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This Body Repair Manual contains information and instructions for repairing the body structure
of the 2000 NISSAN MAXIMA (A33) 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 repair and rebuilding work.
This Body Repair Manual is prepared for technicians who have attained a high level of skilland 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) andthe 2000 NISSAN MAXIMA (A33) Service Manual in order to ensure that the originalfunctions and quality of the vehicle can be maintained. The Body Repair Manual(Fundamentals) contains additional information, including cautions and warnings, thatare not inc luded in this manual. Technicians should refer to both manuals to ensureproper repairs.
Please note that these manuals are prepared for worldwide usage, and as such, certainprocedures might not apply in some regions or countries. In the U.S.A. it is recommended
that a MIG welder be used by a trained technician.
All information in this manual is based on the latest product information at the time of
publication. The right is reserved to make changes in specifications and methods at any time
without notice.
1999 NISSAN NORTH AMERICA, INC.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, without the prior written permission of Nissan North America, Inc., Gardena, California.
Edition: April 1999
Revision: April 1999 (01)
Publication Number: BR0E-1A33U0
2
FOREWORD ................................................................................................................................ 1CONTENTS .................................................................................................................................. 2GENERAL INFORMATION ........................................................................................................... 3
Identification Number.............................................................................................................................. 3Identification Plate .................................................................................................................................. 4Body Exterior Paint Color ....................................................................................................................... 5
BODY COMPONENT PARTS ....................................................................................................... 6Underbody Component Parts ................................................................................................................. 6Body Component Parts .......................................................................................................................... 7
CORROSION PROTECTION ....................................................................................................... 8Description ............................................................................................................................................. 8Anti-Corrosive Wax ................................................................................................................................. 9Undercoating ........................................................................................................................................ 10Stone Guard Coat ................................................................................................................................ 11
BODY SEALING ......................................................................................................................... 12Description ........................................................................................................................................... 12
BODY CONSTRUCTION ............................................................................................................ 15Body Construction ................................................................................................................................ 15
