENERAL INFORMATION
00003
0000
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.
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
Designations
Hole diameter
or bolt or nut
size mm {in}
1
,
0
3
0

{
4
0
.
5
5
}
1
,
1
6
2

{
4
5
.
7
8
}
9
1
8

{
3
8
.
1
4
}
6
9
0

{
2
7
.
1
7
}
8
0
0

{
3
1
.
5
0
}
1
,
0
8
9

{
4
2
.
8
7
}
1
,
0
6
0

{
4
1
.
7
3
}
4
9
5

{
1
9
.
4
8
}
4
8
5

{
1
9
.
0
9
}
6
1
9

{
2
4
.
3
8
}
7
2
5

{
2
8
.
5
5
}
1
,
2
1
1

{
4
7
.
6
8
}
6
0
9

{
2
4
.
0
0
}
5
2
7

{
2
0
.
7
5
}
4
8
7

{
1
9
.
1
9
}
5
8
7

{
2
3
.
1
1
}
5
4
7

{
2
1
.
5
4
}
6
2
4

{
2
4
.
5
6
}
7
0
0

{
2
7
.
5
8
}
716
{28.21}
1,240
{48.82}
320
{12.62}
55
{2.19}
185
{7.28}
98
{3.86}
425
{16.73}
315
{12.40}
489
{19.27}
A
Crossmember No,1 standard
hole
B
Front side frame standard hole
C
Front suspension mounting
block surface hole center
D
Front suspension mounting
bolt
E
Front frame rear standard hole
F
Front frame rear standard hole
G
Rear side frame standard hole
H
Link bracket
I
Rear suspension housing
J
A
B
C
D
E
F
G
H
I
J Rear side frame standard hole
Shows bolt size
Shows hole diameter
Shows
slot
mm {in}
UNDERBODY FLAT-PLANE DIMENSIONS
16 {0.62}
16 {0.62}
16 {0.62}
M14 {0.55}
80 {3.14}
Point
symbol
Designations
Hole diameter
or bolt or nut
size mm {in}
16 {0.62}
12 {0.47}
16 {0.62}
18 {0.62}
17 29.5
{0.661.16}
1
,
2
2
0

