Body Repair: Section

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

B
E
CONTENTS
VEHICLE INFORMATION ............................. 2 REPLACEMENT OPERATIONS ....................... 22 F
Description ...............................................................22
BODY EXTERIOR PAINT COLOR ..................... 2 Radiator Core Support .............................................26
Body Exterior Paint Color ....................................... 2 Hoodledge ...............................................................26 G
Front Side Member ..................................................29
PRECAUTION ............................................... 3 Front Side Member (Partial Replacement) ...........32
REPAIRING HIGH STRENGTH STEEL .............. 3 Front Pillar ..............................................................33 H
High Strength Steel (HSS) ...................................... 3 Outer Step Sill .........................................................36
Handling of Ultra High Strength Steel Plate Parts...... 5 Outer Sill .................................................................37
Rear Fender ............................................................40
Lock Pillar Reinforcement ........................................42 I
PREPARATION ............................................ 6
Rear Panel ..............................................................44
REPAIRING MATERIAL ..................................... 6 Rear Floor Rear .....................................................44
Foam Repair ............................................................. 6 Rear Side Member Extension (LH) ..........................46 J
Rear Side Member Extension (RH) .........................46
BODY COMPONENT PARTS ............................. 8
Underbody Component Parts .................................. 8 SERVICE DATA AND SPECIFICATIONS
BRM
Body Component Parts ........................................... 10 (SDS) ............................................................ 48
REMOVAL AND INSTALLATION ............... 12 BODY ALIGNMENT .......................................... 48
Body Center Marks ................................................48 L
CORROSION PROTECTION .............................12 Description ...............................................................49
Description .............................................................. 12 Engine Compartment ..............................................49
Anti-corrosive Wax .................................................. 12 Underbody ...............................................................51
Undercoating ........................................................... 14 M
Passenger Compartment .........................................54
Body Sealing ........................................................... 15 Rear Body ...............................................................56
BODY CONSTRUCTION ....................................19 LOCATION OF PLASTIC PARTS .................... 58 N
Body Construction ................................................... 19 Precautions for Plastics ...........................................58
Rear Fender Hemming Process .............................. 20 Location of Plastic Parts ..........................................58
O
Revision: 2010 March BRM-1 2009 G37 Convertible

BODY EXTERIOR PAINT COLOR
< VEHICLE INFORMATION >
VEHICLE INFORMATION
BODY EXTERIOR PAINT COLOR
Body Exterior Paint Color INFOID:0000000004373176
JSKIA1257ZZ
Color code BA54 BB21 BKH3 BK23 BK51 BQAA BRAF BNAB BKAD
Light Dark
Description Red Blue Black Silver Gray White Gray
Blue Red
Component Paint type Note CS PM 2S M M 3P M 2P M
Anti scratch
advanced × × × × × × × × ×
paint
1 Bumper fascia Body color BA54 BB21 BKH3 BK23 BK51 BQAA BRAF BNAB BKAD
Chromium
2 Front grille Cr Cr Cr Cr Cr Cr Cr Cr Cr
plate
3 Front pillar finisher Body color BA54 BB21 BKH3 BK23 BK51 BQAA BRAF BNAB BKAD
Door out-
4 Cover Body color BA54 BB21 BKH3 BK23 BK51 BQAA BRAF BNAB BKAD
side mirror
Chromium
5 Trunk lid finisher Cr Cr Cr Cr Cr Cr Cr Cr Cr
plate
Satellite radio anten-
6 Body color BA54 BB21 BKH3 BK23 BK51 BQAA BRAF BNAB BKAD
na
7 Fuel filler lid Body color BA54 BB21 BKH3 BK23 BK51 BQAA BRAF BNAB BKAD
8 Door outside handle Body color BA54 BB21 BKH3 BK23 BK51 BQAA BRAF BNAB BKAD
9 Center mudguard Body color BA54 BB21 BKH3 BK23 BK51 BQAA BRAF BNAB BKAD
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
• TM: Micro titanium metallic
• PM: Pearl metallic