BODY ALIGNMENT .................................................................................................................... 16Body Center Marks .............................................................................................................................. 16Panel Parts Matching Marks ................................................................................................................. 17Description ........................................................................................................................................... 18Engine Compartment ........................................................................................................................... 19Underbody ............................................................................................................................................ 20Passenger Compartment...................................................................................................................... 22Rear Body ............................................................................................................................................ 24
HANDLING PRECAUTIONS FOR PLASTICS ........................................................................... 25Handling Precautions for Plastics ......................................................................................................... 25Location of Plastic Parts ....................................................................................................................... 26
PRECAUTIONS IN REPAIRING HIGH STRENGTH STEEL ...................................................... 28Precautions in Repairing High Strength Steel ....................................................................................... 28
REPLACEMENT OPERATIONS ................................................................................................. 31Description ........................................................................................................................................... 31Radiator Core Support ......................................................................................................................... 32Radiator Core Support (Partial Replacement) ...................................................................................... 33Hoodledge ............................................................................................................................................ 34Hoodledge (Partial Replacement) ......................................................................................................... 35Front Side Member ............................................................................................................................... 36Front Side Member (Partial Replacement) ............................................................................................ 37Front Pillar ............................................................................................................................................ 38Center Pillar .......................................................................................................................................... 39Rear Fender ......................................................................................................................................... 40Rear Floor Rear .................................................................................................................................... 41Rear Side Member Extension ............................................................................................................... 42
REPLACEMENT NOTES ............................................................................................................ 43Front Pillar ............................................................................................................................................ 43
COMMENT FORM...................................................................................................................... 44
GENERAL INFORMATION
3
Identification Number
VEHICLE IDENTIFICATION NUMBER ARRANGEMENT
GENERAL INFORMATION
4
Identification Plate
1.Type
2.Vehicle indentification number (Chassis number)
3.Model
4.Body color code
5.Trim color code
6.Engine model7.Engine displacement
8.Transmission model
9.Axle model
GENERAL INFORMATION
5
Body Exterior Paint Color
S: Solid, 2S: Solid+Clear, M: Metallic, 2P: 2 Coat pearl, 3P: 3 Coat pearl, FPM: Iron oxide pearl metallic,TM: Micro titanium metallic
Component
Color code BBV3 BCP2 BDR2 BEV0 BKH3 BKT3 BKV3 BQT1
DescriptionLightblue
