BRM Body Repair Manual

BODY EXTERIOR, DOORS, ROOF & VEHICLE SECURITY
SECTION BRM BODY REPAIR

B
E
CONTENTS
VEHICLE INFORMATION ............................. 2 Radiator Core Support .............................................27 F
Hoodledge ...............................................................27
BODY EXTERIOR PAINT COLOR ..................... 2 Front Side Member (2WD) ......................................30
Body Exterior Paint Color ....................................... 2 Front Side Member (AWD) ......................................33 G
Front Side Member (Partial Replacement) ...........35
PRECAUTION ............................................... 3 Front Pillar ..............................................................36
Outer Sill .................................................................39
REPAIRING HIGH STRENGTH STEEL .............. 3 H
Rear Fender ............................................................42
High Strength Steel (HSS) ...................................... 3
Lock Pillar Reinforcement ........................................44
PREPARATION ............................................ 6 Lock Pillar Reinforcement (Partial Replacement) ....45
Outer Wheelhouse ...................................................46 I
REPAIRING MATERIAL ..................................... 6 Rear Panel ..............................................................48
Foam Repair ............................................................. 6 Rear Floor Rear .....................................................48
Rear Side Member Extension (2WD) ......................49 J
BODY COMPONENT PARTS ............................. 8 Rear Side Member Extension (AWD) ......................50
Underbody Component Parts .................................. 8
Body Component Parts ........................................... 10 SERVICE DATA AND SPECIFICATIONS
BRM
(SDS) ............................................................ 52
REMOVAL AND INSTALLATION ............... 12
BODY ALIGNMENT .......................................... 52
CORROSION PROTECTION .............................12 Body Center Marks ................................................52 L
Description .............................................................. 12 Description ...............................................................53
Anti-corrosive Wax .................................................. 12 Engine Compartment (2WD) ...................................53
Undercoating (2WD) ............................................... 13 Engine Compartment (AWD) ...................................55
Undercoating (AWD) ............................................... 14 M
Underbody (2WD) ....................................................57
Body Sealing (2WD) ................................................ 15 Underbody (AWD) ...................................................60
Body Sealing (AWD) ............................................... 18 Passenger Compartment ........................................63
Rear Body ...............................................................64 N
BODY CONSTRUCTION ....................................22
Body Construction ................................................... 22 LOCATION OF PLASTIC PARTS .................... 67
Rear Fender Hemming Process .............................. 23 Precautions for Plastics ...........................................67 O
REPLACEMENT OPERATIONS ........................25 Location of Plastic Parts ..........................................68
Description .............................................................. 25
P
Revision: 2009 October BRM-1 2009 G37 Coupe

BODY EXTERIOR PAINT COLOR
< VEHICLE INFORMATION >
VEHICLE INFORMATION
BODY EXTERIOR PAINT COLOR
Body Exterior Paint Color INFOID:0000000004249889
JSKIA0361GB
Color code BA54 BB21 BKH3 BK23 BK51 BK52 BK57 BQAA
Dark
Description Red Blue Black Silver Gray Gray White
Gray
Component Paint type Note CS PM 2S M M PM TPM 3P
Anti scratch
advanced × × × × × × × ×
paint
1 Bumper fascia Body color BA54 BB21 BKH3 BK23 BK51 BK52 BK57 BQAA
Chromium
2 Front grille Cr Cr Cr Cr Cr Cr Cr Cr
plate
3 Front pillar finisher Body color BA54 BB21 BKH3 BK23 BK51 BK52 BK57 BQAA
Door out-
4 Cover Body color BA54 BB21 BKH3 BK23 BK51 BK52 BK57 BQAA
side mirror
5 Trunk lid finisher Body color BA54 BB21 BKH3 BK23 BK51 BK52 BK57 BQAA
Satellite radio an-
6 Body color BA54 BB21 BKH3 BK23 BK51 BK52 BK57 BQAA
tenna
7 Fuel filler lid Body color BA54 BB21 BKH3 BK23 BK51 BK52 BK57 BQAA
8 Door outside handle Body color BA54 BB21 BKH3 BK23 BK51 BK52 BK57 BQAA
9 Center mudguard Body color BA54 BB21 BKH3 BK23 BK51 BK52 BK57 BQAA
NOTE:
• 2S: Solid + Clear
• CS: Color clear solid
• M: Metallic
• P: 2-Coat pearl
• 3P: 3-Coat pearl
• FPM: Iron oxide pearl
• RPM: Multi flex color
• TPM: Titanium pearl metallic
• TM: Micro titanium metallic
• PM: Pearl metallic

REPAIRING HIGH STRENGTH STEEL
< PRECAUTION >
PRECAUTION A
High Strength Steel (HSS) INFOID:0000000004249904
B
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:
C
Tensile strength Major applicable parts
• Front strut housing
• Hoodledge reinforcement D
• Lower dash crossmember assembly
• Lower dash
• Upper front pillar reinforcement
• Trans control reinforcement E
(Center front floor component part)
• 2nd and 3rd crossmember
(Front floor component part)
F
• Inner sill
370 - 590 MPa
• Outer sill reinforcement
• Outer lock pillar reinforcement
• Upper outer rear wheelhouse extension G
• Front side member assembly
• Front side member closing plate assembly
• Front side member outrigger assembly
• Rear side member assembly H
• Outer door panel
• Trunk lid
• Other reinforcements
I
• Front side member stiffener
(Front floor component part)
• Upper inner lock pillar reinforcement
780 - 1350 MPa (Outer lock pillar reinforcement component part) J
• Outer rear sill reinforcement
(Lower outer rear wheelhouse extension component
part)
BRM
Read the following precautions when repairing HSS:
1. Additional points to consider
• The repair of reinforcements (such as side members) by heat- L
ing is not recommended, because it may weaken the compo-
nent. When heating is unavoidable, never heat HSS parts
above 550°C (1,022°F). M
Verify heating temperature with a thermometer.
(Crayon-type and other similar type thermometer are appropri-
ate.)
N
PIIA0115E
O