{
4
8
.
0
3
}
MZZ2010B003
GENERAL INFORMATION
00004
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.
Example
Symbols of Body Dimensions
The following 8 symbols are used to indicate the standard points.
End Of Sie
ROOM STRAIGHT-LINE DIMENSIONS (2)
Shows vehicle section
Shows dimension location
Shows outline drawing
C
D
A
G
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.
A
Fr
Fr
Fr
Fr
Fr
Fr
Fr
Fr
Fr
Measured
location
Dimensions mm {in}
1
2
3
4
5
6
7
1,184 {46.61}
1,064 {41.89}
919 {36.18}
690 {27.17}
1,185 {46.65}
901 {35,47}
607 {23.90}
Measured
location
Dimensions mm {in}
8
9
10
11
B-B'
C-C'
D-D'
1,667 {65.63}
1,672 {65.83}
1,037 {40.83}
1,290 {50.79}
1,208 {47.56}
1,463 {57.60}
1,642 {64.65}
B C D
H G F
E,E
,
E
E
,
H
,
E. E
,
H
I
B
F
,
I
1 5
6
9
7 3
2
4
8
F
11
10
MZZ2010B004
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
MZZ2010B005
GENERAL INFORMATION
00005
0000
SERVICE PRECAUTIONS
CHU000000014B01
Arrangement of Workshop
Arrangement of the workshop is important for safe and efficient work.
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.
Use of Pulling Equipment
When using pulling equipment, keep away from
the pulling area and use safety wires to prevent
accidents.
YMU980PA5
YMU980PA6
GENERAL INFORMATION
00006
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.
Prevent Short Circuits
When removing a wiring harness or electrical
component, disconnect the negative battery
cable.
YMU980PA7
YMU980PA8
GENERAL INFORMATION
00007
0000
Remove Dangerous Articles
Remove the fuel tank before using an open flame
in that area. Plug connection piping to prevent
fuel leakage.
End Of Sie
EFFICIENT REMOVAL OF BODY PANELS
CHU000000015B01
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.
YMU980PA9
YMU980PAA
GENERAL INFORMATION
00008
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.
YMU980PAB
YMU980PAC
GENERAL INFORMATION
00009
0000
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
3050 mm {1.181.97 in} and then rough-cut
the damaged panel.
End Of Sie
INSTALLATION PREPARATIONS
CHU000000016B01
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.
YMU980PAD
YMU980PAE
GENERAL INFORMATION
000010
Determination of Welding Method
If the total thickness at the area to be welded is 3
mm {0.12 in} or more, use a CO
2
gas shielded-arc
welder to make the plug welds.
Making Holes for CO
2
Arc Welding
For places that cannot be spot welded, make a hole for CO
2
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.
Rough Cutting of New Parts
For cut-and-join areas, allow for an overlap of
3050 mm {1.181.97 in} with the remaining
area on the body side and then rough-cut the new
parts.
End Of Sie
YMU980PAF
Panel thickness ( ) Hole diameter ( )
0.600.90 {0.020.03} 5 {0.19}
0.911.20 {0.040.05} 6 {0.23}
1.211.80 {0.0510.07} 8 {0.31}
1.814.50 {0.0710.17} 10 {0.39}
YMU980PAG
YMU980PAH
GENERAL INFORMATION
000011
0000
EFFICIENT INSTALLATION OF BODY PANELS
CHU000000017B01
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.
YMU980PAJ
YMU980PAK
GENERAL INFORMATION
000012
Spot Welding Notes
The shape of the spot welder tip is D=(2t)+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
(mm {in})
t
YMU980PAL
YMU980PAM
YMU980PAN
GENERAL INFORMATION
000013
0000
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
YMU980PAP
YMU980PAQ
GENERAL INFORMATION
000014
ANTICORROSION, SOUND INSULATION, AND VIBRATION INSULATION
CHU000000018B01
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.
Application of Rust Inhibitor
Apply rust inhibitor (wax, oil, etc.) to the back of
the welded areas.
Application of Floor Silencer
Apply floor silencer by heating with an infrared ray
lamp.
End Of Sie
YMU980PAR
YMU980PAS
YMU980PAT
YMU980PAU
GENERAL INFORMATION
000015
0000
ABBREVIATION
CHU000000011B01
End Of Sie
CM Control module
Ctr Center
Fr Front
HU Hydraulic unit
LH Left
M Metallic
MC Mica
RH Right
Rr Rear
0980A1
09
BODY STRUCTURE
SECTION
0980A
Toc of SCT
CONSTRUCTION . . . . . . . . . . . 09-80A
PANEL REPLACEMENT . . . . . 09-80B
WATER-PROOF AND RUST
PREVENTIVE . . . . . . . . . . . . . 09-80C
DIMENSIONS. . . . . . . . . . . . . . 09-80D
PLASTIC BODY PARTS . . . . . 09-80E
Toc of SCT
0980A BODY STRUCTURE [CONSTRUCTION]
BODY COMPONENTS
CONSTRUCTION. . . . . . . . . . . . . . . . . . 0980A2
End of Toc
BODY STRUCTURE [CONSTRUCTION]
0980A2
BODY COMPONENTS CONSTRUCTION
CHU098007000B01
.
9
8
7
5
4
3
10
19
18
17
15
16
14
13
11
12
20
29
28
27
25
26
24
23
21
22
30
39
38
37
35
36
33
31
32
40
49
48
47
45
46
44
43
41
42
50
59
58
57
55
56
54
60
69
68
67
65
66
64
63
61
62
70
78
77
75
76
74
73
71
72
6
1
2
34
51
52
53
CHU0980B094
BODY STRUCTURE [CONSTRUCTION]
0980A3
0980A
x:Applied
-:Not applied
No. Part Name High- tension steel Rust proof steel
Thickness
(mm) {in}
1 Hood (*) - - 0.90 {0.035}
2 Radiator shroud upper panel - x 0.80 {0.031}
3 Radiator shroud side stay - x 0.70 {0.028}
4 Radiator shroud lower panel - x 0.70 {0.028}
5 Hood rock bracket - x 0.80 {0.031}
6 Crossmember No.1
Fr x x 0.80 {0.031}
Rr x x 0.70 {0.028}
7 Crossmember No.1 side bracket x x 0.80 {0.031}
8 Suspension housing
Upper x x 1.40 {0.055}
Lower x x 2.00 {0.079}
9 ABS HU/CM bracket x x 1.60 {0.063}
10 Front side frame outer x x 1.40 {0.055}
11 Front bumper bracket x x 2.60 {0.102}
12 Front side frame inner x x 2.00 {0.079}
13 Apron reinforcement upper x x 0.90 {0.035}
14 Wheel apron panel - x 0.65 {0.026}
15 Front side frame rear reinforcement x x 2.00 {0.079}
16 Apron reinforcement lower x x 0.75 {0.030}
17 Frame reinforcement x x 1.60 {0.063}
18 Dash lower panel - x 0.80 {0.031}
19 Dash lower member x - 1.60 {0.063}
20 Dash cowl panel - x 0.65 {0.026}
21 Cowl upper plate x x 1.00 {0.039}
22 Cowl panel - x 0.65 {0.026}
23 Front pillar reinforcement x - 1.20 {0.047}
24 Side panel inner
Fr x - 2.00 {0.079}
Ctr x - 1.40 {0.055}
Rr x - 1.20 {0.047}
25 Hinge reinforcement x - 1.60 {0.063}
26
Side panel reinforcement front
Upper x - 1.60 {0.063}
Lower x - 1.80 {0.071}
Side panel reinforcement center x - 1.20 {0.047}
Side panel reinforcement rear
Upper x - 1.20 {0.047}
Lower x - 1.00 {0.039}
27 Side sill gusset - - 0.90 {0.035}
28 Rear hinge reinforcement
Upper x - 1.20 {0.047}
Lower x - 2.30 {0.091}
29 Cowl side reinforcement x x 1.20 {0.047}
30 Side panel outer x 0.70 {0.028}
31 Filler box - x 0.70 {0.028}
32 Rear fender lower panel - x 0.70 {0.028}
33 Rear suspension housing upper x - 1.40 {0.055}
34 Package reinforcement x - 0.80 {0.031}
35 Roof rail reinforcement x - 0.80 {0.031}
36 Rear fender rain rail - x 0.70 {0.028}
37 C-pillar reinforcement x - 0.90 {0.035}
38 Package gusset - - 0.80 {0.031}
39 Rear pillar inner - x 0.70 {0.028}
40 Wheel house inner - x 0.65 {0.026}
41 Package member front - - 0.70 {0.028}
42 Package tray - - 0.55 {0.022}
BODY STRUCTURE [CONSTRUCTION]
0980A4
: (*) : Material of hood and rear door are aluminum.
End Of Sie
43 Package member rear - - 0.60 {0.024}
44 Trunk lid panel - - 0.75 {0.030}
45 Front header - - 0.90 {0.035}
46 Roof panel - - 0.85 {0.033}
47 Roof reinforcement - - 0.80 {0.031}
48 Rear header - - 0.90 {0.035}
49 Front door - x 0.70 {0.028}
50 Rear door (*) - - 0.90 {0.035}
51 Front fender panel - x 0.75 {0.030}
52 Front frame rear upper x x 1.60 {0.063}
53 Lower arm bracket - x 2.30 {0.091}
54 Front frame rear x x 1.60 {0.063}
55 Torque box - x 1.20 {0.047}
56 Front B-frame x x 1.40 {0.055}
57 Front Floor pan - x 0.65 {0.026}
58 Crossmember No.2 x - 1.40 {0.055}
59 Front floor reinforcement x x 1.20 {0.047}
60 Crossmember No.2.5 - x 1.20 {0.047}
61 Side sill inner x x 1.40 {0.055}
62 Side sill reinforcement x - 1.80 {0.071}
63 Crossmember No.3
RH x x 1.00 {0.039}
Ctr - x 1.60 {0.063}
LH x x 1.00 {0.039}
64 Crossmember No.4 x x 1.00 {0.039}
65 Crossmember No.5 x x 0.90 {0.035}
66 Crossmember No.3 front - x 1.20 {0.047}
67 Center floor pan - x 0.65 {0.026}
68 Tunnel reinforcement rear - - 0.90 {0.035}
69 Rear side frame x x 1.40 {0.055}
70 Side sill inner rear x x 1.40 {0.055}
