BRM PDF

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

B
E
CONTENTS
VEHICLE INFORMATION ............................. 2 Stone Guard Coat ....................................................22 F
Body Sealing ...........................................................23
BODY EXTERIOR PAINT COLOR ..................... 2
Body Exterior Paint Color .......................................... 2 BODY CONSTRUCTION .................................. 27
G
Body Construction ...................................................27
PRECAUTION ............................................... 3 Rear Fender Hemming Process ..............................28
PRECAUTIONS ................................................... 3 REPLACEMENT OPERATIONS ....................... 30 H

High Voltage Precautions .......................................... 3 Description ...............................................................30
Radiator Core Support .............................................32
REPAIRING HIGH STRENGTH STEEL .............. 5 Hoodledge ...............................................................33
High Strength Steel (HSS) ...................................... 5 I
Hoodledge (Partial Replacement) ...........................34
Handling of Ultra High Strength Steel Plate Parts...... 7 Front Side Member ..................................................35
Front Side Member (Partial Replacement) ..............38
PAINTING BOOTH .............................................. 8 J
Front Pillar ...............................................................40
Criteria for Battery Removal When Drying Painting
Center Pillar .............................................................43
...... 8
Outer Sill (Partial Replacement) ..............................46
PROTECTION OF VEHICLE ............................... 9 Outer Sill ..................................................................47 BRM
Protection of Vehicle ................................................. 9 Rear Fender ............................................................50
Rear Fender Extension ............................................54
PREPARATION ........................................... 10 Rear Panel ...............................................................55 L
Rear Floor Rear .......................................................56
REPAIRING MATERIAL ....................................10 Rear Side Member Extension ..................................57
Foam Repair ........................................................... 10
SERVICE DATA AND SPECIFICATIONS M
BODY COMPONENT PARTS ............................12 (SDS) ............................................................ 59
Underbody Component Parts .................................. 12
Body Component Parts ........................................... 15 BODY ALIGNMENT .......................................... 59 N
Body Center Marks ..................................................59
BASIC INSPECTION ................................... 18 Description ...............................................................60
REPAIR WORK FLOW ......................................18 Motor Room .............................................................60
O
Underbody ...............................................................62
Repair Judgment Flow ............................................ 18
Passenger Compartment .........................................65
REMOVAL AND INSTALLATION ............... 21 Rear Body ...............................................................67
P
CORROSION PROTECTION .............................21 LOCATION OF PLASTIC PARTS .................... 69
Description .............................................................. 21 Precautions for Plastics ...........................................69
Undercoating ........................................................... 21 Location of Plastic Parts ..........................................70
Revision: 2010 November BRM-1 LEAF

BODY EXTERIOR PAINT COLOR
< VEHICLE INFORMATION >
VEHICLE INFORMATION
BODY EXTERIOR PAINT COLOR
Body Exterior Paint Color INFOID:0000000006956121
JSKIA2267ZZ
Color code BKH3 BK23 BNAH BQX1 BRAT

Description Black Silver Red White Blue
Component
Paint type Note 2S M PM 3P 3PM
Hard clear coat × − × − −
1 Outside mirror cover Body color BKH3 BK23 BNAH BQX1 BRAT
2 Charge port lid Body color BKH3 BK23 BNAH BQX1 BRAT
3 Bumper fascia Body color BKH3 BK23 BNAH BQX1 BRAT
4 Rear spoiler Body color BKH3 BK23 BNAH BQX1 BRAT
5 Back door handle Body color BKH3 BK23 BNAH BQX1 BRAT
6 Door outside handle Chromium plate Cr Cr Cr Cr Cr
NOTE:
• S: Solid
• 2S: Solid + Clear
• CS: Color clear solid
• M: Metallic
• P: 2-Coat pearl
• 3P: 3-Coat pearl
• 3PM: 3-Coat pearl metallic
• FPM: Iron oxide pearl
• RPM: Multi flex color
• TM: Micro titanium metallic
• PM: Pearl metallic

PRECAUTIONS
< PRECAUTION >
PRECAUTION A
PRECAUTIONS
High Voltage Precautions INFOID:0000000006956122
B
WARNING:
• Because hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of elec-
C
tric shock, electric leakage, or similar accidents if the high voltage component and vehicle are han-
dled incorrectly. Be sure to follow the correct work procedures when performing inspection and
maintenance.
• Be sure to remove the service plug in order to shut off the high voltage circuits before performing D
inspection or maintenance of high voltage system harnesses and parts.
• Be sure to put the removed service plug in your pocket and carry it with you so that another person
does not accidentally connect it while work is in progress. E
• Be sure to wear insulating protective equipment consisting of glove, shoes and face shield before
beginning work on the high voltage system.
• Clearly identify the persons responsible for high voltage work and ensure that other persons do not
touch the vehicle. When not working, cover high voltage parts with an insulating cover sheet or sim- F
ilar item to prevent other persons from contacting them.
CAUTION:
There is the possibility of a malfunction occurring if the vehicle is changed to READY status while the G
service plug is removed. Therefore do not change the vehicle to READY status unless instructed to do
so in the Service Manual.
HIGH VOLTAGE HARNESS AND EQUIPMENT IDENTIFICATION H
The colors of the high voltage harnesses and connectors are all orange. Orange "High Voltage" labels are
applied to the Li-ion battery and other high voltage devices. Do not carelessly touch these harnesses and
parts.
I
HANDLING OF HIGH VOLTAGE HARNESS AND TERMINALS
Immediately insulate disconnected high voltage connectors and terminals with insulating tape.
REGULATIONS ON WORKERS WITH MEDICAL ELECTRONICS J
WARNING:
The vehicle contains parts that contain powerful magnets. If a person who is wearing a pacemaker or
other medical device is close to these parts, the medical device may be affected by the magnets. Such BRM
persons must not perform work on the vehicle.
PROHIBITED ITEMS TO CARRY DURING THE WORK
L
Because this vehicle uses components that contain high voltage and powerful magnetism, due not carry any
metal products which may cause short circuits, or any magnetic media (cash cards, prepaid cards, etc.) which
may be damaged on your person when working.
M
POSTING A SIGN OF “DANGER! HIGH VOLTAGE AREA. KEEP OUT”

