CONTENTS

G EN ERAL I N FORMATION 1
Identification Number 2
BODY COM PON ENT PARTS 3
Underbody Component Parts 3
Body Component Parts 4
CO R ROSlO N PR OTECTI 0 N 7
Description 7
Anti - Corrosive Wax 8
Undercoating 9
Stone Guard Coat 10
BODY CONSTRUCTION 11
Body Construction .~ 11
BODY ALIG N M ENT 13
Body Center Marks 13
Panel Parts Matching Marks 14
Description 15
Engine Compartment 16
Underbody 17
Passenger Compartment (Sedan -5-door Hatchback) 19
Rear Body (Sedan) 21
Passenger Compartment (3-door Hatchback) 22
Rear Body (3-door Hatchback-5-door Hatchback) 24
HANDLING PRECAUTIONS FOR PLASTICS 25
Handling Precautions for Plastics > - ••••••••••••••••••••••••••••••••••••••••••••••••••••• 25
Location of Plastic Parts - 26
PR ECAUTIONS 28
Precautions For Handling High Strength Steel (HSS) 28
REPLACEM ENT OPERATIONS 32
Description 32
Radiator Core Support (Partial Replacement) 33
Hoodledge (Partial Replacement) 34
Front Side Member (Partial Replacement) 35
Front Pillar ..~ 36
Center Pillar (Sedan -5-door Hatchback) 37
Outer Sill (Sedan -5-door Hatchback) 38
Outer Sill (3-door Hatchback) 39
Rear Fender (Sedan) 40
Rear Fender (5-door Hatchback) 41
Rear Fender (3-door Hatchback) 42
Rear Floor Rear 43
Rear Side Member Extension (Sedan) 44
Rear Side Member Extension (3-door and 5-door Hatchback) 45
 _ REPLACEMENT OPERATIONS
~~~~~~~~_GENERALJNFORM~ION~~~~~~~~_
Rear Side Member Extension Sedan
Identification Number

Vehicle identification number Vehicle identification plate Service Joint

Emission control information label

SGI908
-------
/
/\ \ --- -
/

VEHICLE IDENTIFICATION NUMBER ARRANGEMENT

c-
For Europe
• JN1 B A A N15 U 0 xxxxxx.
~ ~>~
'------- /~ ,,\ I

T T ---c::
0: Stopgap
serial number
(no meaning)
Destination
U: Europe
Model
A: 2-wheel drive
Engine type
A: GA 14DE engine
111
C: GA 16DE engine
E: SR20DE engine
F: CD20 engine
Body type
B: 4-door Sedan
F: 5-door Hatchback
E: 3-door Hatchback
Manufacturer
J N 1: Nissan, Passenger vehicle 114

2-spot welds 3-spot welds M. I. G plug weld M. I. G seam weld/

For 3 panels plug weld method ) Point weld

d r;==
GTJ
( dA~ dB~
~

-44-
-1-
 REPLACEM ENT OPERATIONS ________ GENERAL INFORMATION _

Rear Floor Rear Identification Number (Cont' d)

(Work after rear panel have been removed.) Except for Europe
Service Joint IN 1 . B CAN 15 A 0 XXXXXX
111

T T --c::: 0: Stopgap
serial number
(no meaning)
Destination
~
A: Australia and New Zealand
Z: Except for Europe, Australia, and New Zealand
Model
A: 2-wheel drive
Engine type
B: GA 15DE engine
C: GA 16DE engine
E: SR20DE engine-For Australia and New Zealand only
Body type
B: 4-door Sedan
F: 5-door Hatchback
Manufacturer
IN 1: Nissan, Passenger vehicle

VEHICLE IDENTIFICATION PLATE

Europe Expect Europe 1 Type approval number

2 Vehicle identification
NISSAN MOTOR CO., LTD. JAPAN NISSAN MOTOR CO., LTD. APAN number(Chassis number)
I ~ I ~ tt ~(:l & 3 Gross vehicle weight
4 Gross combination weight
~ ~~~sg~ CNHOA"SIS ~
Gross vehicle weight
~ ~~~~~o & + Gross trailing capacity
(Weight)
o & kgO o ~0:ggtg~ ~~~RNICION ~ &. o 5 Gross axle weight(Front)
1- & cc 6 Gross axle weight(Rear)
kg
~~~~~~~ & £ 7 Type approval number
2- & kg ; ; ~)~ / ~~~~~'. AE~~ A1 L11 8 Body color code
TYPE COlOR. TRIM PLANT 9 Trim color code
TTP FARBE. POlST ~ & PlANTA
10 Model Specification No.
& El ii: 13 IJJ if[ ** it ~ *1 MADE IN JAPAN
11 Engine model
12 Engine displacement
FR 13 Transaxle model
14 Axle model

3D HI B : 3door hatchback _2
5D HI B : 5door hatchback

2-spot welds 3-spot welds M. I. G plug weld

For
.
3 panels plug weld method ) P: F
M I G seam weld/
weld

• GTJrr=- ( • A ===-=
---
.'S ~
~
.L.LLL

-43- -2-
 REPLACEMENT' OPERATIONS

Rear Fender 3-door hatchback

Underbody Component Parts

J: Service Joint
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-42-
-3-
___________ REPLACEMENT OPERATIONS ________ BODY COMPONENT PARTS _
Sedan
Rear Fender 5-door hatch back Body Component Parts 5-door Hatchback

Service Joint

~
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113 o
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(length: 10mm)
@ 4 or 11 3

Rear pillar inner

reinforcement

_ 200r 11 15

Unit:mm 116 c
@ 1 or 111 co
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2-spot welds 3-spot welds M.I. G seam weld/
M.1. G plug wel(d For 3 panels plug weld method ) Point weld