< PRECAUTION >
• When straightening body panels, use caution in pulling any
HSS panel. Because HSS is very strong, pulling may cause
deformation in adjacent sections of the body. In this case,
increase the number of measuring points, and carefully pull
the HSS panel.
PIIA0116E
• 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 (1.97in).
PIIA0117E
• 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 MIG. welding. Do not use
gas (torch) for welding because it is inferior in welding
strength.
JSKIA0082GB
• Spot welding 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.
PIIA0145E

< PRECAUTION >
2. Precautions in spot welding HSS
This work should be performed under standard working condi- A
tions. Always note the following when spot welding HSS:
• The electrode tip diameter must be sized properly according to
the metal thickness.
B
PIIA0146E
D
• The panel surfaces must fit flush to each other, leaving no
gaps.
E
G
PIIA0147E
• Follow the specifications for the proper welding pitch. H

Unit: mm (in)
Thickness (T) Minimum pitch (L)
I
0.6 (0.024) 10 (0.39) or over
0.8 (0.031) 12 (0.47) or over
1.0 (0.039) 18 (0.71) or over
J
1.2 (0.047) 20 (0.79) or over
1.6 (0.063) 27 (1.06) or over
1.8 (0.071) 31 (1.22) or over
BRM
JSKIA0781ZZ

REPAIRING MATERIAL
< PREPARATION >
PREPARATION
REPAIRING MATERIAL
Foam Repair INFOID:0000000004684823
During factory body assembly, foam insulators are installed in certain body panels and locations around the
vehicle. Use the following procedure(s) to replace any factory-installed foam insulators.
URETHANE FOAM APPLICATIONS
Use commercially available Urethane foam for sealant (foam material) repair of material used on vehicle.
<Urethane foam for foaming agent> 3M™ Automix™ Flexible Foam 08463 or equiva-
lent
Read instructions on product for fill procedures.
Example of foaming agent filling operation procedure
1. Fill procedures after installation of service part.
a. Eliminate foam material remaining on vehicle side.
b. Clean area after eliminating form insulator and foam material.
c. Install service part.
d. Insert nozzle into hole near fill area and fill foam material or fill enough to close gap with the service part.
JSKIA0129GB
1. Urethane foam
A. Nozzle insert hole
: Vehicle front
2. Fill procedures before installation of service part.

a. Eliminate foam material remaining on vehicle side.
b. Clean area after eliminating foam insulator and foam material.
c. Fill foam material on wheelhouse outer side.

REPAIRING MATERIAL
< PREPARATION >
A
1. Urethane foam
A. Fill while avoiding flange area
: Vehicle front B
NOTE:
Fill enough to close gap with service part while avoiding flange
area. C
d. Install service part.
NOTE: JSKIA0130GB
Refer to label for information on working times. D
BRM

BODY COMPONENT PARTS
< PREPARATION >
Underbody Component Parts INFOID:0000000004249891
JSKIA0878ZZ
1. Radiator core support assembly (RH 2. Front strut housing (RH & LH) 3. Lower rear hoodledge (RH & LH)
& LH)
4. Upper front hoodledge (RH & LH) 5. Upper rear hoodledge (RH & LH) 6. Hoodledge reinforcement (RH & LH)

< PREPARATION >
7. Upper side cowl top (RH & LH) 8. Upper front cowl top assembly 9. Cowl top bracket
10. Upper dash 11. Lower dash crossmember assembly 12. Lower outer battery support bracket A
13. Lower battery support bracket 14. Lower dash 15. Center front floor
16. Front floor (RH & LH) 17. Inner sill (RH & LH) 18. Rear seat crossmember reinforce-
ment assembly B
19. Rear floor front 20. Rear floor seat belt anchor reinforce- 21. Rear floor rear
ment
22. Spare tire clamp bracket 23. Rear floor side (RH & LH) 24. Front side member assembly (RH & C
LH)
25. Front side member front extension 26. Front side member connector as- 27. Front side member closing plate as-
(RH & LH) sembly (RH & LH) sembly (RH & LH)
D
28. Front side member front closing 29. Front side member center closing 30. Front side member rear extension
plate (RH & LH) plate (RH & LH) (RH & LH)
31. Front side member outrigger assem- 32. Rear seat crossmember 33. 2nd rear crossmember
bly (RH & LH) E
34. Rear crossmember center assembly 35. Rear side member assembly (RH & 36. Rear side member extension (RH &
LH) LH)
37. Front side rear closing reinforcement F
(RH & LH)
: Both sided anti-corrosive precoated steel sections
: High strength steel (HSS) sections G
: Both sided anti-corrosive steel and HSS sections
NOTE:
For the parts without a number described in the figure, it is supplied only with the assembly part that the part is included with. H
BRM

< PREPARATION >
Body Component Parts INFOID:0000000004249892
JSKIA0365GB
1. Hood 2. Front fender (RH & LH) 3. Upper front pillar reinforcement (RH
& LH)
4. Front pillar brace (RH & LH) 5. Outer lock pillar reinforcement (RH & 6. Outer side roof rail reinforcement
LH) (RH & LH)

