1994 MAZDA MX-5 Workshop Manual

PANEL REPLACEMENT w INSTALLATION vz 27 points Cut-and-join of the side sill should not be performed at or. points. 0 When replacing the side sill, install a scrap part under the cut-and-join location to help weld- Ing. Plug welding of points (A) should be performed during installation of the cowl side panel and the rear fender panel. Gartner Banana

PANEL REPLACEMENT FRONT PILLAR, OUTER COWL SlDE PANEL, HINGE PILLAR, INNER COWL SlDE PANEL AND SlDE SILL PANEL REMOVAL cut-and-join location I The following operations are performed when the inner and outer front pillars, cowl side panel, outer hinge pillar, inner cowl side panel, and outer side sill panel are replaced at the same time. Cut away the joint of the outer front pillar and the upper front header (shown by the broken line) with a saw. Rough-cut the outer side sill panel and drill away the spot welding of the hinge pillar and the side sill reinforcement. Do not make open holes when drilling. Cut away the other welded points shown in the illustration. Remove the bolts attached to the instrument panel bracket, the dash side junction, etc. Remove the parts to be replaced. -- Gartner Banana

PANEL REPLACEMENT V REMOVAL =@ Dash side junction bolts Do not damage the side sill reinforcement when rough-cutting. When drilling 14 points indicated by (A), do not make open holes. When drilling away plug welded points, first flatten paddings with a disc grinder. Gartner Banana

PANEL REPLACEMENT FRONT PILLAR, OUTER COWL SlDE PANEL, HINGE PILLAR, INNER COWL SlDE PANEL AND SlDE SILL PANEL INSTALLATION Make plug welding holes in the outer hinge pillar and the cowl side nusset. After temporary installation of the inner and outer front pillar, outer hinge pillar, and inner cowl side panel, measure the dimensions to verify that they are as specified. Check the fit with as- sociating parts, then weld the points indicated by (A). After welding the points (A), remove the front pillar and the hinge pillar from the body. Then spot weld or plug weld the points indicated by (B). A Gartner Banana

PANEL REPLACEMENT INSTALLATION 1 6 bolts Side sill gusset points After installing the side sill gusset as indicated, install the front pillar and the hinge pillar to the body. Check the fit with associating parts, then weld all parts. To weld parts, refer to page 49, cowl side panel and page 51, side sill panel assy to assure a good weld. To install the cowl side panel and the side sill panel, refer to page 49, 51. Gartner Banana

PANEL REPLACEMENT - REAR FENDER PANEL REMOVAL When drilling points for spot welding indicated by (A), (B) and (C), do not make open holes. To drill away 2 points indicated by (B), first drill points (A) and turn up the flange of the rear deck panel. Gartner Banana

PANEL REPLACEMENT V INSTALLATION a Apply body sealer before installing new parts as shown in the illustration. \- a After temporary installation of new parts, check the fit with associating parts (door, trunk lid, rear combination lights, rear bumper, rear finisher etc.). L To plug weld 2 points indicated by (A), first spot weld point (B) and turn down the flange of the rear deck panel to the original position. Gartner Banana

PANEL REPLACEMENT REAR END PANEL REMOVAL I For best results, when drilling spot welded points, do not make open hole?. Gartner Banana