·r .A===-= .B~

-41- -4-
 REPLACEMENT OPERATIONS
~~~~~~~_BODYCOMPONENTPAR~~~~~~~~_
Sedan Rear Fender Sedan
Body Component Parts 5-door Hatchback

Service Joint
..an (length : 10mm)

Unit:mm
Cut off

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113A

o~ ( \ FR

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116

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-5- -40-
 REPLACEMENT OPERATIONS
Body Component Parts 3-door Hatchback
Outer Sill 3-door hatch back

Service Joint

112 :r: :r: -:r:

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--
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.an.
(CNerlap cutting)
111
Unit:mm

2-spot welds 3-spot welds Mol. G plug weld

• G@r;=::::. (
For

• A
3 panels plug weld method

:=::A:=: • 8~
). p:;m
M I G

.u.u.
we
Id/

-6-
-39-
 REPLACEMENT OPERATIONS

Outer Sill Sedan

Description 5-door hatchback

To provide improved corrosion prevention, the following anti-corrosive measures have been implemented in Service Joint
our production plants. When repairing or replacing body panels, it is necessary to use these same anti-corrosive _4A
measures.

FR
ANTI-CORROSIVE PRECOATED STEEL
(DURASTEEL) Zn-Ni alloy

To improve repairability and corrosion resistance, a

new type of anti-corrosive precoated steel sheets have
been adopted taking the place of conventional zinc-
coated steel sheets.
This durasteel is electroplated, zinc-nickel alloy under Steel sheet
organic film, which provides excellent corrosion resis-
tance. One-side precoated
119

Durasteel is classified as either one-side precoated

steel or two-side precoated steel. The two side
precoated steel provides excellent corrosion resis-
tance.

117
~ Outside

Two-side precoated
_4 11 12
(OIerlap
.cm
cutting)

Nissan Genuine Service Parts are fabricated from durasteel sheets. Therefore, it is recommended that 112A 111A
GENUINE NISSAN PARTS be used for panel replacement to maintain the anti-corrosive performance 114 111
112A
built into the vehicle at the factory.
113 114

PHOSPHATE COATING TREATMENT AND

CATIONIC ELECTRODEPOSITION PRIMER

A phosphate coating treatment and a cationic electrodeposition primer, which provide an excellent anti-
corrosion effect, are employed on all body components.
Caution:
Confine paint removal in the welding operation to the absolute minimum.

Cationic electrodeposition primer

_4
Unit:mm
111
2-spot welds 3-spot welds M. I. G plug weld
P.an.0int;=::
M I G seam weld/

·r .A
For 3 panels plug weld method )

Nissan Genuine Service Parts also are treated in the same manner. Therefore, it is recommended tbat
( =6=___ .8=:= V
GENUINE NISSAN PARTS be used for panel replacement to maintain anti-corrosive performance built
into the vehicle at the factory.

-38-
-7-
 REPLACEMENT OPERATIONS ________ CORROSION PROTECTION _
Center Pillar Sedan
5-door hatch back Anti-corrosive Wax

Service Joint 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.
111
117
112 117
FR

A
FR

E
Hatchback
.cm. 111A 111A
( Overl ap cutt ing)

Seat belt ancher Upper center pillar hinge brace

reinforcement

113 114

113 : Indicates anti-corrosive wax coated portions.

112
FR Section A-A: Section 8-8: Section C-C:
Lower center pillar
114
hinge brace

116

Section 0-0: SEDAN Section E-E: Hatchback

Unit:mm
For Australia model For Australia model

2-spot welds 3-spot welds M. I. G plug weld

For 3 panels plug weld method ) P: F
M I G seam weld/
weld

• G1Jrr= ( ==-= •
• A --- B~
~ ..LLLL

-37-
-8-
 REPLACEMENT OPERATIONS

Front Pillar
Undercoating
(Work after hoodledge reinforcement has been removed.)

The undersides of the floor and wheelhouse are undercoated to prevent rust, vibration, noise and stone Service Joint
chipping.
Therefore, when such a panel is replaced or repaired, apply undercoating to that part. Use an undercoating with
the following properties: rust preventive, soundproof, vibration-proof, shock-resistant, adhesive, and durable. <:=i FR
Precautions in undercoating
1. Do not apply undercoating to any place unless specified (such as the areas above the muffler and catalytic
1lIl.. ( Dri p channel)
converter which are subjected to heat).
an (Outer)
2. Do not undercoat the exhaust pipe, other parts which become hot, and rotary parts.
112
3. Apply bitumen wax after applying undercoating.

~I!!!!!!!!iiii!!!!!i!II : Indicates undercoated portions

1lIl..
( Inner)
112

~
113 :::::-----

116

112
112 116
c;;;;?
Unit:mm FR

2-spot welds 3-spot welds

M. I. G plug wel(d For 3 panels plug weld method ) .. ~: G(F:~dm weld/
• rr= • A ==-=.
GTJ ---
B~ ~ .LLLL

-36-
-9-
 REPLACEMENT OPERATIONS
________ CORROSION PROTECTION _
Front Side Member (Partial Replacement)
Stone Guard Coat
(Work after radiator core support has been removed.)

Service Joint To prevent damage caused by stones, the lower outer body panels (fender, door, etc.) have an additional layer
(This figure show right front side member) of Stone Guard Coat over the ED primer coating. Thus, when replacing or repairing these panels, apply
undercoat to the same portions as before. Use a coat which is rust preventive, durable, shockresistant and has
-\
a long shelf life.

~mm1111i : Indicates stone guard coated portions

114

111

8 115

"" " "

Patch

(Thickness: 1mm)
117
118
111

hoodledge panel
Section A-A --r':":' Section B-B

114
Patch
Unit:mm

2-spot welds 3-spot welds M.1. G plug weld

F
M I G seam weld/
weld Section C-C

.A=-= .B~
For 3 panels plug weld method ) P1ID.~irit

• G1Jrr= (
--- ~

-35-
-10-
------------ BODY CONSTRUCTION _ ------------ REPLACEMENT OPERATIONS _

Hoodledge (Partial Replacement)

Body Consb"uction.
(Work after radiator core support has been removed.)

Service Joint
(This figure show right side hoodledge)

Sedan

Before installing
hoodledge reinforcement.
117

3-d oar Hatchback

114A

Unit:mm

2-spot welds 3-spot welds M.1. G plug weld ) M.I. G seam weld/
For 3 panels plug weld method. Point weld
5-door Hatchback

·r ( .A~ .B~ .an.F

-34-
-11-
 REPLACEMENT OPERATIONS _
------------ BODY CONSTRUCTION _
Radiator Core Support (Partial Replacement) -----------
Body Construction

Service Joint * indicatesthat there is an equivalent wel~ing. portion

with the same dimensions on the opposite Side.
Section A-A: Section 8-8: Section C-C: Section D-D:
(

Section E-E: Section F-F: Section G-G: Section H-H:

_1

o Section I-I: Section J-J: Section K-K: Section L-L:

*e 3 or 11 2

FR
Section M-M: . Section N-N: Section 0-0: Section P-P:

e4 orll3

FR \
Section 0-0: Section R-R:
2-spot welds 3-spot welds M.1. G plug weld ) M.I. G seam weld/
Point For 3 panels plug weld m.ethod weld

·r ·=='*= (
A • B ===:= .an F

-33-
-12-
_________ BODY ALIGNMENT _ ________ REPLACEMENT OPERATIONS _
SYMBOLS FOR CUITING AND
Body Center Marks Description WELDING/BRAZING OPERATIONS
The indentification of the cutting and the welding/brazing symbols used throughout this guide is given in the