PRECAUTIONS
< PRECAUTION >
To call the attention of other workers, indicate "High voltage work in progress. Do not touch!" on vehicles
where work is being performed on the high voltage systems.
JSAIA1600GB

REPAIRING HIGH STRENGTH STEEL
< PRECAUTION >
A
High Strength Steel (HSS) INFOID:0000000006956123
High strength steel is used for body panels in order to reduce vehicle weight. B
Accordingly, precautions in repairing automotive bodies made of high strength steel are described below:
Tensile strength Major applicable parts

C
• Rear side member closing plate
• Trans control reinforcement
(Center front floor component part)
• Rear side member front extension D
(Front floor component part)
• Front floor front
• 2nd crossmember E
• 3rd crossmember
• Inner sill reinforcement F
(Inner sill component part)
• Side dash
• Front suspension spring support
G
(Front strut housing component part)
• Front side member front assembly
• Front side member assembly
440 - 780 MPa
• Front side member closing plate assembly H
• Rear seat crossmember
• Rear crossmember center assembly
• Rear side member
• Rear side member extension reinforcement assembly I
• Rear side member extension
• Inner side roof rail
• Upper inner front pillar
• Front pillar brace J
• Lower center pillar brace
• Outer sill reinforcement
• Inner rear pillar reinforcement
• Lower rear panel reinforcement
BRM
(Upper rear panel component part)
• Front roof rail (Lower)
(Front roof rail component part) L
• Roof member reinforcement
(Center roof reinforcement component part)
• Front side member center extension
(Front floor component part) M
• Front side member rear extension
• Inner sill
N
• Inner front sill reinforcement (Upper & Lower)
(Inner sill component part)
• Lower dash crossmember (Upper RH & LH)
(Lower dash component part) O
980 MPa
• Lower dash crossmember (Lower)
• Center pillar seat belt anchor
(Inner center pillar assembly component part)
• Inner center pillar assembly (Upper side) P
• Outer side roof rail reinforcement
• Center pillar reinforcement
(Lower center pillar brace component part)
• Front roof rail reinforcement
(Front roof rail component part)
Read the following precautions when repairing HSS:

< PRECAUTION >
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
above 550°C (1,022°F).
Verify heating temperature with a thermometer.
(Crayon-type and other similar type thermometer are appropri-
ate.)
PIIA0115E
• 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

< PRECAUTION >
• Spot welding on HSS panels is harder than that of an ordinary
steel panel. A
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.
B
PIIA0145E
D
2. Precautions in spot welding HSS
This work should be performed under standard working condi-
tions. Always note the following when spot welding HSS:
E
• The electrode tip diameter must be sized properly according to
the metal thickness.
G
PIIA0146E
• The panel surfaces must fit flush to each other, leaving no H

gaps.
PIIA0147E BRM
• Follow the specifications for the proper welding pitch.

Unit: mm (in) L
Thickness (T) Minimum pitch (L)
0.6 (0.024) 10 (0.39) or more
0.8 (0.031) 12 (0.47) or more M
1.0 (0.039) 18 (0.71) or more
1.2 (0.047) 20 (0.79) or more
1.6 (0.063) 27 (1.06) or more N
1.8 (0.071) 31 (1.22) or more
JSKIA0781ZZ
O
Handling of Ultra High Strength Steel Plate Parts INFOID:0000000006956124
PROHIBITION OF CUT AND CONNECTION P

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).
The front floor assembly must be replaced if this part is damaged.

PAINTING BOOTH
< PRECAUTION >
PAINTING BOOTH
Criteria for Battery Removal When Drying Painting INFOID:0000000006956125
To use painting booth, maintain outer sill (A) temperature at 60°C (140°F) or less to prevent deterioration in li-
ion battery.
NOTE:
• Measure the temperature with a noncontact thermometer.
• If a sill cover (resin) is included, remove the sill cover to measure the temperature.
If outer sill (A) temperature is more than 60°C (140°F), remove li-ion battery beforehand and place in the paint-
ing booth.
JSKIA2340ZZ
A. Outer sill temperature measurement part

PROTECTION OF VEHICLE
< PRECAUTION >
PROTECTION OF VEHICLE
A
Protection of Vehicle INFOID:0000000006956126
The seats, glass, and carpet must be removed or covered with appropriate material (spatter cover), according B
to the type of work to be done, to prevent contamination and welding spatter.
In addition, when cutting the vehicle in an area close to high voltage parts or performing a welding operation,
the high voltage parts must be covered with a heat-resistant insulating cover (spatter cover).
C
BRM

REPAIRING MATERIAL
< PREPARATION >
PREPARATION
REPAIRING MATERIAL
Foam Repair INFOID:0000000006956127
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:0000000006956128
JSKIA2268ZZ

< PREPARATION >
: Both sided anti-corrosive precoated steel sections A

: High strength steel (HSS) sections
: Both sided anti-corrosive steel and HSS sections
*: Aluminum portion B
Both sided
Tensile strength anti-corrosive Aluminum C
No. Parts name
(MPa) precoated portion
steel sections
1. Rear floor rear Under 440 × —
D
2. Rear floor rear side (RH & LH) 590 × —
3. Upper seat crossmember assembly Under 440 — —
4. Rear floor front 440 × — E
5. Rear side member closing plate (RH & LH) 590 × —
6. Rear floor front extension Under 440 × —
F
7. Center front floor 440 × —
T=1.8 mm
a.
(0.071 in) 980caution
8. Front floor (RH & LH) × — G
T=1.8 mm caution
b. 980
(0.071 in)
T=1.4 mm
c. 980caution H
(0.055 in)
T=2.0 mm
9. Inner sill (RH & LH) d. 980caution × —
(0.079 in)
I
T=1.6 mm
e.
(0.063 in) 980caution
10. Cowl top Under 440 × —

