Qashqai J11. Body repair — part 1
BRM-1
BODY EXTERIOR, DOORS, ROOF & VEHICLE SECURITY
C
D
E
F
G
H
I
J
L
M
SECTION
BRM
A
B
BRM
N
O
P
CONTENTS
BODY REPAIR
FOR EUROPE (LHD)
VEHICLE INFORMATION . . . . . . . .
BODY EXTERIOR PAINT COLOR . . . . . .
Body Exterior Paint Color . . . . . . . . . ...
PRECAUTION . . . . . . . . . . . ...
PRECAUTIONS . . . . . . . . . . . . ...
Precautions for Removing Battery Terminal . . .....
REPAIRING HIGH STRENGTH STEEL . . . ..
High Strength Steel (HSS) . . . . . . . . . ....
PREPARATION . . . . . . . . . . ...
REPAIRING MATERIAL . . . . . . . . .
Foam Repair . . . . . . . . . . . . . . ...
BODY COMPONENT PARTS . . . . . . .
2WD . . . . . . . . . . . . . . . . . . ...
2WD : Ultra High Strength Steel Part . . . . . ..
2WD : Underbody Component Parts . . . . . ...
2WD : Body Component Parts . . . . . . . .
4WD . . . . . . . . . . . . . . . . . . ...
4WD : Ultra High Strength Steel Part . . . . . ..
4WD : Underbody Component Parts . . . . . ...
4WD : Body Component Parts . . . . . . . .
REMOVAL AND INSTALLATION . . . ...
CORROSION PROTECTION . . . . . . . .
2WD . . . . . . . . . . . . . . . . . . ...
2WD : Description . . . . . . . . . . . . ...
2WD : Anti-corrosive Wax . . . . . . . . . ...
2WD : Undercoating . . . . . . . . . . . .
2WD : Stone Guard Coat . . . . . . . . . .
2WD : Body Sealing . . . . . . . . . . . .
4WD . . . . . . . . . . . . . . . . . . ...
4WD : Description . . . . . . . . . . . . .
4WD : Anti-corrosive Wax . . . . . . . . . ...
4WD : Undercoating . . . . . . . . . . . .
4WD : Stone Guard Coat . . . . . . . . . . .
4WD : Body Sealing . . . . . . . . . . . .
BODY CONSTRUCTION . . . . . . . . ..
2WD . . . . . . . . . . . . . . . . . . .
2WD : Body Construction . . . . . . . . . .
4WD . . . . . . . . . . . . . . . . . . .
4WD : Body Construction . . . . . . . . . .
REPLACEMENT OPERATIONS . . . . . ...
Description . . . . . . . . . . . . . . . ...
Welding of Ultra High Strength Steel . . . . . ...
Radiator Core Support . . . . . . . . . . . .
Hoodledge . . . . . . . . . . . . . . . ...
Hoodledge (Partial Replacement) . . . . . . ...
Front Side Member . . . . . . . . . . . . ..
Front Side Member (Partial Replacement) . . ...
Front Pillar . . . . . . . . . . . . . . . ...
Center Pillar . . . . . . . . . . . . . . . .
Outer Sill (Partial Replacement) . . . . . . . ..
Outer Sill . . . . . . . . . . . . . . . . .
Outer Sill Reinforcement . . . . . . . . . . .
Inner Sill . . . . . . . . . . . . . . . . ...
Rear Fender . . . . . . . . . . . . . . .
Rear Fender Extension . . . . . . . . . . .
Outer Rear Wheelhouse (2WD) . . . . . . . ..
Outer Rear Wheelhouse (4WD) . . . . . . . ..
Inner Rear Wheelhouse (2WD) . . . . . . . ...
Inner Rear Wheelhouse (4WD) . . . . . . . ...
Inner Rear Pillar Reinforcement . . . . . . . ..
Inner Rear Pillar . . . . . . . . . . . . . ...
Rear Panel . . . . . . . . . . . . . . . ..