A mark has been placed on each part of the body to indicate the vehicle center. When repairing parts damaged following pages
by an accident which might affect the vehicle frame (members, pillars, etc.) more accurate, effective repair will
be possible by using these marks together with body alignment data.

Portion G Saw cut or

air chisel cut
Portion C Portion D-Sedan
Portion E
Portion B -Sedan
..J
Portion A
••••
2-spot
2-SDOt welds
(2-panel overlapping portions)
welds

Spot
weld
0000
Porton H 3-spot 3-spot welds
(3-panel overlapping portions)
3-Door Hatchback welds
Portion F
and 5-Door Hatchback

•• •
M.LG. plug weld
Unit: mm

Portion A Portion 8 Portion C

(ItIlI)
M.LG. seam weld/
Hole(4 dial
Point weld

Brazing

• Upper radiator core support • Cowl top • Front roof

Portion D Portion E Portion F

-Soldering

~
Slot(7X 11)
/~/
• Rear roof • Rear waist panel slot • Second cross member

Portion G Portion H
3-door and 5-door Hatchback 3-door and 5-door Hatchback Sealing

Lozenge
mark

• Rear roof • Rear panel

-32-
-13-
__________ PRECAUTIONS _ _ BODY ALIGNMENT _

Precautions For Handling High Strength Steel Panel Parts Matching Marks

A mark has been placed on each part of the body to indicate the panel parts matching positions. When repairing
• Follow established specifications for the
Pressure Welding parts damaged by an accident which might affect the vehicle frame (members, pillars, etc.) more accurate,
appropriate pressure level, current level and current
effective repair will be possible by using these marks together wi~h body alignment data.
weld time.

• Follow the specifications for the proper

welding pitch. ~ ViewE

Unit: mrr (C • 3-Door Hatchback

Thickness (t) Minimum pitch ( Q ) and 5-Door Hatchback
0.6 (0.024) I 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
~71) 31 11.221 or over

Type W: @----- ~ Et
Type V: ~----- ~
• After welding, welding strength must be
tested.
J View A ViewS ViewC

View D-1 View D-2 ViewE

Sedan and 5-door Hatchback 3-door Hatchback 3-door Hatchback and 5-door Hatchback

/w-..IE
II
'-r
+-W

(-
)
o
-31- -14-
__________ BODY ALIGNMENT _ _ PRECAUTIONS _

Description Precautions For Handling High Strength Steel

• All dimensions indicated in figures are actual ones. • The spot ungget on HSS panel is harder than
• When using a tracking gauge, adjust both pointers to equal length. Then check the pointers and gauge that of an ordinary steel panel.
itself to make sure there is no free play. Therefore, for spot cutting HSS panel, a high
• When a measuring tape is used, check to be sure there is no elongation, twisting or bending. torque drill of a low speed (1,000 to 1,200
• Measurements should be taken at the center of the mounting holes. rpm) may be used to maintain its durability
• An asterisk (*) following the value at the measuring point indicates that the measuring point on the other
and facilitate the operation.
side is symmetrically the same value.
• The coordinates of the measurement points are the distances measured from the standard line of "X", "V"
and "Z".

• 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 bar and in the bumper, is too high in tensile strength to use
for general repairs. When these panels are damaged, the outer panels also sustain consequential
damage; therefore, these panels are never remedied without replacing the door assembly or bumper
assembly.
2. Precautions in spot welding
This work should be performed under standard work conditions. However, work control must be exercised
"Z": Imaginary base line as folloows:
[200 mm below datum line
("OZ" at design plan)]
/
y (_) (0)
Front axle center
• The electrode tip diameter must be reformed
properly according to the panels thickness.
SBF8?4GB

Engine Compartment
D=2T+3 (mm)
D=2T+O.12 (in)

____ MEASURMENT _ D==Tip+diameter T

,::=T====p=la::t_e=-=-_t_h=i_C=k=_n=_e_s=s=
__,-- ~

• The panel surfaces must be fitted to each

other, leaving no gaps.

Correct Incorrect Incorrect

SBT08?

-15- -30-
__________ PRECAUTIONS _ __________ BODY ALIGNMENT _

Precautions For Handling High Stregth Steel Engine Compartment

__ MEASURMENT POINTS __ Unit: mm

Special consideration for HSS must be given to the following points:
1. Additional points to consider

• The repair of reinforcements (such as side Not recommended

members) by heating is not recommended
since it involves the risk of lowering strength.
When heating is unavoidable, do not heat
such parts at temperatures above 550°C (1,
022°F)
Heating temperature should be verified with
a thermometer. (A crayon-type and other
SBT088
thermometer are available.)

Front side
• When straightening body panels, use caution
Traction direction: ...
in pulling any HSS panel. Because it is very
strong, this may cause deformation in adja-
cent portions of the body. In this case,
increase the number of measuring points,
and carefully pull the HSS panel.

• In cutting HSS panel, avoid gas cutting if Radiator core support lower
possible. Instead, use an air saw or a hand
cutter to avoid decreasing the strength of
surrounding portions due to the influence of
heat. In case gas cutting is inevitable, a
minimum allowance of 50 mm (1.97 in)
must be given.

• In welding HSS panel, use spot welding

whenever possible in order to minimize any
GOOD -================ N.G.
Never use acetylene .gas Radiator core support upper center
SBT090 •(b) 11 dia.
SBT094

welding.
decrease in strength of surrounding portions
due to the influence of heat.
If spot welding is impossible, use M.LG.
welding. Donot use acetylene gas welding
because it is inferior in welding strength.

SBT091

-29- -16-
__________ BODY ALIGNMENT _ __________ PRECAUTIONS _

Underbody Precautions For Handling High Strength Steel

____ MEASURMENT _
High strength steel has been used for body panels in order to reduce vehicle weight.
(ij Accordingly, precautions in repairing automotive bodies made of high strength steel are described below:
Q)
er:
E

iJ E

HIGH STRENGTH STEEL (HSS) USED IN NISSAN VEHICLES

-------- Tensile strength Nissan designation Major applicable parts

• Side member
o • Hoodledge
en It)
CD 373N/mm2
N It)
CD CD NP130 • Pillar
IIIlI:t' (38 kg/mm2, 54 klb/sq in)
en • Hood
It)

C!. N
~ en
co
.Trunk lid outer

CD
785-981 N/mm2
It) • Bumper reinforcement
It)
(80-100 kg/mm2 NP150
• Door guard beam
114-142 klb/sq in)
235
CD
It)
~200 ee
@@
C!.
~
N
.. CD • In Nissan vehicles, HSS plates of 373 N/mm2 (38kg/mm2, 54 klb/sq in) (NP130) are most commonly
.. 00
~ N ~
It) CD utilized, and those with a tensile strength of 785 to 981 N/mm2 (80 to 100 kg/mm2, 114 to 142 klb/sq
in) (NP150) are used only on parts requiring much more strength.
127 @>@)

129 @8

..
..0
CD CD
en~ @@
0)
~ .,

..o @)@)
.. It)
0) It)
o
I'

225

SBT096

-17- -28-
______ HANDLING PRECAUTIONS FOR PLASTICS _ _ BODY ALIGNMENT _

Location Of Plastic Parts Underbody

Roof spoilar(FRP)
__ MEASURMENT POINTS __
Side wind molding(PVC) Side wind molding(PVC)