J
11. Upper dash Under 440 × —
T=1.4 mm
12. Lower dash f. 980caution × —
(0.055 in)
BRM
T=2.0 mm
13. Lower dash crossmember 980caution × —
(0.079 in)
14. Side dash (RH & LH) 590 × — L
15. Front strut housing (RH & LH) 590 × —
16. Lower front hoodledge (RH & LH) Under 440 × —
17. Upper hoodledge (RH & LH) Under 440 × — M
18. Hoodledge reinforcement (RH & LH) Under 440 × —
19. Hoodledge connector (RH & LH) Under 440 × —
N
20. Side radiator core support (RH & LH) Under 440 × —
21. Inner center front bumper reinforcement — — ×
22. Front side member front assembly (RH & LH) 590 × — O
23. Front side member assembly (RH & LH) 780 × —
24. Front suspension mounting bracket (RH & LH Front) 590 × —
P
25. Front side member closing plate assembly (RH & LH) 780 × —
26. Outer add on frame bracket (RH & LH) Under 440 × —
27. Front suspension mounting bracket (RH & LH Rear) Under 440 × —
28. Rear seat crossmember 440 × —
29. Rear crossmember center assembly 440 × —
30. 7th crossmember Under 440 × —

< PREPARATION >
Both sided
Tensile strength anti-corrosive Aluminum
No. Parts name
steel sections
31. Rear side member (RH & LH) 780 × —
32. Rear side member extension reinforcement assembly (RH & LH) 440 × —
33. Rear side member extension (RH & LH) 590 × —
NOTE:
• For the parts without a number described in the figure, it is supplied only with the assembly part that the part is included with.
• Tensile strength column shows the largest strength value of a part in the component part.
CAUTION:
If the high strength steel (ultra high strength steel) of this is broken, replace by assembly for the supply part.

< PREPARATION >
Body Component Parts INFOID:0000000006956129
BRM
P
JSKIA2269ZZ
: Both sided anti-corrosive precoated steel sections

: High strength steel (HSS) sections
: Both sided anti-corrosive steel and HSS sections
*: Aluminum portion

< PREPARATION >
Both sided
Tensile strength anti-corrosive Aluminum
No. Parts name
steel sections
1. Hood — — ×
2. Front fender (RH & LH) Under 440 × —
3. Inner side roof rail (RH & LH) 780 — —
4. Upper inner front pillar (RH & LH) 780 — —
T=1.6 mm
a.
(0.063 in) 980caution — —
5. Inner center pillar assembly (RH & LH)
T=1.4 mm
b.
(0.055 in) 980caution — —
6. Side body assembly (RH & LH) Refer to No.7−12

T=1.4 mm
7. Outer side roof rail reinforcement (RH & LH)
(0.055 in) 980caution — —
8. Front pillar brace (RH & LH) 590 — —

T=1.2 mm
9. Lower center pillar brace (RH & LH) c.
(0.047 in) 980caution — —
10. Outer front side body (RH & LH) Under 440 × —
11. Front fender bracket assembly (RH & LH) Under 440 × —
12. Outer sill reinforcement (RH & LH) 780 × —
13. Outer sill (RH & LH) Under 440 × —
14. Front door (RH & LH) — — ×
15. Outer front door panel (RH & LH) — — ×
16. Rear door (RH & LH) — — ×
17. Outer rear door panel (RH & LH) — — ×
18. Inner rear pillar (RH & LH) 440 — —
19. Inner rear pillar reinforcement (RH & LH) 440 — —
20. Inner rear wheelhouse (RH & LH) 590 × —
21. Outer rear wheelhouse (RH & LH) Under 440 × —
22. Outer rear wheelhouse extension (RH & LH) Under 440 × —
23. Roof Under 440 — —
T=1.0 mm
24. Front roof rail d.
(0.039 in) 980caution — —
25. Roof bow No.1 Under 440 — —

26. Center roof reinforcement 590 — —
29. Rear roof rail Under 440 — —
30. Rear fender (RH & LH) Under 440 × —
31. Rear fender extension (RH & LH) Under 440 — —
32. Rear fender corner (RH & LH) Under 440 × —
33. Back door Under 440 × —
34. Upper rear panel 440 × —
35. Upper rear bumper retainer Under 440 × —
36. Rear side bumper bracket Under 440 × —

< PREPARATION >
Both sided
Tensile strength anti-corrosive Aluminum A
No. Parts name
steel sections
37. Rear bumper stay (RH & LH) Under 440 × — B
38. Inner center rear bumper reinforcement — — ×
NOTE:
• For the parts without a number described in the figure, it is supplied only with the assembly part that the part is included with. C
• Tensile strength column shows the largest strength value of a part in the component part.
CAUTION:
If the high strength steel (ultra high strength steel) of this is broken, replace by assembly for the supply part. D
BRM

REPAIR WORK FLOW
< BASIC INSPECTION >
BASIC INSPECTION
REPAIR WORK FLOW
Repair Judgment Flow INFOID:0000000006956130
WARNING:
• Because hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of elec-
tric shock, electric leakage, or similar accidents if the high voltage component and vehicle are han-
dled incorrectly. Be sure to follow the correct work procedures when performing inspection and
maintenance.
• Be sure to remove the service plug in order to shut off the high voltage circuits before performing
inspection or maintenance of high voltage system harnesses and parts.
• Be sure to put the removed service plug in your pocket and carry it with you so that another person
does not accidentally connect it while work is in progress.
• Be sure to wear insulating protective gear consisting of glove, shoes and glasses/face shield before
beginning work on the high voltage system.
• Clearly identify the persons responsible for high voltage work and ensure that other persons do not
touch the vehicle. When not working, cover high voltage parts with an insulating cover sheet or sim-
ilar item to prevent other persons from contacting them.
• Refer to BRM-3, "High Voltage Precautions".
CAUTION:
There is the possibility of a malfunction occurring if the vehicle is changed to READY status while the
service plug is removed. Therefore do not change the vehicle to READY status unless instructed to do
so in the Service Manual.
OVERALL SEQUENCE
JSKIA2341GB
DETAILED FLOW
1.CHECK LIGHTING OF MASTER WARNING LAMP
Check that the master warning lamp is ON.

