Body Repair Manual 2000 Nissan Maxima a33

1

This Body Repair Manual contains information and instructions for repairing the body structure

of the 2000 NISSAN MAXIMA (A33) model. In order to achieve reliable repair work and

ensure customer satisfaction, the technician should study this manual and become familiar

with appropriate sections before starting repair and rebuilding work.

This Body Repair Manual is prepared for technicians who have attained a high level of skilland 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 manual.

Technicians are also encouraged to read Body Repair Manual (Fundamentals) andthe 2000 NISSAN MAXIMA (A33) Service Manual in order to ensure that the originalfunctions and quality of the vehicle can be maintained. The Body Repair Manual(Fundamentals) contains additional information, including cautions and warnings, thatare not inc luded in this manual. Technicians should refer to both manuals to ensureproper repairs.

Please note that these manuals are prepared for worldwide usage, and as such, certainprocedures might not apply in some regions or countries. In the U.S.A. it is recommended

that a MIG welder be used by a trained technician.

All information in this manual is based on the latest product information at the time of

publication. The right is reserved to make changes in specifications and methods at any time

without notice.

1999 NISSAN NORTH AMERICA, INC.All rights reserved. No part of this Body Repair Manual may be reproduced or stored in a retrieval

system, or transmitted in any form, or by any means, electronic, mechanical, photocopying, recording or

otherwise, without the prior written permission of Nissan North America, Inc., Gardena, California.

Edition: April 1999

Revision: April 1999 (01)

Publication Number: BR0E-1A33U0

2

FOREWORD ................................................................................................................................ 1CONTENTS .................................................................................................................................. 2GENERAL INFORMATION ........................................................................................................... 3

Identification Number.............................................................................................................................. 3Identification Plate .................................................................................................................................. 4Body Exterior Paint Color ....................................................................................................................... 5

BODY COMPONENT PARTS ....................................................................................................... 6Underbody Component Parts ................................................................................................................. 6Body Component Parts .......................................................................................................................... 7

CORROSION PROTECTION ....................................................................................................... 8Description ............................................................................................................................................. 8Anti-Corrosive Wax ................................................................................................................................. 9Undercoating ........................................................................................................................................ 10Stone Guard Coat ................................................................................................................................ 11

BODY SEALING ......................................................................................................................... 12Description ........................................................................................................................................... 12

BODY CONSTRUCTION ............................................................................................................ 15Body Construction ................................................................................................................................ 15

BODY ALIGNMENT .................................................................................................................... 16Body Center Marks .............................................................................................................................. 16Panel Parts Matching Marks ................................................................................................................. 17Description ........................................................................................................................................... 18Engine Compartment ........................................................................................................................... 19Underbody ............................................................................................................................................ 20Passenger Compartment...................................................................................................................... 22Rear Body ............................................................................................................................................ 24

HANDLING PRECAUTIONS FOR PLASTICS ........................................................................... 25Handling Precautions for Plastics ......................................................................................................... 25Location of Plastic Parts ....................................................................................................................... 26

PRECAUTIONS IN REPAIRING HIGH STRENGTH STEEL ...................................................... 28Precautions in Repairing High Strength Steel ....................................................................................... 28

REPLACEMENT OPERATIONS ................................................................................................. 31Description ........................................................................................................................................... 31Radiator Core Support ......................................................................................................................... 32Radiator Core Support (Partial Replacement) ...................................................................................... 33Hoodledge ............................................................................................................................................ 34Hoodledge (Partial Replacement) ......................................................................................................... 35Front Side Member ............................................................................................................................... 36Front Side Member (Partial Replacement) ............................................................................................ 37Front Pillar ............................................................................................................................................ 38Center Pillar .......................................................................................................................................... 39Rear Fender ......................................................................................................................................... 40Rear Floor Rear .................................................................................................................................... 41Rear Side Member Extension ............................................................................................................... 42

REPLACEMENT NOTES ............................................................................................................ 43Front Pillar ............................................................................................................................................ 43

COMMENT FORM...................................................................................................................... 44

GENERAL INFORMATION

3

Identification Number

VEHICLE IDENTIFICATION NUMBER ARRANGEMENT

GENERAL INFORMATION

4

Identification Plate

1.Type

2.Vehicle indentification number (Chassis number)

