CONTENTS

G EN ERAL I N FORMATION Identification Number BODY COM PON ENT PARTS Underbody Component Parts Body Component Parts CO R ROSlO N PR OTECTI 0 N Description Anti - Corrosive Wax Undercoating Stone Guard Coat BODY CONSTRUCTION Body Construction .~ BODY ALIG N M ENT Body Center Marks Panel Parts Matching Marks Description Engine Compartment Underbody Passenger Compartment (Sedan -5-door Hatchback) Rear Body (Sedan) Passenger Compartment (3-door Hatchback) Rear Body (3-door Hatchback-5-door Hatchback) HANDLING PRECAUTIONS FOR PLASTICS Handling Precautions for Plastics Location of Plastic Parts PR ECAUTIONS
>

1 2 3 3 4 7 7 8 9 10 11 11 13 13 14 15 16 17 19 21 22 24 25 25 26 28 28 32 32 33 34 35 36 37 38 39 40 41 42 43 44 45

Precautions For Handling High Strength Steel (HSS) REPLACEM ENT OPERATIONS Description Radiator Core Support (Partial Replacement) Hoodledge (Partial Replacement) Front Side Member (Partial Replacement) Front Pillar ..~ Center Pillar (Sedan -5-door Hatchback) Outer Sill (Sedan -5-door Hatchback) Outer Sill (3-door Hatchback) Rear Fender (Sedan) Rear Fender (5-door Hatchback) Rear Fender (3-door Hatchback) Rear Floor Rear Rear Side Member Extension (Sedan) Rear Side Member Extension (3-door and 5-door Hatchback)

~~~~~~~~_GENERALJNFORM~ION~~~~~~~~_
Identification Number
Vehicle identification number Vehicle identification plate

Emission

control information

label

SGI908

VEHICLE
For Europe
JN1

IDENTIFICATION
B

NUMBER
N15 U

ARRANGEMENT
0

T
Model A: 2-wheel Engine type A: GA 14DE engine 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 drive

0: Stopgap

---c::

xxxxxx.
serial number (no meaning)

Destination U: Europe

J N 1: Nissan, Passenger vehicle

-1-

________

GENERAL INFORMATION Identification Number (Cont' d)

Except for Europe

IN 1 . B CAN 15

T --c::: T
0: Stopgap
drive Australia

XXXXXX

serial number

(no meaning)

Destination A: Australia and New Zealand Z: Except for Europe, Australia,

and New Zealand

Model A: 2-wheel Engine type B: GA 15DE engine C: GA 16DE engine E: SR20DE engine-For Body type B: 4-door Sedan F: 5-door Hatchback Manufacturer IN 1: Nissan, Passenger vehicle

and New Zealand only

VEHICLE IDENTIFICATION
Europe NISSAN MOTOR CO., LTD. JAPAN

PLATE
Expect Europe NISSAN MOTOR CO., LTD. APAN 1 Type approval number 2 Vehicle identification number(Chassis number) 3 Gross vehicle weight 4 Gross combination weight Gross vehicle weight + Gross trailing capacity (Weight) 5 Gross axle weight(Front) 6 Gross axle weight(Rear) 7 Type approval number 8 Body color code 9 Trim color code 10 Model Specification No. 11 Engine model 12 Engine displacement 13 Transaxle model 14 Axle model

I
o

~
~ ~

I
&
kgO kg kg

~ tt