REPAIR WORK FLOW
Is master warning lamp ON?
YES >> GO TO 2. A
NO >> GO TO 3.
2.DETECT MALFUNCTIONING PART BY TROUBLE DIAGNOSIS, ACCORDING TO THE SERVICE MANU-
B
AL
Connect CONSULT to check malfunction information.
Is there malfunction information in high voltage parts? C
YES >> GO TO 5.
NO >> GO TO 3.
3.CHECK HIGH VOLTAGE PARTS FOR DAMAGE D
Visually check high voltage parts for damage.
WARNING:
When performing high voltage-related work, always wear insulating protective gear. E
Is there a malfunction in high voltage parts?
YES >> GO TO 5.
NO >> GO TO 4. F
4.CHECK AREA ADJACENT TO DAMAGE FOR THE PRESENCE OF HIGH VOLTAGE PARTS
Check high voltage parts requiring additional removal work. G
Is additional removal work required for high voltage parts?
YES >> GO TO 5.
NO >> Start body repair and painting. H
5.PRECONDITIONING
WARNING: I
Shut off high voltage circuit. Refer to GI-31, "How to Cut Off High Voltage".
Check voltage in high voltage circuit. (Check that condenser are discharged.)
1. Disconnect high voltage connector from front side of Li-ion battery. Refer to EVB-136, "Removal and
Installation". J
DANGER:
Always use protective gear as touching high voltage components without using them will BRM
cause electrocution. (where high voltage might remain/is present on terminals.)
L
2. Measure voltage between high voltage harness terminals.
DANGER:
M
Always use protective gear as touching high voltage
components without using them will cause electrocution.
(where high voltage might remain/is present on terminals.) N
O
Standard : 5 V or less JSAIA1362ZZ
CAUTION: P
For voltage measurements, use a tester which can measure to 500V or higher.
>> GO TO 6.
6.REMOVE HIGH VOLTAGE PARTS AS AN ADDITIONAL WORK, ACCORDING TO THE SERVICE MANU-
AL

REPAIR WORK FLOW
Remove high voltage parts as an additional work, according to the Service Manual.
WARNING:
When performing high voltage-related work, always wear insulating protective gear.
>> Start body repair and painting.

CORROSION PROTECTION
< REMOVAL AND INSTALLATION >
REMOVAL AND INSTALLATION A
Description INFOID:0000000006956131
B
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. C
ANTI-CORROSIVE PRECOATED STEEL (GALVANNEALED STEEL)

To improve repairability and corrosion resistance, a new type of anti-
D
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 E
with cationic electrodeposition primer.
SIIA2294E
G
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-
H
mance built into the vehicle at the factory.
PHOSPHATE COATING TREATMENT AND CATIONIC ELECTRODEPOSITION PRIMER
A phosphate coating treatment and a cationic electrodeposition I
primer, which provide excellent corrosion protection, are employed
on all body components.
CAUTION:
Confine paint removal during welding operations to an absolute J
minimum.
BRM
PIIA0095E L
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 M
built into the vehicle at the factory.
Undercoating INFOID:0000000006956132
N
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.
O
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). P
2. Never undercoat the exhaust pipe or other parts that become hot.
3. Never undercoat rotating parts.
4. Apply bitumen wax after applying undercoating.
5. After putting seal on the vehicle, put undercoating on it.

JSKIA2446ZZ
: Undercoated areas
: Sealed portions
Stone Guard Coat INFOID:0000000006956133
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 the same portions as before. Use a coating which is rust preventive, durable, shock-resistant
and has a long shelf life.

JSKIA2271ZZ
BRM
: Stone guard coated portions

L
Body Sealing INFOID:0000000006956134
The following figure shows the areas that are sealed at the factory. Sealant that is applied to these areas M
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.

JSKIA2272ZZ
: Vehicle front
: Sealed portions

BRM
JSKIA2273ZZ
P
: Vehicle front
: Sealed portions

JSKIA2274ZZ
: Vehicle front
: Sealed portions

BODY CONSTRUCTION
BODY CONSTRUCTION
A
Body Construction INFOID:0000000006956135
BRM
JSKIA2275ZZ
1. Outer side body 2. Outer front pillar reinforcement 3. Inner front side roof rail
4. Upper dash 5. Hoodledge reinforcement 6. Weld nut
7. Side dash 8. Upper hinge plate 9. Inner front pillar reinforcement

