Nissan Pathfinder (2009 year). Manual - part 131

BRM-34

< SERVICE INFORMATION >

BODY REPAIR

Precaution in Repairing High Strength Steel

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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. 

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 since it may weaken the component.
When heating is unavoidable, do not 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.)

LIIA1806E

Tensile strength

Nissan/Infiniti designation

Major applicable parts

373 N/mm

2

(38kg/mm

2

,54klb/sq in)

SP130

• Front inner pillar upper
• Front pillar hinge brace
• Outer front pillar reinforcement
• Other reinforcements

785-981 N/mm

2

(80-100kg/mm

2

114-142klb/sq in)

SP150

• Outer sill reinforcement
• Main back pillar

PIIA0115E

2009 Pathfinder

BODY REPAIR

BRM-35

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• 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 (1.97in).

• 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 M.I.G. welding. Do not use
gas (torch) welding because it is inferior in welding strength.

• The spot weld on HSS panels is harder than that of an ordi-

nary 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/

mm

2

 (80 to 100 kg/mm

2

, 114 to 142 klb/sq in), used as rein-

forcement in the door guard beams, is too strong to repair.
When these HSS parts are damaged, the outer panels also
sustain substantial damage; therefore, the assembly parts
must be replaced.

PIIA0116E

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PIIA0144E

PIIA0145E

2009 Pathfinder

BRM-36

< SERVICE INFORMATION >

BODY REPAIR

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.

• Follow the specifications for the proper welding pitch.

Unit:mm

Foam Repair

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During factory body assembly, foam insulators are installed in certain body panels and locations around the
vehicle. Use the following procedure(s) to replace any factory-installed foam insulators.

URETHANE FOAM APPLICATIONS

Use commercially available spray foam for sealant (foam material) repair of material used on vehicle. Read
instructions on product for fill procedures.

FILL PROCEDURES

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Thickness (t)

Minimum 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)

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

PIIA0148E

2009 Pathfinder

BODY REPAIR

BRM-37

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1.

Body side outer

2.

Body side insulation (foam)

3.

A-pillar lower hinge brace

4.

Sill outer reinforcement

5.

front sill outer reinforcement

6.

Inner A-pillar upper

7.

A-pillar inner bracket

8.

A-pillar upper hinge brace

9.

B-pillar hinge brace

10. Inner B-pillar

11.

Inner sill extension

LIIA1807E

2009 Pathfinder

BRM-38

< SERVICE INFORMATION >

BODY REPAIR

1.

Fill procedures after installation of service part.

1.

Body side outer

2.

Body side insulation (foam)

3.

Rear wheel outer

4.

Side panel inner

5.

D-pillar inner reinforcement

6.

D-pillar outer reinforcement

7.

Roof

8.

Front roof rail

9.

Front roof rail brace

10. B-pillar inner

11.

B-pillar hinge brace

12. Rear side inner extension

13. D-pillar mail lower

LIIA1817E

2009 Pathfinder

BODY REPAIR

BRM-39

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-

Remove foam material remaining on vehicle side.

-

Clean area in which foam was removed.

-

Install service part.

-

Insert nozzle into hole near fill area and fill foam material or fill in enough to close gap with the service
part.

2.

Fill procedures before installation of service part.

-

Remove foam material remaining on vehicle side.

-

Clean area in which foam was removed.

-

Fill foam material on wheelhouse outer side.

NOTE:
Fill in enough to close gap with service part while avoiding flange

area.

-

Install service part.

NOTE:
Refer to label for information on working times.

Replacement Operation

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DESCRIPTION

This section is prepared for technicians who have attained a high level of skill and experience in repairing col-
lision-damaged vehicles and also use modern service tools and equipment. Persons unfamiliar with body
repair techniques should not attempt to repair collision-damaged vehicles by using this section.

Technicians are also encouraged to read Body Repair Manual (Fundamentals) in order to ensure that the orig-
inal functions and quality of the vehicle can be maintained. The Body Repair Manual (Fundamentals) contains
additional information, including cautions and warnings, that are not including in this manual. Technicians
should refer to both manuals to ensure proper repairs.

Please note that this information is prepared for worldwide usage, and as such, certain procedures may not
apply in some regions or countries.

LIIA1081E

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2009 Pathfinder

BRM-40

< SERVICE INFORMATION >

BODY REPAIR

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

PIIA0149E

2009 Pathfinder

BODY REPAIR

BRM-41

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• 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. Refer to the front
pillar section.

• 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 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 is as 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.

HOODLEDGE

LH

PIIA0150E

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PIIA0152E

PIIA0153E

2009 Pathfinder