The document provides information on body repair for a vehicle, including precautions for repairing high strength steel parts, body component parts, body alignment procedures, and descriptions of replacement operations for various body parts. It details markings used for body alignment, procedures for repairing foam and other materials, and specifications for spot welding high strength steel panels.
Indian standard specification for high strength structural boltsJisha John
This document provides specifications for high strength structural bolts used in structural steel joints. It specifies requirements for bolts in sizes M16 to M36 made of steel with property classes 8.8 and 10.9. The document defines dimensions, tolerances, mechanical properties, finishes, testing and marking requirements. It specifies that bolts must be matched with nuts and washers conforming to other Indian Standards to provide assemblies with high strength and resistance to failure from overtightening. Hot-dip galvanized bolts are also covered, with additional specifications for lubrication and anti-seize testing to prevent galling during assembly.
The document discusses metal cutting, metal forming, and metrology. It is divided into three sections. Section I covers the theory of metal cutting, including basics of metal cutting, forces and power in metal cutting, and tool life, wear, economics, and machinability. Section II discusses metal forming processes such as cold working, rolling, forging, extrusion, drawing, and sheet metal operations. Section III covers metrology topics including limits, tolerances, fits, and measurement of lines and surfaces. The document provides an overview of the topics that will be covered in each section and directs the reader to the relevant page numbers for each chapter.
This document discusses various manufacturing processes and techniques. It begins by outlining metal cutting theory and traditional machining processes like turning, drilling, and milling. It then covers non-traditional processes such as ultrasonic machining and electrochemical machining. Further sections discuss welding and casting techniques, tolerances and fits, and metal forming processes like rolling, forging, drawing, and hydroforming. The document provides examples, equations, and multiple choice questions related to these manufacturing topics.
The document discusses various aspects of drilling operations including:
- Types of drill presses like vertical, radial arm, gang, multi-spindle, and numerical control drills.
- Drill geometry parameters like point angle, helix angle, rake angle which vary along the drill.
- Cutting speed, feed rate, and formulas to calculate drilling time and material removal rate.
- Factors that affect drilling like workpiece material hardness, drill material, and geometry.
This document discusses drilling operations. It describes different types of drill presses used for drilling including vertical, radial arm, gang, multi-spindle, and numerical control drills. It explains that twist drills cut cylindrical holes with flutes that carry chips up and out of the hole. Key drill features like point angle, helix angle, rake angle, and their effects on drilling different materials are covered. Formulas for calculating drilling time, material removal rate, and chip geometry are provided. Examples of drilling calculations are included.
Sheet metal stamping was developed in the 1890s for mass production of bicycles, playing an important role in making interchangeable parts economical. Basic sheet forming processes include shearing, bending, drawing, and involve tools like shear presses, brake presses, and finger presses. Material selection is critical, balancing formability with strength, weight, cost, and corrosion resistance. Stretch forming allows tighter tolerances than stamping but is difficult for complex shapes. New developments include tailored blanks, binder force control, and quick die exchange. Alternative auto body materials offer cost and environmental benefits compared to steel.
Machining is used to modify parts after casting or forming to achieve desired surface finishes, dimensions, and tolerances. It involves removing material through cutting processes like turning, milling, and drilling. Parts often require machining to produce features like smooth bearing surfaces, small deep holes, sharp edges, threads, and close tolerances that cannot be achieved through casting or forming alone. Machining also imparts special surface textures and finishes.
This repair manual provides instructions for body panel repair on the Toyota FJ Cruiser, focusing on welding procedures. It emphasizes the importance of following proper safety precautions during repair work. The manual outlines general repair instructions, including pre-removal measurements, cutting guidelines, installation procedures, and anti-rust treatment. Key points covered are avoiding heat repair which can weaken high-strength steel panels, replacing any damaged impact beams or brackets, and measuring panels before reinstallation to ensure correct assembly and fit.
Indian standard specification for high strength structural boltsJisha John
This document provides specifications for high strength structural bolts used in structural steel joints. It specifies requirements for bolts in sizes M16 to M36 made of steel with property classes 8.8 and 10.9. The document defines dimensions, tolerances, mechanical properties, finishes, testing and marking requirements. It specifies that bolts must be matched with nuts and washers conforming to other Indian Standards to provide assemblies with high strength and resistance to failure from overtightening. Hot-dip galvanized bolts are also covered, with additional specifications for lubrication and anti-seize testing to prevent galling during assembly.
The document discusses metal cutting, metal forming, and metrology. It is divided into three sections. Section I covers the theory of metal cutting, including basics of metal cutting, forces and power in metal cutting, and tool life, wear, economics, and machinability. Section II discusses metal forming processes such as cold working, rolling, forging, extrusion, drawing, and sheet metal operations. Section III covers metrology topics including limits, tolerances, fits, and measurement of lines and surfaces. The document provides an overview of the topics that will be covered in each section and directs the reader to the relevant page numbers for each chapter.
This document discusses various manufacturing processes and techniques. It begins by outlining metal cutting theory and traditional machining processes like turning, drilling, and milling. It then covers non-traditional processes such as ultrasonic machining and electrochemical machining. Further sections discuss welding and casting techniques, tolerances and fits, and metal forming processes like rolling, forging, drawing, and hydroforming. The document provides examples, equations, and multiple choice questions related to these manufacturing topics.
The document discusses various aspects of drilling operations including:
- Types of drill presses like vertical, radial arm, gang, multi-spindle, and numerical control drills.
- Drill geometry parameters like point angle, helix angle, rake angle which vary along the drill.
- Cutting speed, feed rate, and formulas to calculate drilling time and material removal rate.
- Factors that affect drilling like workpiece material hardness, drill material, and geometry.
This document discusses drilling operations. It describes different types of drill presses used for drilling including vertical, radial arm, gang, multi-spindle, and numerical control drills. It explains that twist drills cut cylindrical holes with flutes that carry chips up and out of the hole. Key drill features like point angle, helix angle, rake angle, and their effects on drilling different materials are covered. Formulas for calculating drilling time, material removal rate, and chip geometry are provided. Examples of drilling calculations are included.
Sheet metal stamping was developed in the 1890s for mass production of bicycles, playing an important role in making interchangeable parts economical. Basic sheet forming processes include shearing, bending, drawing, and involve tools like shear presses, brake presses, and finger presses. Material selection is critical, balancing formability with strength, weight, cost, and corrosion resistance. Stretch forming allows tighter tolerances than stamping but is difficult for complex shapes. New developments include tailored blanks, binder force control, and quick die exchange. Alternative auto body materials offer cost and environmental benefits compared to steel.
Machining is used to modify parts after casting or forming to achieve desired surface finishes, dimensions, and tolerances. It involves removing material through cutting processes like turning, milling, and drilling. Parts often require machining to produce features like smooth bearing surfaces, small deep holes, sharp edges, threads, and close tolerances that cannot be achieved through casting or forming alone. Machining also imparts special surface textures and finishes.
This repair manual provides instructions for body panel repair on the Toyota FJ Cruiser, focusing on welding procedures. It emphasizes the importance of following proper safety precautions during repair work. The manual outlines general repair instructions, including pre-removal measurements, cutting guidelines, installation procedures, and anti-rust treatment. Key points covered are avoiding heat repair which can weaken high-strength steel panels, replacing any damaged impact beams or brackets, and measuring panels before reinstallation to ensure correct assembly and fit.
The document summarizes key aspects of cutting tool technology. It discusses the three main modes of tool failure and how gradual wear is preferred. Tool materials are described, including high speed steel, cemented carbides, cermets, ceramics, and coatings. Tool geometry, including elements for single-point and multi-point tools, is covered. Functions of cutting fluids in reducing heat and friction are explained.
This document discusses various sheet metal forming processes and their characteristics. It provides tables comparing common sheet metal forming processes such as roll forming, stretching, drawing, stamping, and others. It also discusses specific sheet metal forming operations like bending, flanging, tube bending, and roll forming. Diagrams illustrate the mechanics and terminology used in these various sheet metal forming techniques.
This document discusses different materials and techniques used in cutting tool manufacturing. It covers common materials like high-speed steel and hardmetals like tungsten carbide, as well as advanced materials like ceramics, diamond, and cubic boron nitride. Coatings are also discussed which provide benefits like hardness, thermal protection and improved performance. New machining techniques covered include high-feed milling, plunge milling, spinning tools and trochoidal milling which aim to reduce vibrations. The document concludes by discussing future areas like micro milling and machining of new materials.
The document discusses various mechanical fastening methods used to assemble parts. It describes threaded fasteners like screws, bolts, and nuts which allow for disassembly. It also covers permanent fastening methods like rivets and eyelets. Interference fits that create an interference during or after assembly to hold parts together are also discussed, including press, shrink, and expansion fits. The document provides details on the use, advantages, and considerations for each fastening method.
This document is the Indian Standard specification for galvanized steel sheets, both plain and corrugated. It outlines the requirements, classifications, testing procedures and tolerances for galvanized steel sheets intended for general purposes like panelling and roofing. The standard specifies three classifications for galvanized plain and corrugated sheets based on the grade of raw material used. It also provides requirements for the zinc coating thickness, bend testing, coating mass determination and retests in case of failure. Dimensions and tolerances for plain sheets/coils are defined.
Design and Analysis of Progressive tool in Sheet metal manufacturingvivatechijri
Design and development of Progressive tools for the sheet metal component is one important phase
in sheet metal manufacturing. Sheet metal press working process by progressive tools is a highly complex process
that is vulnerable to various uncertainties such as variation in progressive tools geometry, strip layout, die shear,
material properties, component and press working equipment position error and process parameters related to
its manufacturer. These uncertainties in combinations can induce heavy manufacturing losses through premature
die failure, final part geometric distortion and production risk
The document outlines the requirements for nine grades of hot rolled low, medium, and high tensile structural steel according to the Indian Standard 2062:2006. It specifies chemical composition limits and mechanical properties for each grade. It also describes testing requirements, including tensile testing, bend testing, and impact testing to ensure the steel meets specifications. Defect and freedom from defect standards are provided as well as permissible variations in chemical analysis and testing positions.
This document provides an overview of sheet metal forming processes. It discusses shearing processes like punching and blanking. It describes the effects of clearance between the punch and die on shearing. It also covers other processes like bending, bead forming, flanging, roll forming, and stretch forming. Various press types and die configurations used in sheet metal forming are also summarized.
Shearing of metals is a sheet metalworking process used to cut relatively thin sheets of metal less than 6mm thick. Sheet metal parts are commonly used in automobiles, appliances, furniture and other consumer and industrial products. Common sheet metal processes include cutting, bending, drawing, punching, blanking, perforating and others. Sheet metal operations require precision tools and dies to cut cleanly and maintain dimensional accuracy and surface finish of the cut parts. Process parameters like shear angle, clearance and forces must be properly controlled to achieve quality edges and avoid defects.