Rear Floor Rear . . . . . . . . . . . . . .
Rear Side Member Extension . . . . . . . . ..
Roof (Without Sunroof Models) . . . . . . . ...
Roof (With Sunroof Models) . . . . . . . . .
BRM-2
SERVICE DATA AND SPECIFICATIONS
(SDS) . . . . . . . . . . . . . . ...
BODY ALIGNMENT . . . . . . . . . . ...
2WD . . . . . . . . . . . . . . . . . . ...
2WD : Body Center Marks (Without Sunroof Mod-
els) . . . . . . . . . . . . . . . . . . ..
2WD : Body Center Marks (With Sunroof Models) ...
2WD : Description . . . . . . . . . . . . ...
2WD : Engine Compartment (R9M Engine Mod-
els) . . . . . . . . . . . . . . . . . . ..
2WD : Engine Compartment (Except for R9M En-
gine Models) . . . . . . . . . . . . . . ...
2WD : Underbody . . . . . . . . . . . . ...
2WD : Passenger Compartment (Without Sunroof
Models) . . . . . . . . . . . . . . . . ...
2WD : Passenger Compartment (With Sunroof
Models) . . . . . . . . . . . . . . . . ..
2WD : Rear Body . . . . . . . . . . . . ..
4WD . . . . . . . . . . . . . . . . . . ..
4WD : Body Center Marks (Without Sunroof Mod-
els) . . . . . . . . . . . . . . . . . . .
4WD : Body Center Marks (With Sunroof Models) ..
4WD : Description . . . . . . . . . . . . ..
4WD : Engine Compartment (R9M Engine Mod-
els) . . . . . . . . . . . . . . . . . . .
4WD : Engine Compartment (Except for R9M En-
gine Models) . . . . . . . . . . . . . . ..
4WD : Underbody . . . . . . . . . . . . ..
4WD : Passenger Compartment (Without sunroof
models) . . . . . . . . . . . . . . . . ..
4WD : Passenger Compartment (With sunroof
models) . . . . . . . . . . . . . . . . ..
4WD : Rear Body . . . . . . . . . . . . ..
LOCATION OF PLASTIC PARTS . . . . ...
Precautions for Plastics . . . . . . . . . . .
Location of Plastic Parts . . . . . . . . . .
FOR EUROPE (RHD)
VEHICLE INFORMATION . . . . . . ..
BODY EXTERIOR PAINT COLOR . . . . ..
Body Exterior Paint Color . . . . . . . . .
PRECAUTION . . . . . . . . . . .
PRECAUTIONS . . . . . . . . . . . ...
Precautions for Removing Battery Terminal . . ..
REPAIRING HIGH STRENGTH STEEL . . ..
High Strength Steel (HSS) . . . . . . . . . .
PREPARATION . . . . . . . . . . ..
REPAIRING MATERIAL . . . . . . . . ..
Foam Repair . . . . . . . . . . . . . . ..
BODY COMPONENT PARTS . . . . . . .
2WD . . . . . . . . . . . . . . . . . . .
2WD : Ultra High Strength Steel Part . . . . .
2WD : Underbody Component Parts . . . . .
2WD : Body Component Parts . . . . . . . ..
4WD . . . . . . . . . . . . . . . . . . .
4WD : Ultra High Strength Steel Part . . . . .
4WD : Underbody Component Parts . . . . .
4WD : Body Component Parts . . . . . . . ..
REMOVAL AND INSTALLATION . . . .
CORROSION PROTECTION . . . . . . ...
2WD . . . . . . . . . . . . . . . . . . .
2WD : Description . . . . . . . . . . . . .
2WD : Anti-corrosive Wax . . . . . . . . . .
2WD : Undercoating . . . . . . . . . . . ..
2WD : Stone Guard Coat . . . . . . . . . ..
2WD : Body Sealing . . . . . . . . . . . ..
4WD . . . . . . . . . . . . . . . . . . .
4WD : Description . . . . . . . . . . . . .