< PREPARATION >
7. Outer step sill (RH & LH) 8. Outer sill reinforcement (RH & LH) 9. Upper inner front pillar assembly (RH
& LH) A
10. Front roof rail brace (RH & LH) 11. Inner side roof rail (RH & LH) 12. Rear roof rail brace (RH & LH)
13. Inner center pillar (RH & LH) 14. Inner rear pillar (RH & LH) 15. Rear pillar reinforcement (RH & LH)
16. Outer rear wheelhouse (RH & LH) 17. Upper outer rear wheelhouse exten- 18. Lower outer rear wheelhouse exten- B
sion (RH & LH) sion (RH & LH)
19. Inner rear wheelhouse (RH & LH) 20. Side parcel shelf (RH & LH) 21. Seat back support (RH & LH)
22. Parcel shelf with rear waist 23. Roof 24. Front roof rail C
25. Roof bow No.1 26. Roof bow No.2 27. Rear roof rail
28. Roof assembly 29. Rear fender assembly (RH & LH) 30. Tail pillar assembly (RH & LH)
31. Rear bumper center bracket (RH & 32. Rear fender extension (RH & LH) 33. Rear panel assembly D
LH)
34. Rear bumper fascia center bracket 35. Rear bumper fascia bracket 36. Door assembly (RH & LH)
37. Outer door panel (RH & LH) 38. Trunk lid 39. Inner center front bumper reinforce- E
ment
40. Rear bumper stay (RH & LH) 41. Inner center rear bumper reinforce- 42. Center rear bumper reinforcement
ment assembly
43. Rear bumper overrider assembly
F
: Both sided anti-corrosive precoated steel sections

: High strength steel (HSS) sections
G
: Both sided anti-corrosive steel and HSS sections
* : Aluminum portion
NOTE: H
For the parts without a number described in the figure, it is supplied only with the assembly part that the part is included with.
BRM

CORROSION PROTECTION
< REMOVAL AND INSTALLATION >
REMOVAL AND INSTALLATION
Description INFOID:0000000004684876
To provide improved corrosion prevention, the following anti-corrosive measures have been implemented in
NISSAN production plants. When repairing or replacing body panels, it is necessary to use the same anti-cor-
rosive measures.
Anti-Corrosive Precoated Steel (Galvannealed Steel)
To improve repairability and corrosion resistance, a new type of anti-
corrosive precoated steel sheet is adopted replacing conventional
zinc-coated steel sheet.
Galvannealed steel is electroplated and heated to form Zinc-iron
alloy, which provides excellent and long term corrosion resistance
with cationic electrodeposition primer.
SIIA2294E
NISSAN genuine parts are fabricated from galvannealed steel. Therefore, it is recommended that NISSAN
genuine parts or an equivalent be used for panel replacement to maintain the anti-corrosive performance 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 protection, are applied to
all body components.
CAUTION:
Confine paint removal during welding operation to an absolute
minimum.
PIIA0095E
NISSAN genuine parts are also treated in the same manner. Therefore, it is recommended that NISSAN gen-
uine parts or an equivalent be used for panel replacement to maintain anti-corrosive performance built into the
vehicle at the factory.
Anti-corrosive Wax INFOID:0000000004249894
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 of
the new parts. Select an excellent anti-corrosive wax which will penetrate after application and has a long shelf
life.
DOOR

H
JSKIA0366GB
A. Nozzle insert hole

: Anti-corrosive wax coated portions
I
Undercoating (2WD) INFOID:0000000004249895
J
The underside of the floor and wheelhouse are undercoated to prevent rust, vibration, noise and stone chip-
ping. Therefore, when such a panel is replaced or repaired, apply undercoating to that part. Use an undercoat-
ing which is rust resistant, soundproof, vibration-proof, shock-resistant, adhesive, and durable.
BRM
Precautions in Undercoating
1. Never apply undercoating to any place unless specified (such as the areas above the muffler and three-
way catalyst that are subjected to heat). L
2. Never undercoat the exhaust pipe or other parts that become hot.
3. Never undercoat rotating parts.
4. Apply bitumen wax after applying undercoating. M
5. After putting seal on the vehicle, put undercoating on it.

JSKIA1697ZZ
: Undercoated areas
: Sealed portions
Undercoating (AWD) INFOID:0000000004553935
The underside of the floor and wheelhouse are undercoated to prevent rust, vibration, noise and stone chip-
ping. Therefore, when such a panel is replaced or repaired, apply undercoating to that part. Use an undercoat-
ing which is rust resistant, soundproof, vibration-proof, shock-resistant, adhesive, and durable.
Precautions in Undercoating
1. Never apply undercoating to any place unless specified (such as the areas above the muffler and three-
way catalyst that are subjected to heat).
2. Never undercoat the exhaust pipe or other parts that become hot.
3. Never undercoat rotating parts.
4. Apply bitumen wax after applying undercoating.
5. After putting seal on the vehicle, put undercoating on it.

H
JSKIA1698ZZ
: Undercoated areas
: Sealed portions
I
Body Sealing (2WD) INFOID:0000000004249896
J
DESCRIPTION
The following figure shows the areas that are sealed at the factory. Sealant that is 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 BRM
and not to allow other unaffected parts to come into contact with the sealant.

JSKIA1699ZZ
: Vehicle front
: Sealed portions

BRM
JSKIA0369GB
P
: Vehicle front
: Sealed portions

JSKIA0370GB
: Vehicle front
: Sealed portions
Body Sealing (AWD) INFOID:0000000004554898
DESCRIPTION
The following figure shows the areas that are sealed at the factory. Sealant that is 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.