Brown Green Beige Black SilverGreenish
grayWhite
Paint type TM 2P 2P M 2S M M 3P
Hard clear coat - X X - X - X -
1 Bumper fascia Body color BBV3 BCP2 BDR2 BEV0 BKH3 BKT3 BKV3 BQT1
2 Radiator grill Chromium-plate Cr Cr Cr Cr Cr Cr Cr Cr
3 Outside mirrorBody Body color BBV3 BCP2 BDR2 BEV0 BKH3 BKT3 BKV3 BQT1
Base Black AG01 AG01 AG01 AG01 AG01 AG01 AG01 AG01
4Side guardmolding
Body color BBV3 BCP2 BDR2 BEV0 BKH3 BKT3 BKV3 BQT1
5 Door sashCenter Black tape - - - - - - - -
Rear Black AG01 AG01 AG01 AG01 AG01 AG01 AG01 AG01
6Outside handleescutcheon
Body color BBV3 BCP2 BDR2 BEV0 BKH3 BKT3 BKV3 BQT1
7 Outside handle Body color BBV3 BCP2 BDR2 BEV0 BKH3 BKT3 BKV3 BQT1
8Rear airspoiler
Body color BBV3 BCP2 BDR2 BEV0 BKH3 BKT3 BKV3 BQT1
9Trunk lidfinisher
Gray metallic AG05 AG05 AG05 AG05 AG05 AG05 AG05 AG05
BODY COMPONENT PARTS
6
Underbody Component Parts
1R
adia
tor
core
sup
port
ass
embl
y2
Upp
er r
adia
tor
core
sup
port
3S
ide
radi
ator
cor
e su
ppor
t4
Low
er r
adia
tor
core
sup
port
5H
ood
lock
sta
y6
Hoo
dled
ge a
ssem
bly
(RH
& L
H)
7U
pper
hoo
dled
ge (
RH
& L
H)
8Lo
wer
fron
t hoo
dleg
e (R
H &
LH
)9
Bat
tery
mou
ntin
g re
info
rcem
ent (
LH o
nly)
10E
ngin
e m
ount
ing
rein
forc
emen
t (R
H o
nly)
11H
oodl
edge
rei
nfor
cem
ent a
ssem
bly
(RH
& L
H)
12Fr
ont h
oodl
ege
rein
forc
emen
t (R
H &
LH
)13
Air
box
asse
mbl
y
14C
ente
r co
wl t
op15
Upp
er d
ash
16S
ide
cow
l top
17S
ide
cow
l top
bra
ce18
Low
er d
ash
asse
mbl
y19
Fron
t flo
or20
2nd
cros
smem
ber
asse
mbl
y21
Par
king
bra
ke a
nd s
eat b
elt r
einf
orce
men
t22
Exh
aust
mou
ntin
g br
acke
t23
Inne
r si
ll (R
H &
LH
)24
Bol
t25
Out
er fr
ont s
eat m
ount
ing
brac
ket (
RH
& L
H)
26R
ear
floor
fron
t27
Rea
r flo
or r
ear
28R
ear
seat
bel
t anc
hor
rein
forc
emen
t29
Rea
r flo
or s
ide
(RH
& L
H)
30S
pare
whe
el c
lam
p br
acke
t31
Muf
fler
mou
ntin
g br
acke
t32
Fron
t sid
e m
embe
r as
sem
bly
(RH
& L
H)
33Fr
ont s
ide
mem
ber
clos
ing
plat
e as
sem
bly
(RH
& L
H)
34Fr
ont s
ide
mem
ber
fron
t clo
sing
pla
te (
RH
& L
H)
35Fr
ont s
ide
mem
ber
(RH
& L
H)
36B
atte
ry s
uppo
rt b
rack
et (
LH o
nly)
37Fr
ont s
ide
mem
ber
cent
er e
xten
sion
(R
H &
LH
)38
Fron
t sid
e m
embe
r re
ar e
xten
sion
(R
H &
LH
)39
Rea
r si
de m
embe
r as
sem
bly
(RH
& L
H)
40R
ear
side
mem
ber
exte
nsio
n (R
H &
LH
)41
Rea
r se
at c
ross
mem
ber
42C
ente
r re
ar c
ross
mem
ber
asse
mbl
y43
Rea
r to
win
g ho
ok b
rack
et a
ssem
bly
(LH
onl
y)44
Rea
r tie
-dow
n ho
ok (
RH
onl
y)
: In
dica
tes
two-
side
ant
i-cor
rosi
ve p
reco
ated
ste
el p
ortio
ns :
Indi
cate
s hi
gh s
tren
gth
stee
l (H
SS
) po
rtio
ns :
Indi
cate
s tw
o-si
de a
nti-c
orro
sive
ste
el a
nd H
SS
por
tions
BODY COMPONENT PARTS
7
Body Component Parts1
Hoo
d2
Fron
t fen
der
(RH
& L
H)
3Fr
ont f
ende
r br
acke
t (R
H &
LH
)4
Bod
y si
de a
ssem
bly
(RH
&LH
)5
Out
er b
ody
side
(R
H &
LH
)6
Upp
er in
ner
fron
t pill
ar (
RH
& L
H)
7In
ner
cent
er p
illar
(R
H &
LH
)8
Low
er in
ner
fron
t pill
ar (
RH
& L
H)
9Lo
wer
fron
t pill
ar r
einf
orce
men
t (R
H &
LH)
10S
ide
parc
el s
helf
(RH
& L
H)
11In
ner
rear
pill
ar (
RH
& L
H)
12Lo
wer
inne
r re
ar p
illar
(R
H &
LH
)13
Sea
t bac
k su
ppor
t (R
H &
LH
)
14In
ner
rear
whe
elho
use
(RH
& L
H)
15O
uter
rea
r w
heel
hous
e (R
H &
LH
)16
Out
er r
ear
whe
elho
use
exte
nsio
n (R
H &
LH
)17
Roo
f18
Roo
f ass
embl
y (w
ith s
unro
of)
19Fr
ont r
oof r
ail
20R
ear
roof
rai
l
21R
oof b
ow N
o.1
22R
oof b
ow N
o.2
23R
oof b
ow N
o.3
24R
ear
fend
er (
RH
& L
H)
25R
ear
fend
er d
rip (
RH
& L
H)
26S
trik
er r
etai
ner
(RH
& L
H)
27F
iller
lid
base
28F
uel f
iller
lid
29R
ear
com
bina
tion
lam
p ba
se (
RH
& L
H)
30Ja
ck b
rack
et r
einf
orce
men
t (LH
onl
y)31
Par
cel s
helf
with
rea
r w
aist
32P
arce
l she
lf tr
im b
rack
et33
Upp
er r
ear
pane
l ass
embl
y34
Upp
er r
ear
pane
l stif
fene
r
35Tr
unk
lid36
Fron
t doo
r as
sem
bly
(RH
& L
H)
37O
uter
fron
t doo
r pa
nel (
RH
& L
H)
38R
ear
door
ass
embl
y (R
H &
LH
)39
Out
er r
ear
door
pan
el (
RH
& L
H)
40P
atch
rea
r fe
nder
(R
H &
LH
)41
Fron
t bum
per
arm
atur
e42
Rea
r bu
mpe
r ar
mat
ure
: In
dica
tes
two-
side
ant
i-cor
rosi
ve p
reco
ated
ste
el p
ortio
ns :
Indi
cate
s hi
gh s
tren
gth
stee
l (H
SS
) po
rtio
ns :
Indi
cate
s tw
o-si
de a
nti-c
orro
sive
ste
el a
nd H
SS
por
tions
For
sunr
oof
CORROSION PROTECTION
8
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-corrosive measures.
