BODY REPAIR 1 BODY REPAIR Foreword - Nissan
Contents
1. O 1196 _ EK 1 628 O O 1368 O 571 O 1359 O 1668 1 94 1805 Q O 1451 O 808 6 6 1601 0 0 1183 O O 1121 G 9 1178 G amp O 1607 1155 0 0 1510 O O 1371 O O 1162 HR 1368 0 0 1 101 0 8 1087 0 0 1177 G9 6 779 779 SIIA2598E 24 BODY REPAIR Measurement Points A Cowl top flange end of center positioning mark Front roof flange end of center positioning mark Oo Front pillar joggle B D Front pillar indent P D Door hinge installing nut center 12dia 0 0 0 0 0 0 0 D Center pillar indent Q FD D Door hinge installing nut center 12dia MD m ND m Front seat mounting bracket hole center i ia i A LES Wb LIRE Eo Sa sl EL LA E E E 25 BODY REPAIR REAR BODY Measurement Unit mm 26 BODY REPAIR Measurement Points A Rear roof flange end of center positioning mark Inner rear pillar joggle Rear combination lamp base joggle J V E Rear panel indent of center positioning mark SIIA2601E 27 BODY REPAIR Handling Precautions For Plastics HANDLING PRECAUTIONS FOR PLASTICS Abbre viation Material name Polyethylene Heat resisting temperature Ot F Resistance to gasoline and solvents Gasoline and most solvents are harmless if applied for a very short time wipe up quickly BIS000VD Other cautions2. Chee IN Do not apply undercoating to any place unless specified such as the areas above the muffler and three way catalyst which are subjected to heat Do not undercoat the exhaust pipe or other parts which become hot Do not undercoat rotating parts Apply bitumen wax after applying undercoating After putting seal on the vehicle put undercoating on it Indicates undercoated portions Indicates sealed portions FH side Front wheelhous SIIA2586E 11 BODY REPAIR STONE GUARD COAT To prevent damage caused by stones the lower outer body panel fender door etc have an additional layer of Stone Guard Coating over the ED primer coating When replacing or repairing these panels apply Stone Guard coating to the same portions as before Use a coating which is rust preventive durable shock resistant and has a long shelf life Indicates stone guard coated portions SIIA2587E 12 BODY REPAIR Body Sealing BISO00VA DESCRIPTION The following figure shows the areas which are sealed at the factory Sealant which has been applied to these areas should be smooth and free from cuts or gaps Care should be taken not to apply an excess amount of sealant and not to allow other unaffected parts to come into contact with the sealant SIIA2588E 13 BODY REPAIR 14 BODY REPAIR BODY REPAIR Body Construction BODY CONSTRUCTION BODY REPAIR Body Alignment Bisooovc B
3. Flammable Poly Vinyl Chloride Same as above Poison gas is emitted when burned Ethylene Propylene Diene copolymer Same as above Flammable Thermoplastic Olefine Same as above Flammable Polypropylene Same as above Flammable avoid battery acid Unsaturated Polyester Same as above Flammable Polystyrene Avoid solvents Flammable Acrylonitrile Butadiene Styrene Avoid gasoline and solvents Poly Methyl Methacrylate Same as above Ethylene Vinyl Acetate 90 194 Same as above Acrylonitrile Styrene Acrylate 100 222 Same as above Flammable Poly Phenylene Ether 110 230 Same as above Polycarbonate 120 248 Same as above Polyarylate 180 356 Same as above Polyurethane 90 194 Same as above Poly Oxymethylene 120 248 Same as above Avoid battery acid Poly Butylene Terephthalate Polycarbonate 120 248 Same as above Flammable Polyamide 140 284 Same as above Avoid immersing in water Poly Butylene Terephthalate 140 284 Same as above Polyester 180 356 Same as above Polyetherimide 200 392 Same as above 1 When repairing and painting a portion of the body adjacent to plastic parts consider their characteristics influence of heat and solvent and remove them if necessary or t