4WD : Anti-corrosive Wax . . . . . . . . . .
4WD : Undercoating . . . . . . . . . . . ..
4WD : Stone Guard Coat . . . . . . . . . ..
4WD : Body Sealing . . . . . . . . . . . ..
BODY CONSTRUCTION . . . . . . . . ..
2WD . . . . . . . . . . . . . . . . . . .
2WD : Body Construction . . . . . . . . . ..
4WD . . . . . . . . . . . . . . . . . . .
4WD : Body Construction . . . . . . . . . ..
REPLACEMENT OPERATIONS . . . . . ..
Description . . . . . . . . . . . . . . .
Welding of Ultra High Strength Steel . . . . .
Radiator Core Support . . . . . . . . . . ..
Hoodledge . . . . . . . . . . . . . . . .
Hoodledge (Partial Replacement) . . . . . . .
Front Side Member . . . . . . . . . . . ...
Front Side Member (Partial Replacement) . .
Front Pillar . . . . . . . . . . . . . . . .
Center Pillar . . . . . . . . . . . . . . ..
Outer Sill (Partial Replacement) . . . . . . ...
Outer Sill . . . . . . . . . . . . . . . ..
Outer Sill Reinforcement . . . . . . . . . ...
Inner Sill . . . . . . . . . . . . . . . .
Rear Fender . . . . . . . . . . . . . . ..
Rear Fender Extension . . . . . . . . . . .
Outer Rear Wheelhouse (2WD) . . . . . . .
Outer Rear Wheelhouse (4WD) . . . . . . .
Inner Rear Wheelhouse (2WD) . . . . . . . .
Inner Rear Wheelhouse (4WD) . . . . . . . .
Inner Rear Pillar Reinforcement . . . . . . .
Inner Rear Pillar . . . . . . . . . . . . .
Rear Panel . . . . . . . . . . . . . . ...
Rear Floor Rear . . . . . . . . . . . . ...
BRM-3
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D
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F
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H
I
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L
M
A
B
BRM
N
O
P
Roof (Without Sunroof Models) . . . . . . . .
Roof (With Sunroof Models) . . . . . . . . ..
Roof Rail . . . . . . . . . . . . . . . ...
SERVICE DATA AND SPECIFICATIONS
(SDS) . . . . . . . . . . . . . . ..
BODY ALIGNMENT . . . . . . . . . . .
2WD . . . . . . . . . . . . . . . . . . .
2WD : Body Center Marks (Without Sunroof Mod-
els) . . . . . . . . . . . . . . . . . .
2WD : Body Center Marks (With Sunroof Models)
2WD : Description . . . . . . . . . . . . .
2WD : Engine Compartment (R9M Engine Mod-
els) . . . . . . . . . . . . . . . . . .
2WD : Engine Compartment (Except for R9M En-
gine Models) . . . . . . . . . . . . . . ..
2WD : Underbody . . . . . . . . . . . . ..
2WD : Passenger Compartment (Without sunroof
models) . . . . . . . . . . . . . . . . .
2WD : Passenger Compartment (With Sunroof
Models) . . . . . . . . . . . . . . . . .
2WD : Rear Body . . . . . . . . . . . . .
4WD . . . . . . . . . . . . . . . . . . .
4WD : Body Center Marks (Without Sunroof Mod-
els) . . . . . . . . . . . . . . . . . .
4WD : Body Center Marks (With Sunroof Models)
4WD : Description . . . . . . . . . . . . .
4WD : Engine Compartment (R9M Engine Mod-
els) . . . . . . . . . . . . . . . . . .
4WD : Engine Compartment (Except for R9M En-
gine Models) . . . . . . . . . . . . . . ..
4WD : Underbody . . . . . . . . . . . . ..
4WD : Passenger Compartment (Without Sunroof
Models) . . . . . . . . . . . . . . . . .
4WD : Passenger Compartment (With Sunroof
Models) . . . . . . . . . . . . . . . . .