Sheet metal is generally sheets less than 6 mm thick that are produced through rolling. Sheet metal is widely used for industrial and non-industrial applications like aircraft wings, automotive body panels, and construction roofing. Some common sheet metal materials include aluminum-zinc alloy, galvanized steel, and cold rolled steel. Sheet metal parts offer advantages like good strength, dimensional accuracy, surface finish, and low cost. Common sheet metal manufacturing processes include cutting operations like punching, blanking, and piercing as well as bending, drawing, and squeezing.
This document is the Indian Standard for foundation bolts. It provides specifications for foundation bolts sized M8 to M72. It specifies requirements for dimensions, tolerances, material, mechanical properties, marking, and other technical supply conditions. Foundation bolts are designed for use in masonry and concrete foundations. The standard specifies a property class of 4.6 and allows for hot-dip galvanized coatings if agreed by the supplier and purchaser. It provides typical shank forms and their dimensions in an appendix. The standard is intended to promote the dissemination of public safety information to disadvantaged communities and those engaged in education and knowledge.
1. Reaming is a machining process that removes a small amount of material from the surface of holes to bring them to a more exact size and improve surface finish. It uses multi-flute cutting tools with straight or helical flutes.
2. There are different types of reamers including hand, machine, shell, expansion, and adjustable reamers. Rose reamers cut only on the beveled ends of teeth while chucking reamers can cut on all portions of teeth.
3. Boring is used to enlarge existing holes and make them concentric to the axis of rotation. It is essentially internal turning where the tool feeds parallel to the workpiece rotation axis. Boring
Milling is a machining process that uses a rotating cutting tool called a milling cutter to remove material from a workpiece. Milling cutters come in various types for different purposes like flat surfaces, slots, threads, gears, etc. There are two types of milling: up milling where the cutter moves against the workpiece feed and down milling where they move together. Down milling provides better surface finish and tool life. Milling machines are classified based on their purpose, configuration, orientation, and level of automation. Milling cutters are also classified based on their geometry and how they machine specific features. Key parameters like cutting speed, feed rate, and depth of cut determine the material removal rate
Numerical simulation of friction stir butt welding processes for az91 magnesi...eSAT Journals
Abstract Friction Stir Welding (FSW) is a solid state welding process. In particular, it can be used to join high-strength aerospace magnesium and other metallic alloys that are hard to weld by conventional fusion welding. It was performed on 4 mm thickness AZ91 Magnesium alloy. Magnesium alloy have more advantage than aluminum such as light weight, softer, tendency to bend easily, cost effective in terms of energy requirements so magnesium alloy has selected in this FSW technique. In friction stir welding (FSW), a momentous residual stress is present in weld due to complex nature of fixturing system compared to fusion welding. These residual stresses can affect properties of welded components during service. Therefore, for estimating magnitude of welding residual stresses and their nature of distribution along with thermal history, a three dimensional non- linear thermo-mechanical finite element (NLTMFE) model using ABAQUS/ CAE package was developed for butt welded magnesium alloy AZ91. The objective of this work is to predict the temperature distribution in both materials and evaluate the mechanical properties during the friction stir welding on magnesium alloy. Keywords: Fsw, Nltmfe, Abaqus, Cae, Az91.
Numerical simulation of friction stir butt welding processes for az91 magnesi...eSAT Publishing House
This document describes a numerical simulation of friction stir butt welding for AZ91 magnesium alloy. A 3D nonlinear thermo-mechanical finite element model was developed using ABAQUS to predict temperature distribution and evaluate mechanical properties during the welding process. The model considers heat generation due to friction between the rotating tool and workpiece. Results show the maximum temperature reached was 483°C and residual stress was highest along the weld path. Pressure was also highest in the weld midpoint. Graphs of internal energy and strain energy over time were produced from the simulation results.
B16 c360 free-cutting brass rod, bar and shapes for use in screw machines1Yirlany Mesén Mejías
This document is an ASTM specification for free-cutting brass rod, bar and shapes. It establishes requirements for material composition, mechanical properties, dimensions, ordering information, and other testing and certification requirements. The material is Copper Alloy UNS No. C36000, containing 60-63% copper, 2.5-3.7% lead, and the remainder zinc. Requirements include tensile strength, yield strength, elongation, hardness limits that vary based on shape and size. The specification references other ASTM standards and provides details for ordering, inspection, and certification to ensure products meet standards.
This document discusses sheet metal forming processes. It introduces various sheet metal forming methods like bending, stretching, deep drawing, and identifies common defects. The objectives are to describe sheet metal forming processes, discuss variables that affect formability, and emphasize defects and solutions. Various forming equipment, stresses involved, and classifications of sheet metal parts and processes are outlined over several pages.
The document discusses design considerations for plastic enclosures that will be joined using ultrasonic welding. It addresses factors like joint design, material selection, assembly methods, and addressing stresses from manufacturing processes. Joint design needs a uniform contact area, alignment features, and considerations for welding frequencies and parameters. Material selection requires compatibility in properties like melt temperature. Assembly can be done through methods like staking, insertion, bonding or using alignment features. Stresses from processes like extrusion can be reduced through tempering techniques like annealing.
The document discusses various methods for manufacturing screw threads, including:
1) Thread cutting on lathes for both external and internal threads using tools like dies, taps, and mills.
2) Thread grinding and rolling which produce very accurate threads through forming processes.
3) Other methods like thread milling and chasing that can efficiently machine threads, especially in larger sizes.
Masking tape, also known as sticky tape, is a type of pressure-sensitive tape made of a thin and easy-to-tear paper, and an easily released pressure-sensitive adhesive. It is available in a variety of widths. It is used mainly in painting, to mask off areas that should not be painted. The adhesive is the key element to its usefulness, as it allows the tape to be easily removed without leaving residue or damaging the surface to which it is applied.
paintTROTTER Refinish is a mobile spray booth designed to perform painting and sanding jobs on small surfaces with a flawless quality and reduced cycle time while saving up to 90% of energy consumption compared to a traditional spray booth.
With the paintTROTTER Refinish you don’t have to move vehicles towards the booth... the booth moves to them! It also optimize preparation and painting times to maximize profits and returns thanks to its low maintenance costs and high operability.
The document summarizes key aspects of cutting tool technology. It discusses the three main modes of tool failure and how gradual wear is preferred. Tool materials are described, including high speed steel, cemented carbides, cermets, ceramics, and coatings. Tool geometry, including elements for single-point and multi-point tools, is covered. Functions of cutting fluids in reducing heat and friction are explained.
This document discusses various sheet metal forming processes and their characteristics. It provides tables comparing common sheet metal forming processes such as roll forming, stretching, drawing, stamping, and others. It also discusses specific sheet metal forming operations like bending, flanging, tube bending, and roll forming. Diagrams illustrate the mechanics and terminology used in these various sheet metal forming techniques.
This document discusses different materials and techniques used in cutting tool manufacturing. It covers common materials like high-speed steel and hardmetals like tungsten carbide, as well as advanced materials like ceramics, diamond, and cubic boron nitride. Coatings are also discussed which provide benefits like hardness, thermal protection and improved performance. New machining techniques covered include high-feed milling, plunge milling, spinning tools and trochoidal milling which aim to reduce vibrations. The document concludes by discussing future areas like micro milling and machining of new materials.
The document discusses various mechanical fastening methods used to assemble parts. It describes threaded fasteners like screws, bolts, and nuts which allow for disassembly. It also covers permanent fastening methods like rivets and eyelets. Interference fits that create an interference during or after assembly to hold parts together are also discussed, including press, shrink, and expansion fits. The document provides details on the use, advantages, and considerations for each fastening method.
This document is the Indian Standard specification for galvanized steel sheets, both plain and corrugated. It outlines the requirements, classifications, testing procedures and tolerances for galvanized steel sheets intended for general purposes like panelling and roofing. The standard specifies three classifications for galvanized plain and corrugated sheets based on the grade of raw material used. It also provides requirements for the zinc coating thickness, bend testing, coating mass determination and retests in case of failure. Dimensions and tolerances for plain sheets/coils are defined.
Design and Analysis of Progressive tool in Sheet metal manufacturingvivatechijri
Design and development of Progressive tools for the sheet metal component is one important phase
in sheet metal manufacturing. Sheet metal press working process by progressive tools is a highly complex process
that is vulnerable to various uncertainties such as variation in progressive tools geometry, strip layout, die shear,
material properties, component and press working equipment position error and process parameters related to
its manufacturer. These uncertainties in combinations can induce heavy manufacturing losses through premature
die failure, final part geometric distortion and production risk
The document outlines the requirements for nine grades of hot rolled low, medium, and high tensile structural steel according to the Indian Standard 2062:2006. It specifies chemical composition limits and mechanical properties for each grade. It also describes testing requirements, including tensile testing, bend testing, and impact testing to ensure the steel meets specifications. Defect and freedom from defect standards are provided as well as permissible variations in chemical analysis and testing positions.
This document provides an overview of sheet metal forming processes. It discusses shearing processes like punching and blanking. It describes the effects of clearance between the punch and die on shearing. It also covers other processes like bending, bead forming, flanging, roll forming, and stretch forming. Various press types and die configurations used in sheet metal forming are also summarized.
Shearing of metals is a sheet metalworking process used to cut relatively thin sheets of metal less than 6mm thick. Sheet metal parts are commonly used in automobiles, appliances, furniture and other consumer and industrial products. Common sheet metal processes include cutting, bending, drawing, punching, blanking, perforating and others. Sheet metal operations require precision tools and dies to cut cleanly and maintain dimensional accuracy and surface finish of the cut parts. Process parameters like shear angle, clearance and forces must be properly controlled to achieve quality edges and avoid defects.
Sheet metal is generally sheets less than 6 mm thick that are produced through rolling. Sheet metal is widely used for industrial and non-industrial applications like aircraft wings, automotive body panels, and construction roofing. Some common sheet metal materials include aluminum-zinc alloy, galvanized steel, and cold rolled steel. Sheet metal parts offer advantages like good strength, dimensional accuracy, surface finish, and low cost. Common sheet metal manufacturing processes include cutting operations like punching, blanking, and piercing as well as bending, drawing, and squeezing.
This document is the Indian Standard for foundation bolts. It provides specifications for foundation bolts sized M8 to M72. It specifies requirements for dimensions, tolerances, material, mechanical properties, marking, and other technical supply conditions. Foundation bolts are designed for use in masonry and concrete foundations. The standard specifies a property class of 4.6 and allows for hot-dip galvanized coatings if agreed by the supplier and purchaser. It provides typical shank forms and their dimensions in an appendix. The standard is intended to promote the dissemination of public safety information to disadvantaged communities and those engaged in education and knowledge.