~~~sg~ ~~~~~o
; ; ~)~ /

~(:l &
~

CNHOA"SIS

&
o
cc

1-

2TYPE TTP COlOR. TRIM FARBE. POlST

& & ~

o ~0:ggtg~ ~~~RNICION ~ &. ~~~~~~~ &

~~~~~'. AE~~

A1 L11
PLANT PlANTA

&
El ii: 13 IJJ
if[

&

** it ~ *1

MADE IN JAPAN

-2-

Underbody Component Parts

J: ..J

~
J:

:i
..J

et:

:c

>Q)

:i
..J

en +-' c: cc en co a. ._ 0 co c: en Q) 0) c: 0 +-' Q) '00 co c: +-' a. '00 x c:

0 0)(3
Q)

E Q)

a: . -~
Q) +-'

:i ~

+-' +-'

c:
Q)

+-'

Q)

c:

J: ..J

E
Q)

E Cl)
u ~
+-' Q)

c:
Q)

c:

u ~
"t-

'00 c: +-' ~ c: co 0 0
+-'

(3

c: ~ J: Q) Q) +-' Q) ~ Q) x ~ .0 cC Q) U ~ ~ ~ Q) ~ E ~ Q) ~ Q) Q) Q) Q) Q) Q) .0 .0 .0 .0 E .0 .0 .0 en
"tJo,;.

c:

~ Q)

Q)

'00

c: '0)

~ 0 ~ Q5 m E Q) "t.0 c: +-' ~ l0Q) +-' Q) Q) co co O 0 +-' co "'0 "'0 "'0 "'0 co ~ Q) m 0 0 "'0 "'0 ~ 0 Q) 0 '00 '00 '00 '00 Q) '00 ~ 0) en .0 i:i= m '00 u i:i= '00 'E u en Cl) +-' ~ +-' +-' +-' +-' (0 "'0 loo- ~ ~ ~ ~ ~ +-' Q) c: c: c: c: co c: "'0 .0 c: c: co co co co co c: c: co 0 0 0 ~ co Q) Q) ~ c: ~ 0 ~ Q) Q) Q) Q) ~ ~ 0 ~ ~ 0 u.. :t: CC CC u.. u.. u.. u.. cc CC CC CC "t- ..= l- N ,...... CO m q- LO co ,...... CO 0') 0 CV) N CV) q- LO CO
Q) Q) Q) Q) Q) Q) Q)

E E E E en E E E 0 ~ E E E E u E E E m ~ m
Q) Q) Q) Q)

CV)

a:

~ u E .0 ~ :i, c: Q) 0 ~
Q)

..J

:i (5 ~ ~ ~u co c:
+-'

+-' Q)

.0 Q) 0).0 ',p
:J

c: ~ '0) U ~ co ~ .:t: c: c:
+-'
Cl)

'+-

E Q) u ~
"t-

c: '0)
0 co
+-'

~ ~

co
Q) +-'

..c: u c:

.0

c:

E '00 m en
0
Cl)

+-' Q)

N N N N N N

CV)

CV)

CV)

CV)

CV)

CV)

CV)

CV)

CV)

co -:- .0 J: 0)

\e
co "'0
Q) +-' Q)

"\\

..J

t:: 0 a. a. :J en u

co .0
+-'

co

~ +-' Q) u ~ co u ~ co :i 0 .0 ~ a: E 0..0 ~ 0) Q)
c:
:J
Q)

',p

c:

:i
..J

~
J:

co

en '+= '+=
co

Q)

"'0 co ~ '00 ~:J (3 ~ ~ E 0 0 ~ ',p

Q) Q)

',p
:J

c: c:
0

a:
or-

+-'

N
+-'

+-'
Cl)

cc cc cc

Q)

co

Q)

~ co ~

co
..c:

:J

Q)

x a. w c.n

E ~ ~ co
Q)

:c :a
E E
Q)
Cl) Cl)

>- >Q)
Cl) Cl)

~ Q) u E ~ Q)
c: u
Q)

+-' Q)

..0

N CV) q0 q- q- q- q- q- q-

co J LO

c:
Q) Q)

E
U

"t-

co

Q)

~ ~

co
Q)

'0) ::::J

c: c: c
0 ',p

~
~

0)

"t-

~ ~ E
Q) Q)

.0 .0

"'0

+-' Q) Q) m Q) Q) a. "'0 "'0 "'0 :J '00 '00 '00 '00 ~ Q) a.+-, +-' +-' +-' +-'
Cl) Cl)

'0) E E 0 E E ~ Q) Q) '00 Q) Q) c: >- E E Cl) E E co

c: .0 .0

c:

ui c
0

c:

c:
0 ~

ui c:
0

'f
0
Q.

u.. u.. CO
,...... CO

0 ~

E
:J

C C 0 'u.. LJ-

u..

C 0 ~

'f
0
Q. tJ) tJ)

0')

N N N N

Q)
CD ...,
tJ)

"C CD

...,

ui J: c: "C c m 'f ca
0 0 CJ CD CD 0
Q.

cs.

en
;.
Q)
tJ)

CD ...,
tJ)

CD

';;

:>

tJ)

CD

CD 0 0 ..., ~ ~ '+:i '+:i .J::. ..., c: c

e
m

';;

:>

e
m

:c
Q)

>-

J:

..J

CD "C

c:
tJ)

C)

';; 6
tJ)

! ...,
.J::.
C)

~ ~ :.c ..., ..., CD CD ..., CD ..., ...,

tJ) tJ)

';; 6

CD "C

t:: t:: 0 t:: 0 0 a. a. a. a. a. :J :J t:: a. 0 :J Q) Q) a. ~ ~ a. Q) ~ 0 0

m m co
Cl) Cl) Cl)

~
J:

a:
:c
E
1'1'\

>Q) 0)

.g
Q)

Q)

:J

Cl)

Q)

~ ~ ~

CJ

CJ

~ ~

u
"~

CJ

+-'

.5 .5 .5

0I
~

:.c co
CC

0 +-' co

:.c ~ ~ co
~ ~
~
Q)

0 co

+-'

:.c :.c ~ 5> co co u "'0

...J

0 co

=0
+-'

+-'

0 co

+-'
Cl)

co

>-

Q)
Cl)

"'0 "'0 0 0

0 0

~~..c:

Q)

"'0

U5
N

a. a. ::::>

Q)

.Q

Q)..c:"t-

"'0 0 0 J:

~gs
co,......

=0 CD CD o a. ~
00

CV)

q- LO

-3-

________

BODY COMPONENT Body Component

PARTS Parts

_
Sedan 5-door Hatchback

'"C

o o

iD

~
c
"0 [IJ

co
(]J

.......
[J

:I: ID

"en

~~f~
"0
(]J

co

""

~
c
"0

en
co

:I: 0
LO

[IJ .......

en

(]J

c
"0

co

en

(]J

-4-

