NISSAN ALMERA N15 1995 Service Manual

__________ BODYALIGNMENT _
_HANDLINGPRECAUTIONS FORPLASTICS _
Passenger Compartment Sedan
5-door Hatchback Location
OfPlastic Parts

Side turnsignal lamplens
(Lens: AS)
Housing: ASS
Wind-shield molding
(Upper: PVC )
Side:Stainless+PVC
Doorout-side molding
(Stainless+PVC)
Wheel cover
(Full cover: PP+PA6 )
Half cover: PA66+PPO
Center cap:PA6
Door
mirror
(Housing: AAS)
Garnish: ASS
Front turnsignal lamp
(Lens: PMMA)
Housing: PP
Fog
lamp
(Lens: Glass)
Housing: PP
Head
lamp
(Lens: Glass)
Housing: pp
Radiator grille

(ABS)

Fog lamp finisher
(PM MA)
Front
bumper fascia

(PP)

Front airspoiler

(PP)

Point
Dimension

@-@
1228

CB- 1374

@-@
1366

(8)-{6)
1159

CD--cD
1387
Q)-{J) 1367

@--@
1156

(b)--{[)
1385

~-4iV
1370

@~
1364

@~
1364

C'e)--@
1598

@--@
989*

@-{E)
918*

@~
1156*

@--{[)
917*

@~@
975*

@~(b)
757*

@~
1004*

@--@
723*

,
... ._MEASURMENT _

Figures marked witha
*
show symmetrically identical
dimensions onboth right andlefthand sides ofthe
vehicle.
Unit:
mm

@ :
Cowl tophole center (5dia.)
CB>
:
Front roofflange endatcenter
Positioning mark ~~
~}Outer frontpillarjoggle
Sideguard molding (PVC)
Rear combination lamp
(Lens: PMMA)
Housing: PP
Door
outside handle
(Handle: POM )
Escutcheon: POM
Mud guard (TPR)
Rear
Windowmolding
(PVC)
-for Sedan
Rear bumper fascia

(PP)

License
lamp
(Lens: PC)
Housing: PP
Trunk
lidfinisher(pp)
-for Sedan
Rear
spoiler(PPO)
-for Sedan
High mounted stoplamp
(In Rear SpoilerType)
(Lens: PMMA)-for Sedan
Housing: ASS
(Fixed Trunk LidTipe)
(Lens: PC)-for Sedan
Housing: PP

(f3),Cfi),Q),CD,@,@,CD,CD,~,@ :

Outer center pillarindention

CDCD :
Outer center pillarstandard hole
center

CBCD:
}

~@:
Outerfrontpillar indention

@@
:
Dash upper flange endcorner

-19- -26-

______ HANDLINGPRECAUTIONS FORPLASTICS __
BODYALIGNMENT _
Location OfPlastic Parts
Underbody

Kicking plate(PP)
Front

@,
076
dia.
Rear
@,@
62 dia.

Front
Rear
coordinates: coordinates:
@,@ @,@@
X :250
X:393.5
X:475
V :-632
V:1,460
V:3,082
Z :224.8
Z:126.9
Z:336.8
@,@
(8),
@
@
X :492 X
:572
X:-542
V :-450 V
:1,940
V:3,082
Z :355 Z
:200
Z:336.8
@,@
CD,
CD

X :406
X:600
V :64
V:2,035
Z :172
Z:235.2
@,@
Q)

X :352.7 X
:150
V :69 V
:2,442.9
Z :240 Z
:241

@,
@
@
X :432
X:300
V :338
V:2,480
Z :128
Z:381.8
(f),
CD
@
X :395
X:-300
V :515
V:2,480
Z :129.2
Z:405.8

@,
@)

X :393
Y :2,560
Z :365
@
X :470
Y :2,911
Z :339.6
@
X :-539
Y :2,911
Z :339.6
Unit: mm
Coordinates:
@,0
X :522.2
V :18.1
Z :571.7
@,@ X :465
V :2,456.4
Z :522