To improve repairability and corrosion resistance, a new type
of anti-corrosive precoated steel sheet has been adopted
replacing conventional zinc-coated steel sheet.
Durasteel is electroplated, zinc-nickel alloy under organic film,
which provides excellent corrosion resistance.
Durasteel is classified as either one-side precoated steel or
two-side precoated steel. The two side precoated steel provides
excellent corrosion resistance.
Nissan Genuine Service Parts are fabricated from durasteel sheets. Therefore, it is recommended that GENUINENISSAN PARTS or equivalent be used for panel replacement to maintain the anti-corrosive performance built intothe vehicle at the factory.
A phosphate coating treatment and a cationic electrodeposition primer, which provide an excellent corrosion protection,
are employed on all body components.
Caution:Confine paint removal during welding operations to an absolute minimum.
Nissan Genuine Service Parts are also treated in the same manner. Therefore, it is recommended that GENUINENISSAN PARTS or equivalent be used for panel replacement to maintain anti-corrosive performance built into thevehicle at the factory.
PHOSPHATE COATING TREATMENT ANDCATIONIC ELECTRODEPOSITION PRIMER
ANTI-CORROSIVE PRECOATED STEEL(DURASTEEL)
CORROSION PROTECTION
9
Anti-Corrosive Wax
To improve corrosion resistance, anti-corrosive wax is applied inside the body sill and inside other closed sections. Accordingly,
when replacing these parts, be sure to apply anti-corrosive wax to the appropriate areas of the new parts. Select an
excellent anti-corrosive wax which will penetrate after application and has a long shelf life.
:Indicates anti-corrosive wax coated portions.
Section A-A Section B-B Section C-C
Section D-D
CORROSION PROTECTION
10
Undercoating
The underside of the floor and wheelhouse are undercoated to prevent rust, vibration, noise and stone chipping. Therefore,when such a panel is replaced or repaired, apply undercoating to that part. Use an undercoating which is rust preventive,
soundproof, vibration-proof, shock-resistant, adhesive, and durable.
Precautions in undercoating1. 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).
2. Do not undercoat the exhaust pipe or other parts which become hot.3. Do not undercoat rotating parts.
4. Apply bitumen wax after applying undercoating.
: Indicates undercoated portions.
CORROSION PROTECTION
11
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 thesame portions as before. Use a coating which is rust preventive, durable, shock-resistant and has a long shelf life.
: Indicates stone guard coated portions.
BODY SEALING
12
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 View B
BODY SEALING
13
View C View D
View E View F
View G View H
View I View J
BODY SEALING
14
View K View L
View M View N
View O View P
ViewQ ViewR
BODY CONSTRUCTION
15
Body Construction
Section A-A Section B-B Section C-C Section D-D
Section E-E
Section I-I
Section F-F Section G-G Section H-H
Section J-J Section K-K Section L-L
BODY ALIGNMENT
16
Body Center Marks
A mark has been placed on each part of the body to indicate the vehicle center. When repairing parts damaged by an
accident which might affect the vehicle frame (members, pillars, etc.), more accurate and effective repair will be possible byusing these marks together with body alignment specifications.
Portion A Portion B Portion C
Portion D Portion E Portion F
BODY ALIGNMENT
17
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.
View A View C
View D
View B
View E
BODY ALIGNMENT
18
Description
All dimensions 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 free 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 value.
The coordinates of the measurement points are the distances measured from the standard line of “X”, “Y” and “Z”.