~~~~~~~_BODYCOMPONENTPAR~~~~~~~~_
Sedan

Body Component Parts

5-door Hatchback

I I ..J ..J

~
I ..J t
0
:::J

~
I

:i
..J

.....,
(])

~
cc:
'+Cl)

o.:i 0. "

(]) Co)

er: a; - E
c
I
(])
Cl)

er: er:
(])
Cl)

0 .c '+(]) 0 (]) Co) ~Co) ~.c Ci5 ....., c (]) .c 0 $ 0 co "m .c "'C 0 0 0 0 0 -c co co S "- ....., -c -c -c -c -c -c 0.- (]) 0. "- S """'+- '+- '+- '+- '+- '+- ....., ""0 c Co) co co 0 0 0 0 0 0 co co "- ~ 0 0 (]) ~ (]) ""(]) (]) co 0 0 0 0 0 '+"'C """"- ....., ""0. "0.. "0.. "- "- ....., ""Q) (]) CV) q- LO """"(]) (]) ....., c ....., co co (]) co N c 0 :::J 0 co C C "'C (]) (]) (]) :::J ci ci ci (]) ci ""cc: c US cc: cc: E 0 u. 0 z z z cc: Z u.

s s s

s s

Cl)

"-

"-

C :::J >- co 0. .c .c a; a; E ":::J

:c
Cl) Cl)

:-::

Cl)

to I'"

ex)

en

N CV) q- LO to I'" ex) en 0 N N N N N N N N N N CV)

I ..J

:i
..J

.....,
(]) (]) Co)

~
I ..J

c I
..J

E
"-

I ..J

~
I

.....,

~Co)
Q)
"'C

(])

er: -C
(])
Cl) Cl)

:i

~
I

~
(]) Co)

er: >:c
E
(])
Cl) Cl)

:i
..J

~
"-

'+-

0 ""-

>- "~ (])

er:
'+-

er:
"(]) (])

-C

co "-

E
"-

~
C "'+"(])

"co co "co """-C 0

(])

'+-

"-

er:

"0.. "0..
(]) .....,

~
(]) .....,

co
"-

er:
"-

"-

"-

I ..J

co .....,

"0.. 0
0
"'C

"-

"co "'+-

0 0
"(])

"0.. .....,
C
(]) Co)

C
(]) Co)

C
(]) Co)

co ~
"0.. Q) .....,
(]) Co)

:i

"(])

"(])

"(])

"'C

c c
(])

'+"'C

.....,

0 0

....., ....., c c c
0
"-

'+-

"0..
"U.

u. u.
N CV)

"-

...J

"00 Q)
C C

0 "'C 0 "00
"(]) c .....,

c c
C
"~

er:
"00
:::J
s... (])

~- "co
-C
Cl) Cl)

E
(])

"'+-

.....,

":::J

"(])

(])

(])

"U.

0
ex)

q- LO to I'"

.E: ::::> ...J en 0 ~

0. 0. 0

"co ....., "(]) ....., '+....., 0 c

0 0

0 0 cc: u. N CV) q- LO

:::J

"-

-5-

Body Component Parts

3-door Hatchback

--:-~ _ I

CD $ co .::: C,) ..c CD co $ ..c 0 .0. .0 ;g $ ..0 a; '+- '+O c 0 C C co 0 0 co CD co 0 0 co CD CD "'C '+~ CD 0 0 CD -0 CD CD "'C 0.00 '+- '+C "i= +-' +-' ~C,) co CD CD co N C c Q; co +-' CD +-' Q5 co co +-' 0 0 c CD ::J c 0 ::J CD CD CD ::J co CD C C u. 0 0:: 0:: 0:: u. 0) CC 0:: 0 Z u.

lo-

~ ~ ~ I :r: cC cC
+-'

:i~

:r: :r: -:r: :i:i ~ ~ :i~ ~ ~ ~ c2S ~ ~ ~ :r: :r: ~ :r:o:r: :r: :r: cC cC :r: 0:: ~ 0:: cC -cC --c2S CD
0 0 0

--

en

::J

en
::J

CD

CD

..c ..c
Q5 Q5

>-

0 ..0

=
lolo-

l0-

lo-

Q5 >- c c :0 0 I :0 co 0.. E 00 cC c E CD CD CD 0 en +-' en 0 en >< CD en co CD .::: co "'C C +-' +-' CD CD C O "'C "'C en
0

lo-

l0lo-

lo-

lo-

l0-

l0-

lo-

lo-

lo-

lo-

lo-

lo-

lo-

lo-

lo-

lo-

lo-

I.-

lo-

lo-

c.o

I"'- 00

(j)

0
N N

N N

CV)

LO N

c.o
N

I"'N

00 N

(j)