71 Rear bumper bracket x x 1.20 {0.047}
72 Rear side frame rear x x 1.40 {0.055}
73 Rear floor pan - x 0.65 {0.026}
74 Hook bracket x x 1.20 {0.047}
75 Rear side reinforcement x x 1.80 {0.071}
76 Rear end member - - 0.65 {0.026}
77 Anchor reinforcement - x 1.80 {0.071}
78 Rear end panel - x 0.60 {0.024}
No. Part Name High- tension steel Rust proof steel
Thickness
(mm) {in}
BODY STRUCTURE [PANEL REPLACEMENT]
0980B1
0980B
2004 Mazda RX-8 Bodyshop Manual(33791U03D)
Revised 3/2008 (Ref. No. R045/08)
0980B BODY STRUCTURE [PANEL REPLACEMENT]
RADIATOR SHROUD UPPER PANEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . 0980B2
RADIATOR SHROUD UPPER PANEL
INSTALLATION . . . . . . . . . . . . . . . . . . . 0980B2
RADIATOR SHROUD LOWER PANEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . 0980B3
RADIATOR SHROUD LOWER PANEL
INSTALLATION . . . . . . . . . . . . . . . . . . . 0980B3
FRONT BUMPER BRACKET
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . 0980B4
FRONT BUMPER BRACKET
INSTALLATION . . . . . . . . . . . . . . . . . . . 0980B4
ABS HU/CM BRACKET REMOVAL . . . . 0980B5
ABS HU/CM BRACKET
INSTALLATION . . . . . . . . . . . . . . . . . . . 0980B5
CROSSMEMBER No.1 REMOVAL. . . . . 0980B5
CROSSMEMBER No.1
INSTALLATION . . . . . . . . . . . . . . . . . . . 0980B7
COWL SIDE REINFORCEMENT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . 0980B7
COWL SIDE REINFORCEMENT
INSTALLATION . . . . . . . . . . . . . . . . . . . 0980B9
APRON REINFORCEMENT UPPER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . 0980B9
APRON REINFORCEMENT UPPER
INSTALLATION . . . . . . . . . . . . . . . . . . . 0980B11
APRON REINFORCEMENT LOWER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . 0980B12
APRON REINFORCEMENT LOWER
INSTALLATION . . . . . . . . . . . . . . . . . . . 0980B13
WHEEL APRON PANEL COMPONENT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . 0980B14
WHEEL APRON PANEL COMPONENT
INSTALLATION . . . . . . . . . . . . . . . . . . . 0980B15
FRONT SIDE FRAME REAR
REINFORCEMENT REMOVAL . . . . . . . 0980B15
FRONT SIDE FRAME REAR
REINFORCEMENT INSTALLATION. . . 0980B17
FRONT SIDE FRAME REMOVAL. . . . . . 0980B17
FRONT SIDE FRAME
INSTALLATION . . . . . . . . . . . . . . . . . . . 0980B19
FRONT SIDE FRAME OUTER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . 0980B20
FRONT SIDE FRAME OUTER
INSTALLATION . . . . . . . . . . . . . . . . . . . 0980B21
FRONT SIDE FRAME (PARTIAL CUTTING)
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . 0980B22
FRONT SIDE FRAME (PARTIAL CUTTING)
INSTALLATION. . . . . . . . . . . . . . . . . . . . 0980B23
TORQUE BOX REMOVAL . . . . . . . . . . . . 0980B23
TORQUE BOX INSTALLATION . . . . . . . . 0980B25
FRONT FRAME REAR UPPER
REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . 0980B25
FRONT FRAME REAR UPPER
INSTALLATION. . . . . . . . . . . . . . . . . . . . 0980B27
FRONT FRAME REAR REMOVAL . . . . . 0980B28
FRONT FRAME REAR
INSTALLATION. . . . . . . . . . . . . . . . . . . . 0980B29
FRAME REINFORCEMENT REMOVAL. . 0980B29
FRAME REINFORCEMENT
INSTALLATION. . . . . . . . . . . . . . . . . . . . 0980B31
COWL UPPER PLATE REMOVAL. . . . . . 0980B31
COWL UPPER PLATE
INSTALLATION. . . . . . . . . . . . . . . . . . . . 0980B33
FRONT PILLAR REMOVAL . . . . . . . . . . . 0980B33
FRONT PILLAR INSTALLATION. . . . . . . 0980B36
REAR FENDER PANEL REMOVAL. . . . . 0980B37
REAR FENDER PANEL
INSTALLATION. . . . . . . . . . . . . . . . . . . . 0980B40
REAR FENDER LOWER PANEL
REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . 0980B42
REAR FENDER LOWER PANEL
INSTALLATION. . . . . . . . . . . . . . . . . . . . 0980B43
SIDE SILL PANEL FRONT
REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . 0980B43
SIDE SILL PANEL FRONT
INSTALLATION. . . . . . . . . . . . . . . . . . . . 0980B45
SIDE SILL PANEL REMOVAL . . . . . . . . . 0980B46
SIDE SILL PANEL INSTALLATION . . . . . 0980B47
Drill Hole Install for Rear Deflector . . . . 0980B48
REAR END PANEL REMOVAL . . . . . . . . 0980B49
REAR END PANEL INSTALLATION . . . . 0980B49
REAR FENDER RAIN RAIL AND
CORNER PLATE REMOVAL . . . . . . . . . 0980B50
REAR FENDER RAIN RAIL AND
CORNER PLATE INSTALLATION . . . . . 0980B51
REAR FLOOR PAN REMOVAL . . . . . . . . 0980B51
REAR FLOOR PAN INSTALLATION . . . . 0980B53
REAR SIDE FRAME (PARTIAL CUTTING)
REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . 0980B53
REAR SIDE FRAME (PARTIAL CUTTING)
INSTALLATION. . . . . . . . . . . . . . . . . . . . 0980B55
ROOF PANEL REMOVAL. . . . . . . . . . . . . 0980B55
ROOF PANEL INSTALLATION . . . . . . . . 0980B57
End of Toc
3379-1U-03D(09-80B).fm 1
BODY STRUCTURE [PANEL REPLACEMENT]
0980B2
2004 Mazda RX-8 Bodyshop Manual(33791U03D)
RADIATOR SHROUD UPPER PANEL REMOVAL
CHU098053100B01
1. Remove the radiator shroud upper panel.
End Of Sie
RADIATOR SHROUD UPPER PANEL INSTALLATION
CHU098053100B02
1. When installing new parts, position each part so that the section measurement aligns with the body dimension.
2. Drill holes for plug welds before installing new parts.
3. After temporarily installing new parts, make sure the related parts fit properly.
End Of Sie
8
11
3
2 2
3
3
3
RADIATOR SHROUD UPPER PANEL
CHU0980B036
10
14
3
2 2
4
3
4
RADIATOR SHROUD UPPER PANEL
CHU0980B037
3379-1U-03D(09-80B).fm 2
BODY STRUCTURE [PANEL REPLACEMENT]
0980B3
0980B
RADIATOR SHROUD LOWER PANEL REMOVAL
CHU098053100B03
1. Remove the radiator shroud lower panel.
Note
When removing the radiator shroud side stay and the hood lock bracket separately, drill the 14 weld
locations indicated by (A) and the seven weld locations indicated by (B).
End Of Sie
RADIATOR SHROUD LOWER PANEL INSTALLATION
CHU098053100B04
1. Weld the 14 locations indicated by (A), then temporarily install the condenser bracket and oil cooler bracket.
2. When installing new parts, position each part so that the section measurement aligns with the body dimension.
3. Drill holes for plug welds before installing new parts.
4. Weld the remaining weld locations and install the radiator shroud lower panel.
5. After temporarily installing new parts, make sure the related parts fit properly.
Note
When replacing the radiator shroud side stay and the hood lock bracket separately, weld the 27 locations
indicated by (B).
End Of Sie
(A) 4
(A) 1
(A) 4
(A) 1
(A) 2 (A) 2
(B) 7
1
5
1
5
SHROUD
SIDE STAY
RADIATOR
SHROUD
SIDE STAY
RADIATOR
HOOD LOCK BRACKET
RADIATOR SHROUD LOWER PANEL
CHU0980B038
(B) 5
(B) 1
(B) 5
(B) 1
(B) 3
(A) 5
(A) 5
(A) 2
(B) 3
(B) 9
(A) 2
1
6 1 6
RADIATOR SHROUD LOWER PANEL
CONDENSER BRACKET
SHROUD
SIDE STAY
RADIATOR
SHROUD
SIDE STAY
RADIATOR
HOOD LOCK BRACKET
OIL COOLER BRACKET
OIL COOLER BRACKET
CHU0980B039
BODY STRUCTURE [PANEL REPLACEMENT]
0980B4
FRONT BUMPER BRACKET REMOVAL
CHU098053896B01
1. Remove the front bumper bracket.
End Of Sie
FRONT BUMPER BRACKET INSTALLATION
CHU098053896B02
1. When installing new parts, position each part so that the section measurement aligns with the body dimension.
2. Drill holes for plug welds before installing new parts.
3. After temporarily installing new parts, make sure the related parts fit properly.
End Of Sie
2
2
1
1
FRONT BUMPER BRACKET
CHU0980B032
2
2
1
1
FRONT BUMPER BRACKET
CHU0980B033
BODY STRUCTURE [PANEL REPLACEMENT]
0980B5
0980B
ABS HU/CM BRACKET REMOVAL
CHU098053318B01
1. Remove the ABS HU/CM bracket.
End Of Sie
ABS HU/CM BRACKET INSTALLATION
CHU098053318B02
1. When installing new parts, position each part so that the section measurement aligns with the body dimension.
2. Drill holes for plug welds before installing new parts.
3. After temporarily installing new parts, make sure the related parts fit properly.
End Of Sie
5
3
ABS HU/CM BRACKET
CHU0980B034
5
3
ABS HU/CM BRACKET
CHU0980B035
BODY STRUCTURE [PANEL REPLACEMENT]
0980B6
CROSSMEMBER NO.1 REMOVAL
CHU098053160B01
1. Remove the crossmember No.1.
2. Remove the crossmember No.1 side bracket.
End Of Sie
5
5
5
1
CROSSMEMBER No.1