4WD : Rear Body . . . . . . . . . . . . .
LOCATION OF PLASTIC PARTS . . . . .
Precautions for Plastics . . . . . . . . . . .
Location of Plastic Parts . . . . . . . . . .
FOR RUSSIA
VEHICLE INFORMATION . . . . . . ..
BODY EXTERIOR PAINT COLOR . . . . ..
Body Exterior Paint Color . . . . . . . . ...
PRECAUTION . . . . . . . . . . .
PRECAUTIONS . . . . . . . . . . . .
Precautions for Removing Battery Terminal . . .
REPAIRING HIGH STRENGTH STEEL . . ...
High Strength Steel (HSS) . . . . . . . . .
PREPARATION . . . . . . . . . . .
REPAIRING MATERIAL . . . . . . . . .
Foam Repair . . . . . . . . . . . . . . ..
BODY COMPONENT PARTS . . . . . . .
Ultra High Strength Steel Part . . . . . . . ...
Underbody Component Parts . . . . . . . .
Body Component Parts . . . . . . . . . . .
REMOVAL AND INSTALLATION . . . .
CORROSION PROTECTION . . . . . . ..
Description . . . . . . . . . . . . . . . .
Anti-corrosive Wax . . . . . . . . . . . .
Undercoating . . . . . . . . . . . . . . .
Stone Guard Coat . . . . . . . . . . . . ..
Body Sealing . . . . . . . . . . . . . . .
BODY CONSTRUCTION . . . . . . . .
Body Construction . . . . . . . . . . . . .
REPLACEMENT OPERATIONS . . . . . .
Description . . . . . . . . . . . . . . . .
Welding of Ultra High Strength Steel . . . . . .
Radiator Core Support . . . . . . . . . . ...
Hoodledge . . . . . . . . . . . . . . . .
Hoodledge (Partial Replacement) . . . . . . .
Front Side Member . . . . . . . . . . . .
Front Side Member (Partial Replacement) . . .
Front Pillar . . . . . . . . . . . . . . . .
Center Pillar . . . . . . . . . . . . . . ...
Outer Sill (Partial Replacement) . . . . . . .
Outer Sill . . . . . . . . . . . . . . . ...
Rear Fender . . . . . . . . . . . . . . ..
Rear Panel . . . . . . . . . . . . . . .
Rear Floor Rear . . . . . . . . . . . . ...
Rear Side Member Extension . . . . . . . .
SERVICE DATA AND SPECIFICATIONS
(SDS) . . . . . . . . . . . . . . ..
BODY ALIGNMENT . . . . . . . . . .
Body Center Marks (Without Sunroof Models) . ..
Body Center Marks (With Sunroof Models) . . ...
Description . . . . . . . . . . . . . . . .
Engine Compartment (R9M Engine Models) . . .
Engine Compartment (Except for R9M Engine
Models) . . . . . . . . . . . . . . . . ..
Underbody . . . . . . . . . . . . . . . .
Passenger Compartment (Without sunroof mod-
els) . . . . . . . . . . . . . . . . . . .
Passenger Compartment (With sunroof models) ..
Rear Body . . . . . . . . . . . . . . . .
LOCATION OF PLASTIC PARTS . . . . ..
Precautions for Plastics . . . . . . . . . . .
Location of Plastic Parts . . . . . . . . . .
EXCEPT FOR EUROPE AND RUSSIA (LHD)
VEHICLE INFORMATION . . . . . . .
BRM-4
Body Exterior Paint Color . . . . . . . . .
PRECAUTION . . . . . . . . . . .
Precautions for Removing Battery Terminal . . ..
High Strength Steel (HSS) . . . . . . . . . .
PREPARATION . . . . . . . . . . ..
Foam Repair . . . . . . . . . . . . . . ..
Ultra High Strength Steel Part . . . . . . . ...
Underbody Component Parts . . . . . . . .
Body Component Parts . . . . . . . . . . .