1. Reaming is a machining process that removes a small amount of material from the surface of holes to bring them to a more exact size and improve surface finish. It uses multi-flute cutting tools with straight or helical flutes.
2. There are different types of reamers including hand, machine, shell, expansion, and adjustable reamers. Rose reamers cut only on the beveled ends of teeth while chucking reamers can cut on all portions of teeth.
3. Boring is used to enlarge existing holes and make them concentric to the axis of rotation. It is essentially internal turning where the tool feeds parallel to the workpiece rotation axis. Boring
Milling is a machining process that uses a rotating cutting tool called a milling cutter to remove material from a workpiece. Milling cutters come in various types for different purposes like flat surfaces, slots, threads, gears, etc. There are two types of milling: up milling where the cutter moves against the workpiece feed and down milling where they move together. Down milling provides better surface finish and tool life. Milling machines are classified based on their purpose, configuration, orientation, and level of automation. Milling cutters are also classified based on their geometry and how they machine specific features. Key parameters like cutting speed, feed rate, and depth of cut determine the material removal rate
Numerical simulation of friction stir butt welding processes for az91 magnesi...eSAT Journals
Abstract Friction Stir Welding (FSW) is a solid state welding process. In particular, it can be used to join high-strength aerospace magnesium and other metallic alloys that are hard to weld by conventional fusion welding. It was performed on 4 mm thickness AZ91 Magnesium alloy. Magnesium alloy have more advantage than aluminum such as light weight, softer, tendency to bend easily, cost effective in terms of energy requirements so magnesium alloy has selected in this FSW technique. In friction stir welding (FSW), a momentous residual stress is present in weld due to complex nature of fixturing system compared to fusion welding. These residual stresses can affect properties of welded components during service. Therefore, for estimating magnitude of welding residual stresses and their nature of distribution along with thermal history, a three dimensional non- linear thermo-mechanical finite element (NLTMFE) model using ABAQUS/ CAE package was developed for butt welded magnesium alloy AZ91. The objective of this work is to predict the temperature distribution in both materials and evaluate the mechanical properties during the friction stir welding on magnesium alloy. Keywords: Fsw, Nltmfe, Abaqus, Cae, Az91.
Numerical simulation of friction stir butt welding processes for az91 magnesi...eSAT Publishing House
This document describes a numerical simulation of friction stir butt welding for AZ91 magnesium alloy. A 3D nonlinear thermo-mechanical finite element model was developed using ABAQUS to predict temperature distribution and evaluate mechanical properties during the welding process. The model considers heat generation due to friction between the rotating tool and workpiece. Results show the maximum temperature reached was 483°C and residual stress was highest along the weld path. Pressure was also highest in the weld midpoint. Graphs of internal energy and strain energy over time were produced from the simulation results.
B16 c360 free-cutting brass rod, bar and shapes for use in screw machines1Yirlany Mesén Mejías
This document is an ASTM specification for free-cutting brass rod, bar and shapes. It establishes requirements for material composition, mechanical properties, dimensions, ordering information, and other testing and certification requirements. The material is Copper Alloy UNS No. C36000, containing 60-63% copper, 2.5-3.7% lead, and the remainder zinc. Requirements include tensile strength, yield strength, elongation, hardness limits that vary based on shape and size. The specification references other ASTM standards and provides details for ordering, inspection, and certification to ensure products meet standards.
This document discusses sheet metal forming processes. It introduces various sheet metal forming methods like bending, stretching, deep drawing, and identifies common defects. The objectives are to describe sheet metal forming processes, discuss variables that affect formability, and emphasize defects and solutions. Various forming equipment, stresses involved, and classifications of sheet metal parts and processes are outlined over several pages.
The document discusses design considerations for plastic enclosures that will be joined using ultrasonic welding. It addresses factors like joint design, material selection, assembly methods, and addressing stresses from manufacturing processes. Joint design needs a uniform contact area, alignment features, and considerations for welding frequencies and parameters. Material selection requires compatibility in properties like melt temperature. Assembly can be done through methods like staking, insertion, bonding or using alignment features. Stresses from processes like extrusion can be reduced through tempering techniques like annealing.
The document discusses various methods for manufacturing screw threads, including:
1) Thread cutting on lathes for both external and internal threads using tools like dies, taps, and mills.
2) Thread grinding and rolling which produce very accurate threads through forming processes.
3) Other methods like thread milling and chasing that can efficiently machine threads, especially in larger sizes.
Masking tape, also known as sticky tape, is a type of pressure-sensitive tape made of a thin and easy-to-tear paper, and an easily released pressure-sensitive adhesive. It is available in a variety of widths. It is used mainly in painting, to mask off areas that should not be painted. The adhesive is the key element to its usefulness, as it allows the tape to be easily removed without leaving residue or damaging the surface to which it is applied.
paintTROTTER Refinish is a mobile spray booth designed to perform painting and sanding jobs on small surfaces with a flawless quality and reduced cycle time while saving up to 90% of energy consumption compared to a traditional spray booth.
With the paintTROTTER Refinish you don’t have to move vehicles towards the booth... the booth moves to them! It also optimize preparation and painting times to maximize profits and returns thanks to its low maintenance costs and high operability.
10 Ways to Win at SlideShare SEO & Presentation OptimizationOneupweb
Thank you, SlideShare, for teaching us that PowerPoint presentations don't have to be a total bore. But in order to tap SlideShare's 60 million global users, you must optimize. Here are 10 quick tips to make your next presentation highly engaging, shareable and well worth the effort.
For more content marketing tips: http://www.oneupweb.com/blog/
No need to wonder how the best on SlideShare do it. The Masters of SlideShare provides storytelling, design, customization and promotion tips from 13 experts of the form. Learn what it takes to master this type of content marketing yourself.
SlideShare now has a player specifically designed for infographics. Upload your infographics now and see them take off! Need advice on creating infographics? This presentation includes tips for producing stand-out infographics. Read more about the new SlideShare infographics player here: http://wp.me/p24NNG-2ay
This infographic was designed by Column Five: http://columnfivemedia.com/
This document provides tips for getting more engagement from content published on SlideShare. It recommends beginning with a clear content marketing strategy that identifies target audiences. Content should be optimized for SlideShare by using compelling visuals, headlines, and calls to action. Analytics and search engine optimization techniques can help increase views and shares. SlideShare features like lead generation and access settings help maximize results.
This document provides tips to avoid common mistakes in PowerPoint presentation design. It identifies the top 5 mistakes as including putting too much information on slides, not using enough visuals, using poor quality or unreadable visuals, having messy slides with poor spacing and alignment, and not properly preparing and practicing the presentation. The document encourages presenters to use fewer words per slide, high quality images and charts, consistent formatting, and to spend significant time crafting an engaging narrative and rehearsing their presentation. It emphasizes that an attractive design is not as important as being an effective storyteller.
Each month, join us as we highlight and discuss hot topics ranging from the future of higher education to wearable technology, best productivity hacks and secrets to hiring top talent. Upload your SlideShares, and share your expertise with the world!
Not sure what to share on SlideShare?
SlideShares that inform, inspire and educate attract the most views. Beyond that, ideas for what you can upload are limitless. We’ve selected a few popular examples to get your creative juices flowing.
How to Make Awesome SlideShares: Tips & TricksSlideShare
Turbocharge your online presence with SlideShare. We provide the best tips and tricks for succeeding on SlideShare. Get ideas for what to upload, tips for designing your deck and more.
SlideShare is a global platform for sharing presentations, infographics, videos and documents. It has over 18 million pieces of professional content uploaded by experts like Eric Schmidt and Guy Kawasaki. The document provides tips for setting up an account on SlideShare, uploading content, optimizing it for searchability, and sharing it on social media to build an audience and reputation as a subject matter expert.
Detailed design report on design of upright and hubZubair Ahmed
The document describes the design process for an upright component in an automobile suspension system. It discusses 14 design parameters that were considered. Several design concepts and models were explored before settling on a final design (Design 4). The key points of the final design are that it is CNC milled from aluminum alloy 6351 T-6, weighs 760 grams, and addresses the weaknesses identified in previous designs. Loading scenarios analyzed include steering effort, braking forces, remote bump forces, and cornering forces. Finite element analysis was used to evaluate stresses and predict fatigue life under the different loading conditions.
Assembly of the components (Crank shaft, Connecting rod, Gudgeon pin and Piston) by
using different manufacturing processes from the material generated as a scrap during
manufacturing of different products through various processes.
Sheet metal working involves cutting, bending, and drawing operations on thin metal sheets. There are three major categories of sheet metal processes: cutting uses shearing actions to cut sheet metal, bending strains sheet metal around a straight axis, and drawing forms sheet metal into convex or concave shapes. Common sheet metal parts are used in automobiles, appliances, furniture and other industrial and consumer products.
1. Die casting is a metal casting process where molten metal is forced into a mold cavity under high pressure. This allows for intricate metal parts to be cast with high dimensional accuracy and consistency.
2. The main alloys used are zinc, aluminum, magnesium, copper, and tin-based alloys. Die casting is best suited for high volume production due to the large capital costs of the equipment and tooling.
3. The die casting process involves preparing lubricated dies, filling the mold cavity with molten metal under pressure, maintaining pressure until solidification, then ejecting and separating the castings from the shot and scrap.
The document discusses cutting tool technology, including tool materials, geometry, and failure modes. It describes how tool life is influenced by cutting speed and material properties. Common tool materials include high-speed steel, cemented carbides, ceramics, and coatings. Tool geometry depends on the operation, with single-point and multiple-point tools discussed. Twist drills are a type of multiple-point tool used for hole making.
This document discusses various sheet metal forming processes. It describes cutting processes like shearing, blanking, and punching. It also describes bending, drawing, embossing, stretch forming, roll forming, and spinning. Sheet metal is commonly used to make parts for vehicles, appliances, furniture and more. Cutting is done using punches and dies in presses or shears. Proper clearance and tool sizes are important. Bending involves straining metal around an axis. Drawing forms complex curved shapes using punches and dies.
The document discusses cutting tool technology, including tool life, materials, geometry, and failure modes. It describes how tool life is influenced by cutting speed and material. The preferred failure mode is gradual wear. Common tool materials include high-speed steel, cemented carbides, cermets, ceramics, and coatings. Tool geometry includes rake angle, clearance angle, and different insert shapes. Twist drills are discussed as a common multi-edged tool.
This document discusses various sheet metalworking processes. It covers cutting processes like shearing, blanking, and punching. Bending and drawing are also discussed, along with the factors that influence them like clearance, bending allowance, springback, and drawing ratio. Other forming operations like ironing, embossing, stretch forming, roll bending, and spinning are also summarized. The document concludes with a brief overview of dies for sheet metalworking and high-energy rate forming processes.