CROSSMEMBER No.1 SIDE BRACKET
CHU0980B040
BODY STRUCTURE [PANEL REPLACEMENT]
0980B7
0980B
CROSSMEMBER NO.1 INSTALLATION
CHU098053160B02
1. When installing new parts, position each part so that the section measurement aligns with the body dimension.
2. Drill holes for plug welds before installing new parts.
3. After temporarily installing new parts, make sure the related parts fit properly.
End Of Sie
5
5
5
1
CROSSMEMBER No.1
CROSSMEMBER No.1 SIDE BRACKET
CHU0980B041
BODY STRUCTURE [PANEL REPLACEMENT]
0980B8
COWL SIDE REINFORCEMENT REMOVAL
CHU098053290B01
1. Drill the three weld locations indicated by (A) and remove the fender bracket.
2. Drill the 47 weld locations indicated by (B) and remove the cowl side reinforcement.
3. Drill the five weld locations indicated by (C) and remove the cowl side reinforcement inner.
End Of Sie
(B) 2
(B) 4
(B) 6
(B) 8
(C) 2
(C) 2
(A) 3
(C) 1
(B) 18
(B) 6
(B )3
COWL SIDE REINFORCEMENT
COWL SIDE REINFORCEMENT INNER
FENDER BRACKET
CHU0980B042
BODY STRUCTURE [PANEL REPLACEMENT]
0980B9
0980B
COWL SIDE REINFORCEMENT INSTALLATION
CHU098053290B02
1. When installing new parts, position each part so that the section measurement aligns with the body dimension.
2. Drill holes for plug welds before installing new parts.
3. Weld the 18 locations indicated by (A), then temporarily installing the cowl side reinforcement inner and cowl
side reinforcement.
4. After temporarily installing new parts, make sure the related parts fit properly.
End Of Sie
2
4
8
8
2
2
3
1
(A) 18
6
4
COWL SIDE REINFORCEMENT
COWL SIDE REINFORCEMENT INNER
FENDER BRACKET
CHU0980B043
BODY STRUCTURE [PANEL REPLACEMENT]
0980B10
APRON REINFORCEMENT UPPER REMOVAL
CHU098053260B01
1. Remove the apron reinforcement upper.
End Of Sie
4
10
2
7
APRON REINFORCEMENT UPPER
CHU0980B044
BODY STRUCTURE [PANEL REPLACEMENT]
0980B11
0980B
APRON REINFORCEMENT UPPER INSTALLATION
CHU098053260B02
1. When installing new parts, position each part so that the section measurement aligns with the body dimension.
2. Drill holes for plug welds before installing new parts.
3. After temporarily installing new parts, make sure the related parts fit properly.
End Of Sie
4
10
2
7
APRON REINFORCEMENT UPPER
CHU0980B045
BODY STRUCTURE [PANEL REPLACEMENT]
0980B12
APRON REINFORCEMENT LOWER REMOVAL
CHU098053260B03
1. Remove the apron reinforcement lower.
End Of Sie
6
7
1
APRON REINFORCEMENT LOWER
CHU0980B046
BODY STRUCTURE [PANEL REPLACEMENT]
0980B13
0980B
APRON REINFORCEMENT LOWER INSTALLATION
CHU098053260B04
1. When installing new parts, position each part so that the section measurement aligns with the body dimension.
2. Drill holes for plug welds before installing new parts.
3. After temporarily installing new parts, make sure the related parts fit properly.
End Of Sie
6
7
1
APRON REINFORCEMENT LOWER
CHU0980B047
BODY STRUCTURE [PANEL REPLACEMENT]
0980B14
WHEEL APRON PANEL COMPONENT REMOVAL
CHU098053210B01
1. Drill the 18 weld locations indicated by (A) and 15 locations (B), then remove the wheel apron panel
component.
Note
When removing the wheel apron panel front and the wheel apron panel rear separately, drill the 18 weld
locations indicated by (A) and the three weld locations by (C).
End Of Sie
(A) 5
(A) 3
(C) 3
(B) 6
(B) 9
(A) 5
(A) 5
WHEEL APRON PANEL FRONT
WHEEL APRON
PANEL REAR
CHU0980B048
BODY STRUCTURE [PANEL REPLACEMENT]
0980B15
0980B
WHEEL APRON PANEL COMPONENT INSTALLATION
CHU098053210B02
1. When installing new parts, position each part so that the section measurement aligns with the body dimension.
2. Drill holes for plug welds before installing new parts.
3. After temporarily installing new parts, make sure the related parts fit properly.
Note
When replacing the wheel apron panel front and the wheel apron panel rear separately, weld 16 locations
indicated by (A).
4. Plug the six weld location indicated by (B) when installing the apron reinforcement upper.
End Of Sie
(A) 5
(B) 5
(B) 1
(A) 1
6
9
(A) 5
(A) 5
WHEEL APRON PANEL FRONT
WHEEL APRON
PANEL REAR
CHU0980B049
BODY STRUCTURE [PANEL REPLACEMENT]
0980B16
FRONT SIDE FRAME REAR REINFORCEMENT REMOVAL
CHU098053396B01
1. Remove the front side frame rear reinforcement.
End Of Sie
8
2
1
2
PASSENGER'S SIDE : 7
DRIVER'S SIDE : 6
FRONT SIDE FRAME REAR
REINFORCEMENT
CHU0980B050
BODY STRUCTURE [PANEL REPLACEMENT]
0980B17
0980B
FRONT SIDE FRAME REAR REINFORCEMENT INSTALLATION
CHU098053396B02
1. When installing new parts, position each part so that the section measurement aligns with the body dimension.
2. Drill holes for plug welds before installing new parts.
3. After temporarily installing new parts, make sure the related parts fit properly.
End Of Sie
8
2
1
2
PASSENGER'S SIDE : 7
DRIVER'S SIDE : 6
FRONT SIDE FRAME
REAR REINFORCEMENT
CHU0980B051
BODY STRUCTURE [PANEL REPLACEMENT]
0980B18
FRONT SIDE FRAME REMOVAL
CHU098053300B01
1. Remove the front side frame.
End Of Sie
5
5
5
FRONT SIDE FRAME
FRONT SIDE FRAME
CHU0980B052
BODY STRUCTURE [PANEL REPLACEMENT]
0980B19
0980B
FRONT SIDE FRAME INSTALLATION
CHU098053300B02
1. When installing new parts, position each part so that the section measurement aligns with the body dimension.
2. Drill holes for plug welds before installing new parts.
3. After temporarily installing new parts, make sure the related parts fit properly.
End Of Sie
5
5
5
FRONT SIDE FRAME
FRONT SIDE FRAME
CHU0980B053
BODY STRUCTURE [PANEL REPLACEMENT]
0980B20
FRONT SIDE FRAME OUTER REMOVAL
CHU098053300B03
1. To facilitate removal of the front side frame outer, drill the five weld locations indicated by (A) and bend the
wheel apron panel front upward.
2. Drill the one weld locations indicated by (B) and 15 weld locations (C) then remove the front side frame outer.
End Of Sie
(B) 1
(C) 4
(C) 2
(A) 5
(C) 9
FRONT SIDE FRAME OUTER
WHEEL APRON PANEL FRONT
WHEEL APRON
PANEL FRONT
CHU0980B062
BODY STRUCTURE [PANEL REPLACEMENT]
0980B21
0980B
FRONT SIDE FRAME OUTER INSTALLATION
CHU098053300B04
1. When installing new parts, position each part so that the section measurement aligns with the body dimension.
2. Drill holes for plug welds before installing new parts.
3. Weld the one locations indicated by (A), then temporarily installing the inner and outer.
4. After temporarily installing new parts, make sure the related parts fit properly.
End Of Sie
(A)1
FRONT SIDE FRAME INNER
4
2
5
9
FRONT SIDE FRAME OUTER
WHEEL APRON PANEL FRONT
WHEEL APRON
PANEL FRONT
CHU0980B063
BODY STRUCTURE [PANEL REPLACEMENT]
0980B22
FRONT SIDE FRAME (PARTIAL CUTTING) REMOVAL
CHU098053300B05
1. Rough cut and remove the damaged part of the front side frame.
End Of Sie
180 mm {7.09 in}
40 mm {1.57 in}
CUT-AND-JOIN LOCATION
ROUGH CUT LOCATION
CHU0980B056
BODY STRUCTURE [PANEL REPLACEMENT]
0980B23
0980B
FRONT SIDE FRAME (PARTIAL CUTTING) INSTALLATION
CHU098053300B06
1. Cut the new and old parts at the cut-and-join location, and bevel the parts.
2. To cut-and-join the new part, cut at the locations indicated in the figure below and bevel the cut-and-join
locations of the new parts.
3. When installing the new parts, trial-fit them to the body, and position each part so that the each section
alignment matches the body dimensions.
4. After temporarily installing new parts, make sure the related parts fit properly.
Caution
The cut-and-joint area indicates the maximum size range of the installation position.
End Of Sie
180 mm {7.09 in}
CUT-AND-JOIN LOCATION
CHU0980B057
BODY STRUCTURE [PANEL REPLACEMENT]
0980B24
TORQUE BOX REMOVAL
CHU098053381B01
1. Remove the torque box.
End Of Sie
8
2
3
1
2
6
2
6
4
TORQUE BOX
CHU0980B060
BODY STRUCTURE [PANEL REPLACEMENT]
0980B25
0980B
TORQUE BOX INSTALLATION
CHU098053381B02
1. When installing new parts, position each part so that the section measurement aligns with the body dimension.
2. Drill holes for plug welds before installing new parts.
3. After temporarily installing new parts, make sure the related parts fit properly.
End Of Sie
8
2
3
1
2
6