REPAIRING HIGH STRENGTH STEEL
< PRECAUTION >
PRECAUTION A
High Strength Steel (HSS) INFOID:0000000004373191
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
• Upper front hoodledge D
• Hoodledge reinforcement
• Upper rear hoodledge
• Lower dash crossmember assembly
• Lower dash E
• Front roof assembly
• Upper front pillar reinforcement
• Trans control reinforcement
F
(Center front floor component part)
• 2nd and 3rd crossmember
(Front floor component part)
• Inner sill G
• Rear seat crossmember reinforcement assembly
370 - 780 MPa
• Rear floor seat belt anchor reinforcement
• Rear seat crossmember
• Outer sill reinforcement H
• Lower front pillar reinforcement assembly
• Outer lock pillar reinforcement
• Inner lock pillar
• Outer rear wheelhouse extension I
• Seat back support
• Inner rear wheelhouse reinforcement
• Front side member assembly
• Front side member closing plate assembly
J
• Front side member outrigger assembly
• Rear side member assembly
• Other reinforcements BRM
• Front side member stiffener
(Front floor component part)
980 - 1350 MPa
• Front side member rear extension
(Front floor component part) L
Read the following precautions when repairing HSS:

M
1. Additional points to consider
• The repair of reinforcements (such as side members) by heat-
ing is not recommended, because it may weaken the compo-
nent. When heating is unavoidable, never heat HSS parts N
above 550°C (1,022°F).
Verify heating temperature with a thermometer.
(Crayon-type and other similar type thermometer are appropri-
O
ate.)
P
PIIA0115E

< 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 more
0.8 (0.031) 12 (0.47) or more
1.0 (0.039) 18 (0.71) or more
J
1.2 (0.047) 20 (0.79) or more
1.6 (0.063) 27 (1.06) or more
1.8 (0.071) 31 (1.22) or more
BRM
JSKIA0781ZZ
Handling of Ultra High Strength Steel Plate Parts INFOID:0000000005157513
L
PROHIBITION OF CUT AND CONNECTION
Never cut and Joint the stiffener front side member (front floor inside frame parts) because its material is high
strength steel plate (ultra high strength steel plate). M
The front floor assembly must be replaced if this part is damaged.

REPAIRING MATERIAL
< PREPARATION >
PREPARATION
REPAIRING MATERIAL
Foam Repair INFOID:0000000005157512
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:0000000004373178
JSKIA1230ZZ
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 reinforcement assembly 21. Rear floor seat belt anchor reinforce-
ment
22. Nut plate (RH & LH) 23. Rear floor rear 24. Spare wheel clamp reinforcement C
25. Rear floor side (RH & LH) 26. Front side member assembly (RH & 27. Front side member front extension
LH) (RH & LH)
28. Front side member connector as- 29. Front side member closing plate as- 30. Front side member front closing D
sembly (RH & LH) sembly (RH & LH) plate (RH & LH)
31. Front side rear closing reinforcement 32. Front side member center closing 33. Front side member rear extension
(RH & LH) plate (RH & LH) (RH & LH)
34. Front side member outrigger assem- 35. Rear seat crossmember 36. Rear seat crossmember (RH & LH)
E
bly (RH & LH)
37. 2nd rear crossmember 38. Rear crossmember center assembly 39. Rear side member assembly (RH &
LH) F
40. Rear side member extension (RH &
LH)
: Both sided anti-corrosive precoated steel sections G
: High strength steel (HSS) sections
: Both sided anti-corrosive steel and HSS sections
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

< PREPARATION >
Body Component Parts INFOID:0000000004373179
JSKIA1231ZZ
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 step sill (RH & LH)
LH)