Front
andrear strut tower centers

I

~t-~

Rear
(f
••@
LH side
RHside

Q
Q

Bottom
view of

,1

vehicle

__
MEASURMENT POINTS__

Glove box(PPC)
Side
wind molding(PVC)
Cluster lidC(PPC)
Instrument
panel(PPC)
Console box(PPC)

5-door
Hatchback

Cluster lidA(PPC)

~----_/

Front
pillargarnish(PPC)
Side
wind molding(PVC)
Back doorfinisher(ABS)
Roof
spoilar(FRP)

3-doorHatchback

Center pillarlower garnish(PP)
Center pillarupper garnish(PPC)
Rear pillar garnish(PPC)
High
mounted stoplamp
(Lens: PMMA )
Housing: ABS

FrontSBT097

-27-
-18-

__________ BODYALIGNMENT ___________
PRECAUTIONS _
Underbody Precautions
ForHandling HighStrength Steel

• InNissan vehicles, HSSplates of373 N/mm
2
(38kg/mm
2,
54klb/sq in)(NP130) aremost commonly
utilized, andthose withatensile strength of785 to981 N/mm
2
(80to100 kg/mm
2,
114to142 klb/sq
in) (NP150) areused onlyonparts requiring muchmorestrength.

HIGH
STRENGTH STEEL(HSS)USED INNISSAN VEHICLES

High
strength steelhasbeen usedforbody panels inorder toreduce vehicle weight.
Accordingly, precautionsinrepairing automotive bodiesmadeofhigh strength steelaredescribed below:

Tensile strength Nissan designation Major
applicable parts

• Side member
373N/mm
2
•
Hoodledge
(38 kg/mm
2,
54klb/sq in) NP130
•
Pillar
• Hood
.Trunk lidouter
785-981 N/mm
2

•Bumper reinforcement
(80-100 kg/mm
2

NP150
114-142 klb/sqin) •
Door guard beam

E
E

127
@>@)

235

~200
ee

@@

o

It)

CD

N

.. CD

.. 00

~ N~

It)
CD

CD

It)

C!.

~

CD

It)
It)

en

N
It)

CD CD

IIIlI:t'
(ij

Q)

er:

iJ
--------

en

It)

C!.
N

~ en

co

____
MEASURMENT _

..
o

.. It)

0)
It)

o
I'
..

.. 0

CD CD

en~

0) .,

~
129

@8

@@
@)@)

225

SBT096

-17- -28-

__________ PRECAUTIONS ___________
BODYALIGNMENT _
Precautions ForHandling HighStregth Steel Engine
Compartment

__ MEASURMENT POINTS__

Unit:mm

Front side

SBT088

Traction direction: ...
Not
recommended

• The repair ofreinforcements (suchasside
members) byheating isnot recommended
since itinvolves theriskoflowering strength.
When heating isunavoidable, donot heat
such parts attemperatures above550°C (1,

022°F)

Heating temperature shouldbeverified with
a thermometer. (Acrayon-type andother
thermometer areavailable.)
• When straightening bodypanels, usecaution
in pulling anyHSS panel. Because itis very
strong, thismay cause deformation inadja-
cent portions ofthe body. Inthis case,
increase thenumber ofmeasuring points,
and carefully pulltheHSS panel.
Special
consideration forHSS must begiven tothe following points:
1 .Additional pointstoconsider
• Incutting HSSpanel, avoidgascutting if
possible. Instead,useanairsaw orahand
cutter toavoid decreasing thestrength of
surrounding portionsduetothe influence of
heat. Incase gascutting isinevitable, a
minimum allowance of50 mm (1.97 in)
must begiven.

SBT090
Radiator
coresupport lower

•
(b)

11
dia.

SBT094

• Inwelding HSSpanel, usespot welding
whenever possibleinorder tominimize any
decrease instrength ofsurrounding portions
due tothe influence ofheat.
If spot welding isimpossible, useM.LG.
welding. Donotuseacetylene gaswelding
because itis inferior inwelding strength.
GOOD

-================
N.G.