2
6
4
TORQUE BOX
CHU0980B061
BODY STRUCTURE [PANEL REPLACEMENT]
0980B26
FRONT FRAME REAR UPPER REMOVAL
CHU098053390B01
1. Drill the 16 weld locations indicated by (A) and remove the lower arm bracket.
2. Drill the remaining weld locations and remove the front frame rear upper.
End Of Sie
4
3
2
(A) 6
(A) 6
1
1
3
3
(A) 2
(A) 2
2
FRONT FRAME
REAR UPPER
LOWER ARM BRACKET
CHU0980B064
BODY STRUCTURE [PANEL REPLACEMENT]
0980B27
0980B
FRONT FRAME REAR UPPER INSTALLATION
CHU098053390B02
1. When installing new parts, position each part so that the section measurement aligns with the body dimension.
2. Drill holes for plug welds before installing new parts.
3. Weld the 18 locations indicated by (A) and install the front frame rear upper.
4. After temporarily installing new parts, make sure the related parts fit properly.
5. Plug the one weld location indicated by (B) when installing the torque box.
End Of Sie
(A) 4
(A) 3
6
6
(A) 1
(A) 1
(A) 3
(A) 3
2
2
(A) 2
FRONT FRAME
REAR UPPER
LOWER ARM BRACKET
(A) 1
(B) 1
CHU0980B065
BODY STRUCTURE [PANEL REPLACEMENT]
0980B28
FRONT FRAME REAR REMOVAL
CHU098053390B03
1. Remove the front frame rear.
End Of Sie
4
4
3
11
7
3
FRONT FRAME REAR
CHU0980B068
BODY STRUCTURE [PANEL REPLACEMENT]
0980B29
0980B
FRONT FRAME REAR INSTALLATION
CHU098053390B04
1. When installing new parts, position each part so that the section measurement aligns with the body dimension.
2. Drill holes for plug welds before installing new parts.
3. After temporarily installing new parts, make sure the related parts fit properly.
End Of Sie
4
4
3
11
7
3
FRONT FRAME REAR
CHU0980B069
BODY STRUCTURE [PANEL REPLACEMENT]
0980B30
FRAME REINFORCEMENT REMOVAL
CHU098053342B01
1. Remove the frame reinforcement.
Note
When removing the frame reinforcement inner and the frame reinforcement outer separately, drill the five
weld locations indicated by (A).
End Of Sie
4
2
(A) 1
3
DRIVER'S SIDE : 3
PASSENGER'S SIDE : 2
8
3
FRAME REINFORCEMENT
(A) 4
FRAME
INNER OUTER
REINFORCEMENT
FRAME
REINFORCEMENT
CHU0980B066
BODY STRUCTURE [PANEL REPLACEMENT]
0980B31
0980B
FRAME REINFORCEMENT INSTALLATION
CHU098053342B02
1. When installing new parts, position each part so that the section measurement aligns with the body dimension.
2. Drill holes for plug welds before installing new parts.
3. After temporarily installing new parts, make sure the related parts fit properly.
Note
When replacing the frame reinforcement inner and the frame reinforcement outer separately, weld six
weld locations indicated by (A).
End Of Sie
4
2
(A) 1
3
PASSENGER'S SIDE : 2
DRIVER'S SIDE : 3
8
3
FRAME REINFORCEMENT
FRAME
REINFORCEMENT
INNER
FRAME
REINFORCEMENT
OUTER
(A) 5
CHU0980B067
BODY STRUCTURE [PANEL REPLACEMENT]
0980B32
COWL UPPER PLATE REMOVAL
CHU098053580B01
1. Drill the four weld locations indicated by (A), from the room side.
2. Remove the cowl upper plate.
Caution
Be careful not to damage the windshield when drilling the location indicated by (B).
End Of Sie
DRIVER'S SIDE
PASSENGER'S SIDE
COWL UPPER PLATE
COWL UPPER PLATE
4
2
(A) 2
(A) 2
(B) 2
4
1
1
(B) 2
CHU0980B058
BODY STRUCTURE [PANEL REPLACEMENT]
0980B33
0980B
COWL UPPER PLATE INSTALLATION
CHU098053580B02
1. When installing new parts, position each part so that the section measurement aligns with the body dimension.
2. Drill holes for plug welds before installing new parts.
3. After temporarily installing new parts, make sure the related parts fit properly.
End Of Sie
DRIVER'S SIDE
PASSENGER'S SIDE
COWL UPPER PLATE
COWL UPPER PLATE
4
2
2
2
2
4
1
1
2
CHU0980B059
BODY STRUCTURE [PANEL REPLACEMENT]
0980B34
FRONT PILLAR REMOVAL
CHU098074090B01
1. Rough cut area (A), drill the 42 weld locations indicated by (B), then remove the lower part of the front pillar
outer.
Caution
Avoid cutting with a blowtorch or similar tools as the insulator (shaded area) is flammable.
2. Rough cut area (C), drill the 55 weld locations indicated by (D) and one location (E), then remove the front pillar
outer and reinforcement.
Note
For weld location (E), partially bend back the cowl upper plate before drilling.
3. Rough cut area (F), drill the 11 weld locations indicated by (G), then remove the front pillar inner.
(D) 3
(D) 3
55 mm
{2.17 in}
40 mm
{1.57 in}
C
C
B B
FRONT PILLAR OUTER
FRONT PILLAR REINFORCEMENT
CUT-AND-JOIN LOCATION
CUT-AND-JOIN LOCATION
FOR OUTER
FOR OUTER
(A) ROUGH CUT LOCATION FOR
INSULATOR
(A) ROUGH CUT LOCATION
(C) ROUGH CUT LOCATION FOR
(C) ROUGH CUT LOCATION
OUTER AND REINFORCEMENT
FOR REINFORCEMENT
FOR REINFORCEMENT
(D) 17
(B) 10
(D) 20
(B) 13
(B) 4
(D) 4
(D) 8
{9.45 in}
240 mm
(B) 7 (B) 8
(E) 1
COWL UPPER PLATE
CUT-AND-JOIN LOCATION
CUT-AND-JOIN LOCATION
CUT-AND-JOIN LOCATION
FOR OUTER
FOR OUTER
FOR REINFORCEMENT
{4.33 in}
110 mm
B-B
C-C
A-A
A
A
{3.54 in}
{3.54 in}
90 mm
60 mm
{2.36 in} {1.77 in}
45 mm
90 mm
OUTER
CHU0980B070
BODY STRUCTURE [PANEL REPLACEMENT]
0980B35
0980B
End Of Sie
(G) 2
(G) 4
(G) 5
CUT-AND-JOIN LOCATION
FOR INNER
(F) ROUGH CUT LOCATION
FOR INNER
FRONT PILLAR INNER
{1.38 in}
35 mm
{2.95 in}
75 mm
CHU0980B071
BODY STRUCTURE [PANEL REPLACEMENT]
0980B36
FRONT PILLAR INSTALLATION
CHU098074090B02
1. When joining the new and old parts, temporarily install and fit the new part in position, measure each dimension
according to the body dimension, then adjust the position to align it to the standard dimensions.
2. Drill holes for plug welds before installing new parts.
Note
In areas where the outer, reinforcement, inner, etc. are in 3-4 layers, drill holes for plug welds in all but the
innermost panel.
3. After temporarily installing new parts, make sure the related parts fit properly.
2
4
5
CUT-AND-JOIN LOCATION
FOR INNER
FRONT PILLAR INNER
{2.95 in}
75 mm
CHU0980B073
BODY STRUCTURE [PANEL REPLACEMENT]
0980B37
0980B
End Of Sie
FRONT PILLAR OUTER
27
13
4
4
4
8
3
2
7
8
{3.54 in}
90 mm
{1.77 in}
45 mm
3
40 mm
{1.57 in}
1
COWL UPPER PLATE
CUT-AND-JOIN LOCATION
FOR REINFORCEMENT
CUT-AND-JOIN LOCATION
FOR OUTER
CUT-AND-JOIN LOCATION
FOR OUTER
FRONT PILLAR REINFORCEMENT
CUT-AND-JOIN LOCATION
FOR REINFORCEMENT
{1.38 in}
35 mm
20
CHU0980B072
BODY STRUCTURE [PANEL REPLACEMENT]
0980B38
REAR FENDER PANEL REMOVAL
CHU098074100B01
Caution
Avoid cutting with a blowtorch or similar tools as the insulator (shaded area) is flammable.
Note
For weld location (A), partially bend back the rear end panel before drilling.
1. The rear fender panel and the rear pillar inner are joined with glue at the wheel arch line. Use a chisel or other
to separate the rear fender panel from the rear pillar inner, then remove the rear fender panel.
C-PILLAR REINFORCEMENT
INSULATOR
REAR END PANEL
FOR OUTER
FOR OUTER
CUT-AND-JOIN LOCATION
FOR OUTER
CUT-AND-JOIN LOCATION
FOR C-PILLAR REINFORCEMENT
CUT-AND-JOIN LOCATION
ROUGH CUT LOCATION
FOR OUTER
ROUGH CUT LOCATION
FOR C-PILLAR
REINFORCEMENT
ROUGH CUT LOCATION
6
3
6
7
1
1
1
(A) 1
9
8
15
1
2
2
13
28
4
8
A A
100 mm
{3.94 in} {0.79 in}
20 mm
35 mm {1.38 in}
35 mm {1.38 in}
40 mm {1.57 in}
40 mm {1.57 in}
B
B
A-A
B-B
CHU0980B074
BODY STRUCTURE [PANEL REPLACEMENT]
0980B39
0980B
End Of Sie
CUT-AND-JOIN LOCATION
FOR REINFORCEMENT
CUT-AND-JOIN LOCATION
FOR REINFORCEMENT
SIDE SILL REAR REINFORCEMENT
FOR REINFORCEMENT
ROUGH CUT LOCATION
FOR REINFORCEMENT
ROUGH CUT LOCATION
RH : 3
LH : 2
2
2
2
4
2
3
3
6
2
1
40 mm {1.57 in}
70 mm {2.76 in}
{3.94 in}
100 mm
{2.95 in}
75 mm
CHU0980B075
BODY STRUCTURE [PANEL REPLACEMENT]
0980B40
REAR FENDER PANEL INSTALLATION
CHU098074100B02
1. When joining the new and old parts, temporarily install and fit the new part in position, measure each dimension
according to the body dimension, then adjust the position to align it to the standard dimensions.
2. Drill holes for plug welds before installing new parts.
3. Weld in 24 locations indicated by (A), then temporarily installing the rear pillar hinge reinforcement.
4. Plug the one weld location indicated by (B), when installing the rear end panel.