4. Sama 2 gt iL dimensions on both right and left hand sides of the vehicle Bolt head As viewed from underside All dimensions indicated in this Ne N edh l IN M a l gt S S 1266 TX 1665 1391 1024 LH side 373 1363 1230 2 A O AS O Lu V 03 U D ae REPAIR Unit mm 1663 1388 ON 1116 1389 SIIA2596E 22 BODY REPAIR Measurement Points As viewed from underside Unit mm Coordinates Rear A 4T X 476 X 500 Y 502 Y 2538 2 282 Z 377 X 492 X 488 Y 525 Y 2538 Z 282 Z 377 E X 464 X 498 Y 333 Y 2822 2 493 2 376 b X 467 X 488 Y 210 Y 2822 Z 493 Z 376 X 1410 Y 547 2 190 O X 1189 Y 828 LH side RH side 106 OS X 1163 Y 1200 2 204 D X 1633 Y 2102 Z 318 omo 9 4 DNA E i exu X DN ae sedia DEA t O D v NE Front and rear strut tower centers d R16 16dia Coordinates 12dia Bo pr 17dia A E Le a a Goa a ES Front Front D D 98dia Rear QD D 20dia SIIA2597E 23 BODY REPAIR PASSENGER COMPARTMENT Measurement Unit mm Figures marked with a indicate symmetrically identical dimensions on both right and left hand sides of the vehicle Point Dimension Point Dimension Point Dimension ES 1279 O 1565 _ 1285 0 01 1470 0 0 1271 0 0 717 0 91 1514 O 1 660
5. from the standard line of X Y and Z To base line Z imaginary base line 200 mm below datum line OZ at design plan Vehicle center PIIA0104E 19 BODY REPAIR ENGINE COMPARTMENT Measurement Unit mm Figures marked with a indicate symmetrically identical dimensions on both right and left hand sides of the vehicle Lad Pt O 642 O 656 O 144 Par gt gt 144 642 656 387 406 ooo 910 010 387 O O 406 oe O O SIIA2594E 20 BODY REPAIR Measurement Points A Cowl top indent of center positioning mark b Hood hinge installing hole center 12dia c Front strut installing hole center 11x16 e Front fender installing hole center 7dia D Harness clamp installing hole center 5dia 3 U 3 m d E urn 9 Radiator core support installing hole center 9dia h Engine mounting bracket installing hole center 11dia EN G Radiator core support installing hole center 9dia B Engine mounting bracket installing hole center 14dia JNE D G Bumper stay installing hole center 15dia G ADD on frame bracket hole center 16dia VE 16dia Sa SIIA2595E 21 BODY UNDERBODY Measurement ES c d S ES 2 E gt a mi D D O xX La E e o
6. A2640E For 3 panels plug weld method pea a B 54 BODY REPAIR Service Joint Before installing rear fender 2 spot welds 3 spot welds M IG plug weld dE R xd M I G seam weld For 3 panels plug weld method Point weld N sa NN nA SIIA2641E 59 BODY REPAIR INSTALLATION NOTES Rear fender i Glana ama e Flange of a wheel arch department hem after having Outer rear wheelhouse apply adhesive e Seal up the area around the hemmed end of the flange e Refer to Rear fender hemming process Adhesive 4 Adhesive Sealant 2 spot welds 3 spot welds M IG plug weld M I G seam weld For 3 panels plug weld method Point weld cm EE Joa mA N 1B mf SIIA2491E 56 BODY REPAIR REAR PANEL Service Joint indicates that there is an equivalent welding portion with the same dimensions on the opposite side length 20 A OM 1 length 20 9 1or IB 1 e or 1 KIS B 1A 2 spot welds 3 spot welds M I G plug weld ok eK Change parts fanal M I G seam weld For 3 panels plug weld method Point weld aN nA SIIA2642E Rear panel assembly 57 BODY REPAIR REAR FLOOR REAR e Work after rear panel has been removed Service Joint indicates that there is an equivalent welding portion with the same dimensions on the opposite side a Ce RO 2 spot welds 3 spot welds M I
7. AIR Rear fender hemming process 1 A wheel arch is to be installed and hemmed over left and right outer wheel house 2 In order to hem the wheel arch it is necessary to repair any damaged or defaced parts around outer wheel house CAUTION Ensure that the area that is to be glued around outer wheelhouse is undamaged or defaced Procedure of the hemming process e Peel off old bonding material on the surface of outer wheelhouse and clean thoroughly gt e Peel off a primer coat in the specified area where new adhesive Rear fender is to be applied on rear fender the replacing part e Apply new adhesive to both specified areas of outer wheelhouse and rear fender The gluing area lt Adhesive gt 3M automix panel bond 8115 ma or any equivalents Apply adhesive Outer wheelhouse e Attach rear fender to the body of the car and weld the required part except the hemming part SIIAZ244E e Bend the welded part starting from the center of the wheel arch gradually with a hammer and a dolly Also hem the end of the flange e Hemming with a hammer is conducted to an approximate angle of 80 degrees Appox 80 SIIA2245E e Starting from the center hem the wheel arch gradually using slight back and forth motion with a hemming tool SIIA2246E e Seal up the area around the hemmed end of the flange MAX 4 0mm SIIA2247E 34 BODY REPAIR Foam Repair BISO00VE During factory body assembly foam i