< PREPARATION >
7. Outer sill reinforcement (RH & LH) 8. Lower front pillar reinforcement as- 9. Inner lock pillar (RH & LH)
sembly (RH & LH) A
10. Outer rear wheelhouse (RH & LH) 11. Outer rear wheelhouse extension 12. Inner rear wheelhouse (RH & LH)
(RH & LH)
13. Seat back support 14. Inner rear wheelhouse reinforce- 15. Roof assembly B
ment (RH & LH)
16. Front roof assembly 17. Center roof assembly 18. Rear roof assembly
19. Rear fender assembly (RH & LH) 20. Rear combination lamp base (RH & 21. Rear fender extension (RH & LH)
C
LH)
22. Rear lamp bracket reinforcement as- 23. Rear panel assembly 24. Rear bumper fascia center bracket
sembly (RH & LH)
25. Rear bumper fascia bracket 26. Door assembly (RH & LH) 27. Outer door panel (RH & LH) D
28. Trunk lid 29. Inner center front bumper reinforce- 30. Rear bumper stay (RH & LH)
ment
31. Inner center rear bumper reinforce- E
ment assembly
: Both sided anti-corrosive precoated steel sections
: High strength steel (HSS) sections F
: Both sided anti-corrosive steel and HSS sections
*: Aluminum portion
NOTE: G
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:0000000004373180
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 has been adopted replacing conven-
tional 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 Service Parts are fabricated from galvannealed steel. Therefore, it is recommended that
GENUINE NISSAN PARTS or equivalent be used for panel replacement to maintain the anti-corrosive perfor-
mance 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 employed
on all body components.
CAUTION:
Confine paint removal during welding operations to an absolute
minimum.
PIIA0095E
Nissan Genuine Service Parts are also treated in the same manner. Therefore, it is recommended that GENU-
INE NISSAN 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:0000000004373181
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
JSKIA1135GB
B. Nozzle insert hole

Unit: mm (in) I
: Anti-corrosive wax coated portions
REAR FENDER J
BRM

JSKIA1136GB
1. Rear fender 2. Lock pillar reinforcement 3. Outer sill reinforcement

4. Outer sill brace 5. Outer rear wheelhouse
F. Nozzle insert hole
Unit: mm (in)
: Vehicle front
: Anti-corrosive wax coated portions
Undercoating INFOID:0000000004373182
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. A
5. After putting seal on the vehicle, put undercoating on it.
I
JSKIA1137ZZ
: Undercoated areas
J
: Sealed portions
Body Sealing INFOID:0000000004373183

BRM
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. L

JSKIA1138ZZ
: Vehicle front
: Sealed portions

BRM
JSKIA1139ZZ
P
: Vehicle front
: Sealed portions

JSKIA1140ZZ
: Vehicle front
: Sealed portions

BODY CONSTRUCTION
BODY CONSTRUCTION
A
Body Construction INFOID:0000000004373184
BRM
JSKIA1134ZZ
1. Upper outer front pillar 2. Outer front pillar 3. Outer front pillar reinforcement
4. Upper inner front pillar 5. Front pillar hinge brace 6. Weld nut
7. Upper hinge plate 8. Hoodledge reinforcement 9. Upper hoodledge

BODY CONSTRUCTION
10. Upper dash 11. Upper rear hoodledge 12. Weld bolt
13. Rear hoodledge reinforcement 14. Lower hinge plate 15. Hoodledge reinforcement gusset
16. Lower dash crossmember 17. Outer front sill brace 18. Lower front pillar reinforcement
19. Inner sill reinforcement 20. Front side member outrigger 21. Inner front sill reinforcement
22. Lower dash 23. Lower front pillar gusset 24. Outer sill reinforcement
25. Center sill reinforcement 26. Inner sill 27. Front floor
28. 2nd crossmember 29. Outer sill brace 30. Outer sill step
31. Lock pillar reinforcement 32. Rear fender 33. Striker plate
34. Inner lock pillar 35. Upper inner lock pillar reinforcement 36. Rear tie down hook bracket
37. Rear tie down hook bracket 38. Rear side member front reinforce- 39. Rear seat crossmember
ment
40. Rear seat crossmember reinforce- 41. Rear floor front 42. Outer rear wheelhouse
ment
43. Inner rear wheelhouse reinforce- 44. Inner rear wheelhouse 45. Lower rear window regulator bracket
ment
46. Nut plate 47. Upper rear fender extension 48. Center outer body side reinforce-
ment
Rear Fender Hemming Process INFOID:0000000005110944
1. A wheel arch is to be installed and hemmed over the left and right outer wheel houses.
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.
PROCEDURE OF THE HEMMING PROCESS
• Peel off old bonding material on the surface of the outer wheel-
house and clean thoroughly.
• 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-
house and rear fender.
<Adhesive> 3M™ Automix™ Panel Bonding Adhe-

sive 08115 or equivalent
• Attach rear fender to the body of the car, and weld the required
part except the hemming part. JSKIA0136GB
• 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
flange.)
• Hemming with a hammer is conducted to an approximate angle of
80 degrees.
SIIA2245E