Forging is a metalworking process where a metal workpiece is shaped by applying compressive forces. It can produce parts that are stronger than those made by other metalworking processes. There are two main types of forging: open die forging between flat dies for larger objects, and closed die forging between shaped dies for smaller, more precise components. Common metals forged include carbon steels, aluminum, and titanium. The forging process involves heating metal, shaping it between dies using presses, trimming off excess flash, and often further processing like heat treating. Forgings are found in critical applications like engines and chassis where strength and reliability are important.
The document describes various heat treating practices for ferrous metals including annealing, hardening, normalizing, stress relieving, and tempering. It also discusses common machine tools like drilling machines, milling machines, boring machines, power saws, shapers, planers, and broaching machines. Finally, it provides information on alloying steel with chromium to improve hardenability, corrosion resistance, and strength at high temperatures.
1) The document discusses design considerations for cast iron components, including keeping stressed areas in compression, rounding external corners, avoiding abrupt changes in cross-section thickness, and avoiding thin sections.
2) It recommends consulting the foundryman and patternmaker when designing castings and provides general principles such as keeping sections uniform, avoiding metal concentration at junctions, and using draft angles on patterns.
3) Some ways to improve casting strength are inserting studs, using cored holes, and providing minimum section thicknesses depending on the casting process.
moloy roy tool technology presentationAkash Maurya
This document discusses cutting tool technology, including different tool materials, tool geometries, and cutting fluids. It describes the three main modes of tool failure as fracture, temperature, and gradual wear. High speed steel and cemented carbides are introduced as common tool materials, along with their properties and applications. Various tool geometries are covered, including single-point tools, twist drills, and milling cutters. Finally, the roles of cutting fluids in cooling and lubricating during machining operations are summarized.
This document provides an overview of sheet metal forming processes. It discusses various sheet metal operations including cutting (shearing) operations like punching, blanking, and trimming as well as forming operations like bending, drawing, and squeezing. Bending operations including V-bending and edge bending are described. Drawing operations for forming hollow shapes are also covered along with squeezing processes like embossing and coining.
The document discusses standards for the design, fabrication, and construction of cylindrical steel tanks for oil storage according to API Standard 650. It summarizes key chapters and sections of the standard, including requirements for materials selection and testing, joint design and inspection, shell and bottom plate thickness calculations, and erection procedures. The standard provides guidance for tank manufacturers to ensure structural integrity and safety according to industry best practices.
MULTI-MATERIAL DED FOR HIGH-PERFORMANCE LOW-COST ADDITIVE MANUFACTURINGDesignTeam8
This document summarizes information presented by Brian Matthews, CTO of Meltio, about the company's multi-metal additive manufacturing technology. Some key points:
- Meltio has developed a multi-laser deposition head that can process wire and powder simultaneously or independently, allowing for multi-metal 3D printing.
- Their technology integrates easily with existing CNC or robotic platforms and allows for printing of parts with different metals or creating new alloys on the fly.
- They offer metal 3D printing solutions in the form of turnkey printers, CNC integrations, and robotic integrations to suit different requirements.
- Meltio's process can deliver strong, affordable, and fully
Forging is a manufacturing process that improves the mechanical properties of metal by deforming it under high pressure. Close control over grain flow allows forging to impart desirable properties based on an application's needs. Adequate draft and flash are required in forging dies to allow complete filling and easy removal of the forged part. Common forging operations include fullering, edging, bending, drawing, flattening, blocking, and finishing. Forging can produce parts with better strength and fatigue resistance than casting or machining, though dimensional accuracy and surface finish tend to be lower.
This document summarizes friction stir welding (FSW), including its working principle, microstructure analysis, tool design, process parameters, advantages, challenges, and applications. FSW is a solid state welding technique that uses a rotating tool to generate frictional heat and mechanically deform aluminum alloys below their melting point. It produces high quality welds with improved mechanical properties compared to fusion welding. Main applications are in shipbuilding, aerospace, and automotive industries.
This document provides information on Y strainers from Spence, including:
- Key features of Y strainers such as low pressure drop, large strainer screens, and compact dimensions.
- Materials, sizes, ratings, and end connections available for Y strainers ranging from small bronze or cast iron models up to large fabricated steel models.
- Design details like body-cover joints, screen seating, and screen burst pressure calculations.
- Standard screen materials, sizes and pressure drop curves for 125Y series bronze and cast iron Y strainers with NPT, sweat or flanged connections from 3/8" to 16".
Metal Forming, Production Engineering IIዘረአዳም ዘመንቆረር
The document discusses sheet metal forming and cutting operations. It covers topics like sheet metal forming processes, applications of sheet metal, and basic sheet metal cutting operations like shearing, blanking, and punching. The engineering analysis of sheet metal cutting operations focuses on clearance between the punch and die, cutting forces, and determining punch and die sizes. Forming operations like bending, drawing, and associated engineering analysis are also covered.
[1] The BCM controls various vehicle systems like doors, rear defogger, warning chime, interior lamps, headlamps, and wipers.
[2] CONSULT-III can communicate with the BCM via CAN to perform functions like changing settings, viewing self-diagnostic results and signals, activating tests, and identifying the BCM.
[3] It allows diagnosing the systems controlled by the BCM like doors, rear defogger, warning chime, interior lamps, headlamps, and wipers.
The TPMS monitors tire pressure using transmitters installed in each wheel and a receiver located in the vehicle. The BCM processes signals from the transmitters to determine pressure levels. If low pressure is detected, the BCM illuminates the low tire pressure warning lamp. The system uses turn signals and a diagnostic tool during initialization and troubleshooting.
The document provides information about the warning chime system, including system diagrams and descriptions of the light reminder warning chime, seat belt warning chime, and parking brake release warning chime. It also covers diagnosis procedures for the combination meter, BCM, and symptoms like warning chimes that continue sounding or do not sound as expected.
The document provides exploded views and removal/installation instructions for ventilation system components in a vehicle, including:
- Center ventilator grille
- Side ventilator grille
- Front and side defroster grilles
- Ventilator, side ventilator, and foot ducts
- Front and side defroster nozzles
- Foot grille
- Blower unit and blower motor
The document outlines how to remove each component and the basic reverse procedure for installation. Precautions are provided for working near airbag components and disconnecting the battery.
This document provides information on transmission and driveline components for a 6-speed manual transmission (6MT) and a 7-speed automatic transmission (7AT). It includes sections on function diagnosis, component diagnosis, symptom diagnosis, precautions, preparation, on-vehicle maintenance, removal and installation, disassembly and assembly, service data and specifications, and ECU diagnosis. The document contains exploded views, diagrams, removal/installation procedures, and inspection/repair information for transmission components.
The document provides information on diagnosing and repairing starting systems. It describes manual and automatic transmission starting system diagrams, components, and descriptions. Diagnosis steps include inspecting the battery, starter motor, alternator, B terminal circuit, S connector circuit, and engine rotation. If issues are found, the document provides repair procedures for the starter motor. It also includes service data and specifications for the starter motor.
The document provides information about steering system diagnosis and repair. It includes:
F
Turn the ignition switch OFF.
Disconnect combination meter harness connectors.
Disconnect power steering control unit harness connector.
Check the continuity between combination meter harness connector and power steering control unit harness connector.
STC
H
Combination meter
Power steering control unit
Connector
Terminal
Connector
Terminal
M107
5
M108
11
Continuity
Existed
I
Is the inspection result normal?
YES >> GO TO 3.
NO
>> Repair or replace error-detected parts.
J
3.
The document provides information on servicing the steering system for a vehicle. It includes sections on symptom diagnosis, precautions, preparation, on-vehicle maintenance, on-vehicle repair, and service data. The precautions section outlines safety procedures for working on the supplemental restraint system and describes how to release the steering lock if the battery is disconnected. The document provides exploded views, removal/installation procedures, and inspection steps for various steering components.
This document provides information on diagnosing and repairing issues with a vehicle's supplemental restraint system (SRS) airbag control system. It outlines the system components, diagnostic trouble codes (DTCs), diagnosis procedures, and precautions for working on the SRS. The document is divided into sections covering the basic system description, component diagnosis by DTC, ECU diagnosis, symptom diagnosis, and precautions for working on the SRS. It provides detailed information on testing and repairing the airbags, seat belt pre-tensioners, occupancy sensors and other SRS components.
1. The document provides removal and installation instructions for various supplemental restraint system (SRS) components including the driver air bag module, front passenger air bag module, spiral cable, and other modules.
2. Removal of SRS components requires disconnection of the battery and waiting 3 minutes for safety. The driver air bag module is removed by taking out bolts and disconnecting the harness connector.
3. Proper handling of air bag modules is emphasized to avoid deployment or damage, and self-diagnosis must be performed after repairs to check for faults.
The document provides information on vehicle security systems for Nissan vehicles, including:
1. Sections cover the intelligent key system, Nissan vehicle immobilizer system (NATS), vehicle security system, component diagnosis, and symptom diagnosis.
2. Diagrams and descriptions are provided for each system, along with component locations, wiring diagrams, and diagnostic procedures.
3. The document also includes an ECU diagnosis section for the body control module and intelligent power distribution module, with reference values, wiring diagrams, fail-safe operation, and DTC indexes.
The document provides information on diagnosing and repairing squeaks and rattles in vehicles:
- It outlines a process for diagnosing the issue through customer interviews, duplicating the noise, and narrowing down the source.
- Common areas to inspect are the instrument panel, center console, and doors. Loose or insufficiently insulated components are often the cause.
- Once the cause is found, it should be repaired by tightening, adding insulation, or repositioning components. The repair must then be confirmed by recreating the conditions.
This document provides information on diagnosing issues with the seat belt control system on a vehicle. It begins with an overview of the diagnosis and repair workflow process. It then describes the seat belt warning system, including a system diagram, description, and locations of components. The document outlines procedures for diagnosing issues with specific components like the seat belt buckle switches and seat belt warning lamp circuit. It provides symptom-based diagnosis procedures and concludes with precautions for working on supplemental restraint systems.
This document provides information on inspecting and servicing seat belts. It begins with safety precautions for working on supplemental restraint systems and the battery. It describes inspecting seat belts for damage or improper operation after a collision. Inspection steps are provided to check the seat belt warning light, retractor operation, and for dirt or damage. The document includes an exploded view and procedures for removing and installing the seat belt retractor. Finally, it discusses inspecting and replacing the seat belt buckle.
The document provides information on rear suspension maintenance and repair, including:
1) Inspection procedures for the rear suspension assembly, wheel alignment, rear lower link and coil spring, and rear shock absorber.