REMOVAL AND INSTALLATION . . . ..
Description . . . . . . . . . . . . . . . .
Anti-corrosive Wax . . . . . . . . . . . .
Undercoating . . . . . . . . . . . . . . .
Stone Guard Coat . . . . . . . . . . . . ..
Body Sealing . . . . . . . . . . . . . . .
Body Construction . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . .
Welding of Ultra High Strength Steel . . . . . .
Radiator Core Support . . . . . . . . . . ...
Hoodledge . . . . . . . . . . . . . . . .
Hoodledge (Partial Replacement) . . . . . . .
Front Side Member . . . . . . . . . . . .
Front Side Member (Partial Replacement) . . .
Front Pillar . . . . . . . . . . . . . . . .
Center Pillar . . . . . . . . . . . . . . ...
Outer Sill (Partial Replacement) . . . . . . .
Outer Sill . . . . . . . . . . . . . . . ...
Rear Fender . . . . . . . . . . . . . . ..
Rear Panel . . . . . . . . . . . . . . .
Rear Floor Rear . . . . . . . . . . . . ...
Rear Side Member Extension . . . . . . . .
SERVICE DATA AND SPECIFICATIONS
(SDS) . . . . . . . . . . . . . . ..
Body Center Marks . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . .
Engine Compartment (R9M Engine Models) . . .
Engine Compartment (Except for R9M Engine
Models) . . . . . . . . . . . . . . . . ..
Underbody . . . . . . . . . . . . . . . .
Passenger Compartment . . . . . . . . . ...
Rear Body . . . . . . . . . . . . . . . .
Precautions for Plastics . . . . . . . . . .
Location of Plastic Parts . . . . . . . . . ...
EXCEPT FOR EUROPE AND RUSSIA (RHD)
VEHICLE INFORMATION . . . . . . .
Body Exterior Paint Color . . . . . . . . ...
PRECAUTION . . . . . . . . . . ...
Precautions for Removing Battery Terminal . . .
High Strength Steel (HSS) . . . . . . . . .
PREPARATION . . . . . . . . . . .
Foam Repair . . . . . . . . . . . . . . .
Ultra High Strength Steel Part . . . . . . . ...
Underbody Component Parts . . . . . . . ...
Body Component Parts . . . . . . . . . . .
REMOVAL AND INSTALLATION . . . .
Description . . . . . . . . . . . . . . .
Anti-corrosive Wax . . . . . . . . . . . .
Undercoating . . . . . . . . . . . . . . .
Stone Guard Coat . . . . . . . . . . . . .
Body Sealing . . . . . . . . . . . . . . .
Body Construction . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . .
Welding of Ultra High Strength Steel . . . . .
Radiator Core Support . . . . . . . . . . ..
Hoodledge . . . . . . . . . . . . . . . .
Hoodledge (Partial Replacement) . . . . . . .
Front Side Member . . . . . . . . . . . ...
Front Side Member (Partial Replacement) . .
Front Pillar . . . . . . . . . . . . . . . .
Center Pillar . . . . . . . . . . . . . . ..
Outer Sill (Partial Replacement) . . . . . . ...
Outer Sill . . . . . . . . . . . . . . . ..
Rear Fender . . . . . . . . . . . . . . ..
Rear Panel . . . . . . . . . . . . . . ...
Rear Floor Rear . . . . . . . . . . . . ...
Rear Side Member Extension . . . . . . . ...
SERVICE DATA AND SPECIFICATIONS
(SDS) . . . . . . . . . . . . . . .
BRM-5
C
D
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F
G
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A
B
BRM
N
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Body Center Marks (Without Sunroof Models) . ..
Body Center Marks (With Sunroof Models) . . ...
Description . . . . . . . . . . . . . . .
Engine Compartment (R9M Engine Models) . .
Engine Compartment (Except for R9M Engine
Models) . . . . . . . . . . . . . . . . .
Underbody . . . . . . . . . . . . . . . .