Rear
High mounted stop lamp
Lens: PMMA )
( Housing: ABS
(f Front
coordinates:
@,@
Rear
coordinates:
@,@ @
X : 250 X : 393.5 X : 475
V : -632 V : 1,460 V : 3,082
Z : 224.8 Z : 126.9 Z : 336.8
@,@ (8), @ @
X : 492 X : 572 X : -542
V : -450 V : 1,940 V : 3,082
Z : 355 Z : 200 Z : 336.8
@,@ CD, CD
X : 406 X : 600
V : 64 V : 2,035
Z : 172 Z : 235.2
@,@ Q)
X : 352.7 X : 150
Back door finisher(ABS) V : 69 V : 2,442.9
Z : 240 Z : 241
@, @ @
3-door Hatchback 5-door Hatchback X : 432 X : 300
V : 338 V : 2,480
Z : 128 Z : 381.8
(f), CD @
X : 395 X : -300
V : 515
V : 2,480
Z : 129.2 Z: 405.8

•• @ @, @)
X : 393
Center pillar lower garnish(PP) Cluster lid A(PPC) LH side RH side Y : 2,560

Center pillar upper garnish(PPC)

Front pillar garnish(PPC) Q Q Z : 365
@
Bottom X : 470

,1
view of Y : 2,911
Instrument panel(PPC) vehicle Z : 339.6
Rear pillar garnish(PPC) @
X : -539
Y : 2,911
Z : 339.6
Cluster lid C(PPC)
Unit: mm

Front and rear strut tower centers

I

Console box(PPC)
Glove box(PPC)

@,0
~t-~
Coordinates:
Front @, 076 dia.
X : 522.2
~----_/ Rear @, @ 62 dia.
V : 18.1
Z : 571.7
Kicking plate(PP)
@,@
X : 465
V : 2,456.4
Z : 522
Front

SBT097

-27- -18-
__________ BODY ALIGNMENT _ _ HANDLING PRECAUTIONS FOR PLASTICS _
Sedan
Passenger Compartment 5-door Hatchback Location Of Plastic Parts

, ... ._ MEASURMENT _ Side turn signal lamp lens

Point Dimension Lens: AS )
( Housing: ASS
@-@ 1228
CB-<f) 1374 Door mirror
@-@ 1366 Wind-shield molding Housing: AAS)
( Garnish: ASS
Upper: PVC )
(8)-{6) 1159 Head lamp ( Side:Stainless+PVC
Lens: Glass)
CD--cD 1387 ( Housing: pp
Q)-{J) 1367
@--@ 1156
Radiator grille
(b)--{[) 1385 (ABS)
~-4iV 1370 Front bumper fascia
@~ 1364 (PP)

@~ 1364 Front air spoiler

(PP)
C'e)--@ 1598
@--@ 989*
@-{E) 918*
1156* Door out-side molding
@~
(Stainless+PVC)
@--{[) 917*
@~@ 975*
Wheel cover
@~(b) 757* Full cover: PP+PA6 )
Front turn signal lamp
@~ 1004* Fog lamp Lens: PMMA) ( Half cover: PA66+PPO
Fog lamp finisher ( Housing: PP Center cap: PA6
@--@ 723* (PM MA) Lens: Glass)
( Housing: PP

Figures marked with a * show symmetrically identical

dimensions on both right and left hand sides of the Unit: mm
vehicle.

@ : Cowl top hole center (5 dia.) CB> : Front roof flange end at center
~~ ~ } Outer front pillar joggle
Positioning mark

Door outside handle

Handle: POM )
Rear spoiler(PPO) Rear Windowmolding ( Escutcheon: POM
-for Sedan (PVC)
-for Sedan
High mounted stop lamp
Side guard molding (PVC)
(In Rear SpoilerType)
(Lens: PMMA ) -for Sedan
Housing: ASS
(Fixed Trunk Lid Tipe)
Lens: PC ) -for Sedan
( Housing: PP

@@ : Dash upper flange end corner CBCD: } (f3),Cfi),Q),CD,@,@,CD,CD,~,@ :

~@: Outer front pillar indention Trunk lid finisher(pp)
Outer center pillar indention -for Sedan
CDCD : Outer center pillar standard hole
center
License lamp
Lens: PC )
( Housing: PP

Rear bumper fascia

(PP)
Rear combination lamp
Mud guard (TPR)
Lens: PMMA)
( Housing: PP

-19- -26-
 _________ BODY ALIGNMENT _
______ HANDLING PRECAUTIONS FOR PLASTICS _
Sedan
Handling Precautions For Plastics Passenger Compartment 5-door Hatchback

Heat resisting ____ MEASURMENT _

Resistance to gasoline and
Abbreviation Material name temperature Other cautions
QC rF)
solvents Unit: mm

~@ : Rear fender standard hole center @ : 2nd crossmember standard hole

Gasoline and most solvents
PE Polyethylene 80 (176) Flammable (7dia) center at center positioning mark
are harmless.
(Q)@ : Rear fender indention (8 dia.)

Polyethylene (B@ : Door switch installing hole cen- @([): Rear floor harness installing hole
Gasoline and most solvents
PET 180 (356) ter center (8 dia.)
terephthalate are harmless.
(20 dia.) ~ (D< )
Gasoline and most solvents ~~ ~~ '---- ~ k@(fdiaol",
PVC Polyvinyl chloride 80 (176)
are harmless if applied for a
very short time (wide up
Poison gas is emitted
when burned.
(7diajj \\1 ~;. . · C')\U--
quickly). ~ ~ O"~Wiaol ~ -Z

pp

ABS
Polypropylene

Acrylonitrile
styrene resin
butadiene
90 (194)

80 (176)
Same as above.
Also avoid battery

Avoid gasoline
acid.

and solvents.
Flammable

J D ~
Acrylonitrile ethylene
AES 80 (176) Avoid gasoline and solvents.
styrene

PMMA Polymethyl methacrylate 85 (185) Avoid gasoline and solvents.

Gasoline and most solvents

PUR Polyurethane 90 (194) Avoid battery acid.
are harmless.

Acrylonitrile acrylic
AAS 85 (185) Avoid gasoline and solvents.
ru bber styrene

AS Styre ne-a c rylo n itri Ie 85 (185) Avoid gasoline and solvents.

PPO Polyphenylene oxide 110 (230) Avoid gasoline .and solvents.

Gasoline and solvents

POM Polyacetal 120 (248) Avoid battery acid.
are harmless.

PC Polycarbonate 120 (248) Avoid gasoline and solvents.

Gasoline and most solvents

PA Polyamide (Nylon) 140 (284) Avoid immersing in water.
are harmless.

Gasoline and most solvents

FRP Fiber reinforced plastics 170 (338) Avoid battery acid.
are harmless.

Gasoline and most solvents

PPC Polypropylene composite 115 (239) Flammable
are harmless.

Gasoline and most solvents

PBT Polybutylene terephthalate 140 (284)
are harmless.

TPR Thermoplastic rubber 80 (176) Avoid gasoline and solvents.

TPE Thermoplastic elastomer 80 (176) Avoid gasoline and solvents.

Thermoplastic
TPUR 80 (176) Avoid gasoline and solvents.
polyurethane

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.

-25- -20-
__________ BODY ALIGNMENT _ __________ BODY ALIGNMENT _
3-door Hatchback
Rear Body Sedan Rear Body 5-door Hatchback

____ MEASUREMENT _ Point Dimension

@~(E) 189* ~ MEASUREMENT _
@~CD 1213*
@~(8) 608*
(E)~@ 1110*

Figures marked with a * show symmetrically identical Figures marked with a * show symmetrically identical
dimensions both right and left and left hand sides of the Unit: mm dimensions on both right and left hand sides of the
vehicle. vehicle. Unit: mm

@ : Rear roof flange end at center (Q@: Rear fender corner joggle @ : Rear panel reinforcement back
@@ : Rear fender joggle (6)@ : Rear fender joggle
positioning mark door lock hole center at center
(Q : Roof flonge positioning mark at
(6)@ : Rear fender extension joggle
center positioning mark

CE)@ : Rear fender joggle

\~
CD : Rear panel trunk lid lock installing Q): Rear suspension installing hole ~@ : Rear suspention installing hole
center (9 dia.)
(8(f)<G)@ : Rear fender corner joggle hole flange end at center position- center (9 dia.)
ing mark

-21- -24-
_________ BODY ALIGNMENT _ _________ BODY ALIGNMENT _

Passenger Compartment 3-door Hatchback

Passenger Compartment 3-door Hatchback

Unit: mm ____ MEASUREMENT -' Point Dimension

@ : 2nd crossmember standard hole ~: Rear suspension installing hole @~ 1228
center at center positioning mark center (9 dia.) Cf)~ 1374
(a dia.) C8},{5) 1094
CDCD : =:::e~I~~rd~:~)nessinstalling hole "\ \ \ }J\ (/ ~ Q)~
Q)~
1388
1558
~cp(8 dia.) ,~ ~Yb::~\\ c? (8)~
@~@
871
989*

~~--:q~ ,\'I~I ~
@--{f)
@~(8)
@~Q)
918*
1193*
1043*
~~~~ /~FRONT \ (b)~C8)
- \\\y~ ~ \ (b)~
1017*
655*