5. After temporarily installing new parts, make sure the related parts fit properly.
CUT-AND-JOIN LOCATION
FOR REINFORCEMENT
FOR REINFORCEMENT
SIDE SILL REAR REINFORCEMENT
CUT-AND-JOIN LOCATION
RH:3 RH : 3
LH : 2
2
2
2
4
3
3
6
2
(A) 8
(A) 8
(A) 4
(A) 4
1
2
REAR PILLAR HINGE
REINFORCEMENT
40 mm {1.57 in}
{3.94 in}
100 mm
CHU0980B093
BODY STRUCTURE [PANEL REPLACEMENT]
0980B41
0980B
End Of Sie
C-PILLAR REINFORCEMENT
REAR END PANEL
FOR OUTER
CUT-AND-JOIN LOCATION
FOR OUTER
CUT-AND-JOIN LOCATION
FOR C-PILLAR REINFORCEMENT
CUT-AND-JOIN LOCATION
6
3
6
7
1
1
(B) 1
1
9
8
15
1
2
2
13
28
4
8
{0.79 in}
20 mm
35 mm {1.38 in}
40 mm {1.57 in}
CHU0980B092
BODY STRUCTURE [PANEL REPLACEMENT]
0980B42
REAR FENDER LOWER PANEL REMOVAL
CHU098074100B03
1. Remove the rear fender lower panel.
End Of Sie
7
1
7
REAR FENDER LOWER PANEL
CHU0980B076
BODY STRUCTURE [PANEL REPLACEMENT]
0980B43
0980B
REAR FENDER LOWER PANEL INSTALLATION
CHU098074100B04
1. When installing new parts, position each part so that the section measurement aligns with the body dimension.
2. Drill holes for plug welds before installing new parts.
3. After temporarily installing new parts, make sure the related parts fit properly.
End Of Sie
7
1
7
REAR FENDER LOWER PANEL
CHU0980B077
BODY STRUCTURE [PANEL REPLACEMENT]
0980B44
SIDE SILL PANEL FRONT REMOVAL
CHU098070270B01
1. Rough cut area (A) and drill the 39 weld locations indicated by (B), then remove the side sill outer.
2. Rough cut area (C) and drill the 11 weld locations indicated by (D), then remove the side sill reinforcement.
3. Rough cut area (E) and remove the side sill gusset.
End Of Sie
SIDE SILL OUTER
(B) 21
(D) 10
(D) 1
(B) 18
CUT-AND-JOIN LOCATION
FOR OUTER
CUT-AND-JOIN LOCATION
FOR REINFORCEMENT
CUT-AND-JOIN LOCATION
FOR GUSSET
CUT-AND-JOIN LOCATION
FOR THE GUSSET
CUT-AND-JOIN LOCATION
FOR REINFORCEMENT
CUT-AND-JOIN LOCATION
FOR OUTER FOR OUTER
(A) ROUGH CUT LOCATION
FOR REINFORCEMENT
(C) ROUGH CUT LOCATION
FOR GUSSET
(E) ROUGH CUT LOCATION
FOR GUSSET
(E) ROUGH CUT LOCATION
FOR REINFORCEMENT
(C) ROUGH CUT LOCATION
SIDE SILL REINFORCEMENT
SIDE SILL GUSSET
A
A
B
B
A-A B-B
{7.87 in}
200 mm
{2.76 in}
70 mm
{1.97 in}
50 mm
{1.97 in}
50 mm
40 mm
{1.57 in}
{1.57 in}
40 mm
50 mm
{1.97 in}
30mm
{1.18in}
{1.97 in}
50 mm
{0.79 in}
20 mm 70 mm
70 mm
{2.76 in}
{2.76 in}
CHU0980B086
BODY STRUCTURE [PANEL REPLACEMENT]
0980B45
0980B
SIDE SILL PANEL FRONT INSTALLATION
CHU098070270B02
1. When joining the new and old parts, temporarily install and fit the new part in position, measure each dimension
according to the body dimension, then adjust the position to align it to the standard dimensions.
Caution
When cutting and joining the side sill reinforcement, make sure not to damage or scratch the side
sill gusset.
2. Drill holes for plug welds before installing new parts.
3. After temporarily installing new parts, make sure the related parts fit properly.
End Of Sie
21
10
1
18
SIDE SILL GUSSET
{0.79 in}
20 mm
70 mm
{2.76 in}
CUT-AND-JOIN LOCATION
FOR GUSSET CUT-AND-JOIN LOCATION
FOR GUSSET
50 mm
{1.97 in}
CUT-AND-JOIN LOCATION
FOR REINFORCEMENT
CUT-AND-JOIN LOCATION
FOR REINFORCEMENT
{1.57 in}
40 mm
200 mm
{7.87 in}
CUT-AND-JOIN LOCATION
FOR OUTER
CUT-AND-JOIN LOCATION
FOR OUTER
{1.97 in}
50 mm
SIDE SILL REINFORCEMENT
SIDE SILL OUTER
CHU0980B087
BODY STRUCTURE [PANEL REPLACEMENT]
0980B46
SIDE SILL PANEL REMOVAL
CHU098070270B03
1. Rough cut area (A) and drill the 110 weld locations indicated by (B), then remove the side sill outer.
Caution
Avoid cutting with a blowtorch or similar tools as the insulator (shaded area) is flammable.
2. Rough cut area (C) and drill the 40 weld locations indicated by (D), then remove the side sill reinforcement.
3. Remove the side sill rear reinforcement.
End Of Sie
(B) 4 (B) 8
(B) 6
(B) 43
(D) 19
(D) 3
(D) 3
(D) 6
(D) 3
(D) 3
(D) 3
(B) 41
(B) 6
(B) 2
(A) ROUGH CUT LOCATION
FOR OUTER
(C) ROUGH CUT LOCATION
FOR REINFORCEMENT
(C) ROUGH CUT LOCATION
FOR REINFORCEMENT
CUT-AND-JOIN LOCATION FOR OUTER
(A) ROUGH CUT
CUT-AND-JOIN LOCATION
FOR OUTER
FOR OUTER
CUT-AND-JOIN LOCATION
FOR REINFORCEMENT
CUT-AND-JOIN LOCATION
FOR REINFORCEMENT
INSULATOR
INSULATOR
SIDE SILL GUSSET
SIDE SILL OUTER
SIDE SILL REINFORCEMENT
LOCATION
A A
B
B
B-B
A-A
110 mm {4.33 in}
50 mm {1.97 in}
50 mm {1.97 in}
65 mm {2.56 in}
{2.76 in}
70 mm
{2.76 in}
70 mm
{1.77 in}
45 mm
45 mm {1.77 in}
4
SIDE SILL REAR REINFORCEMENT
2
CHU0980B078
BODY STRUCTURE [PANEL REPLACEMENT]
0980B47
0980B
2004 Mazda RX-8 Bodyshop Manual(33791U03D)
SIDE SILL PANEL INSTALLATION
CHU098070270B04
1. When joining the new and old parts, temporarily install and fit the new part in position, measure each
dimension according to the body dimension, then adjust the position to align it to the standard dimensions.
2. Drill holes for plug welds before installing new parts.
3. Weld the six locations indicated by (A) and install the side sill rear reinforcement.
4. Weld the 28 locations indicated by (B), then temporarily install the side sill gusset.
5. Weld the 12 locations indicated by (C) and install the side sill reinforcement.
6. Weld the 110 locations indicated by (D) and install the side sill outer.
7. After temporarily installing new parts, make sure the related parts fit properly.
(D) 4 (D) 8 (D) 6
(D) 43
(B) 19
(B)3
(B) 3
(C) 6
(C) 3
(B) 3
(C) 3
(D) 41
(D) 6
(C) 2
SIDE SILL GUSSET
SIDE SILL OUTER
SIDE SILL REINFORCEMENT
CUT-AND-JOIN LOCATION
FOR REINFORCEMENT
CUT-AND-JOIN LOCATION
FOR OUTER
CUT-AND-JOIN LOCATION
FOR OUTER
CUT-AND-JOIN LOCATION
FOR REINFORCEMENT
110 mm {4.33 in}
65 mm {2.56 in}
70 mm {2.76 in}
45 mm {1.77 in}
(A) 4
SIDE SILL REAR REINFORCEMENT
(A) 2
CHU0980B079
3379-1U-03D(09-80B).fm 47
BODY STRUCTURE [PANEL REPLACEMENT]
0980B48
2004 Mazda RX-8 Bodyshop Manual(33791U03D)
Added 3/2008 (Ref. No. R045/08)
Drill Hole Install for Rear Deflector
1. Cut out the templates along the cut lines.
2. Face the printed side of the templates to the rear
deflector, align two sides of the templates, and
affix them to the rear deflector using double-sided
adhesive tape.
Caution
Affix double-sided adhesive tape on the
printed side of the templates.
Note
Paper type double-sided adhesive tape is
recommended.
3. Align the rear deflector with the installation
position with no clearance with the body, and
temporarily fix using a rivet.
4. Align the rear deflector bottom surface with the
body, press it so that there is no clearance with
the body.
Caution
Be careful of the alignment of the rear
deflector with the body and verify that it
is firmly attached to the lower surface of
the rear deflector with its height equal
with the body from front to back.
End Of Sie
TEMPLATE
REAR DEFLECTOR
ar8uub00000073
REAR DEFLECTOR
RIVET
REAR
ar8uub00000074
FRONT
ALIGN WITH BODY
WITH NO GAP
ALIGN LOWER
SURFACE FIRMLY
WITH BODY
SIDE SILL (OUTER)
REAR DEFLECTOR
ar8uub00000075
3379-1U-03D(09-80B).fm 48
BODY STRUCTURE [PANEL REPLACEMENT]
0980B481
09-08B
2004 Mazda RX-8 Bodyshop Manual(33791U03D)
Added 3/2008 (Ref. No. R045/08)
0980B48 BODY STRUCTURE [PANEL REPLACEMENT]
SIDE SILL PANEL INSTALLATION
CHU098070270B04
5. Place the templates along the bodyline and affix
them using tape.
6. Remove the fastener and remove the rear
deflector with the templates affixed to the body.
Caution
When removing the rear deflector, be
careful that the templates do not slip or
become ripped.
7. Place the templates along the bodyline and punch
holes through the center of the templates.
Caution
Punch holes through the center of the
templates with the templates affixed to
the body.
8. Remove the templates.
9. Wrap packing tape around the drill bit.
Note
To prevent damage and overdrilling.
10. With the drill bit pointed perpendicular to the
body, drill a hole gradually using a 3 mm {0.1in},
6 mm {0.2in}, then 10mm {0.39in} drill bit.
FRONT
TAPE
ar8uub00000076
DRILL-HOLE CENTER POSITION
am2zzb0000010
DUCT TAPE
DRILL
DRILL
10mm
DRILL BIT
(SHOULDER)