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

REPLACEMENT OPERATIONS
• This section is prepared for technicians who have attained a high level of skill and experience in repairing
collision-damaged vehicles and also use modern service tools and equipment. Persons unfamiliar with body
repair techniques should not attempt to repair collision-damaged vehicles by using this section.
• Technicians are also encouraged to read Body Repair Manual (Fundamentals) in order to ensure that the
original functions and quality of the vehicle can be maintained. The Body Repair Manual (Fundamentals)
contains additional information, including cautions and warning, that are not including in this manual. Techni-
cians should refer to both manuals to ensure proper repairs.
• Please note that these information are prepared for worldwide usage, and as such, certain procedures might
not apply in some regions or countries.
The symbols used in this section for welding operations are shown below.
Symbol marks Description
2-spot welds
JSKIA0049ZZ
JSKIA0053ZZ
3-spot welds
JSKIA0050ZZ
JSKIA0054ZZ
MIG plug weld
For 3 panels plug weld method
JSKIA0051ZZ
JSKIA0055ZZ
MIG seam weld / Point weld
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 A
position A due to the construction of the vehicle. Refer to the front
pillar section.
B
PIIA0150E
D
• 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 inner front pillar cut position. E
G
JSKIA0104GB
• Prepare a cutting jig to make outer pillar easier to cut. Also, this will H
permit service part to be accurately cut at joint position.
BRM
JSKIA0105GB
• An example of cutting operation using a cutting jig is as follows.

L
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. M
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.
N
PIIA0153E
O
REAR FENDER HEMMING PROCESS
1. A wheel arch is to be installed and hemmed over left and right outer wheel house.
2. In order to hem the wheel arch, it is necessary to repair any damaged or defaced parts around outer P
wheel house.
CAUTION:
Ensure that the area that is to be glued around outer wheelhouse is undamaged or defaced.
Procedure of the hemming process

• Peel off old bonding material on the surface of outer wheelhouse
and clean thoroughly.
• 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 outer wheelhouse
and rear fender.
<Adhesive> 3M automix panel bond 8115,

or any equivalents
• Attach rear fender to the body of the car, and weld the required
part except the hemming part. JSKIA0136GB
• 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
flange.)
• Hemming with a hammer is conducted to an approximate angle of
80 degrees.
SIIA2245E
• 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
FOAM REPAIR
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 spray foam for sealant (foam material) repair of material used on vehicle. Read
instructions on product for fill procedures.
1. Fill procedures after installation of service part.
- Remove foam material remaining on vehicle side.
- Clean area in which foam was removed.
- Install service part.

- Insert nozzle into hole near fill area and fill foam material or fill in enough to close gap with the service
part. A
JSKIA0129GB
F
1. Urethane foam
A. Nozzle insert hole
G
: Vehicle front
2. Fill procedures before installation of service part.

- Remove foam material remaining on vehicle side. H
- Clean area in which foam was removed.
- Fill foam material on wheelhouse outer side.
I
1. Urethane foam
A. Fill while avoiding flange area
: Vehicle front
J
NOTE:
Fill in enough to close gap with service part while avoiding flange
BRM
area.
- Install service part.
NOTE:
JSKIA0130GB
Refer to label for information on working times. L

Radiator Core Support INFOID:0000000004373193
JSKIA0373GB
: Vehicle front
Replacement parts
z Radiator core support assembly (LH) z Front side member connector as-
sembly (LH)
Hoodledge INFOID:0000000004373194
Work after radiator core support is removed.

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

BRM
N
JSKIA1109GB
1. Front side member center closing O

plate
Unit: mm (in)
: Vehicle front P
: Weld the parts onto the back of the component part.
Replacement parts
z Upper front hoodledge (LH) z Hoodledge reinforcement (LH) z Front strut housing (LH)

JSKIA1110GB
Unit: mm (in)
: Vehicle front
View C and G: Before installing hoodledge reinforcement

BRM
N
JSKIA1111GB
1. Front side member center closing O

plate
Unit: mm (in)
: Vehicle front P
Front Side Member INFOID:0000000004373195
Work after radiator core support and hoodledge are removed.

Remove the front side member center closing plate (reusable) from the service part ″front side member clos-
ing plate assembly″ for easier installation of hoodledge.

JSKIA1112GB
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
JSKIA1113GB
Unit: mm (in) O
: Vehicle front
P
View G: Before installing front side member outrigger assembly

JSKIA1114GB
: Vehicle front
Refer to GI-4, "Components" for symbols in the figure.
Front Side Member (Partial Replacement) INFOID:0000000004373196
Work after radiator core support is removed.