8. BODY REPAIR BODY REPAIR PFP 60100 Foreword gian This Body Repair Manual contains information and instructions for repairing the body structure of the NISSAN NOTE E11 model In order to achieve reliable repair work and ensure customer satisfaction the technician should study this manual and become familiar with appropriate sections before starting and rebuilding work This Body Repair Manual is prepared for technicians who have attained a high level of skill and experience in repairing collision damaged vehicles and also use modern service tools and equipment Persons unfamiliar with body repair techniques should not attempt to repair collision damaged vehicles by using this manual Technicians are also encouraged to read Body Repair Manual Fundamentals Frame Repair Manual Fundamentals and the NISSAN NOTE E11 Service Manual in order to ensure that the original func tions and quality of the vehicle can be maintained The Body Repair Manual Fundamentals and Frame Repair Manual Fundamentals contains additional information including cautions and warn ings that are not included in this manual Technicians should refer to both manuals to ensure proper repairs Please note that these manuals are prepared for worldwide usage and as such certain procedures might not apply in some regions or countries All information in this manual is based on the latest product information at the time of publication The right is reserved to make chang
9. G plug weld ok eK M I G seam weld For 3 panels plug weld method Point weld mA sga LD SIIA2643E 58 BODY REPAIR Change parts Rear floor rear Spare tire clamp bracket Towing hook bracket Muffler mounting bracket 59 BODY REPAIR REAR SIDE MEMBER EXTENSION e Work after rear panel has been removed Service Joint 2 spot welds 3 spot welds M I G plug weld M I G seam weld For 3 panels plug weld method Point weld cm o Joa mA sga on SIIA2644E 60 BODY REPAIR Change parts Rear side member extension LH 61
10. GE PARTIAL REPLACEMENT RRR a aaa a kag aaa aja aaa a wen wee wale ARRE EET S 42 FRONT SIDE MEMBER CE AAA AAA AA 44 FRONT PILLAR A A Set 48 CENTER PILLAR a aa 50 OUTER SILL a A a ici eee eee 52 REAR FENDER A naa NS MW a NEN WE NM a FEN MN RR WR NR sl bab aa aaa al aaa a WKN ERN RE NER d ia 54 REAHR PANEL SP KE T R E a RN aa TR E RR KER ET RS 57 REAR FLOOR REAR Ww mm PUR ER wil i w aaa a bebe Gin ww A ER ETTR un a ajan OT R eR CS A 58 REAR SIDE MEMBER EXTENSION www e wits wie Sis RR NEC MW EN nM E EN NE RN NR SET R eR What aan E c su MN xis wa 60 BODY REPAIR General Information O IDENTIFICATION NUMBER MA LIC X Vehicle identification number ES ip BT T SZ N ee Vehicle identification plate MAIBOO74E Vehicle Identification Number Arrangement 0 XXXXXX Vehicle serial number Basically 0 Other numbers only by exception Destination U Europe Model A 2 wheel drive Engine type A CR14DE C HR16DE D K9K Body F 5 door Manufacturer SJN Nissan Passenger vehicle UK production MAIBOO75E BODY REPAIR IDENTIFICATION PLATE Type approval number Models for 8 Body color code NISSAN Europe with Euro OBD system 9 Trim color code Blank Models for Europe without 10 Model Euro OBD system A Vehicle identification number kg Chassis number E Gross vehicle weight Gross combination weight kg Gross vehicle weight 2 kg Gross trailing capacity Weight Baiar Tim A Gross axle weight Front Gross ax