2) Removal and installation procedures for the rear lower link and coil spring and rear shock absorber.
3) Inspection criteria for components after removal, disassembly, and installation to check for damage or abnormal wear.
The document provides information on rear axle and drive shaft components. It includes:
1) An exploded view and removal/installation steps for the rear wheel hub and housing.
2) An exploded view and removal/installation instructions for the rear drive shaft.
3) Disassembly and assembly steps for the wheel side of the rear drive shaft.
The document provides information on diagnosing issues with a vehicle's power window control system. It includes:
1) A system diagram showing the components of the power window control system including the BCM, power window switches, motors and encoders.
2) A description of the system including functions like auto-open/close, anti-pinch, retained power operation and use of serial communication between components.
3) Sections on inspecting individual components, performing diagnostics, addressing specific symptoms, and precautions for repairs. The document provides a thorough overview of analyzing and troubleshooting power window problems.
This document provides information about the diagnosis system and relay control system for the IPDM E/R. It describes the auto active test mode which sends drive signals to various vehicle systems to check operation when specific steps are followed. The relay control system section explains that the IPDM E/R uses CAN communication to perform relay ON-OFF control according to input signals from sensors and request signals from control units. It provides a table listing the control relays, input/output, control parts, and reference pages.
The document provides information about parking brake system maintenance and repair for a 2009 370Z. It includes sections on preparation, inspection and adjustment of the parking brake system, parking brake shoe adjustment, and exploded views and repair procedures for the parking brake control and parking brake shoe. Specifications are provided for parking drum brake components and the parking brake control.
The meter system receives signals from various sensors and modules through CAN communication to operate gauges, indicators, warnings and the information display. The combination meter integrates these signals and performs meter and warning functions. It also incorporates a trip computer for the information display. The IPDM E/R module assists by transmitting the oil pressure warning signal and enabling diagnosis of that indicator.
1. BODY EXTERIOR, DOORS, ROOF & VEHICLE SECURITY
SECTION
BRM
BODY REPAIR
A
B
C
D
E
CONTENTS
FEATURES OF NEW MODEL ..................... 2
.
HANDLING PRECAUTIONS ............................. 23
BODY EXTERIOR PAINT COLOR .................... 2
.
F
Precautions for Plastics ..........................................23
.
Location of Plastic Parts .........................................24
.
Body Exterior Paint Color ...................................... 2
.
PRECAUTION .............................................. 4
.
REPAIRING HIGH STRENGTH STEEL ............. 4
.
REMOVAL AND INSTALLATION .............. 26
.
CORROSION PROTECTION ............................ 26
High Strength Steel (HSS) ..................................... 4
.
Handling of Ultra High Strength Steel Plate Parts 6
......
Description ..............................................................26
.
Undercoating ..........................................................26
.
Body Sealing ..........................................................27
.
PREPARATION ........................................... 7
.
BODY CONSTRUCTION .................................. 31
REPAIRING MATERIAL .................................... 7
.
Body Construction ..................................................31
.
Rear Fender Hemming Process .............................32
.
Foam Repair ............................................................ 7
.
BODY COMPONENT PARTS ............................ 9
.
Underbody Component Parts ................................. 9
.
Body Component Parts .......................................... 11
.
ON-VEHICLE MAINTENANCE ................... 13
.
BODY ALIGNMENT ..........................................13
.
Body Center Marks ............................................... 13
.
Description ............................................................. 14
.
Engine Compartment ............................................ 14
.
Underbody .............................................................. 16
.
Passenger Compartment ....................................... 19
.
Rear Body ............................................................. 20
.
ON-VEHICLE REPAIR ................................ 23
.
G
H
I
J
REPLACEMENT OPERATIONS ....................... 34
Description ..............................................................34
.
Radiator Core Support ............................................36
.
Hoodledge ..............................................................36
.
Front Side Member .................................................39
.
Front Side Member (Partial Replacement) ..........42
.
Front Pillar (Partial Replacement) ..........................43
.
Front Pillar ..............................................................45
.
Outer Sill (Partial Replacement by Cutting) ............49
.
Outer Sill (Partial Replacement by Piece) ..............50
.
Outer Sill ................................................................51
.
Rear Fender ...........................................................55
.
Lock Pillar Reinforcement .......................................57
.
Rear Panel .............................................................59
.
Rear Floor Rear ....................................................59
.
Rear Side Member Extension .................................60
.
BRM
L
M
N
O
P
Revision: 2008 October
BRM-1
2009 370Z
2. BODY EXTERIOR PAINT COLOR
< FEATURES OF NEW MODEL >
FEATURES OF NEW MODEL
BODY EXTERIOR PAINT COLOR
Body Exterior Paint Color
INFOID:0000000004609557
JSKIA0899ZZ
Color code
BA54
BEAC
BG41
BK23
BK51
BKAC*
BQAA
BRAE
Description
Red
Yellow
Black
Silver
Gray
Brownish
Gray
White
Blue
Paint type note
CS
2S
P
M
M
TM
3P
3P
Hard clear
coat
×
-
×
-
-
-
-
×
Body
Body color
BA54
BEAC
BG41
BK23
BK51
BKAC
BQAA
BRAE
Grille
Material color
-
-
-
-
-
-
-
-
Component
1
Front
bumper
fascia
2
Front pillar finisher
Body color
BA54
BEAC
BG41
BK23
BK51
BKAC
BQAA
BRAE
3
Door
outside
mirror
Body color
BA54
BEAC
BG41
BK23
BK51
BKAC
BQAA
BRAE
4
Satellite radio
antenna
Body color
BA54
BEAC
BG41
BK23
BK51
BKAC
BQAA
BRAE
5
Fuel filler lid
Body color
BA54
BEAC
BG41
BK23
BK51
BKAC
BQAA
BRAE
6
Door outside
handle and escutcheon
Velour chromium plate
Cr2p
Cr2p
Cr2p
Cr2p
Cr2p
Cr2p
Cr2p
Cr2p
7
Center mudguard
Body color
BA54
BEAC
BG41
BK23
BK51
BKAC
BQAA
BRAE
8
Rear bumper
fascia
Body color
BA54
BEAC
BG41
BK23
BK51
BKAC
BQAA
BRAE
Cover
NOTE:
• 2S: Solid + Clear
• CS: Color clear solid
• M: Metallic
• P: 2-Coat pearl
• 3P: 3-Coat pearl
• FPM: Iron oxide pearl
• RPM: Multi flex color
• TPM: Titanium pearl metallic
Revision: 2008 October
BRM-2
2009 370Z
3. BODY EXTERIOR PAINT COLOR
< FEATURES OF NEW MODEL >
• TM: Micro titanium metallic
A
• PM: Pearl metallic
*: Canada and Mexico only
B
C
D
E
F
G
H
I
J
BRM
L
M
N
O
P
Revision: 2008 October
BRM-3
2009 370Z
4. REPAIRING HIGH STRENGTH STEEL
< PRECAUTION >
PRECAUTION
REPAIRING HIGH STRENGTH STEEL
High Strength Steel (HSS)
INFOID:0000000004687071
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
370 - 590 MPa
Major applicable parts
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
780 - 1350 MPa
Front side member assembly
Front side member closing plate assembly
Front side member outrigger assembly
Upper front hoodledge
Hoodledge reinforcement
Front strut housing
Lower dash
Lower dash crossmember assembly
Front roof rail
Upper front pillar reinforcement
Center front floor
Front floor
(Component part)
Outer sill reinforcement
Inner rear pillar
(Component part)
Outer rear wheelhouse extension
Lock pillar reinforcement assembly
Rear seat crossmember
Rear seat crossmember reinforcement assembly
Rear side member assembly
Rear pillar reinforcement
Other reinforcements
• Upper front pillar reinforcement
(Component part)
• Stiffener front side member
(Front floor component part)
• Front side member rear extension
• Inner sill
• Inner lock pillar assembly
(Component part)
• Inner rear pillar
(Component part)
Read the following precautions when repairing HSS:
1. Additional points to consider
• The repair of reinforcements (such as side members) by heating is not recommended, because it may weaken the component. 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 appropriate.)
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.
Revision: 2008 October
BRM-4
2009 370Z
5. REPAIRING HIGH STRENGTH STEEL
< PRECAUTION >
• 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).
A
B
C
PIIA0117E
D
• When welding HSS panels, use spot welding whenever possible 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.
E
F
G
PIIA0144E
H
• 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.
I
J
BRM
PIIA0145E
2.
Precautions in spot welding HSS
This work should be performed under standard working conditions. Always note the following when spot welding HSS:
• The electrode tip diameter must be sized properly according to
the metal thickness.
L
M
N
PIIA0146E
O
P
Revision: 2008 October
BRM-5
2009 370Z
6. REPAIRING HIGH STRENGTH STEEL
< PRECAUTION >
• The panel surfaces must fit flush to each other, leaving no
gaps.
PIIA0147E
• 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
Handling of Ultra High Strength Steel Plate Parts
INFOID:0000000004687072
PROHIBITION OF CUT AND CONNECTION
Never cut and connect 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.
Revision: 2008 October
BRM-6
2009 370Z
7. REPAIRING MATERIAL
< PREPARATION >
PREPARATION
A
REPAIRING MATERIAL
Foam Repair
INFOID:0000000004609551
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
B
C
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 equivalent
Read instructions on product for fill procedures.
D
E
Example of foaming agent filling operation procedure
1.
a.
b.
c.
d.
Fill procedures after installation of service part.
Eliminate foam material remaining on vehicle side.
Clean area after eliminating form insulator and foam material.
Install service part.
Insert nozzle into hole near fill area and fill foam material or fill enough to close gap with the service part.
F
G
H
I
J
BRM
L
JSKIA0129GB
1.
Urethane foam
A.
Nozzle insert hole
M
: Vehicle front
2.
a.
b.
c.
Fill procedures before installation of service part.
Eliminate foam material remaining on vehicle side.
Clean area after eliminating foam insulator and foam material.
Fill foam material on wheelhouse outer side.
N
O
P
Revision: 2008 October
BRM-7
2009 370Z
8. REPAIRING MATERIAL
< PREPARATION >
1.
A.
Urethane foam
Fill while avoiding flange area
: Vehicle front
d.
NOTE:
Fill enough to close gap with service part while avoiding flange
area.
Install service part.
NOTE:
Refer to label for information on working times.
Revision: 2008 October
BRM-8
JSKIA0130GB
2009 370Z
9. BODY COMPONENT PARTS
< PREPARATION >
BODY COMPONENT PARTS
A
Underbody Component Parts
INFOID:0000000004609552
B
C
D
E
F
G
H
I
J
BRM
L
M
N
O
P
JSKIA0900ZZ
1.
Side radiator core support (RH & LH) 2.