BRM
N
JSKIA1115GB
Unit: mm (in) O
: Vehicle front
Replacement parts P
z Front side member front extension z Front side member front closing z Front side rear closing reinforcement
(RH) plate (RH) (RH)
Front Pillar INFOID:0000000004373197
Work after hoodledge reinforcement and outer step sill are removed.

JSKIA1116ZZ
1. Body sealing
: Vehicle front
Replacement parts
z Upper front pillar reinforcement (LH) z Upper rear hoodledge (LH)

BRM
N
JSKIA1117GB
1. Urethane foam O
Unit: mm (in)
: Vehicle front
P
View B: Before installing upper front pillar reinforcement

JSKIA1118GB
Unit: mm (in)
: Vehicle front
Outer Step Sill INFOID:0000000005038923
Remove the welding point ″b″ for easier replacement.

BRM
N
JSKIA1119ZZ
: Vehicle front O
Replacement parts
z Outer step sill (LH)
P
Outer Sill INFOID:0000000004373198
Work after hoodledge reinforcement, outer step sill, outer lock pillar reinforcement and rear fender are
removed.
Remove the front pillar brace (reusable).

JSKIA1120GB
1. Body sealing 2. Urethane foam (Cover the hole with urethane foam completely.)
Unit: mm (in)
: Vehicle front
Replacement parts
z Outer sill reinforcement (LH) z Outer rear wheelhouse extension
(LH)
View B and C: Before installing front pillar brace

BRM
N
JSKIA1121GB
1. Urethane foam O
Unit: mm (in)
: Vehicle front
: Weld the parts onto the back of the component part. P
View G and H: Before installing front pillar brace and outer sill reinforcement

Rear Fender INFOID:0000000004373199
JSKIA1122ZZ
1. Adhesive 2. Body sealing 3. Hemming portion

: Vehicle front
Replacement parts
z Rear fender assembly (LH)

BRM
N
JSKIA1123ZZ
1. Body sealing 2. Adhesive O

: Vehicle front
P
View H: Right side rear fender
POINT

• Perform the hemming to the flange of wheelarch after applying the
adhesive.
• Apply the sealing to the flange end.
• Refer to BRM-20, "Rear Fender Hemming Process".
1. Outer rear wheelhouse

2. Rear fender
3. Adhesive
4. Sealant
JSKIA0204GB
Lock Pillar Reinforcement INFOID:0000000004373200
Work after rear fender is removed.

BRM
N
JSKIA1124GB
1. Body sealing O
Unit: mm (in)
: Vehicle front
Replacement parts P
z Outer lock pillar reinforcement (LH)

Rear Panel INFOID:0000000004373203
JSKIA1125GB
: Vehicle front
: An equivalent welding portion with the same dimensions is on the opposite side.
Replacement parts
z Rear panel assembly
Rear Floor Rear INFOID:0000000004373204
Work after rear panel is removed.

BRM
N
JSKIA1126GB
1. Body sealing O
Unit: mm (in)
: Vehicle front
: An equivalent welding portion with the same dimensions is on the opposite side. P
Replacement parts
z Rear floor rear z Spare wheel clamp reinforcement
View A: Before installing spare wheel clamp reinforcement

Rear Side Member Extension (LH) INFOID:0000000004373205
Work after rear panel and rear floor side (LH) are removed.
JSKIA1127ZZ
: Vehicle front
Replacement parts
z Rear side member extension (LH)
Rear Side Member Extension (RH) INFOID:0000000005038924
Work after rear panel is removed.