Figures marked with a * show symmetrically identical

dimensions on both right and left hand sides of the Unit: mm
vehicle.

@ : Cowl top hole center (5 dia.) (6) : Front roof flange end at center ~@: }
(B@: Outer front pillar joggle
Positioning mark

@@ : Dash upper flange end corner q:])@ : Rear fender joggle

(BeD:
~@ : } 0 uter f ront pi"11"
ar In d entlon
"
CDCD : Rear fender indention
Q)(D : Door switch installing hole cen-
ter (7 dia.) of nut

-22-
-23-
_________ BODY ALIGNMENT _ _________ BODY ALIGNMENT _

Passenger Compartment 3-door Hatchback

Passenger Compartment 3-door Hatchback

Unit: mm ____ MEASUREMENT -' Point Dimension

@ : 2nd crossmember standard hole ~: Rear suspension installing hole @~ 1228
center at center positioning mark center (9 dia.) Cf)~ 1374
(a dia.) C8},{5) 1094
CDCD : =:::e~I~~rd~:~)nessinstalling hole "\ \ \ }J\ (/ ~ Q)~
Q)~
1388
1558
~cp(8 dia.) ,~ ~Yb::~\\ c? (8)~
@~@
871
989*

~~--:q~ ,\'I~I ~
@--{f)
@~(8)
@~Q)
918*
1193*
1043*
~~~~ /~FRONT \ (b)~C8)
- \\\y~ ~ \ (b)~
1017*
655*

Figures marked with a * show symmetrically identical

dimensions on both right and left hand sides of the Unit: mm
vehicle.

@ : Cowl top hole center (5 dia.) (6) : Front roof flange end at center ~@: }
(B@: Outer front pillar joggle
Positioning mark

@@ : Dash upper flange end corner q:])@ : Rear fender joggle

(BeD:
~@ : } 0 uter f ront pi"11"
ar In d entlon
"
CDCD : Rear fender indention
Q)(D : Door switch installing hole cen-
ter (7 dia.) of nut

-22-
-23-
__________ BODY ALIGNMENT _ __________ BODY ALIGNMENT _
3-door Hatchback
Rear Body Sedan Rear Body 5-door Hatchback

____ MEASUREMENT _ Point Dimension

@~(E) 189* ~ MEASUREMENT _
@~CD 1213*
@~(8) 608*
(E)~@ 1110*

Figures marked with a * show symmetrically identical Figures marked with a * show symmetrically identical
dimensions both right and left and left hand sides of the Unit: mm dimensions on both right and left hand sides of the
vehicle. vehicle. Unit: mm

@ : Rear roof flange end at center (Q@: Rear fender corner joggle @ : Rear panel reinforcement back
@@ : Rear fender joggle (6)@ : Rear fender joggle
positioning mark door lock hole center at center
(Q : Roof flonge positioning mark at
(6)@ : Rear fender extension joggle
center positioning mark

CE)@ : Rear fender joggle

\~
CD : Rear panel trunk lid lock installing Q): Rear suspension installing hole ~@ : Rear suspention installing hole
center (9 dia.)
(8(f)<G)@ : Rear fender corner joggle hole flange end at center position- center (9 dia.)
ing mark

-21- -24-
 _________ BODY ALIGNMENT _
______ HANDLING PRECAUTIONS FOR PLASTICS _
Sedan
Handling Precautions For Plastics Passenger Compartment 5-door Hatchback

Heat resisting ____ MEASURMENT _

Resistance to gasoline and
Abbreviation Material name temperature Other cautions
QC rF)
solvents Unit: mm

~@ : Rear fender standard hole center @ : 2nd crossmember standard hole

Gasoline and most solvents
PE Polyethylene 80 (176) Flammable (7dia) center at center positioning mark
are harmless.
(Q)@ : Rear fender indention (8 dia.)

Polyethylene (B@ : Door switch installing hole cen- @([): Rear floor harness installing hole
Gasoline and most solvents
PET 180 (356) ter center (8 dia.)
terephthalate are harmless.
(20 dia.) ~ (D< )
Gasoline and most solvents ~~ ~~ '---- ~ k@(fdiaol",
PVC Polyvinyl chloride 80 (176)
are harmless if applied for a
very short time (wide up
Poison gas is emitted
when burned.
(7diajj \\1 ~;. . · C')\U--
quickly). ~ ~ O"~Wiaol ~ -Z

pp

ABS
Polypropylene

Acrylonitrile
styrene resin
butadiene
90 (194)

80 (176)
Same as above.
Also avoid battery

Avoid gasoline
acid.

and solvents.
Flammable

J D ~
Acrylonitrile ethylene
AES 80 (176) Avoid gasoline and solvents.
styrene

PMMA Polymethyl methacrylate 85 (185) Avoid gasoline and solvents.

Gasoline and most solvents

PUR Polyurethane 90 (194) Avoid battery acid.
are harmless.

Acrylonitrile acrylic
AAS 85 (185) Avoid gasoline and solvents.
ru bber styrene

AS Styre ne-a c rylo n itri Ie 85 (185) Avoid gasoline and solvents.

PPO Polyphenylene oxide 110 (230) Avoid gasoline .and solvents.

Gasoline and solvents

POM Polyacetal 120 (248) Avoid battery acid.
are harmless.

PC Polycarbonate 120 (248) Avoid gasoline and solvents.

Gasoline and most solvents

PA Polyamide (Nylon) 140 (284) Avoid immersing in water.
are harmless.

Gasoline and most solvents

FRP Fiber reinforced plastics 170 (338) Avoid battery acid.
are harmless.

Gasoline and most solvents

PPC Polypropylene composite 115 (239) Flammable
are harmless.

Gasoline and most solvents

PBT Polybutylene terephthalate 140 (284)
are harmless.

TPR Thermoplastic rubber 80 (176) Avoid gasoline and solvents.

TPE Thermoplastic elastomer 80 (176) Avoid gasoline and solvents.

Thermoplastic
TPUR 80 (176) Avoid gasoline and solvents.
polyurethane

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.

-25- -20-
__________ BODY ALIGNMENT _ _ HANDLING PRECAUTIONS FOR PLASTICS _
Sedan
Passenger Compartment 5-door Hatchback Location Of Plastic Parts

, ... ._ MEASURMENT _ Side turn signal lamp lens

Point Dimension Lens: AS )
( Housing: ASS
@-@ 1228
CB-<f) 1374 Door mirror
@-@ 1366 Wind-shield molding Housing: AAS)
( Garnish: ASS
Upper: PVC )
(8)-{6) 1159 Head lamp ( Side:Stainless+PVC
Lens: Glass)
CD--cD 1387 ( Housing: pp
Q)-{J) 1367
@--@ 1156
Radiator grille
(b)--{[) 1385 (ABS)
~-4iV 1370 Front bumper fascia
@~ 1364 (PP)

@~ 1364 Front air spoiler

(PP)
C'e)--@ 1598
@--@ 989*
@-{E) 918*
1156* Door out-side molding
@~
(Stainless+PVC)
@--{[) 917*
@~@ 975*
Wheel cover
@~(b) 757* Full cover: PP+PA6 )
Front turn signal lamp
@~ 1004* Fog lamp Lens: PMMA) ( Half cover: PA66+PPO
Fog lamp finisher ( Housing: PP Center cap: PA6
@--@ 723* (PM MA) Lens: Glass)
( Housing: PP

Figures marked with a * show symmetrically identical

dimensions on both right and left hand sides of the Unit: mm
vehicle.

@ : Cowl top hole center (5 dia.) CB> : Front roof flange end at center
~~ ~ } Outer front pillar joggle
Positioning mark

Door outside handle

Handle: POM )
Rear spoiler(PPO) Rear Windowmolding ( Escutcheon: POM
-for Sedan (PVC)
-for Sedan
High mounted stop lamp
Side guard molding (PVC)
(In Rear SpoilerType)
(Lens: PMMA ) -for Sedan
Housing: ASS
(Fixed Trunk Lid Tipe)
Lens: PC ) -for Sedan
( Housing: PP

@@ : Dash upper flange end corner CBCD: } (f3),Cfi),Q),CD,@,@,CD,CD,~,@ :

~@: Outer front pillar indention Trunk lid finisher(pp)
Outer center pillar indention -for Sedan
CDCD : Outer center pillar standard hole
center
License lamp
Lens: PC )
( Housing: PP

Rear bumper fascia

(PP)
Rear combination lamp
Mud guard (TPR)
Lens: PMMA)
( Housing: PP

-19- -26-
______ HANDLING PRECAUTIONS FOR PLASTICS _ _ BODY ALIGNMENT _

Location Of Plastic Parts Underbody

Roof spoilar(FRP)
__ MEASURMENT POINTS __
Side wind molding(PVC) Side wind molding(PVC)
Rear
High mounted stop lamp
Lens: PMMA )
( Housing: ABS
(f Front
coordinates:
@,@
Rear
coordinates:
@,@ @
X : 250 X : 393.5 X : 475
V : -632 V : 1,460 V : 3,082
Z : 224.8 Z : 126.9 Z : 336.8
@,@ (8), @ @
X : 492 X : 572 X : -542
V : -450 V : 1,940 V : 3,082
Z : 355 Z : 200 Z : 336.8
@,@ CD, CD
X : 406 X : 600
V : 64 V : 2,035
Z : 172 Z : 235.2
@,@ Q)
X : 352.7 X : 150
Back door finisher(ABS) V : 69 V : 2,442.9
Z : 240 Z : 241
@, @ @
3-door Hatchback 5-door Hatchback X : 432 X : 300
V : 338 V : 2,480
Z : 128 Z : 381.8
(f), CD @
X : 395 X : -300
V : 515
V : 2,480
Z : 129.2 Z: 405.8

•• @ @, @)
X : 393
Center pillar lower garnish(PP) Cluster lid A(PPC) LH side RH side Y : 2,560

Center pillar upper garnish(PPC)

Front pillar garnish(PPC) Q Q Z : 365
@
Bottom X : 470

,1
view of Y : 2,911
Instrument panel(PPC) vehicle Z : 339.6
Rear pillar garnish(PPC) @
X : -539
Y : 2,911
Z : 339.6
Cluster lid C(PPC)