:r: cC--:-:r: .co ~

I.-

~o
o l::J

c2S

'+-

0 0 lo-

t:

en

"'C
lo-

CD en en .00 .00 co
l0-

:r: ..0 .co E '+cC CD 0

lo-

~o

0 ..0
'+lo-

$ $ $ $
0 ..0 0 0 lo-

.c
'+-

0 ..0
'+lo-

0
l0-

0 0

'+-

0 0 lo-

0
lo-

'+-

+-'
lo-

~ @-~~~":::.~
o
,-

\
~
~.~.~..
~: \~~

CD +-' ::J

CD +-' ::J (j)

0 0
00

0:: u. Z Z Z
0 N
CV)

C 0

CV)

LO

co

cc
LO

CD

.~

~-<0h ~

-6-

Description
To provide improved corrosion prevention, the following measures. anti-corrosive measures have been implemented in

our production plants. When repairing or replacing body panels, it is necessary to use these same anti-corrosive

ANTI-CORROSIVE PRECOATED STEEL (DURASTEEL)

To improve repairability and corrosion resistance, a

Zn-Ni alloy

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

Durasteel is classified as either one-side precoated steel or two-side precoated tance. precoated steel. The two side resissteel provides excellent corrosion

Outside

Two-side precoated Nissan Genuine Service Parts are fabricated from durasteel sheets. Therefore, it is recommended that GENUINE NISSAN PARTS 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 Caution: Confine paint removal in the welding operation to the absolute minimum.
Cationic electrodeposition primer

and a cationic electrodeposition

primer, which provide an excellent anti-

corrosion effect, are employed on all body components.

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

-7-

________

CORROSION PROTECTION Anti-corrosive Wax

To improve corrosion resistance, anti-corrosive wax is applied inside the body sill and inside other closed sections. Accordingly, when replacing these parts, be sure to apply anti-corrosive wax to the appropriate areas of the new parts. Select an excellent anti-corrosive wax which will penetrate after application and has a long shelf life.

Hatchback

Indicates anti-corrosive wax coated portions.

Section A-A:

Section 8-8:

Section C-C:

Section 0-0: SEDAN For Australia model

Section E-E: Hatchback For Australia model

-8-

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

~I!!!!!!!!iiii!!!!!i!II

Indicates undercoated portions

-9-

________

CORROSION

PROTECTION

Stone Guard Coat

To prevent damage caused by stones, the lower outer body panels (fender, door, etc.) have an additional layer 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

Section A-A

--r':":'

Section B-B

Section C-C

-10-

------------

BODY CONSTRUCTION
Body Consb"uction.

Sedan

3-d oar Hatchback

5-door Hatchback

-11-

----------Section A-A:

BODY CONSTRUCTION
Body Construction

Section 8-8:

Section C-C:

Section D-D:

Section E-E:

Section F-F:

Section G-G:

Section H-H:

Section I-I:

Section J-J:

Section K-K:

Section L-L:

Section M-M:

. Section N-N:

Section 0-0:

Section P-P:

\
Section 0-0: Section R-R:

-12-

_________

BODY ALIGNMENT Body Center Marks

A mark has been placed on each part of the body to indicate the vehicle center. When repairing parts damaged by an accident which might affect the vehicle frame (members, pillars, etc.) more accurate, effective repair will be possible by using these marks together with body alignment data.

Portion G Portion C Portion B Portion A Portion D-Sedan Portion E -Sedan

Porton H Portion F 3-Door Hatchback and 5-Door Hatchback

Unit: mm

Portion A
Hole(4 dial

Portion 8

Portion C

Upper radiator core support

Cowl top

Front roof

Portion D

Portion E

Portion F

Slot(7X 11)

/~/
Rear roof Rear waist panel slot Second cross member

Portion G
3-door and 5-door Hatchback

Portion H
3-door and 5-door Hatchback

Lozenge
mark

Rear roof

Rear panel

-13-

BODY ALIGNMENT Panel Parts Matching Marks

A mark has been placed on each part of the body to indicate the panel parts matching positions. When repairing parts damaged by an accident which might affect the vehicle frame (members, pillars, etc.) more accurate, effective repair will be possible by using these marks together wi~h body alignment data.

ViewE

3-Door Hatchback and 5-Door Hatchback

Type W: Type V:

@-----

Et

~----- ~

View A

ViewS

ViewC

View D-1
Sedan and 5-door Hatchback

View D-2
3-door Hatchback

ViewE
3-door Hatchback and 5-door Hatchback

/w-..IE
+-W

'r

II
-14-

(-

__________

BODY ALIGNMENT
Description

All dimensions indicated in figures are actual ones. When using a tracking gauge, adjust both pointers to equal length. Then check the pointers and gauge itself to make sure there is no free play. When a measuring tape is used, check to be sure there is no elongation, twisting or bending. Measurements should be taken at the center of the mounting holes. An asterisk (*) following the value at the measuring point indicates that the measuring point on the other side is symmetrically the same value. The coordinates of the measurement points are the distances measured from the standard line of "X", "V" and "Z".

"Z": Imaginary base line [200 mm below datum line ("OZ" at design plan)]

y (_)

(0)

Front axle center

SBF8?4GB

Engine Compartment
____ MEASURMENT _

SBT08?