BRM
N
JSKIA1128ZZ
: Vehicle front O
Replacement parts
z Rear side member extension (RH) P

BODY ALIGNMENT
< SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
BODY ALIGNMENT
Body Center Marks INFOID:0000000004373185
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.
JSKIA1097ZZ
: Vehicle front
Unit: mm (in)
Points Portion Marks
A, B Upper dash Embossment
C Roof Embossment
D Rear panel Indent

BODY ALIGNMENT
Points Portion Marks
A
E Trans control reinforcement Hole φ14 (0.55)
F Rear seat crossmember reinforcement Hole φ5 (0.20)
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 INFOID:0000000004946671
Measurement L
Dimensions marked with ″*″ indicate symmetrically identical dimensions on both the right and left hand of the
vehicle.
M

BODY ALIGNMENT
JSKIA1098GB
Unit: mm (in)
«The others»
Unit: mm (in)
Point Dimension Memo Point Dimension Memo Point Dimension Memo Point Dimension Memo
A-C 744 (29.29)* B-d 1227 (48.31)* E-g 1135 (44.68)* J-j 903 (35.55)*
A-F 1057 (41.61)* C-c 1427 (56.18)* F-f 1199 (47.20)*
B-C 227 (8.94)* D-k 875 (34.45)* F-G 192 (7.56)*
B-c 1490 (58.66)* E-G 412 (16.22)* F-g 1015 (39.96)*
Measurement Points

BODY ALIGNMENT
BRM
L
JSKIA1099ZZ
: Vehicle front M
Unit: mm (in)
Point Material Point Material N

Upper dash positioning mark of center position- Radiator core stay installing hole center φ15
A G, g
ing mark (0.59)
B, b Hood hinge installing hole center φ9 (0.35) H, h Front side member hole center φ20 (0.79) O
C, c, F, f Front fender installing hole center φ7 (0.28) J, j, K, k Nut holder hole center φ16 (0.63)
Front bumper reinforcement installing hole center
D, d Front strut installing hole center φ11 (0.43) M, m, N, n
φ11 (0.43) P
E, e Hoodledge reinforcement hole center φ6 (0.24)
Underbody INFOID:0000000004946702
Measurement
vehicle.

BODY ALIGNMENT
JSKIA1100GB
Unit: mm (in)
: Vehicle front
: Bolt head
Measurement Points

BODY ALIGNMENT
BRM
L
JSKIA1101GB
: Vehicle front M

BODY ALIGNMENT
Unit: mm (in)
Coordinates Coordinates
Points Remarks Points Remarks
X Y Z X Y Z
±416.0 −496.0 224.5 ±437.5 1810.0 81.2
A, a Hole φ13 (0.51) H, h Hole φ16 (0.63)
(±16.378) (−19.528) (8.839) (±17.224) (71.260) (3.197)
416.2 −368.0 303.5 ±604.0 2390.5 128.3
B Hole φ16 (0.63) J, j Hole φ13 (0.51)
(16.386) (−14.488) (11.949) (±23.779) (94.114) (5.051)
−413.0 −368.0 303.5 ±472.6 2603.8 114.0
b Hole φ16 (0.63) K, k Bolt head
(−16.260) (−14.488) (11.949) (±18.606) (102.512) (4.488)
±415.0 −104.0 133.5 ±451.5 3163.9 179.1
C, c Bolt head M, m Bolt head
(±16.339) (−4.094) (5.256) (±17.776) (124.563) (7.051)
±392.0 414.0 64.5 ±533.0 3475.0 316.4
D, d Bolt head N, n Hole φ16 (0.63)
(±15.433) (16.299) (2.539) (±20.984) (136.811) (12.457)
±428.0 816.6 80.0 Hole 16×18 ±423.0 38.0 674.5
E, e O, o Hole φ50.1 (1.972)
(±16.850) (32.150) (3.150) (0.63×0.71) (±16.654) (1.496) (26.555)
±438.0 1100.0 78.0 ±531.2 2692.7 515.6
F, f Hole φ16 (0.63) P, p Hole φ63.5 (2.500)
(±17.244) (43.307) (3.071) (±20.913) (106.012) (20.299)
±437.5 1299.0 76.0
G, g Hole φ16 (0.63)
(±17.224) (51.142) (2.992)
Passenger Compartment INFOID:0000000004946818
Measurement
vehicle.
JSKIA1102GB
Unit: mm (in)

BODY ALIGNMENT
«The others»
Unit: mm (in)
A
E-e 1227 (48.31) F-k 1769 (69.65)* K-k 1451 (57.13) N-H 1309 (51.54)*
E-g 1637 (64.45)* G-g 1440 (56.69) M-E 1015 (39.96)* N-J 1277 (50.28)* B
E-h 1519 (59.80)* G-h 1896 (74.65)* M-F 772 (30.39)* N-K 1174 (46.22)*
E-k 1613 (63.50)* G-k 1734 (68.27)* M-G 736 (28.98)* O-H 1372 (54.02)*
C
F-f 1447 (56.97) H-h 1451 (57.13) M-H 1300 (51.18)* O-J 1283 (50.51)*
F-h 1856 (73.07)* H-k 1526 (60.08)* M-K 1106 (43.54)* O-K 1126 (44.33)*
Measurement Points D
BRM
P
JSKIA1103ZZ
: Vehicle front