Unit: mm

Front and rear strut tower centers

I

Console box(PPC)
Glove box(PPC)

@,0
~t-~
Coordinates:
Front @, 076 dia.
X : 522.2
~----_/ Rear @, @ 62 dia.
V : 18.1
Z : 571.7
Kicking plate(PP)
@,@
X : 465
V : 2,456.4
Z : 522
Front

SBT097

-27- -18-
__________ BODY ALIGNMENT _ __________ PRECAUTIONS _

Underbody Precautions For Handling High Strength Steel

____ MEASURMENT _
High strength steel has been used for body panels in order to reduce vehicle weight.
(ij Accordingly, precautions in repairing automotive bodies made of high strength steel are described below:
Q)
er:
E

iJ E

HIGH STRENGTH STEEL (HSS) USED IN NISSAN VEHICLES

-------- Tensile strength Nissan designation Major applicable parts

• Side member
o • Hoodledge
en It)
CD 373N/mm2
N It)
CD CD NP130 • Pillar
IIIlI:t' (38 kg/mm2, 54 klb/sq in)
en • Hood
It)

C!. N
~ en
co
.Trunk lid outer

CD
785-981 N/mm2
It) • Bumper reinforcement
It)
(80-100 kg/mm2 NP150
• Door guard beam
114-142 klb/sq in)
235
CD
It)
~200 ee
@@
C!.
~
N
.. CD • In Nissan vehicles, HSS plates of 373 N/mm2 (38kg/mm2, 54 klb/sq in) (NP130) are most commonly
.. 00
~ N ~
It) CD utilized, and those with a tensile strength of 785 to 981 N/mm2 (80 to 100 kg/mm2, 114 to 142 klb/sq
in) (NP150) are used only on parts requiring much more strength.
127 @>@)

129 @8

..
..0
CD CD
en~ @@
0)
~ .,

..o @)@)
.. It)
0) It)
o
I'

225

SBT096

-17- -28-
__________ PRECAUTIONS _ __________ BODY ALIGNMENT _

Precautions For Handling High Stregth Steel Engine Compartment

__ MEASURMENT POINTS __ Unit: mm

Special consideration for HSS must be given to the following points:
1. Additional points to consider

• The repair of reinforcements (such as side Not recommended

members) by heating is not recommended
since it involves the risk of lowering strength.
When heating is unavoidable, do not heat
such parts at temperatures above 550°C (1,
022°F)
Heating temperature should be verified with
a thermometer. (A crayon-type and other
SBT088
thermometer are available.)

Front side
• When straightening body panels, use caution
Traction direction: ...
in pulling any HSS panel. Because it is very
strong, this may cause deformation in adja-
cent portions of the body. In this case,
increase the number of measuring points,
and carefully pull the HSS panel.

• In cutting HSS panel, avoid gas cutting if Radiator core support lower
possible. Instead, use an air saw or a hand
cutter to avoid decreasing the strength of
surrounding portions due to the influence of
heat. In case gas cutting is inevitable, a
minimum allowance of 50 mm (1.97 in)
must be given.

• In welding HSS panel, use spot welding

whenever possible in order to minimize any
GOOD -================ N.G.
Never use acetylene .gas Radiator core support upper center
SBT090 •(b) 11 dia.
SBT094

welding.
decrease in strength of surrounding portions
due to the influence of heat.
If spot welding is impossible, use M.LG.
welding. Donot use acetylene gas welding
because it is inferior in welding strength.

SBT091

-29- -16-
__________ BODY ALIGNMENT _ _ PRECAUTIONS _

Description Precautions For Handling High Strength Steel

• All dimensions indicated in figures are actual ones. • The spot ungget on HSS panel is harder than
• When using a tracking gauge, adjust both pointers to equal length. Then check the pointers and gauge that of an ordinary steel panel.
itself to make sure there is no free play. Therefore, for spot cutting HSS panel, a high
• When a measuring tape is used, check to be sure there is no elongation, twisting or bending. torque drill of a low speed (1,000 to 1,200
• Measurements should be taken at the center of the mounting holes. rpm) may be used to maintain its durability
• An asterisk (*) following the value at the measuring point indicates that the measuring point on the other
and facilitate the operation.
side is symmetrically the same value.
• The coordinates of the measurement points are the distances measured from the standard line of "X", "V"
and "Z".

• 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 bar and in the bumper, is too high in tensile strength to use
for general repairs. When these panels are damaged, the outer panels also sustain consequential
damage; therefore, these panels are never remedied without replacing the door assembly or bumper
assembly.
2. Precautions in spot welding
This work should be performed under standard work conditions. However, work control must be exercised
"Z": Imaginary base line as folloows:
[200 mm below datum line
("OZ" at design plan)]
/
y (_) (0)
Front axle center
• The electrode tip diameter must be reformed
properly according to the panels thickness.
SBF8?4GB

Engine Compartment
D=2T+3 (mm)
D=2T+O.12 (in)

____ MEASURMENT _ D==Tip+diameter T

,::=T====p=la::t_e=-=-_t_h=i_C=k=_n=_e_s=s=
__,-- ~

• The panel surfaces must be fitted to each

other, leaving no gaps.

Correct Incorrect Incorrect

SBT08?

-15- -30-
__________ PRECAUTIONS _ _ BODY ALIGNMENT _

Precautions For Handling High Strength Steel Panel Parts Matching Marks

A mark has been placed on each part of the body to indicate the panel parts matching positions. When repairing
• Follow established specifications for the
Pressure Welding parts damaged by an accident which might affect the vehicle frame (members, pillars, etc.) more accurate,
appropriate pressure level, current level and current
effective repair will be possible by using these marks together wi~h body alignment data.
weld time.

• Follow the specifications for the proper

welding pitch. ~ ViewE

Unit: mrr (C • 3-Door Hatchback

Thickness (t) Minimum pitch ( Q ) and 5-Door Hatchback
0.6 (0.024) I 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
~71) 31 11.221 or over

Type W: @----- ~ Et
Type V: ~----- ~
• After welding, welding strength must be
tested.
J View A ViewS ViewC

View D-1 View D-2 ViewE

Sedan and 5-door Hatchback 3-door Hatchback 3-door Hatchback and 5-door Hatchback

/w-..IE
II
'-r
+-W

(-
)
o
-31- -14-
_________ BODY ALIGNMENT _ ________ REPLACEMENT OPERATIONS _
SYMBOLS FOR CUITING AND
Body Center Marks Description WELDING/BRAZING OPERATIONS
The indentification of the cutting and the welding/brazing symbols used throughout this guide is given in the
A mark has been placed on each part of the body to indicate the vehicle center. When repairing parts damaged following pages
by an accident which might affect the vehicle frame (members, pillars, etc.) more accurate, effective repair will
be possible by using these marks together with body alignment data.

Portion G Saw cut or

air chisel cut
Portion C Portion D-Sedan
Portion E
Portion B -Sedan
..J
Portion A
••••
2-spot
2-SDOt welds
(2-panel overlapping portions)
welds

Spot
weld
0000
Porton H 3-spot 3-spot welds
(3-panel overlapping portions)
3-Door Hatchback welds
Portion F
and 5-Door Hatchback

•• •
M.LG. plug weld
Unit: mm

Portion A Portion 8 Portion C

(ItIlI)
M.LG. seam weld/
Hole(4 dial
Point weld

Brazing

• Upper radiator core support • Cowl top • Front roof

Portion D Portion E Portion F

-Soldering

~
Slot(7X 11)
/~/
• Rear roof • Rear waist panel slot • Second cross member

Portion G Portion H
3-door and 5-door Hatchback 3-door and 5-door Hatchback Sealing

Lozenge
mark

• Rear roof • Rear panel

-32-
-13-
 REPLACEMENT OPERATIONS _
------------ BODY CONSTRUCTION _
Radiator Core Support (Partial Replacement) -----------
Body Construction

Service Joint * indicatesthat there is an equivalent wel~ing. portion

with the same dimensions on the opposite Side.
Section A-A: Section 8-8: Section C-C: Section D-D:
(

Section E-E: Section F-F: Section G-G: Section H-H:

_1

o Section I-I: Section J-J: Section K-K: Section L-L:

*e 3 or 11 2

FR
Section M-M: . Section N-N: Section 0-0: Section P-P:

