BODY REPAIR General Information IDENTIFICATION NUMBER Tire placara VEHICLE IDENTIFICATION NUMBER ARRANGEMENT - unt tr A NN mo ou _XXxxxx - t pT is | | ‘Vehicle serial number | Destination Paipoo0seIDENTIFICATION PLATE BODY REPAIR Europe NISSAN EUROPE NV. 1 Type approval number (Models for © Body color coge Europe with Eure-OBD system) 9 Trim color code Blank (Models for Europe without 10 Model Euro-OBD system) 2 Venicie entiieation number (Chacele numb 2 Gross vehicle weight 4 Gross combination weight Vehicle type PAIAO00GEBODY REPAIR BODY EXTERIOR PAINT COLOR [Ganreaie | RAXS | AAXA | AWA] ANS? | AFXO | AKHS | AKKA | ROM | Description | Red | Red | fue | Green | Green | Black | Ct | White Component | 1 Panigpe | P| Sw [P| ew [mw | 2s | | 3 Hard clear T y wartcear J x [ox [ x | x | - 7 x - ] Upper [Body color | BAXS | BAX6 | BBWG | BOS? | BFXO | BKHS | BKXA | BOM + | Bumpertascia| | Bodveclor | BAXS | BANG | BBWE | BOS2 | BFXO | BKHO | BKKA | BOM I Black Aas | AGe4 | AGe* | AGS | AGEA | GEA | AGI | AGA axe | Bawo | BOs2 | BFxO | eKHa | BKxe | BoM | - 2 | Front grile co: | co | ce | eo | ec | aw | oe | | 7 | | Mesh | Black coi | aGot | aco | aGoi | acot | acor | acor | cot oor outside 1 3 fees side | | woay coor | Baxs | Baxe awe | ose | erxo | enna | oxxe | wom | | ee ears] Boaycoor | BANS | BANE | BBWS | BOSD | FXO | AKHS | BKKE | BOM moising | [Bax ‘aes | Ades | aces | Ades | Ades | A@es | AGes | Aes 5 | Lower door | Body color | 84x5 | saxs | sews | spose | srxo | BKHS | aKxe | BoM | | | poe Door outside { 1 | 1 6 | nanae Beeyener | wars | ware | ews | uose | atxo | exro | ure | wan | escutcheon | | Door outside | ‘Chromium- - 1 1 ARs co or} oo | o | oe | oe | oe | oe | le @_| Rear spoier Body color | BAX | BANG | BBWG | ODS2| OFKO | OKHS | aKxa | OMT voce Body color | BAXS | BAXS | BBWG | aDS2| OFKO| eKHO | @Kx | ONT ack door xa GOH MeGM} 9 roma finisher a co | oo | ow | aw | ow | a |e] o plate | l } ‘25: Solid + clear, Mi Metalic, P: Poa, PM: Pearimelall, SMF Silica metalliaBODY REPAIR Body Component Parts ‘soz UNDERBODY COMPONENT PARTS4 12, Is. 1“ 18. 16. 17. 18, 19. 20. 2 22 ‘Raclator core support assembly Upper radiator core support Side radiator core support Lower radiator core support Hood lock stay Hoodledge assembly (RH&LH) Upper hoodledge (RH&LH) Hoodledge reinforcement extension (RH&LH) {ower front hnadladge (RHI H) >. Front hoodledge reinforcement (RH&LH) Roar hoodledge reinforcement (RH&LH) Upper dash assembly Front cow top Upper dash crossmember assembly ‘Side cow top Lower dash Side dash (RH8&LH) Front for ‘Transmission control reinforcement 2nd crossmember assembly Front aor eeinfarcement Front side member rear pateh CContar bearing mounting bracket BODY REPAIR 24, 25, 28, 28 20, 30. 31 20 2 a4, 95, 38, a. 38, 33, 40, 4“ 42, 43 44 4s. Inner sit (RHALH) Fear tloor ont Rear floor rear Rear floor front extension Rear floor belt anchor reinforcement 2nd seat mounting bracket assembly (RH&LH) Rear floor side (RH&LH) Spare tre clamp bracket 8rd e¢nssmemher Front side member closing plate assembly (RHEL) Front side member front closing plate (MHSLH) Front side member (RHBLH) ‘Battery support bracket (LH) Front side member tront extension (HH&LH) Front side member center