Engine Compartment
Unit: mmMEASUREMENT
BODY ALIGNMENT
19
Engine Compartment (Cont’d)
Unit: mm
: Cowl top center : Cowl top side: Strut tower: Hoodledge
: Radiator core support upper center, : Hood lock
: Radiator core support upper side, : Radiator core support side: Front side member
: Hood lock stay, : Radiator core support lower
, : Front side member LH side
MEASUREMENT POINTS
, : Front side member RH side
BODY ALIGNMENT
20
Underbody
Unit: mm
All
dim
ensi
ons
indi
cate
d in
this
figur
e ar
e ac
tual
.A
s vi
ewed
from
und
ersi
de.
Fig
ures
mar
ked
with
a
* in
dica
te s
ymm
etric
ally
iden
tical
dim
ensi
ons
on b
oth
right
and
left
hand
sid
es o
f the
veh
icle
.: B
olt h
ead
MEASUREMENT
BODY ALIGNMENT
21
Underbody (Cont’d)
MEASUREMENT POINTS
Coordinates:, ,
X:330 X:555Y:-710 Y:2,235Z:188.8 Z:239.5
,X:513 X:300Y:-540 Y:2,700Z:322 Z:381.7
,X:450 X:-300Y:68 Y:2,700Z:226.5 Z:407.7
,X:441 X:512Y:354 Y:3,050Z:111.5 Z:326.6
,X:600 X:-544Y:430 Y:3,032Z:154.9 Z:328.2
,X:398 X:546Y:700 Y:3,504Z:109 Z:295.4
,X:414 X:-570.5Y:1,210 Y:3,500Z:108.4 Z:326.6
,X:412.5 X:0Y:1,625 Y:-700.5Z:104 Z:188.8
,X:518.2Y:2,155Z:184.5
Unit: mm
Front and rear strut tower centersCoordinates:
,X:548.8Y:28.7Z:779.3
,X:490.1Y:2,671Z:538.5
Front: , 87 diaRear: , 61.4 dia
As viewed from underside.
BODY ALIGNMENT
22
Passenger Compartment
Figures marked with a * indicate symmetrically identicaldimensions on both right and left hand sides of the vehicle.
: Cowl top center (5 dia) : Front roof flange end of center
positioning mark
, : Outer front pillar joggle
Point Dimension
~
~
~ ~ ~ ~ ~ ~
1,2721,4181,4491,2721,4731,4591,280
1,4731,452
~
, : Upper dash joggle
MEASUREMENT
Point Dimension Point Dimension
~
~ ~ ~
~ ~ ~ ~
819*
1,197*
931* 830*
1,059*
897*
839*
1,063*
901*
~ ~
~ ~ ~ ~ ~
1,527*
1,560*
1,389*1,518*
1,619*1,638*
1,128*
~
Unit: mm
~ 1,205 ~ 727*
~ 1,479 ~ 1,616*
~ 1,448 ~ 1,407*
~ 1,027* ~ 1,877*
~ 980* ~ 1,699*
~ 1,127*
~ 1,173*
~ 1,086*
~ 1,660*
~ 736*
BODY ALIGNMENT
23
Passenger Compartment (Cont’d)
, , , , , : Outer front pillar indention
, , , : Door hinge installing nut center
, : Transmission control reinforcementhole center
: Fuel tank cover installing hole centerof center positioning mark
Unit: mmMEASUREMENT
, : Rear suspension installing hole
center (11 12)
, , , , , ,, , , , , : Outer center pillar
indention, , , : Door hinge installing nut center
, : Rear fender indention rear, : Door switch installing hole center
(20 dia), : Outer sill joggle
BODY ALIGNMENT
24
Rear Body
Figures marked with a * indicate symmetrically identicaldimensions on both right and left hand sides of the vehicle.