e4 orll3

FR \
Section 0-0: Section R-R:
2-spot welds 3-spot welds M.1. G plug weld ) M.I. G seam weld/
Point For 3 panels plug weld m.ethod weld

·r ·=='*= (
A • B ===:= .an F

-33-
-12-
------------ BODY CONSTRUCTION _ ------------ REPLACEMENT OPERATIONS _

Hoodledge (Partial Replacement)

Body Consb"uction.
(Work after radiator core support has been removed.)

Service Joint
(This figure show right side hoodledge)

Sedan

Before installing
hoodledge reinforcement.
117

3-d oar Hatchback

114A

Unit:mm

2-spot welds 3-spot welds M.1. G plug weld ) M.I. G seam weld/
For 3 panels plug weld method. Point weld
5-door Hatchback

·r ( .A~ .B~ .an.F

-34-
-11-
 REPLACEMENT OPERATIONS
________ CORROSION PROTECTION _
Front Side Member (Partial Replacement)
Stone Guard Coat
(Work after radiator core support has been removed.)

Service Joint To prevent damage caused by stones, the lower outer body panels (fender, door, etc.) have an additional layer
(This figure show right front side member) of Stone Guard Coat over the ED primer coating. Thus, when replacing or repairing these panels, apply
undercoat to the same portions as before. Use a coat which is rust preventive, durable, shockresistant and has
-\
a long shelf life.

~mm1111i : Indicates stone guard coated portions

114

111

8 115

"" " "

Patch

(Thickness: 1mm)
117
118
111

hoodledge panel
Section A-A --r':":' Section B-B

114
Patch
Unit:mm

2-spot welds 3-spot welds M.1. G plug weld

F
M I G seam weld/
weld Section C-C

.A=-= .B~
For 3 panels plug weld method ) P1ID.~irit

• G1Jrr= (
--- ~

-35-
-10-
 REPLACEMENT OPERATIONS

Front Pillar
Undercoating
(Work after hoodledge reinforcement has been removed.)

The undersides of the floor and wheelhouse are undercoated to prevent rust, vibration, noise and stone Service Joint
chipping.
Therefore, when such a panel is replaced or repaired, apply undercoating to that part. Use an undercoating with
the following properties: rust preventive, soundproof, vibration-proof, shock-resistant, adhesive, and durable. <:=i FR
Precautions in undercoating
1. Do not apply undercoating to any place unless specified (such as the areas above the muffler and catalytic
1lIl.. ( Dri p channel)
converter which are subjected to heat).
an (Outer)
2. Do not undercoat the exhaust pipe, other parts which become hot, and rotary parts.
112
3. Apply bitumen wax after applying undercoating.

~I!!!!!!!!iiii!!!!!i!II : Indicates undercoated portions

1lIl..
( Inner)
112

~
113 :::::-----

116

112
112 116
c;;;;?
Unit:mm FR

2-spot welds 3-spot welds

M. I. G plug wel(d For 3 panels plug weld method ) .. ~: G(F:~dm weld/
• rr= • A ==-=.
GTJ ---
B~ ~ .LLLL

-36-
-9-
 REPLACEMENT OPERATIONS ________ CORROSION PROTECTION _
Center Pillar Sedan
5-door hatch back Anti-corrosive Wax

Service Joint 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.
111
117
112 117
FR

A
FR

E
Hatchback
.cm. 111A 111A
( Overl ap cutt ing)

Seat belt ancher Upper center pillar hinge brace

reinforcement

113 114

113 : Indicates anti-corrosive wax coated portions.

112
FR Section A-A: Section 8-8: Section C-C:
Lower center pillar
114
hinge brace

116

Section 0-0: SEDAN Section E-E: Hatchback

Unit:mm
For Australia model For Australia model

2-spot welds 3-spot welds M. I. G plug weld

For 3 panels plug weld method ) P: F
M I G seam weld/
weld

• G1Jrr= ( ==-= •
• A --- B~
~ ..LLLL

-37-
-8-
 REPLACEMENT OPERATIONS

Outer Sill Sedan

Description 5-door hatchback

To provide improved corrosion prevention, the following anti-corrosive measures have been implemented in Service Joint
our production plants. When repairing or replacing body panels, it is necessary to use these same anti-corrosive _4A
measures.

FR
ANTI-CORROSIVE PRECOATED STEEL
(DURASTEEL) Zn-Ni alloy

To improve repairability and corrosion resistance, a

new type of anti-corrosive precoated steel sheets have
been adopted taking the place of conventional zinc-
coated steel sheets.
This durasteel is electroplated, zinc-nickel alloy under Steel sheet
organic film, which provides excellent corrosion resis-
tance. One-side precoated
119

Durasteel is classified as either one-side precoated

steel or two-side precoated steel. The two side
precoated steel provides excellent corrosion resis-
tance.

117
~ Outside

Two-side precoated
_4 11 12
(OIerlap
.cm
cutting)

Nissan Genuine Service Parts are fabricated from durasteel sheets. Therefore, it is recommended that 112A 111A
GENUINE NISSAN PARTS be used for panel replacement to maintain the anti-corrosive performance 114 111
112A
built into the vehicle at the factory.
113 114

PHOSPHATE COATING TREATMENT AND

CATIONIC ELECTRODEPOSITION PRIMER

A phosphate coating treatment and a cationic electrodeposition primer, which provide an excellent anti-
corrosion effect, are employed on all body components.
Caution:
Confine paint removal in the welding operation to the absolute minimum.

Cationic electrodeposition primer

_4
Unit:mm
111
2-spot welds 3-spot welds M. I. G plug weld
P.an.0int;=::
M I G seam weld/

·r .A
For 3 panels plug weld method )

Nissan Genuine Service Parts also are treated in the same manner. Therefore, it is recommended tbat
( =6=___ .8=:= V
GENUINE NISSAN PARTS be used for panel replacement to maintain anti-corrosive performance built
into the vehicle at the factory.

-38-
-7-
 REPLACEMENT OPERATIONS
Body Component Parts 3-door Hatchback
Outer Sill 3-door hatch back

Service Joint

112 :r: :r: -:r:

~ ~ :i~ ~:i:i~
--
--:-~
_ I ~ ~ c2S ~ ~
:r: :r: ~ :r:o:r: :r: :r:
0

:i~ 0

~ ~ cC cC :r: 0:: ~
0:: cC
0

-cC -
~ I
:r: cC
CD
en
::J
CD
en ->-
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Q5 >- c
c
:0 0 I
:0 co
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0.. E 00 cC
0

-
cC +-'
CD
$ co .:::£C,) ..c
lo-
..c ..c
Q5 Q5
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E
CD
lo-CD
0 en +-'
en 0 en >< CD
c
CD -l0-

r/
CD CD
$
0
..0
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= co $ ..c
.0. .0 $
en
co "'C ;g
co CD .:::£
lo-°C+-' lo-

O
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CD CDa;
"'C "'C en
l0-
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l0-

0 0 co CD co
lo-
co
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0 C C O c l0-
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lo-
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lo-
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lo-
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11 11 N
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co co Q5
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lo- lo-
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111 Z u. C 0:: 0 C u. 0 0:: 0:: 0:: u. 0) CC

c.o I"'- 00
~ ~
(j)
~ 0 N CV) ~ LO c.o I"'- 00 (j)
N
N N N N N N N N N

:r:
cC--:-
-:r:
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112A c2S
~o
I.-

'+-
0
~-
:r: ..0 .co
$ $ $ $
0 0 0 0
114 .c
cC CDE '+-0
lo-
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lo-
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CD en 0 0 0 0
::J "'C en 0 0 0 0 o
en .00 .00 co l0-
lo- lo- lo- lo-
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CD
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'+-
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co
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lo- 0 0 0 CD
cc
\ 0:: u. Z Z Z
::J ::J
0 0 0 N ~ LO
~ 00 (j)
CV)

@-~~~":::.~ ~
o .~ ~.~.~.. ~-<0h ~
,- ~: \~~

.an.
(CNerlap cutting)
111
Unit:mm

2-spot welds 3-spot welds Mol. G plug weld

• G@r;=::::. (
For

• A
3 panels plug weld method

:=::A:=: • 8~
). p:;m
M I G

.u.u.
we
Id/

-6-
-39-
 REPLACEMENT OPERATIONS
~~~~~~~_BODYCOMPONENTPAR~~~~~~~~_
Sedan Rear Fender Sedan
Body Component Parts 5-door Hatchback