11. H amp LH Outer sill reinforcement RH amp LH Outer side roof rail reinforcement RH amp LH Upper inner front pillar RH amp LH Front roof rail brace RH amp LH Inner side roof rail RH amp LH Inner center pillar RH amp LH Outer sill RH amp LH Jack up point bracket RH amp LH Outer rear wheelhouse RH amp LH Outer rear wheelhouse extension RH amp LH Inner rear wheelhouse RH amp LH Inner rear pillar RH amp LH Back pillar reinforcement RH amp LH Roof Front roof rail Rear roof rail Center roof reinforcement Rear roof bow Rear fender Striker tapping retainer RH amp LH Rear fender corner RH amp LH Outer back pillar RH amp LH Fuel filler lid Fuel filler lid spring Fuel filler lid base Front door RH amp LH Outer front door panel RH amp LH Rear door RH amp LH Outer rear door panel RH amp LH Back door BODY REPAIR Corrosion Protection EIS00ov9 DESCRIPTION To provide improved corrosion prevention the following anti corrosive measures have been implemented in NISSAN production plants When repairing or replacing body panels it is necessary to use the same anti cor rosive measures Anti corrosive Precoated Steel Galvannealed Steel To improve repairability and corrosion resistance a new type of anti corrosive precoated steel sheet has been adopted replacing conven S pee d pete and heated to form Zinc iron E A ec II alloy which
12. ODY CENTER MARKS A mark has been placed on each part of the body to indicate the vehicle center When repairing parts dam aged by an accident which might affect the vehicle frame members pillars etc more accurate and effective repair will be possible by using these marks together with body alignment specifications Portion D Portion B Portion C Portion E Portion A Embossment os P Rear roof Front roof Rear panel SIIA2592E 17 BODY REPAIR PANEL PARTS MATCHING MARKS A mark has been placed on each body panel to indicate the parts matching positions When repairing parts damaged by an accident which might affect the vehicle structure members pillars etc more accurate and effective repair will be possible by using these marks together with body alignment specifications SIIA2593E 18 BODY REPAIR DESCRIPTION e All dimensions indicated in the figures are actual e When using a tracking gauge adjust both pointers to equal length Then check the pointers and gauge itself to make sure there is no free play e When a measuring tape is used check to be sure there is no elongation twisting or bending Measurements should be taken at the center of the mounting holes An asterisk following the value at the measuring point indicates that the measuring point on the other side is symmetrically the same value e The coordinates of the measurement points are the distances measured
13. ON ME cu ER e 13 Body Construction EL 16 BODY CONSTRUCTION ES ee R R RN RN EE PP Wen 16 Body Alignment xe xum wines ue e a aa a RE aa R 0 sen ns ce MR RR RO OR NR n ON nous nn alga a Ninon a aa aa eue deu wed Se 17 BODY CENTER MARKS AA D ORAE E AA AA EE CR CT EE 17 PANEL PARTS MATCHING MARKS DD 18 DESCHIPTION D AAA 19 ENGINE COMPARTMENT LEE E KE anaa FEE GN ERa te 20 UNDERBODY SER NEKENG denis Ste aT RRR BAE Ja EN ERE ERIR Miwa C ERE RRR Ty Ta RR ajang a MENSAS dense Ov Wale ENE a ja ERa Eai E 22 PASSENGER COMPARTMENT a E R wets a ew een Nab RN oboe R TA WA BANJAR 24 REAR BODY WE WR GN FER ERE RET L NU REN NN SLIKE aga a ai M WE M REC N M EIN K RTE M RR BER aj ate tate MR AIL RR E a WR L E Nu 26 Handling Precautions for Plastics O A 28 HANDLING PRECAUTIONS FOR PLASTICS Ra NRT RRR P C a aes 28 LOCATION OF PLASTIC PARTS agar R R NW M aaee A WO RR a 29 Precautions in Repairing High Strength Steel A a N AA 31 HIGH STRENGTH STEEL HSS USED IN NISSAN VEHICLES mnn 31 Foam Repair A A A Le 35 URETHANE FOAM APPLICATIONS nes nr EC anne averses ass sions soc 35 Replacement Operations EE 36 DESCRIPTION none AR a rara aa RRR RR AEN SENG jaja JE Ja ara a ra RI NR RR 9 sut ES uE on een ele le bwin FRE on ons nes R RN AR ANG al a E 06 de win oon eine 36 RADIATOR CORE SUPPORT KR alin wn win Nw RR RR CR aaa aaa an a aa Na e e wc n wc eww ww N wt We won A he s wie R NR N RN FR 39 HOODLEDGE REE win wie hb bie Swine Ng ANA EP I NENNEN 40 HOODLED