3.Model

4.Body color code

5.Trim color code

6.Engine model7.Engine displacement

8.Transmission model

9.Axle model

GENERAL INFORMATION

5

Body Exterior Paint Color

S: Solid, 2S: Solid+Clear, M: Metallic, 2P: 2 Coat pearl, 3P: 3 Coat pearl, FPM: Iron oxide pearl metallic,TM: Micro titanium metallic

Component

Color code BBV3 BCP2 BDR2 BEV0 BKH3 BKT3 BKV3 BQT1

DescriptionLightblue

Brown Green Beige Black SilverGreenish

grayWhite

Paint type TM 2P 2P M 2S M M 3P

Hard clear coat - X X - X - X -

1 Bumper fascia Body color BBV3 BCP2 BDR2 BEV0 BKH3 BKT3 BKV3 BQT1

2 Radiator grill Chromium-plate Cr Cr Cr Cr Cr Cr Cr Cr

3 Outside mirrorBody Body color BBV3 BCP2 BDR2 BEV0 BKH3 BKT3 BKV3 BQT1

Base Black AG01 AG01 AG01 AG01 AG01 AG01 AG01 AG01

4Side guardmolding

Body color BBV3 BCP2 BDR2 BEV0 BKH3 BKT3 BKV3 BQT1

5 Door sashCenter Black tape - - - - - - - -

Rear Black AG01 AG01 AG01 AG01 AG01 AG01 AG01 AG01

6Outside handleescutcheon


7 Outside handle Body color BBV3 BCP2 BDR2 BEV0 BKH3 BKT3 BKV3 BQT1

8Rear airspoiler


9Trunk lidfinisher

Gray metallic AG05 AG05 AG05 AG05 AG05 AG05 AG05 AG05

BODY COMPONENT PARTS

6

Underbody Component Parts

1R

adia

tor

core

sup

port

ass

embl

y2

Upp

er r

adia

tor

core

sup

port

3S

ide

radi

ator

cor

e su

ppor

t4

Low

er r

adia

tor

core

sup

port

5H

ood

lock

sta

y6

Hoo

dled

ge a

ssem

bly

(RH

& L

H)

7U

pper

hoo

dled

ge (

RH

& L

H)

8Lo

wer

fron

t hoo

dleg

e (R

H &

LH

)9

Bat

tery

mou

ntin

g re

info

rcem

ent (

LH o

nly)

10E

ngin

e m

ount

ing

rein

forc

emen

t (R

H o

nly)

11H

oodl

edge

rei

nfor

cem

ent a

ssem

bly

(RH

& L

H)

12Fr

ont h

oodl

ege

rein

forc

emen

t (R

H &

LH

)13

Air

box

asse

mbl

y

14C

ente

r co

wl t

op15

Upp

er d

ash

16S

ide

cow

l top

17S

ide

cow

l top

bra

ce18

Low

er d

ash

asse

mbl

y19

Fron

t flo

or20

2nd

cros

smem

ber

asse

mbl

y21

Par

king

bra

ke a

nd s

eat b

elt r

einf

orce

men

t22

Exh

aust

mou

ntin

g br

acke

t23

Inne

r si

ll (R

H &

LH

)24

Bol

t25

Out

er fr

ont s

eat m

ount

ing

brac

ket (

RH

& L

H)

26R

ear

floor

fron

t27

Rea

r flo

or r

ear

28R

ear

seat

bel

t anc

hor

rein

forc

emen

t29

Rea

r flo

or s

ide

(RH

& L

H)

30S

pare

whe

el c

lam

p br

acke

t31

Muf

fler

mou

ntin

g br

acke

t32

Fron

t sid

e m

embe

r as

sem

bly

(RH

& L

H)

33Fr

ont s

ide

mem

ber

clos

ing

plat

e as

sem

bly

(RH

& L

H)

34Fr

ont s

ide

mem

ber

fron

t clo

sing

pla

te (

RH

& L

H)

35Fr

ont s

ide

mem

ber

(RH

& L

H)

36B

atte

ry s

uppo

rt b

rack

et (

LH o

nly)

37Fr

ont s

ide

mem

ber

cent

er e

xten

sion

(R

H &

LH

)38

Fron

t sid

e m

embe

r re

ar e

xten

sion

(R

H &

LH

)39

Rea

r si

de m

embe

r as

sem

bly

(RH

& L

H)