Passenger Compartment (Without Sunroof Mod-
els) . . . . . . . . . . . . . . . . . . .
Passenger Compartment (With Sunroof Models) ..
Rear Body . . . . . . . . . . . . . . . .
LOCATION OF PLASTIC PARTS . . . . ..
Precautions for Plastics . . . . . . . . . . .
![](/vehicles/gon/roan/med/wang.png)
BRM-6
< VEHICLE INFORMATION >
[FOR EUROPE (LHD)]
BODY EXTERIOR PAINT COLOR
VEHICLE INFORMATION
BODY EXTERIOR PAINT COLOR
Body Exterior Paint Color
INFOID:0000000010287967
NOTE:
• S: 1-Coat solid
• 2M: 2-Coat Metallic
• 2S: 2-Coat solid
• 3P: 3-Coat pearl
• 2PM: 2-Coat Pearl metallic
Component
Color code
B326
BZ11
BKY0
BGAB
BKAD
BNAJ
BCAP
BRBN
BZ10
BQAB
Description
White
Black
Silver
Black
Gray
Red
Brown
Blue
Red
White
Paint type
note
S
2M
2M
2M
2M
2PM
2M
2M
2S
3P
Standard
clear coat
–
×
×
×
×
×
×
×
×
×
Door mirror cover
Body color
B326
BZ11
BKY0
BGAB
BKAD
BNAJ
BCAP
BRBN
BZ10
BQAB
Front grille molding
Chromium
plate
Cr
Cr
Cr
Cr
Cr
Cr
Cr
Cr
Cr
Cr
Front bumper fascia
Body color
B326
BZ11
BKY0
BGAB
BKAD
BNAJ
BCAP
BRBN
BZ10
BQAB
Fillet molding
Material color
–
–
–
–
–
–
–
–
–
–
Door outside handle
Chromium
plate
Cr
Cr
Cr
Cr
Cr
Cr
Cr
Cr
Cr
Cr
Rear spoiler
Body color
B326
BZ11
BKY0
BGAB
BKAD
BNAJ
BCAP
BRBN
BZ10
BQAB
Back door finisher
Body color
B326
BZ11
BKY0
BGAB
BKAD
BNAJ
BCAP
BRBN
BZ10
BQAB
Rear bumper fascia
Body color
B326
BZ11
BKY0
BGAB
BKAD
BNAJ
BCAP
BRBN
BZ10
BQAB
Door outside lower
molding
Material color
–
–
–
–
–
–
–
–
–
–
JSKIA3881ZZ
![](/vehicles/gon/roan/med/unont.png)
PRECAUTIONS
BRM-7
< PRECAUTION >
[FOR EUROPE (LHD)]
C
D
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F
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H
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A
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BRM
N
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PRECAUTION
PRECAUTIONS
Precautions for Removing Battery Terminal
INFOID:0000000010503253
• With the adoption of Auto ACC function, ACC power is automatically supplied by operating the intelligent key
or remote keyless entry or by opening/closing the driver side door. In addition, ACC power is supplied even
after the ignition switch is turned to the OFF position, i.e. ACC power is supplied for a certain fixed time.
• When disconnecting the 12V battery terminal, turn off the ACC
power before disconnecting the 12V battery terminal, observing
“How to disconnect 12V battery terminal” described below.
NOTE:
Some ECUs operate for a certain fixed time even after ignition
switch is turned OFF and ignition power supply is stopped. If the
battery terminal is disconnected before ECU stops, accidental DTC
detection or ECU data damage may occur.
• For vehicles with the 2-batteries, be sure to connect the main bat-
tery and the sub battery before turning ON the ignition switch.
NOTE:
If the ignition switch is turned ON with any one of the terminals of
main battery and sub battery disconnected, then DTC may be detected.
• After installing the 12V battery, always check "Self Diagnosis Result" of all ECUs and erase DTC.
NOTE:
The removal of 12V battery may cause a DTC detection error.