BRM
N
JSKIA1700ZZ
: Vehicle front O
: Sealed portions

JSKIA0872ZZ
: Vehicle front
: Sealed portions

BRM
L
JSKIA0370GB
: Vehicle front M
: Sealed portions

BODY CONSTRUCTION
BODY CONSTRUCTION
Body Construction INFOID:0000000004249897
JSKIA0371GB
1. Upper outer front pillar 2. Outer front pillar reinforcement 3. Upper inner front pillar
4. Inner front pillar reinforcement 5. Lower outer front pillar 6. Front pillar hinge brace
7. Upper hinge plate 8. Weld nut 9. Upper rear hoodledge

BODY CONSTRUCTION
10. Hoodledge reinforcement 11. Upper dash 12. Lower hinge plate
13. Lower dash crossmember 14. Lower front pillar gusset 15. Front fender bracket A
16. Outer sill reinforcement 17. Lower front pillar reinforcement 18. Inner sill
19. Lower dash 20. Front side member outrigger 21. Outer step sill
22. Outer sill brace 23. Inner sill reinforcement 24. Front floor B
25. 2nd crossmember 26. Rear fender 27. Lock pillar reinforcement
28. Center sill reinforcement 29. 3rd crossmember 30. Upper inner lock pillar reinforcement
31. Inner lock pillar 32. Lock pillar seat belt anchor 33. Rear pillar reinforcement C
34. Inner side roof rail 35. Inner rear pillar 36. Outer rear sill reinforcement
37. Outer rear wheelhouse extension 38. Outer rear wheelhouse 39. Rear side member front
40. Rear tie down hook bracket 41. Rear side member front reinforce- 42. Rear floor front
D
ment
43. Outer rear wheelhouse brace 44. Inner rear wheelhouse
E
Rear Fender Hemming Process INFOID:0000000004684833
1. A wheel arch is to be installed and hemmed over the left and right outer wheel houses.
F
2. In order to hem the wheel arch, it is necessary to repair any damaged or defaced parts around outer
wheel house.
CAUTION:
Ensure that the area that is to be glued around the outer wheelhouse is undamaged or defaced. G
PROCEDURE OF THE HEMMING PROCESS
• Peel off old bonding material on the surface of the outer wheel-
house and clean thoroughly. H
• Peel off a primer coat in the specified area where new adhesive is
to be applied on rear fender (the replacing part).
• Apply new adhesive to both specified areas of the outer wheel- I
house and rear fender.
<Adhesive> 3M™ Automix™ Panel Bonding Adhe-

J
sive 08115 or equivalent
• Attach rear fender to the body of the car, and weld the required
part except the hemming part. JSKIA0136GB
BRM
• Bend the welded part starting from the center of the wheel arch
gradually with a hammer and a dolly. (Also hem the end of the L
flange.)
• Hemming with a hammer is conducted to an approximate angle of
80 degrees.
M
SIIA2245E

BODY CONSTRUCTION
• Starting from the center, hem the wheel arch gradually, using slight
back and forth motion with a hemming tool.
SIIA2246E
• Seal up the area around the hemmed end of the flange.
JSKIA0137GB

REPLACEMENT OPERATIONS
A
• This section is prepared for technicians who have attained a high level of skill and experience in repairing B
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 section.
• Technicians are also encouraged to read the Body Repair Manual (Fundamentals) in order to ensure that the
original functions and quality of the vehicle are maintained. The Body Repair Manual (Fundamentals) con- C
tains additional information, including cautions and warnings, that are not including in this manual. Techni-
cians should refer to both manuals to ensure proper repair.
• Please note that this information is prepared for worldwide usage, and as such, certain procedures might not D
apply in some regions or countries.
The symbols used in this section for welding operations are shown below.
Symbol marks Description
E
F
2-spot welds
G
JSKIA0049ZZ
H
JSKIA0053ZZ
3-spot welds
I
JSKIA0050ZZ
BRM
JSKIA0054ZZ L
MIG plug weld
For 3 panels plug weld method
M
JSKIA0051ZZ
N
JSKIA0055ZZ
MIG seam weld / Point weld

P
JSKIA0052ZZ JSKIA0056ZZ

• 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.
PIIA0150E
• Determine cutting position and record distance from the locating

indent. Use this distance when cutting the service part. Cut outer
front pillar over 60 mm (2.36 in) above the inner front pillar cut
position.
JSKIA0104GB
• Prepare a cutting jig to make outer pillar easier to cut. Also, this will
permit the service part to be accurately cut at the joint position.
JSKIA0105GB
• An example of cutting operation using a cutting jig is as per the fol-

lowing.
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.
PIIA0153E

Radiator Core Support INFOID:0000000004249906
BRM
JSKIA0373GB O
: Vehicle front
Replacement parts P
z Radiator core support assembly (LH) z Front side member connector as-
sembly (LH)
Hoodledge INFOID:0000000004249907
Work after radiator core support is removed.

Remove the front side member center closing plate (reusable).

JSKIA0374GB
1. Front side member center closing

plate
: Vehicle front
Replacement parts
z Upper front hoodledge (LH) z Hoodledge reinforcement (LH) z Front strut housing (LH)

BRM
N
JSKIA0375GB
: Vehicle front O
View C and F: Before installing hoodledge reinforcement

JSKIA0376GB
1. Front side member center closing

plate
: Vehicle front
Front Side Member (2WD) INFOID:0000000004249908
Work after radiator core support and hoodledge are removed.

Assemble the hoodledge and check the fitting according to Body Alignment before replacing the front side
member center closing plate.

BRM
N
JSKIA0377GB
: Vehicle front O
Replacement parts
z Front side member assembly (LH) z Front side member closing plate as- z Front side member outrigger assem-
sembly (LH) bly (LH) P

JSKIA0378GB
: Vehicle front
View G: Before installing front side member outrigger assembly

BRM
N
JSKIA0379GB
: Vehicle front O
Front Side Member (AWD) INFOID:0000000004553900
P
Work after radiator core support and hoodledge are removed.
Assemble the hoodledge and check the fitting according to Body Alignment before replacing the front side
member center closing plate.