Front strut housing (RH & LH)
3.
Lower rear hoodledge (RH & LH)
4.
Upper front hoodledge (RH & LH)
5.
Upper rear hoodledge (RH & LH)
6.
Hoodledge reinforcement (RH & LH)
7.
Upper side cowl top (RH & LH)
8.
Front cowl top
9.
Upper dash
Revision: 2008 October
BRM-9
2009 370Z
10. BODY COMPONENT PARTS
< PREPARATION >
10. Lower dash crossmember assembly 11. Lower outer battery support bracket
12. Lower battery support bracket
13. Lower dash
14. Center front floor
15. Front floor (RH & LH)
16. Inner sill (RH & LH)
17. Rear seat crossmember reinforcement assembly
18. Rear floor front
19. Rear floor rear
20. Rear crossmember center assembly 21. Sensor bracket
22. Rear floor side (RH & LH)
23. Front side member assembly (RH &
LH)
25. Front side member connector assembly (RH & LH)
26. Front side member closing plate as- 27. Front side member front closing
sembly (RH & LH)
plate (RH & LH)
24. Front side member front extension
(RH & LH)
28. Front side rear closing reinforcement 29. Front side member center closing
(RH & LH)
plate (RH & LH)
30. Front side member rear extension
(RH & LH)
31. Front side member outrigger assem- 32. Rear seat crossmember
bly (RH & LH)
33. Rear crossmember
34. Rear side member assembly (RH &
LH)
35. Rear side member extension (RH &
LH)
: Both sided anti-corrosive precoated steel sections
: High strength steel (HSS) sections
: Both sided anti-corrosive steel and HSS sections
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.
Revision: 2008 October
BRM-10
2009 370Z
11. BODY COMPONENT PARTS
< PREPARATION >
Body Component Parts
INFOID:0000000004609553
A
B
C
D
E
F
G
H
I
J
BRM
L
M
N
O
P
JSKIA0901ZZ
1.
Hood
2.
Front fender (RH & LH)
3.
Upper front pillar reinforcement (RH
& LH)
4.
Front pillar brace (RH & LH)
5.
Lock pillar reinforcement assembly
(RH & LH)
6.
Outer sill reinforcement (RH & LH)
Revision: 2008 October
BRM-11
2009 370Z
12. BODY COMPONENT PARTS
< PREPARATION >
7.
Outer rear wheelhouse extension
(RH & LH)
8.
Inner side roof rail (RH & LH)
9.
Inner lock pillar assembly (RH & LH)
10. Outer sill brace (RH & LH)
11. Inner rear pillar (RH & LH)
12. Rear pillar reinforcement (RH & LH)
13. Outer rear wheelhouse (RH & LH)
14. Inner rear wheelhouse (RH & LH)
15. Roof
16. Front roof rail
17. Center roof bow
18. Rear roof rail
19. Rear fender assembly (RH & LH)
20. Rear combination lamp base (RH &
LH)
21. Rear fender extension (RH & LH)
22. Rear panel assembly
23. Rear bumper fascia center bracket
24. Rear bumper bracket
25. Door assembly (RH & LH)
26. Outer door panel (RH & LH)
27. Back door
28. Front bumper armature assembly
29. Rear bumper stay (RH & LH)
30. Inner center rear bumper reinforcement assembly
: Both sided anti-corrosive precoated steel sections
: High strength steel (HSS) sections
: Both sided anti-corrosive steel and HSS sections
*: Aluminum portion
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.
Revision: 2008 October
BRM-12
2009 370Z
13. BODY ALIGNMENT
< ON-VEHICLE MAINTENANCE >
ON-VEHICLE MAINTENANCE
A
BODY ALIGNMENT
Body Center Marks
INFOID:0000000004583859
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.
B
C
D
E
F
G
H
I
J
BRM
L
M
N
JSKIA0883ZZ
O
: Vehicle front
Unit: mm (in)
Points
Portion
Marks
Upper dash
Hole φ8 (0.31)
B
Front roof
Embossment
C
Rear roof
Embossment
A
Revision: 2008 October
BRM-13
2009 370Z
P
14. BODY ALIGNMENT
< ON-VEHICLE MAINTENANCE >
Points
Portion
Marks
D
Rear panel
Indent
E
Trans control reinforcement
Embossment
Description
INFOID:0000000004583860
• 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
Engine Compartment
3.
Imaginary base line
INFOID:0000000004583861
Measurement
Dimensions marked with ″*″ indicate symmetrically identical dimensions on both the right and left hand of the
vehicle.
Revision: 2008 October
BRM-14
2009 370Z
15. BODY ALIGNMENT
< ON-VEHICLE MAINTENANCE >
A
B
C
D
E
F
G
H
I
JSKIA0884GB
Unit: mm (in)
J
«The others»
Unit: mm (in)
Point
Dimension
A-C
Memo
Point
Dimension
735 (28.94)*
B-d
A-E
804 (31.65)*
A-G
B-C
Memo
Point
Dimension
1197 (47.13)*
C-c
B-E
381 (15.00)*
967 (38.07)*
B-f
131 (5.16)*
B-G
Memo
Point
Dimension
1423 (56.02)
F-h
1187 (46.73)*
D-m
875 (34.45)*
G-g
1073 (42.24)
1509 (59.41)*
E-e
1349 (53.11)
K-k
903 (35.55)
767 (30.20)*
F-H
Memo
511 (20.12)*
Measurement Points
BRM
L
M
N
O
P
Revision: 2008 October
BRM-15
2009 370Z
16. BODY ALIGNMENT
< ON-VEHICLE MAINTENANCE >
JSKIA0885ZZ
: Vehicle front
Unit: mm (in)
Point
Material
Point
Material
A
Center wiper pivot bracket hole center of center
positioning mark φ8 (0.31)
H, h
Radiator core support stay hole center φ12 (0.47)
B, b, F, f
Hoodledge reinforcement hole center 12×14
(0.47×0.55)
J, j
Front side member hole center φ20 (0.79)
C, c, E, e
Front fender installing hole center φ7 (0.28)
K, k, M, m
Nut holder hole center φ16 (0.63)
D, d
Front strut installing hole center φ11 (0.43)
N, n, O, o
Front bumper reinforcement installing hole center
φ11 (0.43)
G, g
Rear air cleaner bracket hole center φ7 (0.28)
Underbody
INFOID:0000000004583862
Measurement
Revision: 2008 October
BRM-16
2009 370Z
17. BODY ALIGNMENT
< ON-VEHICLE MAINTENANCE >
Dimensions marked with ″*″ indicate symmetrically identical dimensions on both the right and left hand of the
vehicle.
A
B
C
D
E
F
G
H
I
J
BRM
L
M
N
O
P
JSKIA0886GB
Unit: mm (in)
: Vehicle front
: Bolt head
Measurement Points
Revision: 2008 October
BRM-17
2009 370Z
18. BODY ALIGNMENT
< ON-VEHICLE MAINTENANCE >
JSKIA0887ZZ
: Vehicle front
Unit: mm (in)
Points
Coordinates
Remarks
X
Y
Z
A, a
±415.8
(±16.370)
−495.0
(−19.488)
225.6
(8.882)
Hole φ13 (0.51)
B
416.2
(16.386)
−368.0
(−14.488)
303.2
(11.937)
b
−413.2
(−16.268)
−368.0
(−14.488)
C, c
±415.0
(±16.339)
D, d
E, e
Points
Coordinates
Remarks
X
Y
Z
H, h
±437.5
(±17.224)
1765.5
(69.508)
79.0
(3.110)
Hole φ8 (0.31)
Hole φ16 (0.63)
J, j
±604.5
(±23.799)
2090.5
(82.303)
128.3
(5.051)
Hole φ16 (0.63)
303.2
(11.937)
Hole φ16 (0.63)
K, k
±472.6
(±18.606)
2303.8
(90.701)
114.0
(4.488)
Bolt head
−104.0
(−4.094)
133.5
(5.256)
Bolt head
M, m
±451.5
(±17.776)
2863.9
(112.752)
179.1
(7.051)
Bolt head
±392.0
(±15.433)
414.0
(16.299)
64.5
(2.539)
Bolt head
N, n
±533.0
(±20.984)
3175.0
(125.000)
315.4
(12.417)
Hole φ16 (0.63)
±428.0
(±16.850)
815.0
(32.087)
78.4
(3.087)
Hole 16×20
(0.63×0.79)
O, o
±421.6
(±16.598)
38.2
(1.504)
677.9
(26.689)
Hole φ50.1 (1.972)
Revision: 2008 October
BRM-18
2009 370Z
19. BODY ALIGNMENT
< ON-VEHICLE MAINTENANCE >
F, f
±438.0
(±17.244)
1100.0
(43.307)
79.0
(3.110)
Hole φ16 (0.63)
G, g
±437.5
(±17.224)
1421.8
(55.976)
80.0
(3.150)
±488.4
(±19.228)
Hole φ8 (0.31)
P, p
2591.7
(102.035)
825.0
(32.480)
Hole φ68 (2.68)
A
B
Passenger Compartment
INFOID:0000000004583863
Measurement
Dimensions marked with ″*″ indicate symmetrically identical dimensions on both the right and left hand of the
vehicle.
C
D
E
F
G
H
I
J
BRM
L
JSKIA0888GB
Unit: mm (in)
M
«The others»
Unit: mm (in)
Point
Dimension
E-e
Memo
Point
Dimension
1276 (50.24)
F-j
E-g
1599 (62.95)*
E-h
Memo
Point
Dimension
1713 (67.44)*
J-j
G-g
1452 (57.17)
1449 (57.05)*
G-h
E-j
1563 (61.54)*
F-f
F-h
Memo
Point
Dimension
1471 (57.91)
M-H
1273 (50.12)*
K-E
1024 (40.31)*
M-J
1074 (42.28)*
1877 (73.90)*
K-F
1094 (43.07)*
N-H
1376 (54.17)*
G-j
1749 (68.86)*
K-G
1095 (43.11)*
N-J
1071 (42.17)*
1452 (57.17)
H-h
1348 (53.07)
K-H
978 (38.50)*
1748 (68.82)*
H-j
1504 (59.21)*
K-J
Memo
763 (30.04)*
BRM-19
O
P
Measurement Points
Revision: 2008 October
N
2009 370Z
20. BODY ALIGNMENT
< ON-VEHICLE MAINTENANCE >
JSKIA0889ZZ
: Vehicle front
Unit: mm (in)
Point
Material
Point
Material
A
Center wiper pivot bracket hole center of center
positioning mark φ8 (0.31)
G, g
Front pillar hinge brace indent
B
Roof flange end of center positioning mark
H, h, J, j
Rear fender indent
C, c
Front pillar joggle
K
Trans control reinforcement positioning mark of
center positioning mark
D, d, F, f
Front pillar hinge brace joggle
M, m, N, n
Door hinge installing hole center φ12 (0.47)
E, e
Front pillar indent
Rear Body
INFOID:0000000004583865
Measurement
Dimensions marked with ″*″ indicate symmetrically identical dimensions on both the right and left hand of the
vehicle.