40R

ear

side

mem

ber

exte

nsio

n (R

H &

LH

)41

Rea

r se

at c

ross

mem

ber

42C

ente

r re

ar c

ross

mem

ber

asse

mbl

y43

Rea

r to

win

g ho

ok b

rack

et a

ssem

bly

(LH

onl

y)44

Rea

r tie

-dow

n ho

ok (

RH

onl

y)

: In

dica

tes

two-

side

ant

i-cor

rosi

ve p

reco

ated

ste

el p

ortio

ns :

Indi

cate

s hi

gh s

tren

gth

stee

l (H

SS

) po

rtio

ns :

Indi

cate

s tw

o-si

de a

nti-c

orro

sive

ste

el a

nd H

SS

por

tions

BODY COMPONENT PARTS

7

Body Component Parts1

Hoo

d2

Fron

t fen

der

(RH

& L

H)

3Fr

ont f

ende

r br

acke

t (R

H &

LH

)4

Bod

y si

de a

ssem

bly

(RH

&LH

)5

Out

er b

ody

side

(R

H &

LH

)6

Upp

er in

ner

fron

t pill

ar (

RH

& L

H)

7In

ner

cent

er p

illar

(R

H &

LH

)8

Low

er in

ner

fron

t pill

ar (

RH

& L

H)

9Lo

wer

fron

t pill

ar r

einf

orce

men

t (R

H &

LH)

10S

ide

parc

el s

helf

(RH

& L

H)

11In

ner

rear

pill

ar (

RH

& L

H)

12Lo

wer

inne

r re

ar p

illar

(R

H &

LH

)13

Sea

t bac

k su

ppor

t (R

H &

LH

)

14In

ner

rear

whe

elho

use

(RH

& L

H)

15O

uter

rea

r w

heel

hous

e (R

H &

LH

)16

Out

er r

ear

whe

elho

use

exte

nsio

n (R

H &

LH

)17

Roo

f18

Roo

f ass

embl

y (w

ith s

unro

of)

19Fr

ont r

oof r

ail

20R

ear

roof

rai

l

21R

oof b

ow N

o.1

22R

oof b

ow N

o.2

23R

oof b

ow N

o.3

24R

ear

fend

er (

RH

& L

H)

25R

ear

fend

er d

rip (

RH

& L

H)

26S

trik

er r

etai

ner

(RH

& L

H)

27F

iller

lid

base

28F

uel f

iller

lid

29R

ear

com

bina

tion

lam

p ba

se (

RH

& L

H)

30Ja

ck b

rack

et r

einf

orce

men

t (LH

onl

y)31

Par

cel s

helf

with

rea

r w

aist

32P

arce

l she

lf tr

im b

rack

et33

Upp

er r

ear

pane

l ass

embl

y34

Upp

er r

ear

pane

l stif

fene

r

35Tr

unk

lid36

Fron

t doo

r as

sem

bly

(RH

& L

H)

37O

uter

fron

t doo

r pa

nel (

RH

& L

H)

38R

ear

door

ass

embl

y (R

H &

LH

)39

Out

er r

ear

door

pan

el (

RH

& L

H)

40P

atch

rea

r fe

nder

(R

H &

LH

)41

Fron

t bum

per

arm

atur

e42

Rea

r bu

mpe

r ar

mat

ure

: In

dica

tes

two-

side

ant

i-cor

rosi

ve p

reco

ated

ste

el p

ortio

ns :

Indi

cate

s hi

gh s

tren

gth

stee

l (H

SS

) po

rtio

ns :

Indi

cate

s tw

o-si

de a

nti-c

orro

sive

ste

el a

nd H

SS

por

tions

For

sunr

oof

CORROSION PROTECTION

8

Description

To provide improved corrosion prevention, the following 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 measures.

To improve repairability and corrosion resistance, a new type

of anti-corrosive precoated steel sheet has been adopted

replacing conventional zinc-coated steel sheet.

Durasteel is electroplated, zinc-nickel alloy under organic film,

which provides excellent corrosion resistance.

Durasteel is classified as either one-side precoated steel or

two-side precoated steel. The two side precoated steel provides

excellent corrosion resistance.

Nissan Genuine Service Parts are fabricated from durasteel sheets. Therefore, it is recommended that GENUINENISSAN PARTS or equivalent be used for panel replacement to maintain the anti-corrosive performance built intothe vehicle at the factory.