extension (RH&LH) Rear seat crossmember Sth crossmemiber Center rear crossmember assembly Rear side member assembly (RHBLH) Rear side member front extension (RHALH) Rear sice member extension (RHALH) ‘Mutier mounting bracket assembly (LH)BODY REPAIRHood ‘Side body assembly (RH&LH) Outer sill assembly (RH&LH) Front fender bracket (RH&LH) No.1 Front fender bracket (RH&LH) No.2 Upper inner front pillar assembly (RH&LH) Inner side roof rail (RH&LH) Lower front pillar reinforcement (RHALH) center pilar (RHBLH) LLowor inner roar pilar (RHELH) |. Rest root rail brace (P&L!) ‘Lower inner rear pitas (RHELH) Inner rear pillar reinforcement (RH&LH) . Back pillar reinforcement assembly (RH&LH) Lower rear pillar reinforcement (RH&LH) . Outer rear wheelhouse (RH&LH) (Outer rear wheelhouse extension (RH&LH) Inner rear wheelhouse (RH&LH) Inner rear wheelhouse rear extension (RH&LH) Root Root assembly Front roof rail Rear root rail BODY REPAIR 2a, 25, 2%. 21. 28, 29. 30, a 22, 33, 94, 38, 36, 37. 38. 39, 40, a 42, 43, a4, 48, 46. Hoot pow No.1 Foot bow No.2 Root bow No.3 Foot bow No.4 Root bow Nos Rear roof bow Center root rack bracket (RH&LH) Roof raek bracket (RHA H) Rear fonder assambly (RHALH) Roar fender extension (RH&LH) Striker retainer (FHBLH) Feller tid Rear combination lamp base (RH&LH) Rear fender comer (RH&LH) Back door assembly Rear panel assembly Rear bumper side bracket Rear panel sifener Front door assembly (RH&LH) Outer font doar panel (RHAL H) Rear door assembly (RH&LH) (Outer rear door panel (RHELH) Front bumper reinforcementBODY REPAIR Corrosion Protection exon DESCRIPTION To Provide improved corrosion prevention, the following anti-corrosive measures have been implemented in our production plants. When repairing or replacing body panels, it is necessary to use these same anti-corro- sive measures. ANTI-CORROSIVE PRECOATED STEEL (GALVANNEALED STEEL) To improve repalrabllity and corrosion resistance, a new type of anti corrosive precoated steel sheet has been adopted replacing conven- tional zinc-coated steel sheet. In he I LL. Galvannealed steel is electroplated and heated to form Zinc-iron $ LHL ks, alloy, which provides excellent and long term corrosion resistance with cationic electrodeposition primer. Steel hostel 4 ET, Bn rich Tyoside precoated Nissan Genuine Service Parts are fabricated from galvannealed steel. Therefore, it is recommended that GENUINE NISSAN PARTS or equivalent be used for pancl replacoment 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: Contine paint removal during welding operations to an absolute minimum. PUAQORSE Nissan Genuine Service Parts are also treated in the same manner. Therefore, it is recommended that GENU- INE NISSAN PARIS or equivalent be used tor panel replacement to maintain anti-corrosive performance built Into the vehicle at the factory. 