Never useacetylene .gas
welding.
Radiator
coresupport uppercenter

SBT091

-29-
-16-

__________ BODYALIGNMENT _
_ PRECAUTIONS _
Description PrecautionsForHandling HighStrength Steel

• Alldimensions indicatedinfigures areactual ones.
• When usingatracking gauge,adjustbothpointers toequal length. Thencheck thepointers andgauge
itself tomake surethere isno free play.
• When ameasuring tapeisused, check tobe sure there isno elongation, twistingorbending.
• Measurements shouldbetaken atthe center ofthe mounting holes.
• Anasterisk
(*)
following thevalue atthe measuring pointindicates thatthemeasuring pointonthe other
side issymmetrically thesame value.
• The coordinates ofthe measurement pointsarethe distances measured fromthestandard lineof"X", "V"
and "Z".

EngineCompartment

D=2T+3(mm)
D=2T+O.12 (in)

•
The electrode tipdiameter mustbereformed
properly according tothe panels thickness.
•
The spot ungget onHSS panel isharder than
that ofan ordinary steelpanel.
Therefore, forspot cutting HSSpanel, ahigh
torque drillofalow speed (1,000 to1,200
rpm) maybeused tomaintain itsdurability
and facilitate theoperation.
• HSS panels withatensile strength of785 to981 N/mm
2
(80to100 kg/mm
2,
114to142 klb/sq in),
used asreinforcement inthe door guard barand inthe bumper, istoo high intensile strength touse
for general repairs.Whenthesepanels aredamaged, theouter panels alsosustain consequential
damage; therefore, thesepanels arenever remedied withoutreplacing thedoor assembly orbumper
assembly.
2. Precautions inspot welding
This work should beperformed understandard workconditions. However,workcontrol mustbeexercised
as folloows:

SBF8?4GB

"Z":
Imaginary baseline
[200 mmbelow datum line
("OZ" atdesign plan)]
Front axlecenter

/

y (_)
(0)

Incorrect
Incorrect
Correct
D==Tip+diameter

T

,::=T====p=la::t_e=-=-_t_h=i_C=k=_n=_e_s=s= __,-- ~

• The panel surfaces mustbefitted toeach
other, leaving nogaps.

____
MEASURMENT _

SBT08?

-15- -30-

__________ PRECAUTIONS _
_ BODYALIGNMENT _
Precautions ForHandling HighStrength Steel
PanelPartsMatching Marks

~ViewE

3-Door Hatchback
and 5-Door Hatchback

A
mark hasbeen placed oneach partofthe body toindicate thepanel partsmatching positions.Whenrepairing
parts damaged byan accident whichmightaffectthevehicle frame(members, pillars,etc.)more accurate,
effective repairwillbepossible byusing these marks together wi~hbody alignment data.

Welding

current

Pressure

Unit:mrr
(C•

Thickness
(t)
Minimum pitch(
Q )

0.6 (0.024)
I
10 (0.39)
orover

0.8 (0.031) 12(0.47)
orover

1.0 (0.039) 18(0.71)
orover

1.2 (0.047) 20(0.79)
orover

1.6 (0.063) 27(1.06)
orover

~71) 31
11.221
orover
•
Follow established specifications forthe
appropriate pressurelevel,current leveland
weld time.
• Follow thespecifications forthe proper
welding pitch.
• After welding, weldingstrength mustbe
tested.
J
Type
W:
@----- ~
Et

Type V:~----- ~

View A ViewS
ViewC
View D-1 View
D-2
ViewE

Sedan and5-door Hatchback 3-door
Hatchback
3-door
Hatchback and5-door Hatchback

/w-..IE
+-W
II (-

'- r )
o

-31- -14-

Description
_________
BODYALIGNMENT _
Body Center Marks ________
REPLACEMENTOPERATIONS _

SYMBOLS FORCUITING AND
WELDING/BRAZING OPERATIONS

..J

3-spot welds

(3-panel overlapping portions)