BODY ALIGNMENT
Unit: mm (in)
Point Material Point Material

Upper dash positioning mark of center position-
A G, g Rear upper hoodledge joggle
ing mark
B Roof flange end of center positioning mark H, h, K, k Rear fender indent
C, c, D, d Front pillar joggle J, j Door switch installing hole center φ7 (0.28)
Trans control reinforcement hole center of center
E, e Front pillar indent M, m
positioning mark φ14 (0.55)
F, f Front pillar hinge brace joggle N, n, O, o Door hinge installing hole center φ12 (0.47)
Rear Body INFOID:0000000004946819
Measurement
vehicle.
JSKIA1104GB
Unit: mm (in)
«The others»
Unit: mm (in)
A-C 1180 (46.46)* B-d 1392 (54.80)* C-F 1104 (43.46)* G-J 748 (29.45)*
A-D 1110 (43.70)* B-F 813 (32.01)* D-d 1266 (49.84) G-j 1393 (54.84)*
A-d 1617 (63.66)* B-f 1612 (63.46)* D-f 1388 (54.65)* H-j 1175 (46.26)*
B-C 836 (32.91)* C-D 820 (32.28)* G-H 427 (16.81)* J-K 445 (17.52)*
B-D 409 (16.10)* C-E 805 (31.69)* G-h 1578 (62.13)*
Measurement Points
BODY ALIGNMENT
BRM
L
JSKIA1105ZZ
: Vehicle front M
Unit: mm (in)
Point Material Point Material N

Rear seatback support flange end of center posi-
A, a Upper front pillar joggle E
tioning mark
B, b Lock pillar seat belt anchor hole center φ10 (0.39) G, g Rear fender hole center φ8 (0.31) O
Rear seat crossmember reinforcement hole cen-
C H, h, J, j Rear combination lamp base joggle
ter of center positioning mark φ5 (0.20)
Upper rear panel flange end of center positioning P
D, d, F, f Fixing main bearing bolt head K
mark

LOCATION OF PLASTIC PARTS
Precautions for Plastics INFOID:0000000005169148
Heat resisting
Abbre- Resistance to gasoline and
Material name temperature Other cautions
viation solvents
°C (°F)
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. —
EPM/ Ethylene Propylene (Diene) co-
80 (176) harmless if applied for a very Flammable
EPDM polymer
PS Polystyrene 80 (176) Avoid solvents. Flammable
Poisonous gas is emitted
PVC Poly Vinyl Chloride 80 (176) harmless if applied for a very
when burned.
TPO Thermoplastic Olefine 80 (176) ↑ Flammable
AAS Acrylonitrile Acrylic Styrene 85 (185) Avoid gasoline and solvents. —
PMMA Poly Methyl Methacrylate 85 (185) ↑ —
EVAC Ethylene Vinyl Acetate 90 (194) ↑ —
Flammable, avoid bat-
PP Polypropylene 90 (194) harmless if applied for a very
tery acid.
PUR Polyurethane 90 (194) Avoid gasoline and solvents. —
UP Unsaturated Polyester 90 (194) ↑ Flammable
ASA Acrylonitrile Styrene Acrylate 100 (212) ↑ Flammable
PPE Poly Phenylene Ether 110 (230) ↑ —
TPU Thermoplastic Urethane 110 (230) ↑ —
PBT+ Poly Butylene Terephthalate +
120 (248) ↑ Flammable
PC Polycarbonate
PC Polycarbonate 120 (248) ↑ —
POM Poly Oxymethylene 120 (248) ↑ Avoid battery acid.
Avoid immersing in wa-
PA Polyamide 140 (284) ↑
ter.
PBT Poly Butylene Terephthalate 140 (284) ↑ —
PAR Polyarylate 180 (356) ↑ —
PET Polyethylene terephthalate 180 (356) ↑ —
PEI Polyetherimide 200 (392) ↑ —
CAUTION:
• 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.
• Plastic parts should be repaired and painted using methods suiting the materials, characteristics.
Location of Plastic Parts INFOID:0000000005169147

