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BODY EXTERIOR, DOORS, ROOF & VEHICLE SECURITY

BRM
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SECTION
BODY REPAIR C

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CONTENTS
FEATURES OF NEW MODEL ...................... 2 CORROSION PROTECTION ............................ 18 F
Corrosion Protection ................................................18
BODY EXTERIOR PAINT COLOR ..................... 2 Body Sealing ...........................................................20
Body Exterior Paint Color .......................................... 2 G
BODY CONSTRUCTION .................................. 24
PRECAUTION ............................................... 6 Body Construction ...................................................24
PRECAUTIONS ................................................... 6 BODY ALIGNMENT .......................................... 26 H
Precaution for Supplemental Restraint System Body Alignment .......................................................26
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- Body Mounting .........................................................49
SIONER" ................................................................... 6 I
REPAIRING HIGH STRENGTH STEEL ........... 52
HANDLING PRECAUTIONS ............................... 7 Precaution in Repairing High Strength Steel ...........52
Handling Precaution for Plastics ............................... 7
REPLACEMENT OPERATIONS ....................... 55 J
REMOVAL AND INSTALLATION ............... 10 Replacement Operation ...........................................55
Foam Repair ............................................................82
BODY COMPONENT PARTS ............................10
Body Component Parts ........................................... 10 BRM

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Revision: August 2014 BRM-1 2015 Frontier NAM

BODY EXTERIOR PAINT COLOR
< FEATURES OF NEW MODEL >
FEATURES OF NEW MODEL
BODY EXTERIOR PAINT COLOR
Body Exterior Paint Color INFOID:0000000010713490

AWKIA1439ZZ

USA
Color code NAH EAF B17 K23 K26 KH3 QAK RBG
Description Red Orange Blue Silver Gray Black White Blue

Component Paint type M M M M M S S M
Cross
linked clear t t t t t t t t
coat
S Black — — — — — — — —

King SV Black — — — — — — — —
Cab DR Black — — — — — — — —
Pro-4X Body Color NAH EAF B17 K23 K26 KH3 QAK RBG
Door
1 S Black — — — — — — — —
Mirror
SV Black — — — — — — — —
Crew
DR Black — — — — — — — —
Cab
SL Chrome Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P
Pro-4X Body Color NAH EAF B17 K23 K26 KH3 QAK RBG
Side
Crew
2 Guard SL Body color NAH EAF B17 K23 K26 KH3 QAK RBG
Cab
Molding
S Black — — — — — — — —
King
Cab SV/DR
Body Color NAH EAF B17 K23 K26 KH3 QAK RBG
Pro-4X
Front
3 S Black — — — — — — — —
Bumper
SL Chrome Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P
Crew
Cab SV/DR
Body Color NAH EAF B17 K23 K26 KH3 QAK RBG
Pro-4X

Revision: August 2014 BRM-2 2015 Frontier NAM

BODY EXTERIOR PAINT COLOR
< FEATURES OF NEW MODEL >
USA
A
Color code NAH EAF B17 K23 K26 KH3 QAK RBG
Description Red Orange Blue Silver Gray Black White Blue

Component Paint type M M M M M S S M B
Cross
linked clear t t t t t t t t
coat
C
S Black — — — — — — — —

King SV Black — — — — — — — —
Cab DR Black — — — — — — — — D
Door
Pro-4X Body Color NAH EAF B17 K23 K26 KH3 QAK RBG
4 Outside
Handle S/SV/
Black — — — — — — — — E
DR
Crew
Cab SL Chrome Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P
Pro-4X Body Color NAH EAF B17 K23 K26 KH3 QAK RBG
F
S Chrome Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P
SV Chrome Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P
King Satin G
Cab DR — — — — — — — —
Chrome
Satin
Pro-4X — — — — — — — —
Chrome H
Front
5 S Chrome Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P
Grille
SV Chrome Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P
SL Chrome Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P I
Crew
Cab Satin
DR — — — — — — — —
Chrome
J
Satin
Pro-4X — — — — — — — —
Chrome
S Chrome Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P
King
BRM
SV Chrome Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P
Cab
DR Body Color NAH EAF B17 K23 K26 KH3 QAK RBG
Pro-4X Body Color NAH EAF B17 K23 K26 KH3 QAK RBG L
Rear
6 S Chrome Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P
Bumper
SV Chrome Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P
Crew M
SL Chrome Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P
Cab
DR Body Color NAH EAF B17 K23 K26 KH3 QAK RBG
Pro-4X Body Color NAH EAF B17 K23 K26 KH3 QAK RBG N
M: Metallic; S: 1- Coat Solid, 2S: 2-Coat Solid, 2P: 2-Coat Pearl, PM: Pearl + Metallic, t: Primerless carbamate clear coat
†: Cross-linked clear coat
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Revision: August 2014 BRM-3 2015 Frontier NAM