14. ake suitable measures to protect them 2 28 Plastic parts should be repaired and painted using methods suiting the materials characteristics BODY REPAIR LOCATION OF PLASTIC PARTS Windshield molding Roof side molding PVC PVC Door mirror Cover ABS Base PPE Head lamp Lens PC Housing PP Front grille ABS Side turn signal lamp Lens PMMA Housing ABS PC Front bumper fascia PP Fog lamp ue Glass Housing PBT ASA Glass fiber High mount stop lamp Rear combination lamp Lens PC Lens PMMA Housing PC Housing ABS i e Door outside handle Back door finisher ABS P CS BL Licence plate lamp order PA Wee Buc NANA Rear fog lamp Side guard molding PP Lens PC Housing PC Center cap PC ABS Rear bumper fascia Reflector S PP Lens PMMA sa di Housing ABS PC ABS SIIA2602E 29 BODY REPAIR Front pillar garnish Map lamp PP Lens PC Center pillar garnish Housing PA Rear pillar finisher PP Caz k Ce TN lt Cluster lid A Lower luggage side finisher gt C PP PP D n dd H UN Cluster lid C V Upper instrument pane 241 ek Ey O Y EN N S S A N ON CR Ai NG YA ce panel o IN Glove box Console body PP PP SIIA2603E 30 BODY REPAIR Precautions In Repairing High Strength Steel High strength steel is used for body panels in order to reduce vehicle weight Accordi
15. d For 3 panels plug weld method Point weld aA nN SIIA2631E 46 BODY REPAIR Service Joint Before installing front side member closing plate Unit mm 2 spot welds 3 spot welds M I G plug weld E eg M I G seam weld For 3 panels plug weld method Point weld m SIIA2632E N 47 BODY REPAIR FRONT PILLAR e Work after hoodledge reinforcement has been removed Service Joint Before installing outer front pillar amp brace E 2B ET 8A Unit mm 2 spot welds a o 3 spot welds M I G plug weld d TENS 48 For 3 panels plug weld method m B Aw Before installing outer front pillar amp brace outer sill reinforcement i 1A M I G seam weld Point weld SIIA2633E Xy BODY REPAIR Change parts Side body assembly LH Front pillar brace LH Side dash LH Upper inner front pillar LH 6 Outer sill reinforcement LH Service Joint Before installing outer front pillar Outer front pillar reinforcement BL N Before installing outer front pillar on amp brace outer sill reinforcement Unit mm 2 spot welds 3 spot welds M I G plug weld M I G seam weld For 3 panels plug weld method Point weld cm EE Joa ASW apii mf SIIA2634E BODY REPAIR CENTER PILLAR Service Joint enter pillar brace Outer sill reinforcement P P 2 KY Q IN E A Unit mm M I G
16. distance from the locating indent Use this distance when cutting the service part Cut outer front pillar over 60 mm above inner front pillar cut position indent pillar Inner front Record pillar distance PIIA0151E Prepare a cutting jig to make outer pillar easier to cut Also this ae M Inner front pill will permit service part to be accurately cut at joint position E UO ENT os front pillar PIIA0152E An example of cutting operation using a cutting jig is as follows Mark cutting lines A Cut position of outer pillar B Cut position of inner pillar Align cutting line with notch on jig Clamp jig to pillar Cut outer pillar along groove of jig At position A Remove jig and cut remaining portions Cut inner pillar at position B in same manner PIIA0153E 38 BODY REPAIR RADIATOR CORE SUPPORT Service Joint io BB io li io m e or B Point weld panel 6 SIIA2627E Side radiator core support LH O Side radiator core reinforcement LH O Hoodledge connector LH For 3 panels plug weld method RO em fe TeS Change parts 2 spot welds 3 spot welds M I G plug weld M I G seam weld 39 BODY REPAIR HOODLEDGE e Work after radiator core support has been removed Service Joint Before installing hoodledge reinforcement For 3 panels plug weld method Point weld ems Eu BN 40 M 2 spot welds 3 spot welds M G p
17. es in specifications and methods at any time without notice 2006 NISSAN EUROPE S A S All rights reserved No part of this Body Repair Manual may be reproduced or stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise with out the prior written permission of Nissan Europe S A S Paris France BODY REPAIR Contents aiene Foreword A AAA AAA AAA AAA A 1 Contents A a A A A a 2 General Information a aaa NE 3 IDENTIFICATION NUMBER e o econ RR RR R NR RR RER N RR ein 3 IDENTIFICATION PLATE nn een en nn ee wid aw ws i w wes mc WIEN NR E EM E RR ak anana WEE aa te un St en ue ets en NER GEN EM aaa 4 BODY EXTERIOR PAINT COLOR A MEREAR 5 Body Component Parts nun aa aa wine wip wis NS MARTEM CR oly a CER ne Nin Aa A w alec 6 UNDERBODY COMPONENT PARTS Ra aE RRR in et NR ith bw wate et cw n rw n NEW WR wise is wie NT K Ta raaa YR ete NN NSS 6 BODY COMPONENT PARTS A a A a 65 8 Corrosion Protection DD RETE 10 DESCHIPTION I EARN RUREEN T ESEEENNAS ARAM C RE A NAAR SSH ME 10 UNDERCOATING nn nee nn ne Ge EVE REN KENN ERRARE NER NEWER NZW EA S MN RE NEM ww ww QN MESES EE NEM owen wie EE RW 11 STONE GUARD COATING aa aaa a s wis win wis cinta wee RRR AER RRR a GE Sims ae Ce wie RTT EET ERN NAR 12 Body Sealing GN a Mane RAR RR SHEER MEN ROS RARE RENEW EOE a ALN R EDS RSE PBA AAA AAA 13 DESCRIPTION sm aaa MR MEME NEWER R RN RNG Rare a RRR R ananas aan MEAN EE RR ERA NR EN E E