OVER-DRILLING PREVENTION
{0.39 in}
am2zzb0000001
CROSS-SECTION VIEW
SIDE SILL
(OUTER)
HOLE FOR CLIP
(SMALL)
3 mm 6 mm 10 mm
90
{0.1 in} {0.2 in} {0.39 in}
am2zzb0000017
3379-1U-03D(09-80B)_48-1~4.fm 1
BODY STRUCTURE [PANEL REPLACEMENT]
0980B482
2004 Mazda RX-8 Bodyshop Manual(33791U03D)
Added 3/2008 (Ref. No. R045/08)
11. Grind the drilled hole to remove any metal burrs
with a round file to finish the surface.
12. Wipe off dirt from the rear deflector installation
surface on the body using a clean rag dampened
with isopropyl alcohol.
13. Apply sealant for rust protection.
14. Apply touch-up paint.
Caution
Make sure rust protection is performed
properly.
ROUND
FILE TOUCH-UP
PAINT
DRILL-HOLE
BURR
am2zzb0000010
FRONT
REAR DEFLECTOR INSTALLATION SURFACE
ar8uub00000077
3379-1U-03D(09-80B)_48-1~4.fm 2
BODY STRUCTURE [PANEL REPLACEMENT]
0980B483
09-08B
2004 Mazda RX-8 Bodyshop Manual(33791U03D)
Added 3/2008 (Ref. No. R045/08)
Template
End Of Sie
LH
RH
0
{
m
m
}
1
0
0
2
0
0
{mm} 0 100 50
L
H
-
1
L
H
-
2
R
H
-
1
R
H
-
2
TEMPLATE
ar8uub00000078
3379-1U-03D(09-80B)_48-1~4.fm 3
BODY STRUCTURE [PANEL REPLACEMENT]
0980B484
2004 Mazda RX-8 Bodyshop Manual(33791U03D)
THIS PAGE INTENTIONALLY
LEFT BLANK
3379-1U-03D(09-80B)_48-1~4.fm 4
BODY STRUCTURE [PANEL REPLACEMENT]
0980B49
0980B
2004 Mazda RX-8 Bodyshop Manual(33791U03D)
REAR END PANEL REMOVAL
CHU098070750B01
1. Remove the rear end panel.
End Of Sie
REAR END PANEL INSTALLATION
CHU098070750B02
1. When installing new parts, position each part so that the section measurement aligns with the body dimension.
2. Drill holes for plug welds before installing new parts.
3. After temporarily installing new parts, make sure the related parts fit properly.
End Of Sie
7
3
7
7 17
10
3
7
2
5 3
7
2
REAR END PANEL
CHU0980B080
7
3
7
7 17
10
3
7
2
5 3
7
2
REAR END PANEL
CHU0980B081
3379-1U-03D(09-80B).fm 49
BODY STRUCTURE [PANEL REPLACEMENT]
0980B50
2004 Mazda RX-8 Bodyshop Manual(33791U03D)
REAR FENDER RAIN RAIL AND CORNER PLATE REMOVAL
CHU098070440B01
1. Remove the rear fender rain rail and corner plate.
Note
When removing the rear fender rain rail and the corner plate separately, drill three weld locations indicated
by (A).
End Of Sie
REAR FENDER RAIN RAIL
CORNER PLATE
(A) 3
3
1
3
3
CHU0980B082
3379-1U-03D(09-80B).fm 50
BODY STRUCTURE [PANEL REPLACEMENT]
0980B51
0980B
REAR FENDER RAIN RAIL AND CORNER PLATE INSTALLATION
CHU098070440B02
1. When installing new parts, position each part so that the section measurement aligns with the body dimension
2. Drill holes for plug welds before installing new parts.
3. After temporarily installing new parts, make sure the related parts fit properly.
Note
When replacing the rear fender rain rail and the corner plate separately, weld three locations indicated by
(A).
End Of Sie
REAR FENDER RAIN RAIL
CORNER PLATE
(A) 3
3
1
3
3
CHU0980B083
BODY STRUCTURE [PANEL REPLACEMENT]
0980B52
REAR FLOOR PAN REMOVAL
CHU098053750B01
1. Remove the rear floor pan.
End Of Sie
2
10
11
22
11
10
1
3
2
REAR FLOOR PAN
CHU0980B084
BODY STRUCTURE [PANEL REPLACEMENT]
0980B53
0980B
REAR FLOOR PAN INSTALLATION
CHU098053750B02
1. Drill holes for plug welds before installing new parts.
2. After temporarily installing new parts, make sure the related parts fit properly.
End Of Sie
2
10
11
22
11
10
1
3
2
REAR FLOOR PAN
CHU0980B085
BODY STRUCTURE [PANEL REPLACEMENT]
0980B54
REAR SIDE FRAME (PARTIAL CUTTING) REMOVAL
CHU098053810B01
1. Rough cut and remove the damaged part of the rear side frame.
End Of Sie
CUT-AND-JOIN LOCATION
ROUGH CUT LOCATION
40 mm
{1.57 in}
{5.12 in}
130 mm
CHU0980B088
BODY STRUCTURE [PANEL REPLACEMENT]
0980B55
0980B
REAR SIDE FRAME (PARTIAL CUTTING) INSTALLATION
CHU098053810B02
1. Cut the new and old parts at the cut-and-join location, and bevel the parts.
2. To cut-and-join the new part, cut at the locations indicated in the figure below and bevel the cut-and-join
locations of the new parts.
3. When installing the new parts, trial-fit them to the body, and position each part so that the each section
alignment matches the body dimensions.
4. After temporarily installing new parts, make sure the related parts fit properly.
Caution
The cut-and-joint area indicates the maximum size range of the installation position.
End Of Sie
CUT-AND-JOIN LOCATION
{5.12 in}
130 mm
CHU0980B089
BODY STRUCTURE [PANEL REPLACEMENT]
0980B56
ROOF PANEL REMOVAL
CHU098070600B01
1. Remove the roof panel.
End Of Sie
13
13
15 15
ROOF PANEL
CHU0980B090
BODY STRUCTURE [PANEL REPLACEMENT]
0980B57
0980B
ROOF PANEL INSTALLATION
CHU098070600B02
1. When installing new parts, position each part so that the section measurement aligns with the body dimension.
2. Drill holes for plug welds before installing new parts.
3. After temporarily installing new parts, make sure the related parts fit properly.
End Of Sie
13
13
15 15
ROOF PANEL
CHU0980B091
BODY STRUCTURE [WATER-PROOF AND RUST PREVENTIVE TREATMENT]
0980C1
0980C
2004 Mazda RX-8 Bodyshop Manual(33791U03D)
Revised 11/2003 (Ref. No. R042/03)
0980C BODY STRUCTURE [WATER-PROOF AND RUST
PREVENTIVE TREATMENT]
BODY SEALING . . . . . . . . . . . . . . . . . . . 0980C1
UNDER COATING. . . . . . . . . . . . . . . . . . 0980C4
CHIPPING-RESISTANT COATING. . . . . . 0980C4
RUST PREVENTIVE TREATMENT . . . . . 0980C5
End of Toc
BODY SEALING
CHU098007000B02
Sealant is applied to the parts where the panels meet and to the hemmed parts of the door panel and hood panel
to provide water proofing and rust proofing.
CHU0980B024
BODY STRUCTURE [WATER-PROOF AND RUST PREVENTIVE TREATMENT]
0980C2
2004 Mazda RX-8 BodyShop Manual(33791U03D)
Revised 11/2003 (Ref. No. R042/03)
CHU0980B025
BODY STRUCTURE [WATER-PROOF AND RUST PREVENTIVE TREATMENT]
0980C3
0980C
2004 Mazda RX-8 Bodyshop Manual(33791U03D)
Revised 11/2003 (Ref. No. R042/03)
End Of Sie
HOOD
DOOR
TRUNK LID
CHU0980B026
BODY STRUCTURE [WATER-PROOF AND RUST PREVENTIVE TREATMENT]
0980C4
2004 Mazda RX-8 BodyShop Manual(33791U03D)
Revised 11/2003 (Ref. No. R042/03)
UNDER COATING
CHU098007000B03
The shaded areas indicated under body locations that are undercoated to prevent noise and rusting.End Of Sie
CHIPPING-RESISTANT COATING
CHU098007000B04
The coating locations are indicated by the shaded areas.End Of Sie
WITHOUT MUD GUARD
CHU0980B227
A
A
A-A
URETHANE PAINT
CHU0980B228
BODY STRUCTURE [WATER-PROOF AND RUST PREVENTIVE TREATMENT]
0980C4
UNDER COATING
CHU098007000B03
The shaded areas indicated under body locations that are undercoated to prevent noise and rusting.End Of Sie
PCV PAINTING
CHU098007000B04
The coating locations are indicated by the shaded areas.End Of Sie
WITHOUT MUD GUARD
CHU0980B027
CHU0980B028
BODY STRUCTURE [WATER-PROOF AND RUST PREVENTIVE TREATMENT]
0980C5
0980C
RUST PREVENTIVE TREATMENT
CHU098007000B05
End Of Sie
HOOD HINGE
DOOR
TRUNK LID
CHU0980B029
BODY STRUCTURE [DIMENSIONS]
0980D1
0980D
0980D BODY STRUCTURE [DIMENSIONS]
UNDERBODY FLAT-PLANE
DIMENSIONS . . . . . . . . . . . . . . . . . . . . 0980D2
UNDERBODY STRAIGHT-LINE
DIMENSIONS . . . . . . . . . . . . . . . . . . . . 0980D3
FRONT BODY STRAIGHT-LINE
DIMENSIONS (1) . . . . . . . . . . . . . . . . . . 0980D4
FRONT BODY STRAIGHT-LINE
DIMENSIONS (2) . . . . . . . . . . . . . . . . . . 0980D5
FRONT BODY STRAIGHT-LINE
DIMENSIONS (3) . . . . . . . . . . . . . . . . . . 0980D6
CABIN SIDE FRAME STRAIGHT-LINE
DIMENSIONS (1) . . . . . . . . . . . . . . . . . . 0980D7
CABIN SIDE FRAME STRAIGHT-LINE
DIMENSIONS (2) . . . . . . . . . . . . . . . . . . 0980D8
ROOM STRAIGHT-LINE
DIMENSIONS (1) . . . . . . . . . . . . . . . . . . 0980D9
ROOM STRAIGHT-LINE
DIMENSIONS (2) . . . . . . . . . . . . . . . . . . 0980D10
ROOM STRAIGHT-LINE
DIMENSIONS (3) . . . . . . . . . . . . . . . . . . 0980D11
REAR BODY STRAIGHT-LINE
DIMENSIONS . . . . . . . . . . . . . . . . . . . . . 0980D12
End of Toc
BODY STRUCTURE [DIMENSIONS]
0980D2
UNDERBODY FLAT-PLANE DIMENSIONS
CHU098053010B01
.
A B C D E F G H I J K L N O M
7
9
6