Revision: 2008 October
BRM-20
2009 370Z
21. BODY ALIGNMENT
< ON-VEHICLE MAINTENANCE >
A
B
C
D
E
F
G
H
I
JSKIA0890GB
Unit: mm (in)
J
Measurement Points
BRM
L
M
N
O
P
Revision: 2008 October
BRM-21
2009 370Z
22. BODY ALIGNMENT
< ON-VEHICLE MAINTENANCE >
JSKIA0891ZZ
: Vehicle front
Point
Material
Point
Material
A
Roof flange end of center positioning mark
D, d
Rear combination lamp base joggle
B, b
Rear fender joggle
E
Upper rear panel reinforcement indent of center
positioning mark
C, c
Rear combination lamp base extension joggle
Revision: 2008 October
BRM-22
2009 370Z
23. HANDLING PRECAUTIONS
< ON-VEHICLE REPAIR >
ON-VEHICLE REPAIR
A
HANDLING PRECAUTIONS
Precautions for Plastics
Abbreviation
Material name
INFOID:0000000004609549
Heat resisting
temperature
°C (°F)
Resistance to gasoline and
solvents
Other cautions
PE
Polyethylene
60 (140)
Gasoline and most solvents are
harmless if applied for a very
short time (wipe out quickly).
Flammable
ABS
Acrylonitrile Butadiene Styrene
80 (176)
Avoid gasoline and solvents.
Ethylene Propylene (Diene) copolymer
80 (176)
Gasoline and most solvents are
harmless if applied for a very
short time (wipe out quickly).
Flammable
PS
Polystyrene
80 (176)
Avoid solvents.
Flammable
PVC
Poly Vinyl Chloride
80 (176)
Gasoline and most solvents are
harmless if applied for a very
short time (wipe out quickly).
Poisonous gas is emitted
when burned.
TPO
Thermoplastic Olefine
80 (176)
↑
AAS
Acrylonitrile Acrylic Styrene
85 (185)
PMMA
Poly Methyl Methacrylate
85 (185)
↑
—
EVAC
Ethylene Vinyl Acetate
90 (194)
↑
—
PP
Polypropylene
90 (194)
Gasoline and most solvents are
harmless if applied for a very
short time (wipe out quickly).
Flammable, avoid battery acid.
PUR
Polyurethane
90 (194)
Avoid gasoline and solvents.
—
UP
Unsaturated Polyester
90 (194)
↑
Flammable
ASA
Acrylonitrile Styrene Acrylate
100 (212)
↑
Flammable
PPE
Poly Phenylene Ether
110 (230)
↑
—
TPU
Thermoplastic Urethane
110 (230)
↑
—
PBT+
PC
Poly Butylene Terephthalate +
Polycarbonate
120 (248)
↑
Flammable
PC
Polycarbonate
120 (248)
↑
—
POM
Poly Oxymethylene
120 (248)
↑
Avoid battery acid.
PA
Polyamide
140 (284)
↑
Avoid immersing in water.
PBT
Poly Butylene Terephthalate
140 (284)
↑
—
PAR
Polyarylate
180 (356)
↑
—
PET
Polyester
180 (356)
↑
—
PEI
Polyetherimide
200 (392)
↑
—
C
—
EPM/
EPDM
B
Avoid gasoline and solvents.
D
E
F
G
Flammable
—
H
I
J
BRM
L
M
N
O
CAUTION:
• When repairing and painting a portion of the body adjacent to plastic parts, consider their characteristics (influence of heat
and solvent) and remove them if necessary or take suitable measures to protect them.
• Plastic parts should be repaired and painted using methods suiting the materials, characteristics.
Revision: 2008 October
BRM-23
2009 370Z
P
24. HANDLING PRECAUTIONS
< ON-VEHICLE REPAIR >
Location of Plastic Parts
INFOID:0000000004609550
JSKIA0902ZZ
Component
1
2
Front combination lamp
3
Upper windshield molding
4
Material
Bumper fascia
Front pillar finisher
Door outside mirror
Satellite radio antenna
ASA + PC
Lens
PC
9
Fuel filler lid
PA + PPE
Housing
PP
10
Door outside molding
PVC + Stainless
TPO
11
Door outside handle
PC + ABS
PC + PET
12
Center mudguard
PP + EPM
13
Rear combination lamp
14
Rear fog lamp
15
License plate lamp
ABS
Housing
ASA
Base
6
7
Side turn signal lamp
High mount stop lamp
Revision: 2008 October
Material
8
Cover
5
Component
PP + EPM
PA + Glass fiber
Lens
PMMA
Housing
Lens
Housing
ABS
PMMA
Lens
Housing
Lens
Housing
Lens
Housing
PMMA
PP
PMMA
ASA
PMMA
PC
ABS
BRM-24
2009 370Z
25. HANDLING PRECAUTIONS
< ON-VEHICLE REPAIR >
A
B
C
D
E
F
G
H
JSKIA0903ZZ
Component
Material
Component
Material
1
Rear pillar finisher
PP
6
Cluster lid C
PC + ABS
2
Front pillar garnish
PP
7
Cluster lid C finisher
PC + ABS
3
Map lamp
8
Instrument panel
4
Cluster lid A
PP
9
Glove box
PP
5
Triple meter panel
PP
10
Center console
PP
I
Lens
PC
Housing
PP
Skin
TPU
Pad
PP
J
BRM
L
M
N
O
P
Revision: 2008 October
BRM-25
2009 370Z
26. CORROSION PROTECTION
< REMOVAL AND INSTALLATION >
REMOVAL AND INSTALLATION
CORROSION PROTECTION
Description
INFOID:0000000004687069
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-corrosive measures.
Anti-Corrosive Precoated Steel (Galvannealed Steel)
To improve repairability and corrosion resistance, a new type of anticorrosive precoated steel sheet is adopted replacing conventional
zinc-coated steel sheet.
Galvannealed steel is electroplated and heated to form Zinc-iron
alloy, which provides excellent and long term corrosion resistance
with cationic electrodeposition primer.
SIIA2294E
NISSAN genuine parts are fabricated from galvannealed steel. Therefore, it is recommended that NISSAN
genuine parts or an equivalent be used for panel replacement to maintain the anti-corrosive performance built
into the vehicle at the factory.
Phosphate Coating Treatment and Cationic Electrodeposition Primer
A phosphate coating treatment and a cationic electrodeposition
primer, which provide excellent corrosion protection, are applied to
all body components.
CAUTION:
Confine paint removal during welding operation to an absolute
minimum.
PIIA0095E
NISSAN genuine parts are also treated in the same manner. Therefore, it is recommended that NISSAN genuine parts or an equivalent be used for panel replacement to maintain anti-corrosive performance built into the
vehicle at the factory.
Undercoating
INFOID:0000000004609559
The underside of the floor and wheelhouse are undercoated to prevent rust, vibration, noise and stone chipping. Therefore, when such a panel is replaced or repaired, apply undercoating to that part. Use an undercoating which is rust resistant, soundproof, vibration-proof, shock-resistant, adhesive, and durable.
Precautions in Undercoating
1.
2.
3.
4.
5.
Never apply undercoating to any place unless specified (such as the areas above the muffler and three
way catalyst that are subjected to heat).
Never undercoat the exhaust pipe or other parts that become hot.
Never undercoat rotating parts.
Apply bitumen wax after applying undercoating.
After putting seal on the vehicle, put undercoating on it.
Revision: 2008 October
BRM-26
2009 370Z
27. CORROSION PROTECTION
< REMOVAL AND INSTALLATION >
A
B
C
D
E
F
G
H
JSKIA0897ZZ
: Undercoated areas
I
: Sealed portions
Body Sealing
INFOID:0000000004609560
J
The following figure shows the areas that are sealed at the factory. Sealant that is applied to these areas
should be smooth and free from cuts or gaps. Care should be taken not to apply an excess amount of sealant
and not to allow other unaffected parts to come into contact with the sealant.
BRM
L
M
N
O
P
Revision: 2008 October
BRM-27
2009 370Z
28. CORROSION PROTECTION
< REMOVAL AND INSTALLATION >
JSKIA0894ZZ
: Vehicle front
: Sealed portions
Revision: 2008 October
BRM-28
2009 370Z
29. CORROSION PROTECTION
< REMOVAL AND INSTALLATION >
A
B
C
D
E
F
G
H
I
J
BRM
L
M
N
O
JSKIA0895ZZ
P
: Vehicle front
: Sealed portions
Revision: 2008 October
BRM-29
2009 370Z
30. CORROSION PROTECTION
< REMOVAL AND INSTALLATION >
JSKIA0896ZZ
: Vehicle front
: Sealed portions
Revision: 2008 October
BRM-30
2009 370Z
31. BODY CONSTRUCTION
< REMOVAL AND INSTALLATION >
BODY CONSTRUCTION
A
Body Construction
INFOID:0000000004609561
B
C
D
E
F
G
H
I
J
BRM
L
M
N
O
P
JSKIA0898ZZ
1.
Upper outer front pillar
2.
Outer front pillar reinforcement
3.
Upper inner front pillar
4.
Front roof rail brace
5.
Front pillar hinge brace
6.
Hoodledge reinforcement gusset
7.
Rear hoodledge reinforcement
8.
Upper dash
9.
Upper rear hoodledge
Revision: 2008 October
BRM-31
2009 370Z
32. BODY CONSTRUCTION
< REMOVAL AND INSTALLATION >
10. Upper front pillar reinforcement
11. Weld nut
12. Weld bolt
13. Lower dash crossmember
14. Lower hinge plate
15. Outer sill reinforcement
16. Outer front sill brace
17. Lower front pillar reinforcement
18. Front side member outrigger
19. Lower dash
20. Inner sill
21. Outer sill brace
22. Front floor
23. Plate nut
24. 2nd crossmember
25. Center sill reinforcement
26. Rear fender
27. Lock pillar reinforcement
28. Outer rear wheelhouse extension
29. 3rd crossmember
30. Inner rear sill reinforcement
31. Lower inner lock pillar
32. Upper inner lock pillar
33. Upper inner lock pillar reinforcement
34. Inner side panel
35. Rear pillar reinforcement
36. Inner rear pillar
37. Rear roof rail brace
38. Roof
39. Upper rear roof rail
40. Rear tie down hook bracket
41. Rear side member front
42. Rear side member front reinforcement
43. Rear floor
44. Calk nut
45. Outer rear wheelhouse
46. Inner rear wheelhouse
47. Shock absorber mounting bracket
48. Shock absorber bracket reinforcement
49. Inner rear pillar reinforcement
Rear Fender Hemming Process
INFOID:0000000004686778
1.