-15-

__________

BODY ALIGNMENT
Engine Compartment

__

MEASURMENT

POINTS __

Unit: mm

SBT088

Front side

Radiator core support lower

SBT090

(b) 11

dia.
SBT094

Radiator core support upper center

SBT091

-16-

__________

BODY ALIGNMENT Underbody

____

MEASURMENT
(ij
Q)

_
er:

iJ
en
en
It)

E E

-------o
It)

N CD

It)

CD

CD IIIlI:t'

C!. N ~ en

co

CD
It) It)

CD
It)

235 ~200
N .. CD 00 N ~

C!.

ee @@

.. ~
It)

CD

127

@>@)

129

@8

.. CD

.. 0
~

en~ 0)

CD
.,

@@
@)@)

.. o
..

o
I'

0)

It) It)

225

SBT096

-17-

BODY ALIGNMENT Underbody

__

MEASURMENT

POINTS __
Rear

(f

Front coordinates:

Rear coordinates:

@,@
X : 250 V : -632 Z : 224.8

@,@
X : 393.5 V : 1,460 Z : 126.9

@
X : 475 V : 3,082 Z : 336.8

@,@
X : 492 V : -450 Z : 355

(8), @
X : 572 V : 1,940 Z : 200

@
X : -542 V : 3,082 Z : 336.8

@,@
X : 406 V : 64 Z : 172

CD, CD
X : 600 V : 2,035 Z : 235.2

@,@
X : 352.7 V : 69 Z : 240

Q)
X : 150 V : 2,442.9 Z : 241

@, @
X : 432 V : 338 Z : 128

@
X : 300 V : 2,480 Z : 381.8

(f),

CD

@
X : -300 V : 2,480 Z: 405.8

X : 395 V : 515 Z : 129.2

LH side

@
RH side

@, @)

Q
Bottom view of vehicle

X : 393 Y : 2,560 Z : 365

@
X : 470 Y : 2,911 Z : 339.6

,1
Unit: mm

@
X : -539 Y : 2,911 Z : 339.6

Front and rear strut tower centers I

Coordinates:

~t-~
Front Rear

@,0
X : 522.2 V : 18.1 Z : 571.7

@,

076 dia.
dia.

@, @ 62

@,@
X : 465

V : 2,456.4
Z : 522 Front
SBT097

-18-

__________

BODY ALIGNMENT Passenger Compartment

_
Sedan 5-door Hatchback

...

._ MEASURMENT

_
1228 1374 @-@ 1366 (8)-{6) 1159 1387 CD--cD Q)-{J) 1367 1156 @--@ (b)--{[) 1385 1370 ~-4iV 1364 @~ 1364 @~ C'e)--@ 1598 @--@ 989* @-{E) 918* 1156* @~ @--{[) 917* @~@ 975* @~(b) 757* 1004* @~ 723* @--@
Point @-@ Dimension

CB-<f)

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

Unit: mm

@ : Cowl top hole center (5 dia.)

CB> : Front roof flange end at center Positioning mark

~~

~ } Outer front pillar joggle

@@ : Dash upper flange

end corner

CBCD: } ~@:

Outer front pillar indention

(f3),Cfi),Q),CD,@,@,CD,CD,~,@

: hole

Outer center pillar indention

CDCD :

Outer center pillar standard center

-19-

_________

BODY ALIGNMENT Passenger Compartment

_
Sedan 5-door Hatchback

____

MEASURMENT

_
Unit: mm

~@

: Rear fender standard hole center (7dia)

@ : 2nd crossmember (8 dia.)

standard

hole mark hole

center at center positioning installing ~ hole cen@([): Rear floor harness installing center (8 dia.)

(Q)@ : Rear fender indention (B@ : Door switch ter (20 dia.)

(D<

(7diajj \\1
~

~~

~~ '---O"~Wiaol

~;.
~

. C')\U--Z

k@(fdiaol",

-20-

__________

BODY ALIGNMENT Rear Body

_
Sedan
Point Dimension @~(E) 189* @~CD 1213* @~(8) 608* (E)~@ 1110*

____

MEASUREMENT

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

Unit: mm

@@ : Rear fender joggle

(Q : Roof flonge positioning mark mark at center positioning

(6)@ : Rear fender joggle

\~
CE)@ : Rear fender joggle (8(f)<G)@ : Rear fender corner joggle

CD :

Rear panel trunk lid lock installing hole flange end at center positioning mark

Q):

Rear

suspension

installing

hole

center (9 dia.)

-21-

_________

BODY ALIGNMENT
Passenger Compartment

_
3-door Hatchback

____

MEASUREMENT

-'

Point Dimension

@~
Cf)~
C8},{5)

Q)~
Q)~

(8)~ @~@ @--{f) @~(8) @~Q)

(b)~C8) (b)~

1228 1374 1094 1388 1558 871 989* 918* 1193* 1043* 1017* 655*

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

Unit: mm
~@: (B@: }

@ : Cowl top hole center (5 dia.)