JSKIA0866GB
Unit: mm (in)
: Vehicle front
Replacement parts
z Front side member assembly (LH) z Front side member closing plate as- z Front side member outrigger assem-
sembly (LH) bly (LH)

BRM
N
JSKIA0867GB
Unit: mm (in) O
: Vehicle front
View F and H: Before installing front side member outrigger assembly

P
Front Side Member (Partial Replacement) INFOID:0000000004249909
Work after radiator core support is removed.

JSKIA0873GB
Unit: mm (in)
: Vehicle front
Replacement parts
z Front side member front extension z Front side member front closing
(RH) plate (RH)
Front Pillar INFOID:0000000004249910
Work after hoodledge reinforcement and outer step sill are removed.

BRM
N
JSKIA0381GB
1. Urethane foam O
: Vehicle front
Replacement parts
z Upper front pillar reinforcement (LH) z Upper rear hoodledge (LH) z Upper inner front pillar assembly P
(LH)

JSKIA0382GB
: Vehicle front
View D: Before installing upper front pillar reinforcement

BRM
N
JSKIA0383GB
1. Urethane foam 2. Inner front pillar reinforcement O

: Vehicle front
Outer Sill INFOID:0000000004249911

P
Work after hoodledge reinforcement, outer lock pillar reinforcement and rear fender are removed.
Remove the welding point (A) for easier replacement.

JSKIA0384GB
1. Urethane foam (Cover the hole with urethane foam completely.)

: Vehicle front
Replacement parts
z Outer step sill (LH) z Outer sill reinforcement (LH) z Upper outer rear wheelhouse exten-
sion (LH)
z Lower outer rear wheelhouse exten-
sion (LH)
Remove the welding point (A) for easier replacement.

BRM
N
JSKIA0385GB
: Vehicle front O
: Drill φ8 mm (0.31 in) hole for the plug welding hole (ultra high strength steel plate).
View D: Before installing outer sill reinforcement P

View E: Before installing outer sill reinforcement and upper outer rear wheelhouse extension
View F: Before installing outer sill reinforcement, upper outer rear wheelhouse extension and lower outer rear
wheelhouse extension
View G: Before installing outer step sill

Rear Fender INFOID:0000000004249912
JSKIA0386GB
A. Hemming portion
: Vehicle front
: Drill φ10 mm (0.39 in) hole for the plug welding hole (ultra high strength plate).
Replacement parts
z Rear fender assembly (LH)

BRM
N
JSKIA0387GB
: Vehicle front O
: Drill φ8 mm (0.31 in) hole for the plug welding hole (ultra high strength plate).
INSTALLATION NOTES P

• Apply the adhesive to the flange of wheel arch and hem it.
• Seal up the area around the hemmed end of the flange.
• Refer to BRM-23, "Rear Fender Hemming Process".
1. Outer rear wheelhouse 2. Rear fender

3. Adhesive 4. Sealant
JSKIA0204GB
Lock Pillar Reinforcement INFOID:0000000004249913
Work after roof and rear fender are removed.

Never cut and joint the shaded area (see Figure) of lock pillar reinforcement, because it is made of ultra high
strength steel plate.

BRM
N
JSKIA0388GB
: Vehicle front O
: Drill φ10 mm (0.39 in) hole for the plug welding hole (ultra high strength steel plate).
Replacement parts
z Outer lock pillar reinforcement (LH)
P
Lock Pillar Reinforcement (Partial Replacement) INFOID:0000000004249914
Work after rear fender are removed.

Never cut and joint the shaded area (see Figure) of lock pillar reinforcement and the upper inner lock pillar
reinforcement, because they are made of ultra high strength steel plate.

JSKIA0389GB
1. Upper inner lock pillar reinforcement

: Vehicle front
Replacement parts
z Outer lock pillar reinforcement (LH)
Outer Wheelhouse INFOID:0000000004249915
Work after rear fender is removed.

Cut the upper outer rear wheelhouse extension and the rear pillar reinforcement as shown in the figure for
repairing the hidden welding point.
Reuse the upper outer rear wheelhouse extension and the rear pillar reinforcement (cut parts).

BRM
N
JSKIA0390GB
: vehicle front O
Replacement parts
z Outer rear wheelhouse (LH)
P
View B: Before installing upper outer rear wheelhouse extension
View C: Before installing rear pillar reinforcement

Rear Panel INFOID:0000000004249916
JSKIA0391GB
: An equivalent welding portion with the same dimensions is on the opposite side.
Replacement parts
z Rear panel assembly
Rear Floor Rear INFOID:0000000004249917
Work after rear panel is removed.