HOW TO DISCONNECT 12V BATTERY TERMINAL
Disconnect 12V battery terminal according to Instruction 1 or Instruction 2 described below.
For vehicles parked by ignition switch OFF, refer to Instruction 2.
INSTRUCTION 1
1.
Open the hood.
2.
Turn key switch to the OFF position with the driver side door opened.
3.
Get out of the vehicle and close the driver side door.
4.
Wait at least 3 minutes. For vehicle with the engine listed below, remove the battery terminal after a lapse
of the specified time.
CAUTION:
While waiting, never operate the vehicle such as locking, opening, and closing doors. Violation of
this caution results in the activation of ACC power supply according to the Auto ACC function.
5.
Remove 12V battery terminal.
CAUTION:
After installing 12V battery, always check self-diagnosis results of all ECUs and erase DTC.
INSTRUCTION 2 (FOR VEHICLES PARKED BY IGNITION SWITCH OFF)
1.
Unlock the door with intelligent key or remote keyless entry.
NOTE:
At this moment, ACC power is supplied.
2.
Open the driver side door.
3.
Open the hood.
4.
Close the driver side door.
5.
Wait at least 3 minutes.
SEF289H
D4D engine
: 20 minutes
HRA2DDT
: 12 minutes
K9K engine
: 4 minutes
M9R engine
: 4 minutes
R9M engine
: 4 minutes
V9X engine
: 4 minutes
BRM-8
< PRECAUTION >
[FOR EUROPE (LHD)]
PRECAUTIONS
CAUTION:
While waiting, never operate the vehicle such as locking, opening, and closing doors. Violation of
this caution results in the activation of ACC power supply according to the Auto ACC function.
6.
Remove 12V battery terminal.
CAUTION:
After installing 12V battery, always check self-diagnosis results of all ECUs and erase DTC.
![](/vehicles/gon/roan/med/pat.png)
REPAIRING HIGH STRENGTH STEEL
BRM-9
< PRECAUTION >
[FOR EUROPE (LHD)]
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REPAIRING HIGH STRENGTH STEEL
High Strength Steel (HSS)
INFOID:0000000010287972
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:
Tensile strength
Major applicable parts
440 - 780 MPa
• Trans control reinforcement
(Center front floor assembly component part)
• 2nd crossmember
(Front floor assembly component part)
• 3rd crossmember
(Front floor assembly component part)
• 3rd crossmember reinforcement
(Front floor assembly component part)
• Lower dash crossmember
(Lower dash assembly component part)
• Side dash
(Side dash assembly component part)
• Inner front pillar reinforcement
(Side dash assembly component part)
• Front suspension spring support
(Front strut housing assembly component part)
• Engine mounting bracket reinforcement
(Front strut housing assembly component part)
• Engine mounting bracket
(Front strut housing assembly component part)
• Front bumper reinforcement assembly
• Lower front bumper stay
• Front side member closing plate (Front)
(Side member closing plate assembly component part)
• Outer add on frame bracket
(Side member closing plate assembly component part)
• Closing plate reinforcement
(Side member closing plate assembly component part)
• Front side member assembly
• Engine mounting member bracket assembly
• Front suspension mounting rear bracket assembly
• Inner sill extension
(Rear side member assembly component part)
• Inner rear sill
(Rear side member assembly component part)
• Outer rear anchor reinforcement
(Rear side member assembly component part)
• Rear side member extension assembly
• Inner front side roof rail assembly
• Upper inner front pillar assembly
• Inner center pillar (Lower)
(Inner center pillar assembly component part)
• Lower front pillar hinge brace
• Rear bumper stay assembly
![](/vehicles/gon/roan/med/lake.png)
BRM-10
< PRECAUTION >
[FOR EUROPE (LHD)]
REPAIRING HIGH STRENGTH STEEL
Read the following precautions when repairing HSS:
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.)
• 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.
• 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).