BODY CONSTRUCTION
10. Lower front pillar hinge brace 11. Lower hinge plate 12. Inner front sill reinforcement
13. Inner sill 14. Front side member center extension 15. Front side member closing plate
16. Front outrigger 17. Front floor front 18. Lower front pillar reinforcement
19. Outer sill reinforcement 20. Outer sill brace 21. Front side member rear extension
22. Floor member extension 23. Center sill reinforcement 24. Roof
25. Center roof reinforcement 26. Roof member reinforcement 27. Inner center pillar
28. Center pillar seat belt anchor 29. Center pillar reinforcement 30. Center pillar hinge brace
31. Outer side roof rail 32. Front floor side 33. Rear side member closing plate
34. Rear side member reinforcement 35. Rear side member 36. Inner sill extension
37. Inner rear sill reinforcement 38. Outer rear wheelhouse extension 39. Inner rear wheelhouse
40. Outer rear wheelhouse 41. Rear fender extension 42. Back door stay bracket
43. Inner rear pillar 44. Rear roof rail brace 45. Inner rear pillar reinforcement
46. Rear pillar seat belt anchor
Rear Fender Hemming Process INFOID:0000000006956136
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 the Body Repair Manual (Fundamentals) in order to ensure that the
original functions and quality of the vehicle are maintained. The Body Repair Manual (Fundamentals) con-
tains additional information, including cautions and warnings, that are not including in this manual. Techni-
cians should refer to both manuals to ensure proper repair.
• Please note that this information is prepared for worldwide usage, and as such, certain procedures might not
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.
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 the inner front pillar cut E
position.
G
JSKIA0104GB
• Prepare a cutting jig to make outer pillar easier to cut. Also, this will H
permit the service part to be accurately cut at the joint position.
BRM
JSKIA0105GB
• An example of cutting operation using a cutting jig is as per the fol-

L
lowing.
1. Mark cutting lines.
A: Cut position of outer pillar
B: Cut position of inner pillar M
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.
N
5. Cut inner pillar at position B in same manner.
PIIA0153E
O

Radiator Core Support INFOID:0000000006956138
JSKIA2302ZZ
: Vehicle front
Replacement parts
z Side radiator core support (LH) z Hoodledge connector (LH)
High voltage system parts (Removal required depending on damage)
z Service plug z Front side Li-ion battery high voltage harness connector
z Charge port

Hoodledge INFOID:0000000006956139
A
Work after radiator core support is removed.
BRM
O
JSKIA2303ZZ
: Vehicle front
P
: Weld the parts onto the back of the component part.
Replacement parts
z Front strut housing (LH) z Hoodledge reinforcement (LH)

z Charge port z PTC elements heater z Traction motor
z Electric compressor z Traction motor inverter z DC/DC-J/B
View C: Before installing hoodledge reinforcement

Hoodledge (Partial Replacement) INFOID:0000000006956140
JSKIA2304GB
Unit: mm (in)
: Vehicle front
Replacement parts
z Upper hoodledge (RH) z Lower front hoodledge (RH) z Hoodledge reinforcement (RH)

z Service plug z Front side Li-ion battery high voltage harness connector A
B
View B and D: Before installing hoodledge reinforcement
Front Side Member INFOID:0000000006956141
C
Work after radiator core support and hoodledge are removed.
BRM
JSKIA2305ZZ

: Vehicle front
: Drill φ11 mm (0.43 in) hole for the plug welding hole (ultra high strength steel plate).
Replacement parts
z Front side member assembly (LH) z Front side member closing plate as- z Front suspension mounting bracket
sembly (LH) (LH Rear)

BRM
N
JSKIA2306ZZ
: Vehicle front O
P
View D and G: Before installing front suspension mounting bracket (Rear)

JSKIA2307GB
: Vehicle front
: N·m (kg-m, ft-lb)
Front Side Member (Partial Replacement) INFOID:0000000006956142

BRM
N
JSKIA2308ZZ
: Vehicle front O
Replacement parts
z Front suspension mounting bracket z Outer add on frame bracket (RH) P
(RH Front)
z Charge port
View A: Before installing outer add on frame bracket

Front Pillar INFOID:0000000006956143
Work after hoodledge reinforcement is removed.
JSKIA2309GB
1. Body sealing 2. Front pillar brace 3. Urethane foam

Unit: mm (in)
: Vehicle front
Replacement parts
z Side body assembly (LH) z Side dash (LH)

BRM
N
JSKIA2310GB
1. Urethane foam O
Unit: mm (in)
: Vehicle front
: Drill φ6 mm (0.24 in) hole for the plug welding hole (ultra high strength steel plate). P
View F: Before installing outer front side body

JSKIA2311GB
1. Urethane foam
Unit: mm (in)
: Vehicle front
View G: Before installing side body assembly

View M: Before installing outer front side body

Center Pillar INFOID:0000000006956144
A
Install the inner center pillar assembly to the side body assembly as shown in the figure for repairing the hid-
den welding point ″View E″.
B
BRM
JSKIA2312GB
P
1. Inner center pillar assembly 2. Lower center pillar brace 3. Outer sill reinforcement
Unit: mm (in)
: Vehicle front

Replacement parts
z Side body assembly (LH) z Inner center pillar assembly (LH)
JSKIA2313GB
Unit: mm (in)
: Vehicle front
View B: Before installing outer front side body

View E: Inner center pillar assembly and side body assembly (replacement parts)

BRM
N
JSKIA2314GB
1. Inner center pillar assembly 2. Outer sill reinforcement O

Unit: mm (in)
: Vehicle front
: Drill φ9 mm (0.35 in) hole for the plug welding hole (ultra high strength steel plate). P
View G: Before installing outer front side body

Outer Sill (Partial Replacement) INFOID:0000000006956145
JSKIA2315GB
Unit: mm (in)
Replacement parts
z Outer sill (LH)

Outer Sill INFOID:0000000006956146
BRM
JSKIA2316GB O
1. Urethane foam 2. Front pillar brace 3. Inner center pillar assembly

4. Lower center pillar brace 5. Outer sill reinforcement P
Unit: mm (in)
: Vehicle front
Replacement parts
z Outer sill (LH) z Front fender bracket assembly (LH)

JSKIA2317GB
1. Hemming portion 2. Outer sill reinforcement 3. Inner center pillar assembly