10BODY REPAIR ANTI-CORROSIVE WAX To improve corrosion resistance, anti-corrosive wax is applied inside the body sill and inside other closed sec- tions. Accordingly, when replacing these parts, be sure to apply anti-corrosive wax to the appropriate areas ot the new paris. Select an excellent anti-corrosive wax which will penetrate after application and has a long shelf lite, Indicates ant-corrsive wax coated portions. Section AA wae —] om ) — Puacoose 1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 under- coating which is rust preventive, soundproof, vibration-proot, shock-resistant, adhesive, and durable. Precautions in undercoating 1. sep 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 nol undercoat rotating parts. Apply biturnen wax atter applying undercoating. Indias undercoated portions. Pungaeee 12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. Section A-A PADDBOE 13BODY REPAIR Body Sealing sore 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. View A PuADDOTE 14BODY REPAIR 3 \. Font j ee Sie Fe) ee! =BODY REPAIR PuACaeSEBODY REPAIR Body Construction BODY CONSTRUCTION Section C-C Si Section B-B L tion D-D = = Ad j fe Aap lil | = ee NN TMT | g Section @-3) Section K-K FL | icf ALNBODY REPAIR Body Alignment ome BODY 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 ine vehicle frame (members, pars, etc), more accurate and effective repair will be possible by using these marks together with body alignment specifications. Portion 6,0 @ Front root © Rear :00f ly noses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. PuAca96E 19BODY REPAIR DESCRIPTION ‘* Alldimensions indicated in the figures are actual. © When using a tracking gauge, adjust both pointers to equal length. Then check the pointers and gauge itself to make sure there is no tree play. 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 vali ‘The coordinates of the measurement points are the distances measured from the standard line of "x", "Y" a Vato cane Ltrs at ne “D'simaginary base line [200 mm Delow catum ine (02 at design plan) Puagio4e 20BODY REPAIR ENGINE COMPARTMENT MEASUREMENT mmetically dental Unit - mm nd ses of he vice, PuADaaTE 21BODY REPAIR MEASUREMENT POINTS (a Cow to dent of enter osonna mark (B): Roar hoodie Fronts ‘orcoment oninstaing hole Front fonder instatng hole center (7h oy 1) Fron fonder ctling ole oortor (73) \): Sto ratator core support hola cantor (26a) sg [© eprom o sro oot ooer ena rk a) 5 Hoste eating nl soe 18a) [= A8S sang now coner (ea) @ = Bauory mounting bracket inetaling hol [@.O: From sce member now comer Gyieaa, Dida) PI Lower radar core support hole center (1204) Fock sry hate (0) PuACOOSEUnit : mm, BODY REPAIR UNDERBODY MEASUREMENT Q Q® @ ® Q @G B® Ee wicnog ©O @ © @ @G 08 68 v | a & coy seoy C3. enyoe o1e esnby x re guenpue ne on vo pul SuD!SuaUUIp ITY Puaossee 23BODY REPAIR MEASUREMENT POINTS As viewed from underside. Unit : mm Coorcnatas: ® x80 a ¥:607 tT za87 ® X:-285 609 xr? Yea80 7355 Front and rer eit tower contore Coordinates: @@ ¥:29 —_ 2778 ae 0@ “} X576 V27i5 Front:®),@ e7dia 2:790 RearsO),@ 87dia PUAOAO0E 24BODY REPAIR PASSENGER COMPARTMENT MEASUREMENT lowes marked with (+) neste symmeticaly ental (mensions on both righ and let hand ses ofthe vehi Unit : mm T Point | Dimension || Point | Dimension |] Point | Dimension G-O| 1317 _[[@-O] 1,530" 736 ©-@| 1,692*_|[@-@| 1,206 1,225, G-O| 146 [| @~O| 1,616" [1169 G~O| 1435 |[O~@] 1.420 y [7,075 @-O[ 1437 | @-O | 1.442 [7,030 @-O|_ 187" [[O~@|_1.117* 800 G@~O| 1661* || @~@ | 1.059" 738, @-0| 1.328 [[@~@| ava 1,059 ®~O| __ 1,607" @-@| 1,213" 1,022 @-0] 1456 _|[@~@| 1,050" 1,079" =D] 1.442 [[@=O|__ 8027 ane w-w| 1.327 [[o~w] 1182 1,102" @-O|_ 147" [[@-O] 1,092 1,028" ®~@| 1,662" || @~O| 988 4,152 O-@| 1.456 [| @~@| 938 @-@| 1442 |[e~@| 799BODY REPAIR MEASUREMENT POINTS [ARDRDDWOOVAWi) Comer ptr ndort ‘Door hinge insaling nt center (M8) [@:zna cosenember now cantor of conver poatonng manaz> 14) [eRe oor rot extension hole carter (cn) 26BODY REPAIR MEASUREMENT POINTS. [@ ‘oot flange end of center posioring mark ©G nner rear pitarjoggte ner roar ilar joggle PuADKOAE, 28BODY REPAIR Handling Precautions for Plastics HANDLING PRECAUTIONS FOR PLASTICS T 1 ] J teat T Abbro- | teat | resisting Resistancato gasoline and | er cautor Viation Material name temperature soWvents jrmer cauons mer | | ‘Gasoline and most solvents are | PE — | Polyethylene 60(140) | harmless if applied fora very | Flammable short time (wipe up quickly). | Poison gas is emited Pvc | Polyvinyl Chloride 80(176) | Same as above. ae EP | Ethylone Propylene (Diane) a ~ — Ey (Ge 80(176) | Same as above. Flammabh TPO! | Themapanie eine! smo avahow ammaie PR | Thermoplastic Rubber Cl) Rae feces Flarable, avond PP Polypropylene (194) | Same as above. aaa uP Polyester thermoset 301798) | Sameas above Flammable Ps Polystyrene 0(176)__| Avoid solvents, Flammable aps | Aloniirie Butadiene Stvrene 20(176) | Avoid yasutine and solvents ‘AES: ‘Acrylonitrile Ethylene Styrene 801176) | Same as above. PMMA | Polymethy! Methacryate 25(185) | Same aa above. AAS: ‘Acryioniinie Acryic Styrene | __-wb(T85) ‘Same as above, AS | Acrylonitrile Styrene 85(185) ‘Same as above. EVA__|_Polvinyl Ethyl Acetate so(194) | Same as above. ‘Aerylonitilo Styrone Acryiato 100/222) | Same as above, Flammable PPO! | Poiyphenyiene Oxider PRE | Polyphenylene Ether a | cece PC Polycarbonate 201248) | Same as above. PAR | Polyacryate 180(356) | “Same as above. i Gasoline aad inst aovents ara {ope | Lenear Low Density He oqo) | Raenine Flammable Pur | Polyuretiane v(104) | Same as above, 7PU | Thermoplastic Urethane io(@30) | Same as above PPC | Polypropylene Composite 1151238) | Same as above. Flammable POM | Poiyacetal 120248) _| Same as above. ‘Avoid battery acie Pats | Poiyburylene | es ee 120248) || Same as above. | Fammabie ea | alyamide von) woe) | Same ab above [ Aas inmersngin Polybutyiene Terephthalate 140804) | Same as above, - ‘Fiber Reinforces Plastios ~ 7701886) | Same as above. Polyethylene Terephthalate 160(856) | Same as above, PEI__| Poletherimide 2601982) | _Same a5 above. | When repairing and painting @ portion of the body adjacent (o plastic parts, consider their characteristics, (influence of heat and solvent) and remove them if necessary of take suitable measures to protect them. 2. Plastic parts should be repaired and painted using methods suiting the materials’ characteristics. 