18. le weight Rear Vehicle type MAIBOO19E BODY EXTERIOR PAINT COLOR BODY REPAIR Component Bumper fascia Color code Description Paint type Hard clear coat Body color BE42 Yellow M x BKYO Silver M x SIIA2583E Front grille Metallic color Material color Door outside mirror Body color Material color Door outside handle Body color Material color Side guard molding Body color Material color Rear fender cover Body color Back door finisher Body color S 1 Coat solid 2S Solid Clear M Metallic TM Micro titanium metallic PM Pearl metallic 2P 2 Coat pearl 3P 3 Coat pearl FPM Iron oxide pearl RPM Multi flex color BODY REPAIR Body Component Parts Bisooove UNDERBODY COMPONENT PARTS Indicates aluminum portion x Wig EE Indicates both sided anti corrosive precoated steel portions A Indicates both sided anti corrosive steel and HSS portions E Indicates high strength steel HSS portions SIIA2584E E l OE as Ges Ih KR A A WO OO GM G O M mo M m m M M MMM a A 0 BODY REPAIR Side radiator core support Side radiator core reinforcement Hoodledge connector Side dash RH amp LH Upper hoodledge RH amp LH Hoodledge reinforcement Front strut housing Upper side cowl top Cowl top Upper dash assembly Lo
19. lug weld MI G seam weld SIIA2628E BODY REPAIR Change parts Upper hoodledge LH Hoodledge reinforcement LH Front strut housing LH 41 BODY REPAIR HOODLEDGE PARTIAL REPLACEMENT e Work after radiator core support has been removed Service Joint This figure shows right front side member Before installing hoodledge reinforcement Before installing hoodledge reinforcement Before installing hoodledge reinforcement 2 spot welds 3 spot welds M I G plug weld M I G seam weld For 3 panels plug weld method Point weld cm o s G an apa mf SIIA2629E 42 BODY REPAIR Change parts Engine mounting member bracket RH Upper hoodledge RH Hoodledge reinforcement RH 43 BODY REPAIR FRONT SIDE MEMBER e Work after hoodledge and radiator core support have been removed Service Joint Front side member Unit mm 2 spot welds 3 spot welds M I G plug weld M 1G seam weld For 3 panels plug weld method Point weld d ce T m 44 BODY REPAIR Change parts Front side member LH Front side member closing plate LH Add on frame bracket LH O Front side member flange LH Outer add on frame bracket LH Tie down hook reinforcement LH Sensor harness bracket LH Front suspension mounting bracket LH Brake hose bracket LH O Front hook LH 45 BODY REPAIR Service Joint 2 spot welds 3 spot welds M G plug weld E E E M I G seam wel
20. ngly precautions in repairing automotive bodies made of high strength steel are described below HIGH STRENGTH STEEL HSS USED IN NISSAN VEHICLES Tensile strength 373 N mm 38kg mm 54klb sq in Nissan Infiniti designation Renault designation X Z E220P BISOOOVE Major applicable parts e Front side member assembly e Pillar hinge brace assembly e Rear side member assembly e Other reinforcements 785 981 N mm 80 100kg mm 114 142klb sq in SP130 is the most commonly used HSS SP150 HSS is used only on parts that require much more strength XE 450P 31 e Front bumper reinforcement BODY REPAIR Read the Following Precautions When Repairing HSS Additional points to consider e he repair of reinforcements such as side members by heat 1 ing is not recommended since it may weaken the component When heating is unavoidable do not heat HSS parts above 550 C 1 022 F Verify heating temperature with a thermometer Crayon type and other similar type thermometer are appro priate When straightening body panels use caution in pulling any HSS panel Because HSS is very strong pulling may cause deformation in adjacent portions of the body In this case increase the number of measuring points and carefully pull the HSS panel When cutting HSS panels avoid gas torch cutting if possi ble Instead use a saw to avoid weakening surrounding areas due to heat If gas torch c