Tensile strength
Major applicable parts
980 - 1350 MPa
• Front side member rear extension
(Front floor assembly component part)
• Inner sill assembly
• Lower center dash crossmember assembly
• Front bumper reinforcement assembly
• Front side member closing plate (Rear)
(Side member closing plate assembly component part)
• Front side member (Rear)
(Front side member assembly component part)
• Inner center pillar (Upper)
(Inner center pillar assembly component part)
• Outer side roof rail
• Center pillar hinge brace (Upper)
(Center pillar hinge brace assembly component part)
• Outer front pillar reinforcement
(Front pillar hinge brace assembly component part)
• Outer sill reinforcement
(Outer sill reinforcement assembly component part)
• Rear bumper reinforcement assembly
PIIA0115E
PIIA0117E
![](/vehicles/gon/roan/med/quen.png)
REPAIRING HIGH STRENGTH STEEL
BRM-11
< PRECAUTION >
[FOR EUROPE (LHD)]
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• 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.
• 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.
2.
Precautions in spot welding HSS
This work should be performed under standard working condi-
tions. 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.
PIIA0144E
PIIA0145E
PIIA0146E
PIIA0147E
![](/vehicles/gon/roan/med/utoue.png)
BRM-12
< PRECAUTION >
[FOR EUROPE (LHD)]
REPAIRING HIGH STRENGTH STEEL
• Follow the specifications for the proper welding pitch.
Unit: mm (in)
Thickness (T)
Minimum pitch (L)
0.6 (0.024)
0.8 (0.031)
1.0 (0.039)
1.2 (0.047)
1.6 (0.063)
1.8 (0.071)
10 (0.39) or more
12 (0.47) or more
18 (0.71) or more
20 (0.79) or more
27 (1.06) or more
31 (1.22) or more
JSKIA0781ZZ
![](/vehicles/gon/roan/med/valitor.png)
REPAIRING MATERIAL
BRM-13
< PREPARATION >
[FOR EUROPE (LHD)]
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PREPARATION
REPAIRING MATERIAL
Foam Repair
INFOID:0000000010287974
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.
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.
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.
<Urethane foam for foaming agent>
3M™ Automix™ Flexible Foam 08463 or equiva-
lent
Urethane foam
Nozzle insert hole
: Vehicle front
JSKIA0129GB
![](/vehicles/gon/roan/med/isonje.png)
BRM-14
< PREPARATION >
[FOR EUROPE (LHD)]
REPAIRING MATERIAL
NOTE:
Fill enough to close gap with service part while avoiding flange
area.
d.
Install service part.
NOTE:
Refer to label for information on working times.
Urethane foam
Fill while avoiding flange area
: Vehicle front
JSKIA0130GB
BODY COMPONENT PARTS
BRM-15
< PREPARATION >
[FOR EUROPE (LHD)]
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BODY COMPONENT PARTS
2WD
2WD : Ultra High Strength Steel Part
INFOID:0000000010505342
DESCRIPTION
Ultra high strength steel parts signify high strength steel plates with tensile strength of 980 MPa or more.
When replacing parts made of ultra high strength steel or parts including ultra high strength steel, never per-
form the prohibition described below:
PROHIBITION
WARNING:
Never cut ultra high strength steel parts or perform butt welding. Violation of this prohibition causes
extreme strength degradation, and the strength before damage cannot be secured.
PART REPLACEMENT
To replace an ultra high strength part, be sure to replace it by panel supply unit of ultra high strength steel part.
For the welding method, refer to
BRM-48, "Welding of Ultra High Strength Steel"
2WD : Underbody Component Parts
INFOID:0000000010287975
Refer to parts catalogue for the replacement parts.
![](/vehicles/gon/roan/med/sos.png)
BRM-16
< PREPARATION >
[FOR EUROPE (LHD)]
BODY COMPONENT PARTS
R9M engine models
: Both sided anti-corrosive precoated steel sections
: High strength steel (HSS) sections
: Both sided anti-corrosive steel and HSS sections
JSKIA3883ZZ
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