Service Joint
..an (length : 10mm)

Unit:mm
Cut off

@ 1 orll 1
113A

o~ ( \ FR

e3 orll2
@ 13 orll10
116

I I
..an
..J ..J :i
~ ~ ..J
I ~
I I
er: er:
t
0
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.....,
(])

E
(])
Cl)
(])
Cl)
I

o.:i
0. "
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Co)
:::J
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0 0
C
>- co
0. :c e4 orll3
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a; a; E "-
"-
.c '+-
e3
Cl)
0 - '+-

s s orll 2
(]) 0
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s s s
0 0 0 0 0 -c
$ 0
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.....,
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c (]) .c(])
co "m .c co
0
"'C
Cl)
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-c -c -c -c -c -c 0.- (]) 0. "- S "- S "- .....,

:-:: Cl)

'+- '+- '+- '+- '+- '+- ....., "- "- 0 c

@ 1 orll 1
0 0 0 0 0 0 co co "- ~
"- Co) "-
co co 0 0
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co co (]) ....., c .....,
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ci ci ci (]) ci "- 0 co (]) C "'C (]) (]) C :::J 0 :::J

cc: c US cc: cc: E 0 u. 0
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z z z cc: Z u.
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I e 20 orll15
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114
:i ....., I 116
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~
(])

E ..J ..J ->- ..J

:i
(])
Co) ~ ~ :c ~ 2-spot welds 3-spot welds M. I. G plug weld M I G seam weld/
I er: "-
E
--
"- "-

.A=-= .B~
0 I I For 3 panels plug weld method ) P..an.~i~t
(Fweld
~ ~ I
-er:"co
..J '+- (])
....., er: Cl)
er:
>- "~
• G@rr=
"0.. "0.. I
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Cl)
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(])
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-C Cl)
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Q)
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(]) (]) -
"0..
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"-
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....., .....,
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(])
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c c c Q) c .....,
(])
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0. 0
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I u. u. U. ...J
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N CV) q- LO to I'" ex) en 0 ~ N CV) q- LO

-5- -40-
___________ REPLACEMENT OPERATIONS ________ BODY COMPONENT PARTS _
Sedan
Rear Fender 5-door hatch back Body Component Parts 5-door Hatchback

Service Joint

~
@ 1 or 111 o
113 o
'"C
@ 1 or 11 1 iD
111
_ 7 orll5 112
111
112

~
c [IJ
.......
co
"0 :I:
(]J
[J
"en ID

1IIl.

_ 4 orll3
@90r1l7
_50r1l4
_ 5 orll4
c
co
"0
~~f~
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(]J
en
_ 3 orll2
c
co
@ 1 or 111 "0
(]J
[IJ
en
_ 12 orll 9 111 .......
:I:
0
LO

@ 5 orll 4

1IIl.
(length: 10mm)
@ 4 or 11 3

Rear pillar inner

reinforcement

_ 200r 11 15

Unit:mm 116 c
@ 1 or 111 co
"0
(]J
en
2-spot welds 3-spot welds M.I. G seam weld/
M.1. G plug wel(d For 3 panels plug weld method ) Point weld

·r .A===-= .B~

-41- -4-
 REPLACEMENT' OPERATIONS

Rear Fender 3-door hatchback

Underbody Component Parts

J: Service Joint
..J
~ -\
:i
J: ..J :i @ 1 or 11 1
et: ~ ..J
>- :i ~
@ 1 or 11 1
:c a: .
E
Q)
en +-'
en co 0
Q)

co -a. ._
-~
c: cc +-'
c:
+-'
c:
Q)

E
+-'
c:
Q)
112
111
en c: Q)
Q) 0) c: 0
E
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u E
co c: +-'
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a. '00 x c: Q)
J:
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Q)
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-42-
-3-
 REPLACEM ENT OPERATIONS ________ GENERAL INFORMATION _

Rear Floor Rear Identification Number (Cont' d)

(Work after rear panel have been removed.) Except for Europe
Service Joint IN 1 . B CAN 15 A 0 XXXXXX
111

T T --c::: 0: Stopgap
serial number
(no meaning)
Destination
~
A: Australia and New Zealand
Z: Except for Europe, Australia, and New Zealand
Model
A: 2-wheel drive
Engine type
B: GA 15DE engine
C: GA 16DE engine
E: SR20DE engine-For Australia and New Zealand only
Body type
B: 4-door Sedan
F: 5-door Hatchback
Manufacturer
IN 1: Nissan, Passenger vehicle

VEHICLE IDENTIFICATION PLATE

Europe Expect Europe 1 Type approval number

2 Vehicle identification
NISSAN MOTOR CO., LTD. JAPAN NISSAN MOTOR CO., LTD. APAN number(Chassis number)
I ~ I ~ tt ~(:l & 3 Gross vehicle weight
4 Gross combination weight
~ ~~~sg~ CNHOA"SIS ~
Gross vehicle weight
~ ~~~~~o & + Gross trailing capacity
(Weight)
o & kgO o ~0:ggtg~ ~~~RNICION ~ &. o 5 Gross axle weight(Front)
1- & cc 6 Gross axle weight(Rear)
kg
~~~~~~~ & £ 7 Type approval number
2- & kg ; ; ~)~ / ~~~~~'. AE~~ A1 L11 8 Body color code
TYPE COlOR. TRIM PLANT 9 Trim color code
TTP FARBE. POlST ~ & PlANTA
10 Model Specification No.
& El ii: 13 IJJ if[ ** it ~ *1 MADE IN JAPAN
11 Engine model
12 Engine displacement
FR 13 Transaxle model
14 Axle model

3D HI B : 3door hatchback _2
5D HI B : 5door hatchback

2-spot welds 3-spot welds M. I. G plug weld

For
.
3 panels plug weld method ) P: F
M I G seam weld/
weld

• GTJrr=- ( • A ===-=
---
.'S ~
~
.L.LLL

-43- -2-
 _ REPLACEMENT OPERATIONS
~~~~~~~~_GENERALJNFORM~ION~~~~~~~~_
Rear Side Member Extension Sedan
Identification Number

Vehicle identification number Vehicle identification plate Service Joint

Emission control information label

SGI908
-------
/
/\ \ --- -
/

VEHICLE IDENTIFICATION NUMBER ARRANGEMENT

c-
For Europe
• JN1 B A A N15 U 0 xxxxxx.
~ ~>~
'------- /~ ,,\ I

T T ---c::
0: Stopgap
serial number
(no meaning)
Destination
U: Europe
Model
A: 2-wheel drive
Engine type
A: GA 14DE engine
111
C: GA 16DE engine
E: SR20DE engine
F: CD20 engine
Body type
B: 4-door Sedan
F: 5-door Hatchback
E: 3-door Hatchback
Manufacturer
J N 1: Nissan, Passenger vehicle 114

2-spot welds 3-spot welds M. I. G plug weld M. I. G seam weld/

For 3 panels plug weld method ) Point weld

d r;==
GTJ
( dA~ dB~
~

-44-
-1-
___________ REPLACEMENT OPERATIONS _

Rear Side Member Extension 3-door hatch back

5-door hatch back

Service Joint
(This figure show left side member extension)

LH : Left side
RH : Right side

----
_ 4 (LH)
_ 6 (RH)

11 1 (LH) FR
FR 11 2 (RH)
~
~
/
111 (LH)

2-spot welds 3-spot welds M. I. G seam weld/

M. I. G plug weld( For 3 panels plug weld method ) Point weld

·r ·===-= A • B:::::C=

-45-