21. nsulators are installed in certain body panels and locations around the vehicle Use the following procedure s to replace any factory installed foam insulators URETHANE FOAM APPLICATIONS Use commercially available spray foam for sealant foam material repair of material used on vehicle Read instructions on product for fill procedures 1 Fill procedures after installation of service part Remove foam material remaining on vehicle side Clean area in which foam was removed Install service part Insert nozzle into hole near fill area and fill foam material or fill in enough to close gap with the service part De E Foam material Foam material QT f SON Nozzle insert LIIA1081E 2 Fill procedures before installation of service part Remove foam material remaining on vehicle side Clean area in which foam was removed Fill foam material on wheelhouse outer side NOTE st s Fill while avoiding Fill in enough to close gap with service part while avoiding flange area flange ones Foam material Install service part NOTE Refer to label for information on working times LIIA1082E 35 BODY REPAIR Replacement Operations Bisooove DESCRIPTION This section is prepared for technicians who have attained a high level of skill and experience in repairing col lision damaged vehicles and also use modern service tools and equipment Persons unfamiliar with body repair techniques should no
22. provides excellent and long term corrosion resistance with cationic electrodeposition primer Steel sheet Fe RR SHEO Both sided precoated SIIA2294E Nissan Genuine Service Parts are fabricated from galvannealed steel Therefore it is recommended that GENUINE NISSAN PARTS or equivalent be used for panel replacement to maintain the anti corrosive perfor mance built into the vehicle at the factory Phosphate Coating Treatment and Cationic Electrodeposition Primer A phosphate coating treatment and a cationic electrodeposition primer which provide excellent corrosion pro tection are employed on all body components CAUTION Confine paint removal during welding operations to an absolute minimum Body Panel Cationic electrodepos ition primer VILLE coating treatment GENES NE PIIA0095E Nissan Genuine Service Parts are also treated in the same manner Therefore it is recommended that GENU INE NISSAN PARTS or equivalent be used for panel replacement to maintain anti corrosive performance built into the vehicle at the factory 10 BODY REPAIR UNDERCOATING The underside of the floor and wheelhouse are undercoated to prevent rust vibration noise and stone chip ping Therefore when such a panel is replaced or repaired apply undercoating to that part Use an undercoat ing which is rust preventive soundproof vibration proof shock resistant adhesive and durable Precautions in Undercoating 1
23. seam weld 2 spot welds 3 spot welds M I G plug weld For 3 panels plug weld method Point weld 7 o nf lende 52 m Change parts 50 BODY REPAIR Side body assembly LH O Center pillar brace LH O Inner center pillar LH 6 Outer sill reinforcement LH Service Joint Before installing outer center pillar Center pillar reinforcement Before installing outer center pillar Outer sill reinforcement Unit mm 2 spot welds 3 spot welds M I G plug weld M I G seam weld For 3 panels plug weld method Point weld cm EE Joa DAT apii mf SIIA2636E 51 BODY REPAIR OUTER SILL Service Joint Unit mm 2 spot welds 3 spot welds M I G plug weld MI G seam weld For 3 panels plug weld method Point weld e J u mA on m SIIA2637E Change parts O Outer sill LH 52 BODY REPAIR Service Joint 2 spot welds 3 spot welds M I G plug weld M I G seam weld For 3 panels plug weld method Point weld cm EE Joao aN B mf SIIA2638E 53 BODY REPAIR REAR FENDER Service Joint 7o M5 2o B 7 3 os OT 1 or IM 1 io MH Olar 3 or I 2A er CS e or MH 30or IM 2 Urethane form 7o Ws 1 or IM 1 e or B 1 e 1or BM 1 Unit mm 3 spot welds 2 spot welds EE Change parts Rear fender LH M G plug weld d Cam 2 om 4 length 20 length 20 M I G seam weld Point weld M SII