4. Front pillar brace 5. Lower center pillar brace 6. Adhesive
7. Body sealing
Unit: mm (in)
: Vehicle front
POINT

• Perform the hemming to the flange of wheelarch after applying the
adhesive. A
• Apply the sealing to the flange end.
• Refer to BRM-28, "Rear Fender Hemming Process".
B
1. Outer rear wheelhouse
2. Rear fender
3. Adhesive C
4. Sealant
JSKIA0204GB
BRM

Rear Fender INFOID:0000000006956149
JSKIA2322GB
1. Urethane foam 2. Adhesive 3. Hemming portion

Unit: mm (in)
: Vehicle front
Replacement parts
z Rear fender (LH)

BRM
N
JSKIA2323GB
1. Body sealing O
Unit: mm (in)
: Vehicle front
: Weld the parts onto the back of the component part. P

JSKIA2324GB
1. Urethane foam
Unit: mm (in)
: Vehicle front
View K: Before installing rear fender

POINT

• Perform the hemming to the flange of wheelarch after applying the
adhesive. A
• Apply the sealing to the flange end.
• Refer to BRM-28, "Rear Fender Hemming Process".
B
1. Outer rear wheelhouse
2. Rear fender
3. Adhesive C
4. Sealant
JSKIA0204GB
BRM

Rear Fender Extension INFOID:0000000006956150
JSKIA2325ZZ
1. Body sealing
: Vehicle front
Replacement parts
z Rear fender corner (LH)

Rear Panel INFOID:0000000006956155
BRM
JSKIA2330GB O
Unit: mm (in)
: Vehicle front P
: Welding method and the number of welding points apply to both side of the vehicle.
Replacement parts
z Upper rear panel

Rear Floor Rear INFOID:0000000006956156
Work after rear panel is removed.
JSKIA2331ZZ
1. LH side 2. RH side
: Vehicle front
: Welding method and the number of welding points apply to both side of the vehicle.
Replacement parts
z Rear floor rear z Rear floor rear side (LH)

z On board charger A
Rear Side Member Extension INFOID:0000000006956157
B
Work after rear panel is removed.
BRM
P
JSKIA2332ZZ
: Vehicle front
Replacement parts
z Rear side member extension (LH) z Rear side member extension rein-
forcement assembly (LH)

View D: Before installing replacement parts (Weld the rear side member extension and rear side member
extension reinforcement assembly)

BODY ALIGNMENT
< SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS) A
BODY ALIGNMENT
Body Center Marks INFOID:0000000006956160
B
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. C
BRM
JSKIA2276ZZ
O
: Vehicle front
P
Unit: mm (in)
Points Portion Marks
A Front roof Embossment
B Cowl top Embossment
C Trans control reinforcement Hole φ31 (1.22)

BODY ALIGNMENT
Points Portion Marks
D Center front floor Hole φ11 (0.43)
E Rear roof Embossment
• 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″.
• ″Z″: Imaginary base line [200 mm (7.87 in) below datum line (″0Z″ at design plan)]
JSKIA0073GB
1. Vehicle center 2. Front axle center 3. Imaginary base line
Motor Room INFOID:0000000006956162
MEASUREMENT
Dimensions marked with ″*″ indicate symmetrically identical dimensions on both the right and left hand of the
vehicle.

BODY ALIGNMENT
I
JSKIA2277GB
Unit: mm (in)
J
«The others»
Unit: mm (in)
Point Dimension Memo Point Dimension Memo Point Dimension Memo Point Dimension Memo
BRM
A-C 319 (12.56) A-j 790 (31.10) D-d 1447 (56.97) H-j 843 (33.19)
A-c 738 (29.06) A-K 659 (25.94) E-e 1447 (56.97) h-J 840 (33.07)
A-D 565 (22.24) A-k 914 (35.98) F-G 358 (14.09) H-k 923 (36.34) L
A-d 968 (38.11) B-C 268 (10.55)* f-g 363 (14.29) h-K 937 (36.89)
A-E 588 (23.15) B-c 1272 (50.08)* F-g 1086 (42.76) J-j 822 (32.36)
M
A-e 982 (38.66) B-f 1563 (61.54)* f-G 1092 (42.99) J-k 878 (34.57)
A-J 550 (21.65) C-c 1037 (40.83) H-h 782 (30.79) j-K 893 (35.16)
MEASUREMENT POINTS N

BODY ALIGNMENT
JSKIA2278ZZ
: Vehicle front
Unit: mm (in)
Point Material Point Material

A Upper dash hole center φ7 (0.28) G, g Side radiator core support hole center φ9 (0.35)
Traction motor inverter member mounting hole
B, b Hood hinge installing hole center φ11 (0.43) H, h, J, j
center φ18 (0.71)
Front strut installing hole center 18×13
C, c K, k Front side member hole center 12×7 (0.47×0.28)
(0.71×0.51)
Front bumper stay installing hole center φ15
D, d, E, e Front fender installing hole center φ7 (0.28) M, m, N, n
(0.59)
F, f Hoodledge reinforcement hole center φ12 (0.47)
Underbody INFOID:0000000006956163
MEASUREMENT

BODY ALIGNMENT
vehicle. A
The following figure shows a bottom view and a side view of the vehicle.
BRM
P
JSKIA2279GB
Unit: mm (in)
: Vehicle front
: Vehicle left side
MEASUREMENT POINTS