29BODY REPAIR LOCATION OF PLASTIC PARTS Front fender (Aree) ‘wnasniets motaing Door micror (evo) J (reaing ABs Y Base: PA Front ur signal amp. (laren sete Zen oats Bas (See| ieee ae 2 Side guard molding (PP) Lower door protector (PVC+Siainess) Front umpar fascia Front fog lama Side turn signal lamp (usnsPe ) (kensPMMA Housing:PP+Glass fiber Housing ABS Rear spoiler Sie window making Rear combinaton amp we) (less oot al Honing PP ws) | > Licence pate hisher \ | 08s 4 =p ZX tye Lans:PC aa oti rade ly Housing PC EE) ccwae (ET tee om saeinana anes wudgas eee ey @P) xaos 30BODY REPAIR Map tam oom tam (iss Pe )\ Lens ria \ Housing: PP Housing: PP Cluster id A. (PC+ABS) — Luggage room amp - Lene: PMMA) o~ (Hotsng PP tater ido — (ecraasy \. nue “ LA 2 Zz love box Gi ‘Luggage side tinisner oe Heater conta ihe. Lerner " ‘AIT finisher (PP) Center console Custer she (ses) Sen (PP) WT finite (aa) PHAOEOBE 31BODY REPAIR Precautions in Repairing High Strength Steel High strength steel is used for body panels in order to reduce vehicle weight. Accordingly, precautions in repairing automotive bodies made of high strength steel are described below: HIGH STRENGTH STEEL (HSS) USED IN NISSAN VEHICLES Tensile strength ‘Nissanvinfiniti designation Major applicable parts 373 Nim? ‘¢ Frontside member assembly « Pillar hinge brace assembly Seeman P1390 ‘¢ Front & center pillar assembly Rata ti '¢ Rear sida member assembly '¢ Other reinforeomants 785-281 Nimmé sPr90 «Front bumper inner center ramtorcement (80-100kg/mmé 114-142K00/6q n) ‘5P19016 he most commonly used HSS, ‘SP150 HSS is used only on parts that require much more strength. 32BODY REPAIR Read the following precautions when repairing HSS: 1 ‘Additional points to consider ‘¢ The repair of reinforcements (such as side members) by heat- ing is not racammended sinca 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 pane. ‘¢ When cutting HSS panels, avoid gas (torch) cutting if possi- ble. Instead, use a saw to avoid weakening surrounding areas due to heat. It gas (torch) cutting is unavoidable, allow a mini- mum margin of 50 mm (1.97in). ‘¢ When welding HSS panels, use spot welding whenever possi- ble in order to minimize weakening surrounding areas due to heat. If spot welding is impossible, use M.L.G. welding. Do not use gas (torch) welding because it is inferior in welding strength. 33 Tat recomend Side sever. — nore _| Traction direction: PUAOTE we Never wee acetylene ensBODY REPAIR ‘ The spot weld on HSS panels is harder than that of an ordi- nary steal panel Therefore. when cutting spot welds on a HSS panel, use a low speed high torque drill (1,000 to 1,200 rpm) to increase drill bit durability and facilitate the operation. # SP150 HSS panels with a tensile strength of 785 to 981 N/ mm? (80 to 100 kg/mm? , 114 to 142 kib/sq in), used as rein- forcement in the door guard beams. is too strong to repair When these HSS parts are damaged. the outer panels also sustain substantial damage; therefore, the assembly parts must be replaced, Precautions in spot welding HSS This work should be performed under standard working condi- tions. Always note the following when spot welding HSS: ¢ The electrode tip diameter must be sized properly according to the metal thickness. PUAOTESE m7 D=Tip cianeter Punorsee ‘© The panel surfaces must fil flush to each ollier, leaving no gaps. Correct Ineorreet —Inoorrect uaosere ‘ Follow the specifications for the proper welding pitch. Unite Thickness (t) Minimum pitch (I) ‘ t 0.6 (0.024) 70 (0.39) or over r t 0.8 (0.031) 12 (0.47) or over t 1.0 (0.039) 18 (0.71) or over 4 1.2 (0.047) 20 (0.79) or over T 1.6 (0.063) 27 (1.06) or over 1.8 (0.071) 31 (1.22) or over PUA WBE 34