Unit: mm
: Rear roof flange end of centerpositioning mark
, : Rear fender joggle
, : Rear fender joggle : Rear waist flange end of centerpositioning mark
MEASUREMENT
, : Rear fender joggle
, : Rear combination lamp base joggle
, : Rear panel upper reinforcement hole
center
, : Rear suspension installing hole
center (11 12)
HANDLING PRECAUTIONS FOR PLASTICS
25
Handling Precautions for Plastics
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 take suitable measures to protect them.
2. Plastic parts should be repaired and painted using methods suiting the materials characteristics.
Abbreviation Material nameHeat resistingtemperature
oC(oF)
Resistance to gasoline andsolvents Other cautions
PVC Polyvinyl chloride 80(176)Gasoline and most solvents areharmless if applied for a veryshort time(wipe up quickly).
Poison gas is emitted whenburned.
PP Polypropylene 90(194) Same as above. Flammable,avoid battery acid.
EPM/EPDM Ethylene Propylene (Diene)rubber 80(176) Same as above. Flammable
UP Polyester thermoset 90(194) Same as above. Flammable
TPO/TPR Thermoplastic olefine/Thermoplastic rubber 80(176) Same as above. Flammable
ABS Acrylonitrile butadienestyrene resin 80(176) Avoid gasoline and solvents.
AAS Acrylonitrile acrylic styrene 85(185) Avoid gasoline and solvents.
ASA Acrylonitrile styreneacrylate 100(222) Avoid gasoline and solvents. Flammable
AS Acrylonitrile styrene 85(185) Avoid gasoline and solvents.
AES Acrylonitrile ethylenestyrene 80(176) Avoid gasoline and solvents.
PMMA Polymethyl methacrylate 85(185) Avoid gasoline and solvents.
EVA Polyvinyl ethyl acetate 90(194) Avoid gasoline and solvents.
PPO/PPE Polyphenylene oxide/ether 110(230) Avoid gasoline and solvents.
PC Polycarbonate 120(248) Avoid gasoline and solvents.
L-LDPE Lenear low densitypolyethylene 45(100) Gasoline and most solvents are
harmless. Flammable
PUR Polyurethane 90(194) Same as above.
PPC Polypropylene composite 115(239) Same as above. Flammable
POM Polyacetal 120(248) Same as above. Avoid battery acid.
PA Polyamide(Nylon) 140(284) Same as above. Avoid immersing in water.
PET Polyethylene terephthalate 180(356) Same as above.
PBT Polybutylene terephthalate 140(284) Same as above.
HANDLING PRECAUTIONS FOR PLASTICS
26
Location of Plastic Parts
HANDLING PRECAUTIONS FOR PLASTICS
27
Location of Plastic Parts (Cont’d)
PRECAUTIONS IN REPAIRING HIGH STRENGTH STEEL
28
Door guard beamSP150785-981 N/mm2
(80-100 kg/mm2
114-142 klb/sq in)
Front side member
Hoodledge
Inner sill
2nd crossmember assembly
Rear side member extension
SP130373 N/mm2
(38 kg/mm2, 54 klb/sq in)
Major applicable partsNissan designationTensile strength
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
SP130 is the most commonly used HSS.
SP150 HSS is used only on parts that require much more strength.
PRECAUTIONS IN REPAIRING HIGH STRENGTH STEEL
29
Precautions in Repairing High Strength Steel (Cont’d)
Read the following precautions when repairing HSS:1. Additional points to consider
The repair of reinforcements (such as side members)
by heating is not recommended since it may weaken
the component. When heating is unavoidable, do not
heat HSS parts above 550oC (1, 022 oF)Verify heating temperature with a thermometer.
(Crayon-type and other similar type thermometer are
available.)
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 possible. Instead, use a saw to avoid weakening
surrounding areas due to heat. If gas (torch) cutting
is unavoidable, allow a minimum margin of 50 mm
(1.97 in).
When welding HSS panels, use spot welding
whenever possible in order to minimize weakeningsurrounding 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.