(6) : Front roof flange end at center Positioning mark

Outer front pillar joggle

@@ : Dash upper flange end corner

(BeD: ~@ : }

0 uter f ront pi"11" " ar In d entlon

q:])@ : Rear fender joggle

CDCD :

Rear fender indention installing hole center (7 dia.) of nut

Q)(D : Door switch

-22-

_________

BODY ALIGNMENT
Passenger Compartment
Unit: mm

_
3-door Hatchback

@ : 2nd crossmember

standard

hole mark

~:

Rear

suspension

installing

hole

center at center positioning (a dia.)

center (9 dia.)

CDCD : =:::e~I~~rd~:~)nessinstalling hole

~cp(8 dia.)

"\

\ \

}J\ (/
,\'I~I

~
~

,~

~Yb::~\\ c?
/~FRONT

~~--:q~
- \\\y~
~~~~

-23-

__________

BODY ALIGNMENT Rear Body

_
3-door Hatchback 5-door Hatchback

MEASUREMENT

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

Unit: mm
Rear fender corner joggle @ : Rear door panel lock reinforcement hole center at back center

@ : Rear roof flange positioning mark

end at center joggle

(Q@:

(6)@ : Rear fender extension

~@

: Rear suspention center (9 dia.)

installing

hole

-24-

______

HANDLING PRECAUTIONS FOR PLASTICS Handling Precautions For Plastics

Heat resisting Abbreviation Material name temperature

Resistance to gasoline solvents

and

Other cautions

QC rF)
PE Polyethylene 80 (176)

Gasoline and most solvents are harmless. Gasoline and most solvents are harmless. Gasoline and most solvents

Flammable

PET

Polyethylene terephthalate

180 (356)

PVC

Polyvinyl

chloride

80 (176)

are harmless quickly).

if applied for a

Poison gas is emitted when burned.

very short time (wide up

pp

Polypropylene Acrylonitrile styrene resin ethylene butadiene

90 (194)

Same as above. Also avoid battery Avoid gasoline acid.

Flammable

ABS

80 (176)

and solvents.

AES

Acrylonitrile styrene Polymethyl

80 (176)

Avoid

gasoline

and solvents.

PMMA

methacrylate

85 (185)

Avoid

gasoline

and solvents.

PUR

Polyurethane Acrylonitrile acrylic

90 (194)

Gasoline and most solvents are harmless. Avoid gasoline and solvents.

Avoid

battery

acid.

AAS

ru bber styrene Styre ne-a c rylo n itri Ie Polyphenylene oxide

85 (185)

AS PPO

85 (185) 110 (230)

Avoid Avoid

gasoline

and solvents.

gasoline .and solvents.

POM PC PA

Polyacetal Polycarbonate Polyamide (Nylon)

120 (248) 120 (248) 140 (284)

Gasoline and solvents are harmless. Avoid gasoline and solvents.

Avoid

battery

acid.

Gasoline and most solvents are harmless. Gasoline and most solvents are harmless. Gasoline and most solvents are harmless. Gasoline and most solvents are harmless. Avoid Avoid gasoline gasoline and solvents. and solvents.

Avoid

immersing

in water.

FRP

Fiber reinforced

plastics

170 (338)

Avoid

battery

acid.

PPC

Polypropylene

composite

115 (239)

Flammable

PBT

Polybutylene

terephthalate

140 (284)

TPR TPE

Thermoplastic Thermoplastic Thermoplastic polyurethane

rubber elastomer

80 (176) 80 (176)

TPUR

80 (176)

Avoid

gasoline

and solvents.

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-

HANDLING PRECAUTIONS FOR PLASTICS Location Of Plastic Parts

Side turn signal lamp lens Lens: AS ) ( Housing: ASS Door mirror Housing: AAS) ( Garnish: ASS

Head lamp Lens: Glass) ( Housing: pp

Wind-shield molding Upper: PVC ( Side:Stainless+PVC

Radiator grille (ABS) Front bumper

(PP)

fascia

Front

air spoiler
(PP)

Door out-side molding (Stainless+PVC)

Fog lamp finisher (PM MA)

Fog lamp Lens: Glass) ( Housing: PP

Front turn signal Lens: PMMA) ( Housing: PP

lamp

Wheel cover Full cover: PP+PA6 ) ( Half cover: PA66+PPO Center cap: PA6

Rear spoiler(PPO) -for Sedan High mounted stop lamp (In Rear SpoilerType) (Lens: PMMA ) -for Sedan Housing: ASS (Fixed Trunk Lid Tipe) Lens: PC ) -for Sedan ( Housing: PP

Rear Windowmolding (PVC) -for Sedan

Door outside handle Handle: POM ) ( Escutcheon: POM

Side guard

molding

(PVC)

Trunk

lid finisher(pp) -for Sedan

License lamp Lens: PC ) ( Housing: PP

Rear bumper
(PP)

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

-26-

______

HANDLING PRECAUTIONS FOR PLASTICS Location Of Plastic Parts

Roof spoilar(FRP) Side wind molding(PVC)

Side wind molding(PVC)

