NISSAN BODY REPAIR MANUAL This Body Repair Manual on the following pages is prepared to provide service personnel with the general knowledge necessary to perform body repairs on NISSAN vehicles. This will allow us to maintain the original quality built into all NISSAN vehicles and to provide our customers with lasting satisfaction. This manual contains information on auto body construction, sheet metal work, welding, plastic repair, safety & health, etc. It is useful for training not only body repair technicians but also anyone who wants to learn body repair technique. INDIVIDUAL SERVICE MANUALS The applicable model Service Manual and this Body Repair Manual should be used together when performing body repair work. Individual Service Manuals for respective models are available at nissan-techinfo.com to provide the detailed repair procedures for specific NISSAN vehicle models. Repair information and procedures specific to the vehicle model and year should be referenced for each and every repair. Individual Service Repair Manuals are available here: LEARN MORE Learn to navigate the service manuals here: LEARN MORE Nissan Collision Repair Position Statements are available here: LEARN MORE BODY EXTERIOR, DOORS, ROOF & VEHICLE SECURITY A B SECTION BRM BODY REPAIR C D CONTENTS E FUNDAMENTALS Kingpin Angle ..........................................................41 Toe ..........................................................................41 F SERVICE INFORMATION ............................ 5 Non-standard Conditions Caused by Improper Wheel Alignment .....................................................42 FOREWORD ........................................................ 5 Foreword ...................................................................5 BODY MATERIALS ..........................................43 G AUTO BODY CONSTRUCTION ......................... 6 SHEET STEEL ...........................................................43 Properties of Sheet Steel .........................................43 H BODY TYPES AND STRUCTURE ..............................6 Thermal Effects on Steel .........................................45 Body Types and Structure .........................................6 Types of Sheet Steel ...............................................46 Frame Body ...............................................................6 Uni-body ....................................................................6 ALUMINUM ................................................................48 I Requirements for Passenger Car Body ..................17 Aluminum .................................................................48 To Increase Vehicle Rigidity and Strength ..............18 Lightweight ..............................................................48 To Reduce Noise and Vibration ..............................20 Corrosion Resistance ..............................................48 J Excellent Heat Conductor ........................................48 COLLISION DYNAMICS ...........................................20 Excellent Electrical Conductor .................................48 Collision Dynamics ..................................................20 Anti-magnetic ...........................................................48 Five Elements of Force ...........................................20 Recyclable ...............................................................48 BRM Direction of Impact Force ........................................21 Structure of Aluminum Alloy (Used for Vehicle Impact Force and Collision Area .............................22 Body Parts) ..............................................................48 Concentration of Stress ...........................................22 L Propagation of Impact Force ...................................23 TYPES OF PLASTIC .................................................49 Direct Damage and Indirect Damage ......................23 Classification of Plastic ............................................49 Features of Impact Applied to Each Portion of Characteristics .........................................................50 M Body ........................................................................23 Location of Plastic Parts (Example) .........................51 Handling Precautions for Plastics (Example) ..........52 BODY ALIGNMENT ..................................................25 Body Alignment .......................................................25 RUST PREVENTION .................................................53 N Engine Compartment ..............................................25 Rust Prevention .......................................................53 Underbody ...............................................................27 Anti-corrosive Wax ..................................................53 Passenger Compartment and Rear Body ...............31 Sealing .....................................................................54 O Body Center Marks (Example) ................................35 Spot Sealer, Weld Through Primer and Adhesive Measurement Mark Types ......................................36 Sealer ......................................................................57 Undercoating and Stone Guard Coat ......................57 SUSPENSION TYPES ...............................................37 P Suspension Types ...................................................37 SHEET METAL WORK .....................................59 Front Suspension ....................................................37 Rear Suspension .....................................................39 SHEET METAL WORK TOOLS ................................59 Sheet Metal Work Tools ..........................................59 WHEEL ALIGNMENT ................................................41 Hammers .................................................................59 Wheel Alignment .....................................................41 Dollies ......................................................................62 Camber Angle .........................................................41 How to Use Hammer and Dolly ...............................65 Caster Angle ...........................................................41 Spoons ....................................................................68 BRM-1 Scribing Chisels ...................................................... 70 Cutting Torch ........................................................ 115 Types and Uses of Tinman's Shears ...................... 72 Flame Types ......................................................... 116 Tools for Pulling ...................................................... 73 BRAZING ................................................................. 117 SHRINKING THE SHEET METAL ............................ 78 Principle ................................................................ 117 Shrinking The Sheet Metal ..................................... 78 Features of Brazing ............................................... 117 Shrinking Methods .................................................. 78 Types of Brazing Filler .......................................... 117 How to Heat Sheet Metal ........................................ 80 COMPARISON BETWEEN WELDING METHODS CORRECTING A DEFORMED PANEL .................... 82 FOR REPLACED PANEL ....................................... 118 Determining Panel Damage ................................... 82 Comparison between Welding Methods for Re- Basic Types of Damage ......................................... 83 placed Panel ......................................................... 118 Examination of Panel Damage ............................... 83 Elastic VS. Plastic Deformation .............................. 85 SAFETY AND HEALTH ....................................119 Basic Repair Procedure .......................................... 86 PRECAUTIONS FOR OPERATION ........................ 119 COLORED SHEET METAL WORK .......................... 90 Precautions for Operation ..................................... 119 Colored Sheet Metal Work ..................................... 90 Protectors .............................................................. 119 Confirmation of The Panel ...................................... 90 Safety Stand ......................................................... 119 Selection of Repair Tools ....................................... 91 Inflammables ......................................................... 119 Panel Repair Methods ............................................ 92 Working Environment ............................................ 119 Polishing of Panel Surface and Anti-corrosive Handling of Welding Equipment ............................ 120 Treatment ............................................................... 94 WORKING WITH BODY STRAIGHTENING Examination of Panel .............................................. 94 EQUIPMENT ............................................................ 122 BODY WELDING AND PRECAUTIONS ........... 95 Use of Protectors .................................................. 122 Precautions while Working .................................... 122 OUTLINE OF WELDING ........................................... 95 Protection of Vehicle ............................................. 122 Outline of Welding .................................................. 95 Types of Welding .................................................... 95 WORKING WITH GRINDING THE BODY FILLER Features of Welding ..............................................