PRECAUTIONS IN REPAIRING HIGH STRENGTH STEEL
30
10 (0.39) or over
12 (0.47) or over
18 (0.71) or over
20 (0.79) or over
27 (1.06) or over
31 (1.22) or over
The spot weld on HSS panels is harder than that of an
ordinary steel 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/mm2 (80 to 100 kg/mm2, 114 to 142 klb/sq in),
used as reinforcement in the door guard beams and in
the bumper, is too strong to repair. When these HSSparts are damaged, the outer panels also sustain
substantial damage; therefore, the door assembly or
bumper assembly must be replaced.
2. Precautions in spot welding HSS
This work should be performed under standard workingconditions. Always note the following when spot welding
HSS:
The electrode tip diameter must be sized properly
according to the metal thickness.
The panel surfaces must fit flush to each other, leaving
no gaps.
Follow the specifications for the proper welding pitch.
0.6 (0.024)
0.8 (0.031)
1.0 (0.039)
1.2 (0.047)
1.6 (0.063)
1.8 (0.071)
Minimum pich ( )Thickness (t)
Precautions in Repairing High Strength Steel (Cont’d)
Unit:mm
REPLACEMENT OPERATIONS
31
Spotweld
Description
The symbols used in this manual for cutting and welding / brazing operations are shown below.
Saw cut or air chisel cut
2-spotwelds
3-spotwelds
MIG plug weld
MIG seam weld/Point weld
Brazing
Soldering
Sealing
2-spot welds(2-panel overlapping portions)
3-spot welds(3-panel overlapping portions)
REPLACEMENT OPERATIONS
32
Radiator Core Support
Service Joint Indicates that there is an equivalent welding portionwith the same dimensions on the opposite side.
REPLACEMENT OPERATIONS
33
Radiator Core Support (Partial Replacement)
Service Joint
Unit: mm
REPLACEMENT OPERATIONS
34
Hoodledge
Service Joint
Work after radiator core support has been removed.
Unit: mm
REPLACEMENT OPERATIONS
35
Hoodledge (Partial Replacement)
Service Joint(This figure shows right side hoodledge)
Work after radiator core support has been removed.
Unit: mm
REPLACEMENT OPERATIONS
36
Front Side Member
Service Joint
Work after hoodledge and radiator core support have been removed.
REPLACEMENT OPERATIONS
37
Front Side Member (Partial Replacement)
Service Joint (This figure shows right front side member)
Work after radiator core support has been removed.
Unit: mm
REPLACEMENT OPERATIONS
38
Front Pillar
Service Joint
See REPLACEMENT NOTES. Work after hoodledge reinforcement has been removed.
Unit: mm
REPLACEMENT OPERATIONS
39
Center Pillar
Service Joint
Unit: mm
REPLACEMENT OPERATIONS
40
Rear Fender
Service Joint
Unit: mm
REPLACEMENT OPERATIONS
41
Rear Floor Rear
Service Joint
Work after rear panel has been removed.
Indicates that there is an equivalent welding portionwith the same dimensions on the opposite side.
REPLACEMENT OPERATIONS
42
Rear Side Member Extension
Service Joint
Work after rear panel has been removed.
REPLACEMENT NOTES
43
Front Pillar
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.
Determine cutting position and record distance from
location cutout. Use this distance when cutting service
part. Cut outer front pillar 60 mm above inner front pillar
cut position.
Prepare a cutting jig to make outer pillar easier to cut.
Also, this will permit service part to be accurately cut
at joint position.
An example of cutting operation using a cutting jig isas follows:
1 Mark cutting lines.
A: Cut position of outer pillar
B: Cut position of inner pillar
2 Align cutting line with notch on jig. Clamp jig to pillar.3 Cut outer pillar along groove of jig. (At position A)
4 Remove jig and cut remaining portions.
5 Cut inner pillar at position B in same manner.
COMMENT FORM
44
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Technical Service Information
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