BRM
N
JSKIA0392GB
: Vehicle front O
: An equivalent welding portion with the same dimensions is on the opposite side.
Replacement parts
z Rear floor rear z Spare tire clamp bracket
P
Rear Side Member Extension (2WD) INFOID:0000000004249918

JSKIA0393GB
: Vehicle front
Replacement parts
z Rear side member extension (LH)
Rear Side Member Extension (AWD) INFOID:0000000004553901

BRM
N
JSKIA0869ZZ
: Vehicle front O
Replacement parts
z Rear side member extension (LH)
P

BODY ALIGNMENT
< SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
BODY ALIGNMENT
Body Center Marks INFOID:0000000004674753
A mark is placed on each part of the body to indicate the vehicle center. When repairing the vehicle frame
(members, pillars, etc.) damaged by an accident which it enables more accurate and effective repair by using
these marks together with body alignment specifications.
JSKIA0372GB
: Vehicle front
Unit: mm (in)
Points Portion Marks
A, B Upper dash Embossment
C Front roof Embossment
D Rear roof Embossment

BODY ALIGNMENT
Points Portion Marks
A
E Rear waist Embossment
F Trans control reinforcement Hole 14×12 (0.55×0.47)
B
• 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 C
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.
D
• 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″. E
• ″Z″: Imaginary base line [200 mm (7.87 in) below datum line (″0Z″ at design plan)]
J
JSKIA0073GB
1. Vehicle center 2. Front axle center 3. Imaginary base line

BRM
Engine Compartment (2WD) INFOID:0000000004555403
Measurement L
Dimensions marked with ″*″ indicate symmetrically identical dimensions on both the right and left hand of the
vehicle.
M

BODY ALIGNMENT
JSKIA0352GB
«The others»
Unit: mm (in)
Point Dimension Memo Point Dimension Memo Point Dimension Memo

A-D 744 (29.29)* B-d 1489 (58.62)* D-d 1427 (56.18)
B-D 227 (8.94)* C-h 875 (34.45)* J-j 903 (35.55)
Measurement Points

BODY ALIGNMENT
BRM
L
JSKIA0353GB
: Vehicle front M
Unit: mm (in)
Point Material Point Material N

Radiator core stay installing hole center φ12
A Upper dash indent of center positioning mark F, f
(0.47)
B, b Hood hinge installing hole center φ12 (0.47) G, g Front side member hole center φ20 (0.79) O
Front strut installing hole center 16×10
C, c H, h, J, j Nut holder hole center φ16 (0.63)
(0.63×0.39)
Upper front fender bracket installing hole center Front bumper stay installing hole center φ11 P
D, d K, k, M, m
φ7 (0.28) (0.43)
E, e Hoodledge reinforcement hole center φ12 (0.47)
Engine Compartment (AWD) INFOID:0000000004555408
Measurement

BODY ALIGNMENT
vehicle.
JSKIA0874GB
Unit: mm (in)
«The others»
Unit: mm (in)
Point Dimension Memo Point Dimension Memo Point Dimension Memo

A-D 744 (29.29)* B-d 1489 (58.62)* D-d 1427 (56.18)
B-D 227 (8.94)* C-h 878 (34.57)* J-j 906 (35.67)
Measurement Points

BODY ALIGNMENT
BRM
L
JSKIA0875ZZ
: Vehicle front M
Unit: mm (in)
Point Material Point Material N

Radiator core stay installing hole center φ12
A Upper dash indent of center positioning mark F, f
(0.47)
B, b Hood hinge installing hole center φ12 (0.47) G, g Front side member hole center φ20 (0.79) O
Front strut installing hole center 16×10
C, c H, h, J, j Nut holder hole center φ16 (0.63)
(0.63×0.39)
Upper front fender bracket installing hole center Front bumper stay installing hole center φ11 P
D, d K, k, M, m
φ7 (0.28) (0.43)
E, e Hoodledge reinforcement hole center φ12 (0.47)
Underbody (2WD) INFOID:0000000004249901
Measurement

BODY ALIGNMENT
vehicle.
JSKIA0893GB
Unit: mm (in)
: Vehicle front
: Bolt head
Measurement Points

BODY ALIGNMENT
BRM
L
JSKIA0355GB
: Vehicle front M
Unit: mm (in)
Coordinates Coordinates
Points Remarks Points Remarks N
X Y Z X Y Z
±416.0 −496.0 224.5 ±451.5 3163.9 179.1
A, a Hole φ13 (0.51) J, j Bolt head
(±16.378) (−19.528) (8.839) (±17.776) (124.563) (7.051) O
±415.0 −104.0 133.5 550.0 3264.6 318.0
B, b Bolt head K Hole φ8 (0.31)
(±16.339) (−4.094) (5.256) (21.654) (128.527) (12.520)
±392.0 414.0 64.5 −500.0 3273.3 318.0 P
C, c Bolt head k Hole φ8 (0.31)
(±15.433) (16.299) (2.539) (−19.685) (128.870) (12.520)
±428.0 816.6 80.0 Hole 16×18 533.0 3475.0 317.0
D, d M Hole φ16 (0.63)
(±16.850) (32.150) (3.150) (0.63×0.71) (20.984) (136.811) (12.480)
±438.0 1100.0 78.0 −533.0 3475.0 316.4
E, e Hole φ16 (0.63) m Hole φ16 (0.63)
(±17.244) (43.307) (3.071) (−20.984) (136.811) (12.457)
±437.5 1810.0 81.2 ±423.0 38.0 674.5
F, f Hole φ16 (0.63) N, n Hole φ50.1 (1.972)
(±17.224) (71.260) (3.197) (±16.654) (1.496) (26.555)

BODY ALIGNMENT
Points Remarks Points Remarks
X Y Z X Y Z
±604.0 2390.5 128.3 ±488.4 2891.7 825.0
G, g Hole φ13 (0.51) O, o Hole φ68 (2.68)
(±23.779) (94.114) (5.051) (±19.228) (113.846) (32.480)
±472.6 2603.8 114.0
H, h Bolt head
(±18.606) (102.512) (4.488)
Underbody (AWD) INFOID:0000000004555222
Measurement
vehicle.