A phosphate coating treatment and a cationic electrodeposition primer, which provide an excellent corrosion protection,

are employed on all body components.

Caution:Confine paint removal during welding operations to an absolute minimum.

Nissan Genuine Service Parts are also treated in the same manner. Therefore, it is recommended that GENUINENISSAN PARTS or equivalent be used for panel replacement to maintain anti-corrosive performance built into thevehicle at the factory.

PHOSPHATE COATING TREATMENT ANDCATIONIC ELECTRODEPOSITION PRIMER

ANTI-CORROSIVE PRECOATED STEEL(DURASTEEL)


9

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.

:Indicates anti-corrosive wax coated portions.

Section A-A Section B-B Section C-C

Section D-D


10

Undercoating

The underside 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 which is rust preventive,

soundproof, vibration-proof, shock-resistant, adhesive, and durable.

Precautions in undercoating1. Do not apply undercoating to any place unless specified (such as the areas above the muffler and three way catalyst

which are subjected to heat).

2. Do not undercoat the exhaust pipe or other parts which become hot.3. Do not undercoat rotating parts.

4. Apply bitumen wax after applying undercoating.

: Indicates undercoated portions.


11

Stone Guard Coat

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

Guard Coating over the ED primer coating. When replacing or repairing these panels, apply Stone Guard coating to thesame portions as before. Use a coating which is rust preventive, durable, shock-resistant and has a long shelf life.

: Indicates stone guard coated portions.

BODY SEALING

12

Description

The following figure shows the areas which are sealed at the factory. Sealant which has been 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.

View A View B

BODY SEALING

13

View C View D

View E View F

View G View H

View I View J

BODY SEALING

14

View K View L

View M View N

View O View P

ViewQ ViewR

BODY CONSTRUCTION

15

Body Construction

Section A-A Section B-B Section C-C Section D-D

Section E-E

Section I-I

Section F-F Section G-G Section H-H

Section J-J Section K-K Section L-L

BODY ALIGNMENT

16

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 and effective repair will be possible byusing these marks together with body alignment specifications.

Portion A Portion B Portion C

Portion D Portion E Portion F

BODY ALIGNMENT

17

Panel Parts Matching Marks

A mark has been placed on each body panel to indicate the parts matching positions. When repairing parts damaged by an

accident which might affect the vehicle structure (members, pillars, etc.), more accurate and effective repair will be possible

by using these marks together with body alignment specifications.

View A View C

View D

View B

View E

BODY ALIGNMENT

18

Description

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 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”, “Y” and “Z”.

Engine Compartment

Unit: mmMEASUREMENT

BODY ALIGNMENT

19

Engine Compartment (Cont’d)

Unit: mm

: Cowl top center : Cowl top side: Strut tower: Hoodledge

: Radiator core support upper center, : Hood lock

: Radiator core support upper side, : Radiator core support side: Front side member

: Hood lock stay, : Radiator core support lower

, : Front side member LH side

MEASUREMENT POINTS

, : Front side member RH side

BODY ALIGNMENT

20

Underbody

Unit: mm

All

dim

ensi

ons

indi

cate

d in

this

figur

e ar

e ac

tual

.A

s vi

ewed

from

und

ersi

de.

Fig

ures

mar

ked

with

a

* in

dica

te s

ymm

etric

ally

iden

tical

dim

ensi

ons

on b

oth

right

and

left

hand

sid

es o

f the

veh

icle

.: B

olt h

ead

MEASUREMENT

BODY ALIGNMENT

21

Underbody (Cont’d)

MEASUREMENT POINTS

Coordinates:, ,

X:330 X:555Y:-710 Y:2,235Z:188.8 Z:239.5

,X:513 X:300Y:-540 Y:2,700Z:322 Z:381.7

,X:450 X:-300Y:68 Y:2,700Z:226.5 Z:407.7

,X:441 X:512Y:354 Y:3,050Z:111.5 Z:326.6

,X:600 X:-544Y:430 Y:3,032Z:154.9 Z:328.2

,X:398 X:546Y:700 Y:3,504Z:109 Z:295.4

,X:414 X:-570.5Y:1,210 Y:3,500Z:108.4 Z:326.6

,X:412.5 X:0Y:1,625 Y:-700.5Z:104 Z:188.8

,X:518.2Y:2,155Z:184.5

Unit: mm

Front and rear strut tower centersCoordinates:

,X:548.8Y:28.7Z:779.3

,X:490.1Y:2,671Z:538.5

Front: , 87 diaRear: , 61.4 dia

As viewed from underside.