{
3
1
.
3
4
}
7
7
8

{
3
0
.
6
3
}
8
1
0

{
3
1
.
8
9
}
7
9
6

{
3
1
.
3
4
}
7
9
6

{
3
1
.
3
4
}
9
9
2

{
3
9
.
0
6
}
8
2
8

{
3
2
.
6
0
}
8
2
4

{
3
2
.
4
4
}
8
3
2

{
3
2
.
7
6
}
1
,
0
2
1

{
4
0
.
2
0
}
1
,
2
4
0

{
4
8
.
8
2
}
{
1
5
.
7
5
}
4
0
0
3
9
6
{
1
5
.
5
9
}
7
9
6

{
3
1
.
3
4
}
7
9
6

{
3
1
.
3
4
}
3
2
1

{
1
2
.
6
4
}
253
{9.96}
283
{11.14}
324
{12.76}
570
{22.44}
470
{18.50}
530
{20.87}
426
{16.77}
mm {in}
265
{10.43}
200
{7.87}
115
{4.53}
46
{1.81}
189
{7.44}
3
0
4

{
1
1
.
9
7
}
1
0
9

{
4
.
2
9
}
155
{6.10}
4
6

{
1
.
8
1
}
4
3

{
1
.
6
9
}
1
5

{
0
.
5
9
}
6
0

{
2
.
3
6
}
2
5
6

{
1
0
.
0
8
}
2
9
4

{
1
1
.
5
7
}
1
9
3

{
7
.
6
0
}
4
4
8

{
1
7
.
6
4
}
9
1

{
3
.
5
8
}
2
0
4

{
8
.
0
3
}
R
H
:
1
8
9

{
7
.
4
4
}
L
H
:
2
0
4

{
8
.
0
3
}
5
7
2

{
2
2
.
5
2
}
9
5
0

{
3
7
.
4
0
}
CHU0980B005
Point
symbol
Designation
Hole diameter
or bolt or nut
size mm {in}
A Front side frame standard hole 9.8 {0.39}
B
Crossmember No.1 standard
hole
7 {0.28}
C
Front crossmember mounting
bolt
M14 {0.55}
D
Front suspension mounting
block
44 {1.73}
E
Front crossmember mounting
bolt
M14 {0.55}
F Front frame rear standard hole 16 {0.63}
G Front frame rear standard hole
16 20
{0.63 0.79}
H Front B frame standard hole M14 {0.55}
I Front B frame standard hole 20 {0.79}
J Rear side frame standard hole 16 {0.63}
K
Rear crossmember mounting
bolt
M14 {0.55}
L
Rear crossmember mounting
bolt
M14 {0.55}
M
Rear suspension mounting
block
97 {3.82}
N
Rear crossmember mounting
bolt
M14 {0.55}
O Bumper bracket standard hole
14 10
{0.55 0.39}
Point
symbol
Designation
Hole diameter
or bolt or nut
size mm {in}
BODY STRUCTURE [DIMENSIONS]
0980D3
0980D
End Of Sie
UNDERBODY STRAIGHT-LINE DIMENSIONS
CHU098053010B02
.
A B C E F G H I J K L N O
9
8
7
5
4
3
10
19
18
17
15
16
14
13 11
12
20
29
28
27
25
26
24
23
21
22
30
6
1
2
CHU0980B006
A B C,E F G
O N K,L I,J
J
I
H
Fr
Fr
Fr
Fr
Fr
Fr
Fr
Fr
Fr C
K
L
E
Fr
CHU0980B007
Measured
location
Dimensions mm {in}
1 254 {10.00}
2 827 {32.56}
3 184 {7.24}
4 808 {31.81}
5 RH:116 {4.57}, LH:115 {4.53}
6 804 {31.65}
7 RH:855 {33.66}, LH:857 {33.74}
8 RH:294 {11.57}, LH:299 {11.77}
9 1,157 {45.55}
10 833 {32.80}
11 330 {12.99}
12 868 {34.17}
13 570 {22.44}
14 979 {38.54}
15 471 {18.54}
16 RH:923 {36.34}, LH:927 {36.50}
17 RH:307 {12.09}, LH:310 {12.20}
18 RH:1,585 {62.40}, LH:1,587 {62.48}
19 1,367 {53.82}
20 RH:1,042 {41.02}, LH:1,039 {40.91}
21 545 {21.46}
22 1,236 {48.66}
23 339 {13.35}
24 968 {38.11}
25 243 {9.57}
26 861 {33.90}
27 438 {17.24}
28 937 {36.89}
29 1,799 {70.83}
30 1,485 {58.46}
Measured
location
Dimensions mm {in}
BODY STRUCTURE [DIMENSIONS]
0980D4
End Of Sie
FRONT BODY STRAIGHT-LINE DIMENSIONS (1)
CHU098053020B01
.
A
B
C
D
E
F
G
A
,
B
,
C
,
E
,
F
,
G
,
D
,
9
8
7
5
4
3
10
19
18
17
15
16
14
13
11
12
6
1
2
CHU0980B008
A
Fr
D
E
B,C D,E
Fr
Fr
F F'
Fr
G
Fr
Fr
B
C
CHU0980B009
Measured
location
Dimensions mm {in}
1 954 {37.56}
2 1,350 {53.15}
3 676 {26.61}
4 1,430 {56.30}
5 1,406 {55.35}
6 1,604 {63.15}
7 675 {26.57}
8 1,214 {47.80}
9 584 {22.99}
10 1,450 {57.09}
11 1,254 {49.37}
12 358 {14.09}
13 1,313 {51.69}
14 903 {35.55}
15 1,266 {49.84}
16 1,176 {46.30}
17 314 {12.36}
18 1,010 {39.76}
19 783 {30.83}
Measured
location
Dimensions mm {in}
BODY STRUCTURE [DIMENSIONS]
0980D5
0980D
End Of Sie
FRONT BODY STRAIGHT-LINE DIMENSIONS (2)
CHU098053020B02
.
End Of Sie
A
B
C
E
G
H
F
D
F
,
9
8
7
5
4
3
10
6
1
2
CHU0980B010
A B C,D E F
Fr
Fr
Fr
Fr
G H
Fr
Fr
G'
Fr
Fr
D
C
CHU0980B011
Measured
location
Dimensions mm {in}
1 760 {29.92}
2 696 {27.40}
3 585 {23.03}
4 882 {34.72}
5 868 {34.17}
6 983 {38.70}
7 512 {20.16}
8 758 {29.84}
9 816 {32.13}
10 796 {31.34}
Measured
location
Dimensions mm {in}
BODY STRUCTURE [DIMENSIONS]
0980D6
FRONT BODY STRAIGHT-LINE DIMENSIONS (3)
CHU098053020B03
.
End Of Sie
A A
,
B
,
C
,
D
,
B
D
C
5
4
3
1
2
6
9
8
7
10
CHU0980B012
A B C,D
D
C
Fr Fr
Fr
CHU0980B013
Measured
location
Dimensions mm {in}
1 1,550 {61.02}
2 1,554 {61.18}
3 1,547 {60.91}
4 868 {34.17}
5 879 {34.61}
6 868 {34.17}
7 405 {15.94}
8 461 {18.15}
9 356 {14.02}
10 384 {15.12}
Measured
location
Dimensions mm {in}
BODY STRUCTURE [DIMENSIONS]
0980D7
0980D
CABIN SIDE FRAME STRAIGHT-LINE DIMENSIONS (1)
CHU098070010B01
.
G
I
J
D
F
A
C
H
E
B
9
8
7
5
4
3
10
6
1
2
19
18
17
15
16
14
13
11
12
CHU0980B014
A B C D E
I J H G F
Fr
Fr
Fr
Fr
Fr Fr Fr
Fr
Fr
Fr
CHU0980B015
Measured
location
Dimensions mm {in}
1 785 {30.91}
2 840 {33.07}
3 1,036 {40.79}
4 1,015 {39.96}
5 901 {35.47}
6 1,686 {66.38}
7 1,706 {67.17}
8 1,653 {65.08}
9 1,230 {48.43}
10 484 {19.06}
11 1,103 {43.43}
12 1,809 {71.22}
13 1,765 {69.49}
14 1,667 {65.63}
15 1,162 {45.75}
16 993 {39.09}
17 1,039 {40.91}
18 788 {31.02}
19 592 {23.31}
Measured
location
Dimensions mm {in}
BODY STRUCTURE [DIMENSIONS]
0980D8
End Of Sie
CABIN SIDE FRAME STRAIGHT-LINE DIMENSIONS (2)
CHU098070010B02
.
End Of Sie
B
E
F
G
D
A
C
9
8
7
5
4
3
10
13
11
12
6
1
2
CHU0980B016
A B C D
G F
Fr Fr
Fr
E
Fr
Fr
Fr
Fr
CHU0980B017
Measured
location
Dimensions mm {in}
1 1,217 {47.91}
2 1,310 {51.57}
3 1,315 {51.77}
4 1,045 {41.14}
5 681 {26.81}
6 964 {37.95}
7 1,571 {61.85}
8 1,492 {58.74}
9 1,376 {54.17}
10 403 {15.87}
11 1,016 {40.00}
12 631 {24.84}
13 1,080 {42.52}
Measured
location
Dimensions mm {in}
BODY STRUCTURE [DIMENSIONS]
0980D9
0980D
ROOM STRAIGHT-LINE DIMENSIONS (1)
CHU098070001B01
.
End Of Sie
K
B
A
E
G
H
I
J
D
C
F
9
8
7
5
4
3
1
2
6
CHU0980B018
A,B C C' D
E
F
E,F
J K I H G
Fr
Fr
Fr
Fr
Fr
Fr
Fr
Fr Fr
Fr
B
A
CHU0980B019
Measured
location
Dimensions mm {in}
1 RH:892 {35.12}, LH:839 {33.03}
2 RH:800 {31.50}, LH:734 {28.90}
3 RH:788 {31.02}, LH:711 {27.99}
4 RH:1,160 {45.67}, LH:1,125 {44.29}
5 RH:1,367 {53.82}, LH:1,337 {52.64}
6 RH:1,618 {63.70}, LH:1,593 {62.72}
7 RH:1,886 {74.25}, LH:1,862 {73.31}
8 RH:1,742 {68.58}, LH:1,710 {67.32}
9 RH:1,529 {60.20}, LH:1,490 {58.66}
K-K 1,512 {59.53}
Measured
location
Dimensions mm {in}
BODY STRUCTURE [DIMENSIONS]
0980D10
ROOM STRAIGHT-LINE DIMENSIONS (2)
CHU098070001B02
.
End Of Sie
K
B
A
E
G
H
I
J
L
C
F
9
8
7
5
4
3
1
2
6
CHU0980B020
A,B C C
,
L
E
F
E,F
I J H
G
Fr
Fr
Fr
Fr
Fr
Fr
Fr
B
A
Fr
Fr
Fr
K
CHU0980B021
Measured
location
Dimensions mm {in}
1 1,115 {43.90}
2 1,265 {49.80}
3 1,350 {53.15}
4 978 {38.50}
5 951 {37.44}
6 1,015 {39.96}
7 1,144 {45.04}
8 1,007 {39.65}
9 822 {32.36}
F-F 1,001 {39.41}
K-K 1,568 {61.73}
Measured
location
Dimensions mm {in}
BODY STRUCTURE [DIMENSIONS]
0980D11
0980D
ROOM STRAIGHT-LINE DIMENSIONS (3)
CHU098070001B03
.
End Of Sie
K
B
C
A
E
G
H
I
J
M
F
9
8
7
5
4
3
1
2
6
CHU0980B030
A,B C C
,
M
E
F
E,F
I J K H
G
Fr
Fr
Fr
Fr
Fr
Fr
Fr
B
A
Fr
Fr
Fr
CHU0980B031
Measured
location
Dimensions mm {in}
1 1,524 {60.00}
2 1,737 {68.39}
3 1,858 {73.15}
4 1,225 {48.23}
5 1,049 {41.30}
6 921 {36.26}
7 862 {33.94}
8 794 {31.26}
9 752 {29.61}
K-K 1,546 {60.87}
Measured
location
Dimensions mm {in}
BODY STRUCTURE [DIMENSIONS]
0980D12
REAR BODY STRAIGHT-LINE DIMENSIONS
CHU098070002B01
.
End Of Sie
A A
,
B
,
C
,
D
,
E
,
F
,
B
D
E
F
C
9
8
7
5
4
3
10
15
16
14
13
11
12
6
1
2
CHU0980B022
D,E
D
E
A B C F
Fr
Fr
Fr Fr Fr
CHU0980B023
Measured
location
Dimensions mm {in}
1 885 {34.84}
2 1,120 {44.09}
3 592 {23.31}
4 1,022 {40.24}
5 849 {33.43}
6 491 {19.33}
7 470 {18.50}
8 1,268 {49.92}
9 1,253 {49.33}
10 198 {7.80}
11 RH:968 {38.11}, LH:952 {37.48}
12 RH:576 {22.68}, LH:574 {22.60}
13 1,207 {47.52}
14 RH:873 {34.37}, LH:853 {33.58}
15 RH:433 {17.05}, LH:427 {16.81}
16 467 {18.39}
Measured
location
Dimensions mm {in}
BODY STRUCTURE [PLASTIC BODY PARTS]
0980E1
0980E
0980E BODY STRUCTURE [PLASTIC BODY PARTS]
PLASTIC PARTS HEAT RESISTING
TEMPERATURE . . . . . . . . . . . . . . . . . . 0980E1
REPAIRABLE RANGE OF
POLYPROPYLENE BUMPERS . . . . . . 0980E2
Repairable Bumpers . . . . . . . . . . . . . . . 0980E2
POLYPROPYLENE BUMPER REPAIR. . 0980E3
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . 0980E4
End of Toc
PLASTIC PARTS HEAT RESISTING TEMPERATURE
CHU098050000B01
Note
The application of temperatures higher than heat resisting temperatures may result in part deformation.
End Of Sie
Part Name Code Material Name
Heat resisting
Temperature C { F}
WINDSHIELD MOULDING PVC POLYVINYLCHLORIDE 95 {203}
COWL GRILLE PP POLYPROPYLENE 100 {212}
FRONT COMBINATION
LIGHT
LENS PC POLYCARBONATE 130 {266}
HOUSING PP POLYPROPYLENE 95 {203}
FRONT BUMPER PP POLYPROPYLENE 100 {212}
FRONT SIDE MARKER
LIGHT
LENS PMMA ACRYLIC 75 {167}
HOUSING ASS ASS 80 {176}
OUTER HANDLE
HANDLE BASE PC-PET POLYCARBONATE-PET 80 {176}
HANDLE LEVER PC-PBT POLYCARBONATE-PBT 80 {176}
OUTSIDE MIRROR ABS ABS 90 {194}
REAR COMBINATION
LIGHT
LENS PMMA ACRYLIC 80 {176}
HOUSING AES AES 70 {158}
REAR BUMPER PP POLYPROPYLENE 100 {212}
HIGH-MOUNT BRAKE LIGHT PC POLYCARBONATE 100 {212}
ROOF MOULDING PVC POLYVINYLCHLORIDE 95 {203}
BELTLINE MOLDING PVC POLYVINYLCHLORIDE 95 {203}
FENDER GRILLE PP POLYPROPYLENE 100 {212}
BODY STRUCTURE [PLASTIC BODY PARTS]
0980E2
REPAIRABLE RANGE OF POLYPROPYLENE BUMPERS
CHU098050010B01
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.
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
YMU980PCP
BODY STRUCTURE [PLASTIC BODY PARTS]
0980E3
0980E
POLYPROPYLENE BUMPER REPAIR
CHU098050010B02
End Of Sie
YMU980PCQ
BODY STRUCTURE [PLASTIC BODY PARTS]
0980E4
PROCEDURE
CHU098050010B03
Repair of polypropylene bumpers having damage that has reached the surface of the polypropylene and are too
serious to be restored by painting only.
1. Cut the rough edges around the damage with a knife to make it smooth. Sand the area with a sander to make
an angle of about 45.
YMU980PCR
YMU980PCS
BODY STRUCTURE [PLASTIC BODY PARTS]
0980E5
0980E
2. Weld the damaged area.
For repair of a cracked area, melt the crack together with a heat gun and a melting attachment.
For repair of a hole, degrease the area on both sides of the bumper and apply aluminium tape on the
reverse side of the damage area.
3. Melt the polypropylene welding rod with a heat gun and deposit it in the cracked area.
Note
Heat the shaded area to melt it.
Take care not to overly melt welding rod. If the part is welded with the welding rod melted like jelly, the
welding strength will be reduced.
Hold the heat gun 1020 mm {0.390.79 in} from the part being welded.
Do not move the welding rod until the welded parts cool.
YMU980PCT
YMU980PCU
YMU980PCV
YMU980PCW
BODY STRUCTURE [PLASTIC BODY PARTS]
0980E6
4. Sand the surface of the polypropylene gradually as it is easily melted by the abrasion heat. Sand the area to
which repair agent will be applied.
5. Uniformly apply polypropylene primer with a brush to an area larger than the repaired area. Allow to dry about
10 minutes at 20 C {68 F}.
6. Mix the main agent and the stiffening agent in a ratio of one to one. Apply the mixed repair agent to the
damaged area.
Note
When mixing the main and stiffening agents, take care not to allow bubbles to form.
The repair agent hardens quickly (about 5 minutes); proceed with the work immediately after mixing the
agents.
Allow about 30 minutes to dry (20 C {68 F}) before sanding.
The repair agent is a two part epoxy adhesive.
When the repair agent hardens, it will provide a good finish with the same flexibility as the polypropylens.
The repair agent for a urethane bumper is also a two part adhesive compound. However, this is different from
that for a polypropylene bumper. If the incorrect repair agent is used, the repair will be faulty.
YMU980PCX
YMU980PCY
YMU980PCZ
BODY STRUCTURE [PLASTIC BODY PARTS]
0980E7
0980E
7. Sand the area with #180240 sandpaper.
Note
If excessive force is applied to the area when sanding, the surface will be damaged.
If fuzz remains around the repaired area, melt it with a heat gun.
8. Degrease the painted surface.
9. Mix the primer and the hardener at a ratio of one to one. Apply the primer to the repaired area and the surface
of the bumper with a brush or spray.
Use the primer within 16 hours after it is mixed.
Note
Polypropylene primer will dissolve even after drying if it is wiped with solvent. Use only water to clean
around the primer.
10. Allow the part to dry.
YMU980PD0
YMU980PD1
BODY STRUCTURE [PLASTIC BODY PARTS]
0980E8
11. Add the softener to the urethane primer surfacer and spray it on the repaired area.
a. Mixing method
Urethane primer surfacer + Softener ..... Mixture A
Mixture A + hardener ..... Mixture B
Dilute mixture B with thinner to spray on bumper
b. Viscosity
1416 seconds/viscosimeter 20 C {68 F}
Note
Mix the solutions at the specified ratio.
c. Spray pressure
300400 kPa {34 kg/cm
2
, 4357 psi}
d. Standard film thickness
3040
e. Spray method
Spot-spray primer surfacrer on bumper three of four times
12. Air drying 20 C {68 F} 8 hours minimum.
Forced drying 60 C {140 F} 1 hour
13. Lightly sand the complete surface of the bumper with #400#600 sandpaper. Do not expose the surface of the
polypropylene. (Wet or dry sanding is acceptable.)
14. Wipe the complete surface of the bumper with degreasing agent. Quickly wipe the surface with a clean rag to
degrease it.
15. Apply a matching coat of body color to the polypropylene bumper.
Note
Be sure to use only urethane primer for a urethane bumper and polypropylene primer for a polypropylene
bumper. Other paints for repairing a polypropylene bumper are the same as those for the urethane
bumper.
16. Air drying 20 C {68 F} 8 hours minimum.
Forced drying 60 C {140 F} 1 hour
Note
Let the part air dry when possible as forced drying could cause bubbles in the top coat.
End Of Sie
YMU980PD2