BODY ALIGNMENT
BRM
JSKIA0876GB
P
Unit: mm (in)
: Vehicle front
: Bolt head
Measurement Points

BODY ALIGNMENT
JSKIA0877ZZ
: Vehicle front
Unit: mm (in)
Points Remarks Points Remarks
X Y Z X Y Z
±416.0 −496.0 224.5 ±451.5 3163.9 179.1
A, a Hole φ13 (0.51) J, j Bolt head
(±16.378) (−19.528) (8.839) (±17.776) (124.563) (7.051)
±411.0 −261.0 105.5 ±550.0 3264.6 318.0
B, b Bolt head K Hole φ8 (0.31)
(±16.181) (−10.276) (4.154) (21.654) (128.527) (12.520)
±395.0 76.0 129.5 −500.0 3273.3 318.0
C, c Bolt head k Hole φ8 (0.31)
(±15.551) (2.992) (5.098) (−19.685) (128.870) (12.520)
±428.0 816.6 80.0 Hole 16×18 533.0 3475.0 317.0
D, d M Hole φ16 (0.63)
(±16.850) (32.150) (3.150) (0.63×0.71) (20.984) (136.811) (12.480)
±438.0 1100.0 78.0 −533.0 3475.0 316.4
E, e Hole φ16 (0.63) m Hole φ16 (0.63)
(±17.244) (43.307) (3.071) (−20.984) (136.811) (12.457)
±437.5 1810.0 81.2 ±423.0 38.0 674.5
F, f Hole φ16 (0.63) N, n Hole φ50.1 (1.972)
(±17.224) (71.260) (3.197) (±16.654) (1.496) (26.555)

BODY ALIGNMENT
Points Remarks Points Remarks A
X Y Z X Y Z
±604.0 2390.5 128.3 ±488.4 2891.7 825.0
G, g Hole φ13 (0.51) O, o Hole φ68 (2.68)
(±23.779) (94.114) (5.051) (±19.228) (113.846) (32.480)
B
±472.6 2603.8 114.0
H, h Bolt head
(±18.606) (102.512) (4.488)
Passenger Compartment INFOID:0000000004249902 C
Measurement
Dimensions marked with ″*″ indicate symmetrically identical dimensions on both the right and left hand of the D
vehicle.
BRM
M
JSKIA0356GB
«The others»
Unit: mm (in)
Point Dimension Memo Point Dimension Memo Point Dimension Memo Point Dimension Memo
N
E-e 1253 (49.33) F-j 1796 (70.71)* J-j 1451 (57.13) M-H 1434 (56.46)*
E-g 1607 (63.27)* G-g 1447 (56.97) K-E 987 (38.86)* M-J 1186 (46.69)*
O
E-h 1472 (57.95)* G-h 1997 (78.62)* K-F 793 (31.22)* N-H 1558 (61.34)*
E-j 1607 (63.27)* G-j 1822 (71.73)* K-G 749 (29.49)* N-J 1170 (46.06)*
F-f 1446 (56.93) H-h 1240 (48.82) K-H 1443 (56.81)* P
F-h 1861 (73.27)* H-j 1503 (59.17)* K-J 1164 (45.83)*
Measurement Points

BODY ALIGNMENT
JSKIA0357GB
: Vehicle front
Unit: mm (in)
Point Material Point Material

Upper dash positioning mark of center position-
A H, h, J, j Rear fender indent
ing mark
Trans control reinforcement hole center of center
B Roof flange end of center positioning mark K
positioning mark 14×12 (0.55×0.47)
Door hinge installing hole center
C, c, D, d Front pillar joggle M, m, N, n M, m: φ14 (0.55)
N, n: φ12 (0.47)
E, e, F, f, G, g Front pillar indent
Rear Body INFOID:0000000004249903
Measurement

BODY ALIGNMENT
vehicle. A
BRM
JSKIA0358GB
M
Measurement Points

BODY ALIGNMENT
JSKIA0359GB
: Vehicle front
Point Material Point Material

A Roof flange end of center positioning mark F, f, G, g Rear combination lamp base joggle
Upper rear panel flange end of center positioning
B, b, C, c, E, e Rear fender corner joggle H
mark
D Rear waist flange end of center positioning mark

LOCATION OF PLASTIC PARTS
A
Precautions for Plastics INFOID:0000000004684865
B
Heat resisting
Abbre- Resistance to gasoline and
Material name temperature Other cautions
viation solvents
°C (°F)
C
Gasoline and most solvents are
PE Polyethylene 60 (140) harmless if applied for a very Flammable
short time (wipe out quickly).
ABS Acrylonitrile Butadiene Styrene 80 (176) Avoid gasoline and solvents. — D
EPM/ Ethylene Propylene (Diene) co-
80 (176) harmless if applied for a very Flammable
EPDM polymer
short time (wipe out quickly). E
PS Polystyrene 80 (176) Avoid solvents. Flammable
Poisonous gas is emitted
PVC Poly Vinyl Chloride 80 (176) harmless if applied for a very F
when burned.
TPO Thermoplastic Olefine 80 (176) ↑ Flammable
AAS Acrylonitrile Acrylic Styrene 85 (185) Avoid gasoline and solvents. — G
PMMA Poly Methyl Methacrylate 85 (185) ↑ —
EVAC Ethylene Vinyl Acetate 90 (194) ↑ —
H
Flammable, avoid bat-
PP Polypropylene 90 (194) harmless if applied for a very
tery acid.
I
PUR Polyurethane 90 (194) Avoid gasoline and solvents. —
UP Unsaturated Polyester 90 (194) ↑ Flammable
ASA Acrylonitrile Styrene Acrylate 100 (212) ↑ Flammable J
PPE Poly Phenylene Ether 110 (230) ↑ —
TPU Thermoplastic Urethane 110 (230) ↑ —
PBT+ Poly Butylene Terephthalate +
BRM
120 (248) ↑ Flammable
PC Polycarbonate
PC Polycarbonate 120 (248) ↑ —
L
POM Poly Oxymethylene 120 (248) ↑ Avoid battery acid.
Avoid immersing in wa-
PA Polyamide 140 (284) ↑
ter.
M
PBT Poly Butylene Terephthalate 140 (284) ↑ —
PAR Polyarylate 180 (356) ↑ —
PET Polyethylene terephthalate 180 (356) ↑ — N
PEI Polyetherimide 200 (392) ↑ —
CAUTION:
• When repairing and painting a portion of the body adjacent to plastic parts, consider their characteristics (influence of heat O
and solvent) and remove them if necessary or take suitable measures to protect them.
• Plastic parts should be repaired and painted using methods suiting the materials, characteristics.
P