BODY ALIGNMENT

22

Passenger Compartment

Figures marked with a * indicate symmetrically identicaldimensions on both right and left hand sides of the vehicle.

: Cowl top center (5 dia) : Front roof flange end of center

positioning mark

, : Outer front pillar joggle

Point Dimension

~

~

~ ~ ~ ~ ~ ~

1,2721,4181,4491,2721,4731,4591,280

1,4731,452

~

, : Upper dash joggle

MEASUREMENT

Point Dimension Point Dimension

~

~ ~ ~

~ ~ ~ ~

819*

1,197*

931* 830*

1,059*

897*

839*

1,063*

901*

~ ~

~ ~ ~ ~ ~

1,527*

1,560*

1,389*1,518*

1,619*1,638*

1,128*

~

Unit: mm

~ 1,205 ~ 727*

~ 1,479 ~ 1,616*

~ 1,448 ~ 1,407*

~ 1,027* ~ 1,877*

~ 980* ~ 1,699*

~ 1,127*

~ 1,173*

~ 1,086*

~ 1,660*

~ 736*

BODY ALIGNMENT

23

Passenger Compartment (Cont’d)

, , , , , : Outer front pillar indention

, , , : Door hinge installing nut center

, : Transmission control reinforcementhole center

: Fuel tank cover installing hole centerof center positioning mark

Unit: mmMEASUREMENT

, : Rear suspension installing hole

center (11 12)

, , , , , ,, , , , , : Outer center pillar

indention, , , : Door hinge installing nut center

, : Rear fender indention rear, : Door switch installing hole center

(20 dia), : Outer sill joggle

BODY ALIGNMENT

24

Rear Body

Figures marked with a * indicate symmetrically identicaldimensions on both right and left hand sides of the vehicle.

Unit: mm

: Rear roof flange end of centerpositioning mark

, : Rear fender joggle

, : Rear fender joggle : Rear waist flange end of centerpositioning mark

MEASUREMENT

, : Rear fender joggle

, : Rear combination lamp base joggle

, : Rear panel upper reinforcement hole

center

, : Rear suspension installing hole

center (11 12)

HANDLING PRECAUTIONS FOR PLASTICS

25

Handling Precautions for Plastics

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 characteristics.

Abbreviation Material nameHeat resistingtemperature

oC(oF)

Resistance to gasoline andsolvents Other cautions

PVC Polyvinyl chloride 80(176)Gasoline and most solvents areharmless if applied for a veryshort time(wipe up quickly).

Poison gas is emitted whenburned.

PP Polypropylene 90(194) Same as above. Flammable,avoid battery acid.

EPM/EPDM Ethylene Propylene (Diene)rubber 80(176) Same as above. Flammable

UP Polyester thermoset 90(194) Same as above. Flammable

TPO/TPR Thermoplastic olefine/Thermoplastic rubber 80(176) Same as above. Flammable

ABS Acrylonitrile butadienestyrene resin 80(176) Avoid gasoline and solvents.

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

ASA Acrylonitrile styreneacrylate 100(222) Avoid gasoline and solvents. Flammable

AS Acrylonitrile styrene 85(185) Avoid gasoline and solvents.

AES Acrylonitrile ethylenestyrene 80(176) Avoid gasoline and solvents.

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

EVA Polyvinyl ethyl acetate 90(194) Avoid gasoline and solvents.

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

PC Polycarbonate 120(248) Avoid gasoline and solvents.

L-LDPE Lenear low densitypolyethylene 45(100) Gasoline and most solvents are

harmless. Flammable

PUR Polyurethane 90(194) Same as above.

PPC Polypropylene composite 115(239) Same as above. Flammable

POM Polyacetal 120(248) Same as above. Avoid battery acid.

PA Polyamide(Nylon) 140(284) Same as above. Avoid immersing in water.

PET Polyethylene terephthalate 180(356) Same as above.

PBT Polybutylene terephthalate 140(284) Same as above.