BODY EXTERIOR PAINT COLOR
< FEATURES OF NEW MODEL >

CANADA
Color code NAH EAF B17 K23 K26 KH3 QAK RBG
Description Red Orange Blue Silver Gray Black White Blue
Component Paint type M M M M M S S M
Cross linked
t t t t t t t t
clear coat
S Black — — — — — — — —
King
SV Black — — — — — — — —
Cab
Door Pro-4X Body Color NAH EAF B17 K23 K26 KH3 QAK RBG
1
Mirror SV Black — — — — — — — —
Crew
SL Chrome Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P
Cab
Pro-4X Body Color NAH EAF B17 K23 K26 KH3 QAK RBG
Side
Crew
2 Guard SL Body color NAH EAF B17 K23 K26 KH3 QAK RBG
Cab
Molding
S Half Black — — — — — — — —
King
Cab SV/
Body Color NAH EAF B17 K23 K26 KH3 QAK RBG
Front Pro-4X
3
Bumper SL Chrome Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P
Crew
Cab SV/
Body Color NAH EAF B17 K23 K26 KH3 QAK RBG
Pro-4X
S Black — — — — — — — —
King
SV Black — — — — — — — —
Cab
Door Pro-4X Body Color NAH EAF B17 K23 K26 KH3 QAK RBG
4 Outside
Handle SV Black — — — — — — — —
Crew
SL Chrome Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P
Cab
Pro-4X Body Color NAH EAF B17 K23 K26 KH3 QAK RBG
S Chrome Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P
King SV Chrome Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P
Cab
Satin
Pro-4X — — — — — — — —
Front Chrome
5
Grille SV Chrome Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P
Crew SL Chrome Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P
Cab
Satin
Pro-4X — — — — — — — —
Chrome
S Chrome Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P
King
SV Chrome Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P
Cab
Rear Pro-4X Body Color NAH EAF B17 K23 K26 KH3 QAK RBG
6
Bumper SV Chrome Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P
Crew
SL Chrome Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P Cr2P
Cab
Pro-4X Body Color NAH EAF B17 K23 K26 KH3 QAK RBG
M: Metallic; S: 1- Coat Solid, 2S: 2-Coat Solid, 2P: 2-Coat Pearl, PM: Pearl + Metallic, t: Primerless carbamate clear coat
†: Cross-linked clear coat

Revision: August 2014 BRM-4 2015 Frontier NAM

S: 1. 2P: 2-Coat Pearl. BODY EXTERIOR PAINT COLOR < FEATURES OF NEW MODEL > MEXICO A Color code EAF B17 K23 K26 KH3 QAK NAH RBG Description Orange Blue Silver Gray Black White Red Blue Component B Paint type M M M M S S M M Clear coat t t t t t t t t Door Pro-4X Body Color EAF B17 K23 K26 KH3 QAK NAH RBG C 1 Mirror S Black — — — — — — — — Front Pro-4X Body Color EAF B17 K23 K26 KH3 QAK NAH RBG 2 Bumper S Black — — — — — — — — D Door Pro-4X Body Color EAF B17 K23 K26 KH3 QAK NAH RBG 3 Outside Handle S Black — — — — — — — — E Front Pro-4X Satin Chrome — — — — — — — — 4 Grille S Chrome — — — — — — — — F Rear Pro-4X Body Color EAF B17 K23 K26 KH3 QAK NAH RBG 5 Bumper S Chrome — — — — — — — — M: Metallic.Coat Solid. t: Primerless carbamate clear coat G †: Cross-linked clear coat H I J BRM L M N O P Revision: August 2014 BRM-5 2015 Frontier NAM . PM: Pearl + Metallic. 2S: 2-Coat Solid.

• When using air or electric power tools or hammers. • Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. DO NOT use air or electric power tools or strike near the sensor(s) with a hammer. PRECAUTIONS < PRECAUTION > PRECAUTION PRECAUTIONS Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER" INFOID:0000000010713491 The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”. • Improper maintenance. The SRS system uses the seat belt switches to determine the front air bag deployment. always switch the Ignition OFF. WARNING: • To avoid rendering the SRS inoperative. see the SR section. used along with a front seat belt. including incorrect removal and installation of the SRS. PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS WARNING: • When working near the Airbag Diagnosis Sensor Unit or other Airbag System sensors with the Igni- tion ON or engine running. Heavy vibration could activate the sensor(s) and deploy the air bag(s). possibly causing serious injury. disconnect the battery and wait at least three minutes before performing any service. helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. all maintenance must be performed by an authorized NISSAN/INFINITI dealer. which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation. For removal of Spiral Cable and Air Bag Module. can lead to personal injury caused by unintentional activation of the system. This system includes seat belt switch inputs and dual stage front air bag modules. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har- ness connectors. Revision: August 2014 BRM-6 2015 Frontier NAM . Information necessary to service the system safely is included in the SR and SB section of this Service Man- ual. depending on the severity of a collision and whether the front occupants are belted or unbelted. and may only deploy one front air bag.