24. t attempt to repair collision damaged vehicles by using this section Technicians are also encouraged to read Body Repair Manual Fundamentals and Frame Repair Manual Fundamentals in order to ensure that the original functions and quality of the vehicle can be maintained The Body Repair Manual Fundamentals and Frame Repair Manual Fundamentals contains additional informa tion including cautions and warning that are not including in this manual Technicians should refer to both manuals to ensure proper repairs Please note that these information are prepared for worldwide usage and as such certain procedures might not apply in some regions or countries 36 BODY REPAIR The symbols used in this section for cutting and welding brazing operations are shown below WWW Saw cut or air chisel cut 2 spot welds 2 panel overlapping portions 3 panel overlapping portions HAN MIG plug weld OM MIG seam weld Point weld SLOP ODP R gt SSR NG eoe ose RESISITE 0 9 92977 Brazing Solder ing Seal ing PIIAO149E 37 C deco qw BODY REPAIR Front pillar butt joint can be determined anywhere within shaded area as shown in the figure The best location for the butt joint is at position A due to the construction of the vehicle Refer to the front pillar section PIIA0150E Determine cutting position and record
25. utting is unavoidable allow a mini mum margin of 50 mm 1 97in ble in order to minimize weakening surrounding areas due to heat If spot welding is impossible use M I G welding Do not use gas torch welding because it is inferior in welding strength 32 Not recommended Side member Rear side member PIIAO116E PIIAO117E Never use acetylene gas welding PIIA0144E BODY REPAIR e The spot weld on HSS panels is harder than that of an ordi nary steel panel tu do Therefore when cutting spot welds on a HSS panel use a 1 200 rpm low speed high torque drill 1 000 to 1 200 rpm to increase drill bit durability and facilitate the operation PIIAO145E Precautions in spot welding HSS This work should be performed under standard working condi tions Always note the following when spot welding HSS e The electrode tip diameter must be sized properly according to the metal thickness D 2T43 mm D D 2T 0 12 in D Tip diameter T T Metal thickness PIIA0146E e The panel surfaces must fit flush to each other leaving no gaps Correct Incorrect Incorrect PIIA0147E e Follow the specifications for the proper welding pitch Unit mm Thickness t Minimum pitch 0 6 0 024 10 0 39 or over 0 8 0 031 12 0 47 or over 1 0 0 039 18 0 71 or over 1 2 0 047 20 0 79 or over 1 6 0 063 27 1 06 or over 1 8 0 071 31 1 22 or over PIIA0148bE 33 BODY REP
26. wer dash crossmember Lower dash Steering hole patch Center front floor Front floor Rear floor front Rear floor rear Spare tire clamp bracket Towing hook bracket Muffler mounting bracket Rear floor side Front side member Engine mounting reinforcement Front suspension mounting bracket Add on frame bracket Tie down hook reinforcement Front side member closing plate Outer add on frame bracket Front side member flange Sensor harness bracket Front hook Brake hose bracket Engine mounting member bracket Front suspension mounting bracket Rear seat crossmember Center rear crossmember assembly Rear side member Rear side member extension Rear panel assembly Upper rear bumper retainer Lower rear bumper retainer Rear side bumper bracket BODY REPAIR BODY COMPONENT PARTS Right side Indicates aluminum portion EE Indicates both sided anti corrosive precoated steel portions ZZA Indicates both sided anti corrosive steel and HSS portions E Indicates high strength steel HSS portions SIIA2585E OO eae ON ee I E OwWWWWWWWONNNNNNANN ND ON 222 a a a a 0 0 QE ND A oO WE QM O7 MN DUREN BODY REPAIR Hood Front fender RH amp LH Lower front fender bracket RH amp LH Side body assembly RH amp LH Front pillar brace RH amp LH Lower front pillar hinge brace RH amp LH Center pillar brace R
Download Pdf Manuals
Related Search