Location of Plastic Parts INFOID:0000000004249890
JSKIA0362GB
Component Material Component Material

1 Bumper fascia PP Lens PMMA
9 High mount stop lamp
2 Front grille ABS Housing ABS
Lens PC 10 Satellite radio antenna ASA + PC
3 Front combination lamp
Housing PP 11 Fuel filler lid PA + PPE
4 Windshield molding TPO 12 Door outside molding PVC + Stainless
5 Roof side molding PVC + Stainless 13 Door outside handle PC + PET
6 Front pillar finisher PC + PET Lens PMMA
14 License plate lamp
Cover ABS Housing PC
7 Door outside mirror Housing PP 15 Wheel disk cap PC + ABS
Base PA + Glass fiber 16 Center mudguard PP
8 Trunk lid finisher ABS

H
JSKIA0363GB
Component Material Component Material

I
1 Rear pillar finisher PP Core PP
2 Front pillar finisher PP 7 Instrument panel Pad PUR
Lens PC Skin TPU J
3 Map lamp
Housing PP Core ABS
Upper ABS 8 Glove box Pad PUR
4 Cluster lid A BRM
Lower PP Skin PVC
5 Cluster lid D ABS 9 Center console PP + PVC
Standard
ABS L
finisher
6 Cluster lid C
Wood fin-
PC + ABS
isher
M

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BODY EXTERIOR, DOORS, ROOF & VEHICLE SECURITY

SECTION BRM BODY REPAIR

Revision: 2009 October BRM-1 2009 G37 Coupe

Revision: 2009 October BRM-2 2009 G37 Coupe

Revision: 2009 October BRM-3 2009 G37 Coupe

• When cutting HSS panels, avoid gas (torch) cutting if possible.

• When welding HSS panels, use spot welding whenever possi-

• Spot welding on HSS panels is harder than that of an ordinary

Revision: 2009 October BRM-4 2009 G37 Coupe

• Follow the specifications for the proper welding pitch. H

Revision: 2009 October BRM-5 2009 G37 Coupe

2. Fill procedures before installation of service part.

Revision: 2009 October BRM-6 2009 G37 Coupe

Revision: 2009 October BRM-7 2009 G37 Coupe

Revision: 2009 October BRM-8 2009 G37 Coupe

Revision: 2009 October BRM-9 2009 G37 Coupe

Revision: 2009 October BRM-10 2009 G37 Coupe

: Both sided anti-corrosive precoated steel sections

Revision: 2009 October BRM-11 2009 G37 Coupe

Revision: 2009 October BRM-12 2009 G37 Coupe

A. Nozzle insert hole

Undercoating (2WD) INFOID:0000000004249895

Revision: 2009 October BRM-13 2009 G37 Coupe

Undercoating (AWD) INFOID:0000000004553935

Revision: 2009 October BRM-14 2009 G37 Coupe

Body Sealing (2WD) INFOID:0000000004249896

Revision: 2009 October BRM-15 2009 G37 Coupe

Revision: 2009 October BRM-16 2009 G37 Coupe

Revision: 2009 October BRM-17 2009 G37 Coupe

Body Sealing (AWD) INFOID:0000000004554898

Revision: 2009 October BRM-18 2009 G37 Coupe

Revision: 2009 October BRM-19 2009 G37 Coupe

Revision: 2009 October BRM-20 2009 G37 Coupe

Revision: 2009 October BRM-21 2009 G37 Coupe

Revision: 2009 October BRM-22 2009 G37 Coupe

<Adhesive> 3M™ Automix™ Panel Bonding Adhe-

Revision: 2009 October BRM-23 2009 G37 Coupe

• Seal up the area around the hemmed end of the flange.

Revision: 2009 October BRM-24 2009 G37 Coupe

MIG seam weld / Point weld

Revision: 2009 October BRM-25 2009 G37 Coupe

• Determine cutting position and record distance from the locating

• An example of cutting operation using a cutting jig is as per the fol-

Revision: 2009 October BRM-26 2009 G37 Coupe

Work after radiator core support is removed.

Revision: 2009 October BRM-27 2009 G37 Coupe

1. Front side member center closing

Revision: 2009 October BRM-28 2009 G37 Coupe

Revision: 2009 October BRM-29 2009 G37 Coupe

1. Front side member center closing

Front Side Member (2WD) INFOID:0000000004249908

Work after radiator core support and hoodledge are removed.

Revision: 2009 October BRM-30 2009 G37 Coupe

Revision: 2009 October BRM-31 2009 G37 Coupe

View G: Before installing front side member outrigger assembly

Revision: 2009 October BRM-32 2009 G37 Coupe

Front Side Member (AWD) INFOID:0000000004553900

Revision: 2009 October BRM-33 2009 G37 Coupe

Revision: 2009 October BRM-34 2009 G37 Coupe

View F and H: Before installing front side member outrigger assembly