26

Location of Plastic Parts


27

Location of Plastic Parts (Cont’d)

PRECAUTIONS IN REPAIRING HIGH STRENGTH STEEL

28

Door guard beamSP150785-981 N/mm2

(80-100 kg/mm2

114-142 klb/sq in)

Front side member

Hoodledge

Inner sill

2nd crossmember assembly

Rear side member extension

SP130373 N/mm2

(38 kg/mm2, 54 klb/sq in)

Major applicable partsNissan designationTensile strength

Precautions in Repairing High Strength Steel

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:

HIGH STRENGTH STEEL (HSS) USED IN NISSAN VEHICLES

SP130 is the most commonly used HSS.

SP150 HSS is used only on parts that require much more strength.


29

Precautions in Repairing High Strength Steel (Cont’d)

Read the following precautions when repairing HSS:1. Additional points to consider

The repair of reinforcements (such as side members)

by heating is not recommended since it may weaken

the component. When heating is unavoidable, do not

heat HSS parts above 550oC (1, 022 oF)Verify heating temperature with a thermometer.

(Crayon-type and other similar type thermometer are

available.)

When straightening body panels, use caution in

pulling any HSS panel. Because HSS is very strong,

pulling may cause deformation in adjacent portions

of the body. In this case, increase the number of

measuring points, and carefully pull the HSS panel.

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

(1.97 in).

When welding HSS panels, use spot welding

whenever possible in order to minimize weakeningsurrounding areas due to heat.

If spot welding is impossible, use M.I.G. welding. Do

not use gas (torch) welding because it is inferior in

welding strength.


30

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

31 (1.22) or over

The spot weld 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.

SP150 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 beams and in

the bumper, is too strong to repair. When these HSSparts are damaged, the outer panels also sustain

substantial damage; therefore, the door assembly or

bumper assembly must be replaced.

2. Precautions in spot welding HSS

This work should be performed under standard workingconditions. Always note the following when spot welding

HSS:

The electrode tip diameter must be sized properly

according to the metal thickness.

The panel surfaces must fit flush to each other, leaving

no gaps.

Follow the specifications for the proper welding pitch.

0.6 (0.024)

0.8 (0.031)

1.0 (0.039)

1.2 (0.047)

1.6 (0.063)

1.8 (0.071)

Minimum pich ( )Thickness (t)

Precautions in Repairing High Strength Steel (Cont’d)

Unit:mm

REPLACEMENT OPERATIONS

31

Spotweld

Description

The symbols used in this manual for cutting and welding / brazing operations are shown below.

Saw cut or air chisel cut

2-spotwelds

3-spotwelds

MIG plug weld

MIG seam weld/Point weld

Brazing

Soldering

Sealing

2-spot welds(2-panel overlapping portions)

3-spot welds(3-panel overlapping portions)


32

Radiator Core Support

Service Joint Indicates that there is an equivalent welding portionwith the same dimensions on the opposite side.


33

Radiator Core Support (Partial Replacement)

Service Joint

Unit: mm


34

Hoodledge

Service Joint

Work after radiator core support has been removed.

Unit: mm


35

Hoodledge (Partial Replacement)

Service Joint(This figure shows right side hoodledge)


Unit: mm


36

Front Side Member

Service Joint

Work after hoodledge and radiator core support have been removed.


37

Front Side Member (Partial Replacement)

Service Joint (This figure shows right front side member)


Unit: mm


38

Front Pillar

Service Joint

See REPLACEMENT NOTES. Work after hoodledge reinforcement has been removed.

Unit: mm


39

Center Pillar

Service Joint

Unit: mm


40

Rear Fender

Service Joint

Unit: mm


41

Rear Floor Rear

Service Joint

Work after rear panel has been removed.

Indicates that there is an equivalent welding portionwith the same dimensions on the opposite side.


42

Rear Side Member Extension

Service Joint

Work after rear panel has been removed.

REPLACEMENT NOTES

43

Front Pillar

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.

Determine cutting position and record distance from

location cutout. Use this distance when cutting service

part. Cut outer front pillar 60 mm above inner front pillar

cut position.

Prepare a cutting jig to make outer pillar easier to cut.

Also, this will permit service part to be accurately cut

at joint position.

An example of cutting operation using a cutting jig isas follows:

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.

COMMENT FORM

44

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Technical Service Information

39001 Sunrise Drive, P.O. Box 9200

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FAX: (248) 488-3910

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Body Repair Manual 2000 Nissan Maxima a33

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