BODY ALIGNMENT
JSKIA2280ZZ
: Vehicle front
Unit: mm (in)
Coordinates Coordinates
Points Remarks Points Remarks
X Y Z X Y Z
470.0 −582.0 327.3 ±626.8 1904.4 318.0
A Hole φ11 (0.43) G, g Hole φ16 (0.63)
(18.504) (−22.913) (12.886) (±24.677) (74.976) (12.520)
−484.0 −582.0 327.3 ±575.4 2060.0 220.0
a Hole φ11 (0.43) H, h Hole φ13 (0.51)
(−19.055) (−22.913) (12.886) (±22.653) (81.102) (8.661)
472.4 −455.0 327.3 ±350.0 2423.0 390.4
B Hole φ20 (0.79) J, j Hole φ16 (0.63)
(18.598) (−17.913) (12.886) (±13.780) (95.394) (15.370)
−489.7 −455.0 327.3 ±482.3 2544.2 348.3
b Hole φ20 (0.79) K, k Hole φ12 (0.47)
(−19.279) (−17.913) (12.886) (±18.988) (100.165) (13.713)
M: Hole φ16 (0.63)
462.4 −346.0 492.8 ±331.3 2821.5 419.8
C Hole φ16 (0.63) M, m m: Hole 18×16
(18.205) (−13.622) (19.402) (±13.043) (111.082) (16.528)
(0.71×0.63)

BODY ALIGNMENT
Coordinates Coordinates
Points Remarks Points Remarks A
X Y Z X Y Z
−474.7 −372.0 492.8 ±488.5 2964.4 375.4 Hole 17×16
c Hole φ16 (0.63) N, n
(−18.689) (−14.646) (19.402) (±19.232) (116.708) (14.779) (0.67×0.63)
B
±458.8 572.9 189.2 ±583.6 6.6 868.2
D, d Hole φ16 (0.63) O, o Hole φ98 (3.86)
(±18.063) (22.555) (7.449) (±22.976) (0.260) (34.181)
±538.0 1062.0 220.0 ±575.4 2739.3 737.6
E, e Hole φ15 (0.59) P, p Hole φ20 (0.79) C
(±21.181) (41.811) (8.661) (±22.653) (107.846) (29.039)
±538.0 1540.0 220.0
F, f Hole φ15 (0.59)
(±21.181) (60.630) (8.661)
D
Passenger Compartment INFOID:0000000006956164
MEASUREMENT E
vehicle.
F
BRM
N
JSKIA2281GB
Unit: mm (in) O
«The others»

BODY ALIGNMENT
Unit: mm (in)
Point Dimension Memo Point Dimension Memo Point Dimension Memo Point Dimension Memo
E-e 1227 (48.31) J-j 1420 (55.91) P-p 1160 (45.67) T-N 847 (33.35)*
E-g 1582 (62.28)* K-k 1441 (56.73) P-r 1562 (61.50)* T-O 732 (28.82)*
E-h 1397 (55.00)* M-m 1267 (49.88) Q-q 1392 (54.80) T-P 1378 (54.25)*
E-k 1599 (62.95)* M-o 1545 (60.83)* R-r 1441 (56.73) T-Q 1169 (46.02)*
F-f 1420 (55.91) M-p 1385 (54.53)* S-E 1068 (42.05)* T-R 983 (38.70)*
F-j 1663 (65.47)* M-r 1630 (64.17)* S-F 855 (33.66)* U-W 1162 (45.75)*
G-g 1425 (56.10) N-n 1420 (55.91) S-G 772 (30.39)* U-X 1133 (44.61)*
G-h 1852 (72.91)* N-q 1575 (62.01)* S-H 1297 (51.06)* V-W 1215 (47.83)*
G-k 1666 (65.59)* O-o 1441 (56.73) S-J 1068 (42.05)* V-X 1105 (43.50)*
H-h 1270 (50.00) O-p 1717 (67.60)* S-K 925 (36.42)*
H-k 1555 (61.22)* O-r 1558 (61.34)* T-M 1070 (42.13)*
MEASUREMENT POINTS
JSKIA2282ZZ

BODY ALIGNMENT
: Vehicle front A
Unit: mm (in)

B
A Cowl top flange end of center positioning mark P, p, Q, q, R, r Rear fender indent
Trans control reinforcement hole center of center
B Roof flange end of center positioning mark S
positioning mark φ31 (1.22) C
Center front floor hole center of center position-
C, c, F, f Outer side body joggle T
ing mark φ11 (0.43)
Door hinge installing hole center D
U, u, V, v, W,
D, d, E, e, G, g Outer side body indent U, u, V, v, X, x: φ12 (0.47)
w, X, x
W, w: φ9 (0.35)
H, h, J, j, K, k,
E
M, m, N, n, O, Center pillar indent
o
Rear Body INFOID:0000000006956165

F
MEASUREMENT
Dimensions marked with ″*″ indicate symmetrically identical dimensions on both the right and left hand of the G
vehicle.
BRM
JSKIA2283GB P
Unit: mm (in)
MEASUREMENT POINTS

BODY ALIGNMENT
JSKIA2284ZZ
: Vehicle front
Unit: mm (in)

A Roof indent of center positioning mark C, c, D, d Rear combination lamp base joggle
B, b Rear fender extension joggle E, e Back door striker installing hole center φ15 (0.59)