H
JSKIA1258ZZ
Component Material Component Material

I
1 Bumper fascia PP + EPM 8 High mount stop lamp cover ABS
2 Front grille ABS 9 Satellite radio antenna cover PC + ASA
Lens PC 10 Fuel filler lid PA + PPE J
3 Front combination lamp
Housing PP 11 Door outside molding PVC + Stainless
4 Windshield molding TPO 12 Door outside handle PC + PET
5 Front pillar finisher PC + PET 13 Center mudguard PP BRM
Cover PP Lens PMMA
14 Rear combination lamp
6 Door outside mirror Housing ASA Housing ABS
L
Base PA + Glass fiber Lens PMMA
15 License plate lamp
Front PP Housing PC
7 Fender protector
Rear PET M

JSKIA1259ZZ
Component Material Component Material

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

Body Repair: Section

Uploaded by

Copyright:

Available Formats

Body Repair: Section

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Body Repair: Section

Uploaded by

Copyright:

Available Formats

BODY EXTERIOR, DOORS, ROOF & VEHICLE SECURITY

SECTION BRM BODY REPAIR

Revision: 2010 March BRM-1 2009 G37 Convertible

Revision: 2010 March BRM-2 2009 G37 Convertible

Read the following precautions when repairing HSS:

Revision: 2010 March BRM-3 2009 G37 Convertible

• 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: 2010 March BRM-4 2009 G37 Convertible

• Follow the specifications for the proper welding pitch. H

Handling of Ultra High Strength Steel Plate Parts INFOID:0000000005157513

Revision: 2010 March BRM-5 2009 G37 Convertible

2. Fill procedures before installation of service part.

Revision: 2010 March BRM-6 2009 G37 Convertible

Revision: 2010 March BRM-7 2009 G37 Convertible

Revision: 2010 March BRM-8 2009 G37 Convertible

Revision: 2010 March BRM-9 2009 G37 Convertible

Revision: 2010 March BRM-10 2009 G37 Convertible

Revision: 2010 March BRM-11 2009 G37 Convertible

Revision: 2010 March BRM-12 2009 G37 Convertible

B. Nozzle insert hole

Revision: 2010 March BRM-13 2009 G37 Convertible

1. Rear fender 2. Lock pillar reinforcement 3. Outer sill reinforcement

Revision: 2010 March BRM-14 2009 G37 Convertible

Body Sealing INFOID:0000000004373183

Revision: 2010 March BRM-15 2009 G37 Convertible

Revision: 2010 March BRM-16 2009 G37 Convertible

Revision: 2010 March BRM-17 2009 G37 Convertible

Revision: 2010 March BRM-18 2009 G37 Convertible

Revision: 2010 March BRM-19 2009 G37 Convertible

Rear Fender Hemming Process INFOID:0000000005110944

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

Revision: 2010 March BRM-20 2009 G37 Convertible

Revision: 2010 March BRM-21 2009 G37 Convertible

MIG seam weld / Point weld

Revision: 2010 March BRM-22 2009 G37 Convertible

• An example of cutting operation using a cutting jig is as follows.

Revision: 2010 March BRM-23 2009 G37 Convertible

<Adhesive> 3M automix panel bond 8115,

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

Revision: 2010 March BRM-24 2009 G37 Convertible

2. Fill procedures before installation of service part.

Revision: 2010 March BRM-25 2009 G37 Convertible

Work after radiator core support is removed.

Revision: 2010 March BRM-26 2009 G37 Convertible

1. Front side member center closing O

Revision: 2010 March BRM-27 2009 G37 Convertible

View C and G: Before installing hoodledge reinforcement

Revision: 2010 March BRM-28 2009 G37 Convertible

1. Front side member center closing O

Front Side Member INFOID:0000000004373195

Work after radiator core support and hoodledge are removed.

Revision: 2010 March BRM-29 2009 G37 Convertible

Revision: 2010 March BRM-30 2009 G37 Convertible

Revision: 2010 March BRM-31 2009 G37 Convertible

Front Side Member (Partial Replacement) INFOID:0000000004373196

Work after radiator core support is removed.

Revision: 2010 March BRM-32 2009 G37 Convertible