2-SDOt

welds

(2-panel overlapping portions)

••••

2-spot
welds

0000

3-spot
welds
Spot
weld
Brazing
Soldering
(ItIlI)

M.LG. seamweld/
Point weld
Saw
cutor
air chisel cut

•
•
•

M.LG. plugweld

-

The
indentification ofthe cutting andthewelding/brazing symbolsusedthroughout thisguide isgiven inthe
following pages

Portion F
Portion
C
Unit:
mm

Porton
H
3-Door Hatchback
and 5-Door Hatchback

• Front roof
• Second crossmember

Portion
D-Sedan
Portion E
-Sedan
Portion F

Portion E
Portion
8
Portion
G

~

Slot(7X 11)

/~/

• Rear waist panelslot
•
Cowl top

Portion
BPortion
C

Hole(4
dial

Portion
A
Portion D

Portion
A

• Rear roof
•
Upper radiator coresupport

A
mark hasbeen placed oneach partofthe body toindicate thevehicle center.Whenrepairing partsdamaged
by an accident whichmightaffectthevehicle frame(members, pillars,etc.)more accurate, effectiverepairwill
be possible byusing these marks together withbody alignment data.

Portion G

3-door and5-door Hatchback

Lozenge
mark
Portion
H

3-door and5-door Hatchback Sealing
• Rear roof •
Rear panel

-13- -32-

REPLACEMENTOPERATIONS _

------------

RadiatorCoreSupport (PartialReplacement) BODY
CONSTRUCTION _

-----------

BodyConstruction

\

Section
L-L:
Section P-P:
Section
D-D:
Section H-H:
Section K-K:
Section
C-C:
Section G-G:
Section 0-0:
Section

J-J:

Section
F-F:
Section
8-8:
. Section N-N:
Section
I-I:
Section
E-E:
Section
A-A:
Section M-M:

_1

FR

(

e
4orll3 *
indicates thatthere isan equivalent wel~ing.portion
with thesame dimensions onthe opposite Side.

o

*
e
3
or 112

FR

Service
Joint

Section
0-0:
Section
R-R:

2-spot welds 3-spotwelds
M.1.Gplug weld )M.I.Gseam weld/
(Point weld
For 3panels plugweld m.ethod

· r ·
A
=='*= •
B
===:=
.an
F

-33- -12-

BODYCONSTRUCTION _

------------

BodyConsb"uction. REPLACEMENT
OPERATIONS _

------------

Hoodledge(PartialReplacement)
(Work afterradiator coresupport hasbeen removed.)
114AUnit:mm
Before
installing
hoodledge reinforcement.
117

Service
Joint

(This figure showrightsidehoodledge)
Sedan
3-d oar Hatchback
5-door Hatchback 2-spot
welds 3-spotwelds

M.1.
Gplug weld )
M.I.
Gseam weld/
(For 3panels plugweld method. Pointweld

· r
.A~ .B~
.an.F

-34-
-11-

REPLACEMENTOPERATIONS
Front SideMember (PartialReplacement)
(Work afterradiator coresupport hasbeen removed.) ________
CORROSIONPROTECTION _
Stone Guard Coat
SectionB-B
Section
A-A
--r':":'

To
prevent damage causedbystones, thelower outerbodypanels (fender, door,etc.)have anadditional layer
of Stone Guard CoatovertheEDprimer coating. Thus,when replacing orrepairing thesepanels, apply
undercoat tothe same portions asbefore. Useacoat which isrust preventive, durable,shockresistant andhas
a long shelf life.

~mm1111i :
Indicates stoneguard coated portions

114

Patch

118

111

115
114

hoodledge
panel

117

111

Unit:mm

8

Patch

""

"
"

(Thickness: 1mm)

-\

Service
Joint

(This figure showrightfront sidemember)
2-spot welds 3-spotwelds M.1.
Gplug weld MIG seam weld/
(For 3panels plugweld method )P1ID.~irit
F
weld

• rr=
.A=-= .B~
G1J --- ~
Section
C-C

-35- -10-