LOCATION OF PLASTIC PARTS
A
Precautions for Plastics INFOID:0000000006956166
B
Heat resisting
Abbre- Resistance to gasoline and
Material name temperature Other cautions
viation solvents
°C (°F)
C
Gasoline and most solvents are
PE Polyethylene 60 (140) harmless if applied for a very Flammable
short time (wipe out quickly).
ABS Acrylonitrile Butadiene Styrene 80 (176) Avoid gasoline and solvents. — D
EPM/ Ethylene Propylene (Diene) co-
80 (176) harmless if applied for a very Flammable
EPDM polymer
short time (wipe out quickly). E
PS Polystyrene 80 (176) Avoid solvents. Flammable
Poisonous gas is emitted
PVC Poly Vinyl Chloride 80 (176) harmless if applied for a very F
when burned.
TPO Thermoplastic Olefine 80 (176) ↑ Flammable
AAS Acrylonitrile Acrylic Styrene 85 (185) Avoid gasoline and solvents. — G
PMMA Poly Methyl Methacrylate 85 (185) ↑ —
EVAC Ethylene Vinyl Acetate 90 (194) ↑ —
H
Flammable, avoid bat-
PP Polypropylene 90 (194) harmless if applied for a very
tery acid.
I
PUR Polyurethane 90 (194) Avoid gasoline and solvents. —
UP Unsaturated Polyester 90 (194) ↑ Flammable
ASA Acrylonitrile Styrene Acrylate 100 (212) ↑ Flammable J
PPE Poly Phenylene Ether 110 (230) ↑ —
TPU Thermoplastic Urethane 110 (230) ↑ —
PBT+ Poly Butylene Terephthalate +
BRM
120 (248) ↑ Flammable
PC Polycarbonate
PC Polycarbonate 120 (248) ↑ —
L
POM Poly Oxymethylene 120 (248) ↑ Avoid battery acid.
Avoid immersing in wa-
PA Polyamide 140 (284) ↑
ter.
M
PBT Poly Butylene Terephthalate 140 (284) ↑ —
PAR Polyarylate 180 (356) ↑ —
PET Polyethylene terephthalate 180 (356) ↑ — N
PEI Polyetherimide 200 (392) ↑ —
CAUTION:
• When repairing and painting a portion of the body adjacent to plastic parts, consider their characteristics (influence of heat O
and solvent) and remove them if necessary or take suitable measures to protect them.
• Plastic parts should be repaired and painted using methods suiting the materials, characteristics.
P

Location of Plastic Parts INFOID:0000000006956167
JSKIA2285ZZ
Component Material Component Material

Side roof molding PVC + Stainless 10 Door outside molding PVC + Stainless
1
Lower side molding ASA Lens PMMA
11 Rear combination lamp
2 Upper windshield molding TPO Housing ASA
Lens PMMA 12 Rear spoiler ABS
3 Front side marker lamp
Housing PP Lens PMMA
13 High mount stop lamp
Lens PC Housing ABS
4 Front combination lamp
Housing PP 14 Back door handle ABS
5 Charge port lid PC + PET Lens PMMA
15 License plate lamp
6 Bumper fascia PP + EPM Housing PC
7 Front fender protector PP Lens PMMA
16 Reflex reflector
Lens PMMA Housing ABS
8 Side turn signal lamp PC + PET +
Housing PC + ABS Grip body
17 Door outside handle Glass fiber
Case PP + Glass fiber Grip cover PC + ABS
PBT + PET +
9 Door outside mirror Base
Glass fiber
Cover ABS

H
JSKIA2286ZZ
Component Material Component Material

I
1 Front pillar garnish PP 5 Rear pillar finisher PP
Lens PC Body PP
6 Center console
Map lamp Housing PP Console finisher PC + ABS J
2 Center cover PP 7 Cluster lid C PC + ABS
Case PP 8 Glove box PP
Sunglass holder BRM
Holder PC + ABS 9 Instrument panel PP
3 Center pillar garnish PP Cluster lid A PP
Lens PC 10 Cluster lid finisher PP
4 Room lamp L
Housing PP Meter cover PC + ABS

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BODY EXTERIOR, DOORS, ROOF & VEHICLE SECURITY

SECTION BRM BODY REPAIR

PRECAUTIONS ................................................... 3 REPLACEMENT OPERATIONS ....................... 30 H

Revision: 2010 November BRM-1 LEAF

Color code BKH3 BK23 BNAH BQX1 BRAT

Revision: 2010 November BRM-2 LEAF

Revision: 2010 November BRM-3 LEAF

Revision: 2010 November BRM-4 LEAF

Tensile strength Major applicable parts

Read the following precautions when repairing HSS:

Revision: 2010 November BRM-5 LEAF

• When straightening body panels, use caution in pulling any

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

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

Revision: 2010 November BRM-6 LEAF

• The panel surfaces must fit flush to each other, leaving no H

• Follow the specifications for the proper welding pitch.

PROHIBITION OF CUT AND CONNECTION P

Revision: 2010 November BRM-7 LEAF

A. Outer sill temperature measurement part

Revision: 2010 November BRM-8 LEAF

Revision: 2010 November BRM-9 LEAF

2. Fill procedures before installation of service part.

Revision: 2010 November BRM-10 LEAF

Revision: 2010 November BRM-11 LEAF

Revision: 2010 November BRM-12 LEAF

: Both sided anti-corrosive precoated steel sections A

10. Cowl top Under 440 × —

Revision: 2010 November BRM-13 LEAF

Revision: 2010 November BRM-14 LEAF

: Both sided anti-corrosive precoated steel sections

Revision: 2010 November BRM-15 LEAF

6. Side body assembly (RH & LH) Refer to No.7−12

8. Front pillar brace (RH & LH) 590 — —

25. Roof bow No.1 Under 440 — —

Revision: 2010 November BRM-16 LEAF

Revision: 2010 November BRM-17 LEAF

Revision: 2010 November BRM-18 LEAF

Revision: 2010 November BRM-19 LEAF

>> Start body repair and painting.

Revision: 2010 November BRM-20 LEAF

ANTI-CORROSIVE PRECOATED STEEL (GALVANNEALED STEEL)

Revision: 2010 November BRM-21 LEAF

Stone Guard Coat INFOID:0000000006956133

Revision: 2010 November BRM-22 LEAF

: Stone guard coated portions

Revision: 2010 November BRM-23 LEAF

Revision: 2010 November BRM-24 LEAF

Revision: 2010 November BRM-25 LEAF

Revision: 2010 November BRM-26 LEAF

Revision: 2010 November BRM-27 LEAF

Rear Fender Hemming Process INFOID:0000000006956136

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

Revision: 2010 November BRM-28 LEAF

Revision: 2010 November BRM-29 LEAF

MIG seam weld / Point weld

Revision: 2010 November BRM-30 LEAF

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

Revision: 2010 November BRM-31 LEAF