2.
A wheel arch is to be installed and hemmed over the left and right outer wheel houses.
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 wheelhouse 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 wheelhouse and rear fender.
<Adhesive>
3M™ Automix™ Panel Bonding Adhesive 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
Revision: 2008 October
BRM-32
2009 370Z
33. BODY CONSTRUCTION
< REMOVAL AND INSTALLATION >
• Starting from the center, hem the wheel arch gradually, using slight
back and forth motion with a hemming tool.
A
B
C
SIIA2246E
D
• Seal up the area around the hemmed end of the flange.
E
F
G
JSKIA0137GB
H
I
J
BRM
L
M
N
O
P
Revision: 2008 October
BRM-33
2009 370Z
34. REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
REPLACEMENT OPERATIONS
Description
INFOID:0000000004687070
• 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) contains additional information, including cautions and warnings, that are not including in this manual. Technicians 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
Revision: 2008 October
JSKIA0056ZZ
BRM-34
2009 370Z
35. REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
• 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.
A
B
C
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
position.
E
F
G
JSKIA0104GB
H
• Prepare a cutting jig to make outer pillar easier to cut. Also, this will
permit the service part to be accurately cut at the joint position.
I
J
BRM
JSKIA0105GB
• An example of cutting operation using a cutting jig is as per the following.
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.
L
M
N
PIIA0153E
O
P
Revision: 2008 October
BRM-35
2009 370Z
36. REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
Radiator Core Support
INFOID:0000000004609576
JSKIA0904ZZ
: Vehicle front
Replacement parts
Side radiator core support (LH)
Front side member connector assembly (LH)
Hoodledge
INFOID:0000000004609577
Work after radiator core support is removed.
Remove the front side member center closing plate (reusable).
Revision: 2008 October
BRM-36
2009 370Z
37. REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
A
B
C
D
E
F
G
H
I
J
BRM
L
M
N
JSKIA0905ZZ
1.
Front side member center closing
plate
O
: Vehicle front
Replacement parts
Upper front hoodledge (LH)
Revision: 2008 October
P
Hoodledge reinforcement (LH)
BRM-37
Front strut housing (LH)
2009 370Z
38. REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
JSKIA0906GB
1.
Front side member center closing
plate
Unit: mm (in)
: Vehicle front
View H: Before installing hoodledge reinforcement
Revision: 2008 October
BRM-38
2009 370Z
39. REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
A
B
C
D
E
F
G
H
I
J
BRM
L
M
N
JSKIA0907ZZ
O
: Vehicle front
View O: Before installing hoodledge reinforcement
Front Side Member
INFOID:0000000004609578
Work after radiator core support and hoodledge are removed.
Assemble the hoodledge and check the fitting according to Body Alignment before replacing the front side
member center closing plate.
Revision: 2008 October
BRM-39
2009 370Z
P
40. REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
JSKIA0908GB
Unit: mm (in)
: Vehicle front
Replacement parts
Front side member assembly (LH)
Front side member closing plate assembly (LH)
Front side member outrigger assembly (LH)
View A: Before installing front side member closing plate assembly
Revision: 2008 October
BRM-40
2009 370Z
41. REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
A
B
C
D
E
F
G
H
I
J
BRM
L
M
N
JSKIA0909GB
Unit: mm (in)
O
: Vehicle front
View F and H: Before installing front side member outrigger assembly
Revision: 2008 October
BRM-41
P
2009 370Z
42. REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
JSKIA0910GB
: Vehicle front
Refer to GI-4, "Components" for symbols in the figure.
Front Side Member (Partial Replacement)
INFOID:0000000004609580
Work after radiator core support is removed.
Revision: 2008 October
BRM-42
2009 370Z
43. REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
A
B
C
D
E
F
G
H
I
J
BRM
L
M
N
JSKIA0911GB
Unit: mm (in)
O
: Vehicle front
Replacement parts
Front side member front extension
(RH)
Front side member front closing
plate (RH)
Front Pillar (Partial Replacement)
Front side rear closing reinforcement
(RH)
INFOID:0000000004609581
Work after hoodledge reinforcement is removed.
Revision: 2008 October
BRM-43
2009 370Z
P
44. REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
JSKIA0912GB
1.
Body sealing
Unit: mm (in)
: Vehicle front
Replacement parts
Upper front pillar reinforcement (LH)
Upper rear hoodledge (LH)
Inner side roof rail (LH)
View A: Before installing upper front pillar reinforcement
Revision: 2008 October
BRM-44
2009 370Z
45. REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
A
B
C
D
E
F
G
H
I
J
BRM
L
M
N
JSKIA0913GB
Unit: mm (in)
O
: Vehicle front
Front Pillar
INFOID:0000000004675514
Work after hoodledge reinforcement is removed.
Remove the front roof rail brace (reusable).
Revision: 2008 October
BRM-45
2009 370Z
P
46. REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
JSKIA0914GB
1.
Body sealing
Unit: mm (in)
: Vehicle front
Replacement parts
Upper front pillar reinforcement (LH)
Upper rear hoodledge (LH)
Inner side roof rail (LH)
View A: Before installing upper front pillar reinforcement
Revision: 2008 October
BRM-46
2009 370Z
47. REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
A
B
C
D
E
F
G
H
I
J
BRM
L
M
N
JSKIA0915GB
Unit: mm (in)
O
: Vehicle front
P
Revision: 2008 October
BRM-47
2009 370Z
48. REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
JSKIA0916GB
1.
Front roof rail brace
Unit: mm (in)
: Vehicle front
Refer to GI-4, "Components" for symbols in the figure.
View H: Before installing front roof rail brace
View N: Before installing upper outer front pillar
Revision: 2008 October
BRM-48
2009 370Z
49. REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
Outer Sill (Partial Replacement by Cutting)
INFOID:0000000004609582
A
B
C
D
E
F
G
H
I
J
BRM
L
M
N
JSKIA0917GB
1.
O
Outer sill brace
Unit: mm (in)
P
: Vehicle front
Refer to GI-4, "Components" for symbols in the figure.
Replacement parts
Outer sill reinforcement (LH)
Revision: 2008 October
BRM-49
2009 370Z
50. REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
Outer Sill (Partial Replacement by Piece)
INFOID:0000000004675517
Work after hoodledge reinforcement is removed.
Remove the front pillar brace (reusable).
JSKIA0918GB
1.
Body sealing
Unit: mm (in)
: Vehicle front
Replacement parts
Outer sill reinforcement (LH)
Revision: 2008 October
BRM-50
2009 370Z
51. REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
A
B
C
D
E
F
G
H
I
J
BRM
L
M
N
JSKIA0919GB
Unit: mm (in)
O
: Vehicle front
Refer to GI-4, "Components" for symbols in the figure.
P
Outer Sill
INFOID:0000000004675518
Work after hoodledge reinforcement, rear fender, and lock pillar reinforcement are removed.
Remove the front pillar brace (reusable).
Revision: 2008 October
BRM-51
2009 370Z
52. REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
JSKIA0920GB
1.
Body sealing
Unit: mm (in)
: Vehicle front
Replacement parts
Outer sill reinforcement (LH)
Revision: 2008 October
Outer rear wheelhouse extension
(LH)
BRM-52
2009 370Z
53. REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
A
B
C
D
E
F
G
H
I
J
BRM
L
M
N
JSKIA0921GB
1.
Body sealing
2.
Outer sill brace
O
Unit: mm (in)
: Vehicle front
P
Refer to GI-4, "Components" for symbols in the figure.
View D: Before installing outer sill reinforcement
View E and G: Before installing outer rear wheelhouse extension
Revision: 2008 October
BRM-53
2009 370Z
54. REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
JSKIA0922GB
Unit: mm (in)
: Vehicle front
Refer to GI-4, "Components" for symbols in the figure.
View H: Before installing outer sill reinforcement
Revision: 2008 October
BRM-54
2009 370Z
55. REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
Rear Fender
INFOID:0000000004609583
A
B
C
D
E
F
G
H
I
J
BRM
L
M
N
JSKIA0923GB
1.
Body sealing
J.
2.
Hemming portion
Adhesive
P
Unit: mm (in)
: Vehicle front
: Perform the plug welding instead of the laser welding.
Replacement parts
Rear fender assembly (LH)
Revision: 2008 October
O
BRM-55
2009 370Z
56. REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
JSKIA0924GB
1.
Adhesive
2.
Body sealing
3.
Urethane foam
Unit: mm (in)
: Vehicle front
View H: Right side rear fender
POINT
Revision: 2008 October
BRM-56
2009 370Z
57. REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
• Perform the hemming to the flange of wheelarch after applying the
adhesive.
• Apply the sealing to the flange end.
• Refer to BRM-32, "Rear Fender Hemming Process".
1.
2.
3.
4.
A
B
Outer rear wheelhouse
Rear fender
Adhesive
Sealant
C
JSKIA0204GB
D
Lock Pillar Reinforcement
INFOID:0000000004609584
Work after rear fender is removed.
E
F
G
H
I
J
BRM
L
M
N
O
P
Revision: 2008 October
BRM-57
2009 370Z
58. REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
JSKIA0925GB
1.
Urethane foam
Unit: mm (in)
: Vehicle front
: Drill φ9 mm (0.35 in) hole for the plug welding hole (ultra high strength steel plate).
Replacement parts
Lock pillar reinforcement assembly
(LH)
Revision: 2008 October
BRM-58
2009 370Z
59. REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
Rear Panel
INFOID:0000000004609587
A
B
C
D
E
F
G
H
I
J
BRM
L
M
N
JSKIA0926ZZ
O
: An equivalent welding portion with the same dimensions is on the opposite side.
Replacement parts
P
Rear panel assembly
Rear Floor Rear
INFOID:0000000004609588
Work after rear panel is removed.
Revision: 2008 October
BRM-59
2009 370Z
60. REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
JSKIA0927GB
Unit: mm (in)
: Vehicle front
: An equivalent welding portion with the same dimensions is on the opposite side.
Replacement parts
Rear floor rear
Rear Side Member Extension
INFOID:0000000004609589
Work after rear panel is removed.
Revision: 2008 October
BRM-60
2009 370Z
61. REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
A
B
C
D
E
F
G
H
I
J
BRM
L
M
N
JSKIA0928ZZ
O
: Vehicle front
Replacement parts
Rear side member extension (LH)
P
Revision: 2008 October
BRM-61
2009 370Z