High mounted stop lamp Lens: PMMA ) ( Housing: ABS

Back door finisher(ABS)

3-door Hatchback

5-door Hatchback

Center pillar lower garnish(PP) Front pillar garnish(PPC) Center pillar upper garnish(PPC)

Cluster lid A(PPC)

Instrument Rear pillar garnish(PPC)

panel(PPC)

Cluster lid C(PPC)

Glove box(PPC)

Console box(PPC)

~----_/
Kicking plate(PP)

-27-

__________

PRECAUTIONS Precautions For Handling High Strength Steel

High strength steel has been used for body panels in order to reduce vehicle weight. Accordingly, precautions in repairing automotive bodies made of high strength steel are described below:

HIGH STRENGTH STEEL (HSS) USED IN NISSAN VEHICLES

Tensile strength Nissan designation Major applicable parts Side member 373N/mm2 (38 kg/mm2, 54 klb/sq in) Hoodledge NP130 Pillar Hood .Trunk 785-981 (80-100 114-142 N/mm2 kg/mm2 klb/sq in) NP150 lid outer

Bumper reinforcement Door guard beam

In Nissan vehicles, HSS plates of 373 N/mm2 (38kg/mm2,

54 klb/sq in) (NP130) are most commonly 114 to 142 klb/sq

utilized, and those with a tensile strength of 785 to 981 N/mm2 (80 to 100 kg/mm2, in) (NP150) are used only on parts requiring much more strength.

-28-

__________

PRECAUTIONS
Precautions For Handling High Stregth Steel

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 550C (1, 022F) Heating temperature should be verified with a thermometer. (A crayon-type and other thermometer are available.)

When straightening body panels, use caution in pulling any HSS panel. Because it is very strong, this may cause deformation in adjacent portions of the body. In this case, increase the number of measuring points, and carefully pull the HSS panel.

Traction direction: ...

In cutting

HSS panel, avoid gas cutting

if

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 minimum must be given. is inevitable, a allowance of 50 mm (1.97 in)

In welding

HSS panel, use spot welding

GOOD

-================

N.G.
Never use acetylene .gas welding.

whenever possible in order to minimize any 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.

-29-

PRECAUTIONS
Precautions For Handling High Strength Steel
The spot ungget on HSS panel is harder than that of an ordinary steel panel. Therefore, for spot cutting HSS panel, a high torque drill of a low speed (1,000 to 1,200 rpm) may be used to maintain its durability and facilitate the operation.

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 as folloows: The electrode tip diameter must be reformed properly according to the panels thickness.

D=2T+3 D=2T+O.12 D==Tip+diameter

T

(mm) (in)

,::=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

-30-

__________

PRECAUTIONS Precautions For Handling High Strength Steel

Follow

established

specifications

for

the

Pressure

Welding
current

appropriate pressure level, current level and weld time.

Follow

the

specifications

for

the

proper

welding pitch.
Unit: mrr Thickness (t) Minimum
I

(C

pitch ( Q

0.6 (0.024) 0.8 (0.031) 1.0 (0.039) 1.2 (0.047) 1.6 (0.063)

10 (0.39) or over 12 (0.47) or over 18 (0.71) or over 20 (0.79) or over 27 (1.06) or over

~71)

31

11.221 or over

After tested.

welding,

welding

strength

must

be

-31-

________

REPLACEMENT OPERATIONS Description

SYMBOLS FOR CUITING AND WELDING/BRAZING OPERATIONS

this guide is given in the

The indentification of the cutting and the welding/brazing following pages

symbols used throughout

Saw cut or air chisel cut

..J
2-spot welds Spot weld

2-SDOt welds (2-panel overlapping portions)

0000
3-spot welds

3-spot welds (3-panel overlapping portions)

M.LG. plug weld

(ItIlI)
M.LG. seam weld/ Point weld

Brazing

Soldering Sealing

-32-

-----------Radiator
Service Joint

REPLACEMENT OPERATIONS

Core Support (Partial * indicates

Replacement)

that there is an equivalent wel~ing. portion with the same dimensions on the opposite Side.

_1
o

*e
FR

3 or 11 2

e4

orll3 FR

2-spot

welds

3-spot

welds

M.1. G plug weld Point For 3 panels plug weld m. ethod

M.I. G seam weld/ weld

r =='*=
(

B ===:=

.an

-33-

-----------(Work after radiator core support

REPLACEMENT OPERATIONS

Hoodledge (Partial
has been removed.)

Replacement)

Service Joint
(This figure show right side hoodledge)

Before installing hoodledge reinforcement. 117

114A

Unit:mm
2-spot welds 3-spot welds

M.1. G plug weld

) 3 panels plug weld method.

For (

M.I. G seam weld/ Point weld

.A~

.B~

.an.F

-34-

REPLACEMENT OPERATIONS

Front Side Member (Partial Replacement)

(Work after radiator core support has been removed.)

Service Joint
(This figure show right front
-\

side member)

114

111

8
"" " "
Patch (Thickness: 1mm)

115

117

111

118

hoodledge panel

114
Unit:mm
2-spot welds 3-spot welds M.1. G plug weld For M I G seam weld/ weld P1ID.~irit

Patch

G1J rr=

.A=-= .B~
--~
-35-

3 panels plug weld method

REPLACEMENT OPERATIONS

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

Service Joint

<:=i

FR

1lIl.. ( Dri p channel)

an

(Outer)

112

1lIl..
( Inner)

112
~

113

:::::-----

116

112 112
Unit:mm
2-spot welds 3-spot welds M. I. G plug wel(d

c;;;;?
FR
) .. ~:

116

rr= A ==-=.
GTJ ---

For 3 panels plug weld method

G(F:~dm weld/

B~ ~

.LLLL

-36-

REPLACEMENT OPERATIONS

Center Pillar
Service Joint

Sedan 5-door hatch back

111 117 112 117 FR

FR

.cm.
( Overl ap cutt ing) Seat belt ancher reinforcement

111A
Upper center pillar hinge brace

111A

113

114

113 112
114 116
Lower center pillar hinge brace

FR

Unit:mm
2-spot welds 3-spot welds M. I. G plug weld For M I G seam weld/ weld P:
..LLLL

G1J rr=

A ---

==-=

3 panels plug weld method

B~ ~

-37-

REPLACEMENT OPERATIONS

Outer Sill
Service Joint

Sedan 5-door hatchback

_4A

FR

119

_4
112A
113

117 11 12

.cm
(OIerlap cutting)

112A 114

111A 111
114

_4
111
2-spot welds 3-spot welds M. I. G plug weld

Unit:mm
M I G seam weld/

r . A
For (

3 panels plug weld method

P.an.0int

=6=___

.8=:=

;=::

-38-

REPLACEMENT OPERATIONS

Outer Sill
Service Joint

3-door hatch back

112

r/
11 11 111

112A
114

111
Unit:mm
2-spot welds 3-spot welds

(CNerlap cutting)

.an.

Mol. G plug weld

For 3 panels plug weld method ).

G@ r;=::::.

p:;m
M I G
.u.u.

Id/ we

:=::A:=:

8~

-39-

REPLACEMENT OPERATIONS

Rear Fender
Service Joint
Unit:mm Cut off
@

Sedan

..an

(length

: 10mm)

1 orll 1

113A

o~
( \

FR

e3
@

orll2

13 orll10

116

..an

e4

orll3 orll 2

e3
@

1 orll 1

12 orll 9

e 20
~

orll15
114
@

116
2-spot welds 3-spot welds M. I. G plug weld For

1 orll 1

M I G seam weld/

G@ rr=

.A=-= .B~
--~
-40-

3 panels plug weld method

P..an.~i~t (Fweld

___________

REPLACEMENT OPERATIONS

Rear Fender
Service Joint

5-door hatch back

113 111 _ 7 orll5

@ 1 or 111 1 or 11 1 112 111

@

112

1IIl.

@90r1l7 _50r1l4 _ 5 orll4 _ 4 orll3 _ 3 orll2 @ 1 or 111 _ 12 orll 9 @ 5 orll 4

1IIl. (length: 10mm)
@ 4

111

or 11 3

Rear pillar inner reinforcement

_ 200r 11 15
Unit:mm
2-spot welds

116
3-spot welds M.1. G plug wel(d

@ 1 or 111
M.I. G seam weld/ Point weld

For 3 panels plug weld method

.A===-= .B~

-41-

REPLACEMENT'

OPERATIONS

Rear Fender
Service Joint
-\

3-door hatchback

@
@

1 or 11 1 1 or 11 1

112 111 112

,~-

-- - - -""

e8
116
@3

or

or

112

e5
114

or

114
Unit:mm
2-spot welds

114
3-spot welds M, I. G plug weld For

113
M I G 3 panels plug weld method ) P:
..u..u.

F:~~m

Id/

we

G@ rr=

.A~

B~

-42-

REPLACEM ENT OPERATIONS

Rear Floor Rear

(Work after rear panel have been removed.)

Service Joint

111

FR

3D 5D

HI HI

B : 3door hatchback B : 5door hatchback

3-spot welds

_2
M. I. G plug weld For . 3 panels plug weld method ) M I G seam weld/ weld P:
.L.LLL

2-spot welds

GTJ rr=-

A ===-= ---

.'S ~
~

-43-

REPLACEMENT

OPERATIONS Sedan

Rear Side Member Extension

Service Joint

/\ \ /
'------/~

~ ~>~

--,,\ I

-------

c-

111

114

2-spot welds

3-spot

welds

M. I. G plug weld For d 3 panels plug weld method dB~ )

M. I. G seam weld/ Point weld

GTJ

r;==

dA~

-44-

___________

REPLACEMENT OPERATIONS

_ 3-door hatch back 5-door hatch back

Rear Side Member Extension

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 plug weld(

r ===-=
A

For 3 panels plug weld method

M. I. G seam weld/ Point weld

B:::::C=

-45-