1. Flammable C late+Polycarbonate O Avoid immersing in wa- PA Polyamide (Nylon) 140 (284) Same as above. L L. PEI Polyetherimide 200 (392) Same as above. UP Polyester thermoset 90 (194) Same as above. BRM PPE Polyphenylene Ether PC Polycarbonate 120 (248) Same as above. PAR Polyacrylate 180 (356) Same as above. PUR Polyurethane 90 (194) Same as above. Flammable PPO/ Polyphenylene Oxide/ 110 (230) Same as above. when burned. AS Acrylonitrile Styrene 85 (185) Same as above. D Poison gas is emitted PVC Polyvinyl Chloride 80 (176) Same as above. N PBT+P Polybutylene Terephtha- 120 (248) Same as above. acid. PPC Polypropylene Composite 115 (239) Same as above. Flammable POM Polyacetal 120 (248) Same as above. Revision: August 2014 BRM-7 2015 Frontier NAM . J ASA Acrylonitrile Styrene Acrylate 100 (222) Same as above. ter. HANDLING PRECAUTIONS < PRECAUTION > HANDLING PRECAUTIONS A Handling Precaution for Plastics INFOID:0000000010713492 HANDLING PRECAUTIONS FOR PLASTICS B Heat resisting Abbre. Gasoline and most solvents are Lenear Low Density PE 45 (100) Flammable LDPE harmless. Flammable G PS Polystyrene 80 (176) Avoid solvents. P FRP Fiber Reinforced Plastics 170 (338) Same as above. When repairing and painting a portion of the body adjacent to plastic parts. characteristics. Avoid battery acid. PBT Polybutylene Terephthalate 140 (284) Same as above. Resistance to gasoline and Material name temperature Other cautions C viation solvents °C (°F) Gasoline and most solvents are PE Polyethylene 60 (140) harmless if applied for a very Flammable short time (wipe up quickly). EVA Polyvinyl Ethyl Acetate 90 (194) Same as above. M TPU Thermoplastic Urethane 110 (230) Same as above. H resin AES Acrylonitrile Ethylene Styrene 80 (176) Same as above. avoid battery PP Polypropylene 90 (194) Same as above. I AAS Acrylonitrile Acrylic Styrene 85 (185) Same as above. PMMA Polymethyl Methacrylate 85 (185) Same as above. PET Polyethylene Terephthalate 180 (356) Same as above. Flammable Acrylonitrile Butadiene Styrene ABS 80 (176) Avoid gasoline and solvents. Avoid battery acid. 2. Flammable EPDM ber TPO/ Thermoplastic Olefine/ 80 (176) Same as above. E EPM/ Ethylene Propylene (Diene) rub- 80 (176) Same as above. consider their characteristics (influence of heat and solvent) and remove them if necessary or take suitable measures to protect them. Flammable F TPR Thermoplastic Rubber Flammable. Plastic parts should be repaired and painted using methods suiting the materials.

HANDLING PRECAUTIONS < PRECAUTION > LOCATION OF PLASTIC PARTS AWKIA2733ZZ Revision: August 2014 BRM-8 2015 Frontier NAM .

HANDLING PRECAUTIONS < PRECAUTION > A B C D E F G LIIA2079E H I J BRM L M N O P Revision: August 2014 BRM-9 2015 Frontier NAM .

BODY COMPONENT PARTS < REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION BODY COMPONENT PARTS Body Component Parts INFOID:0000000010713493 UNDERBODY COMPONENT PARTS LIIA2026E Revision: August 2014 BRM-10 2015 Frontier NAM .

Storage box bracket 24. BODY COMPONENT PARTS < REMOVAL AND INSTALLATION > 1. Battery tray C 8. Lower dash 7. Hoodledge reinforcement (RH/LH) D 11. Accessory storage box bracket I BODY COMPONENT PARTS J BRM L M N O P Revision: August 2014 BRM-11 2015 Frontier NAM . Rear floor reinforcement 4. Inner sill extension (RH/LH) 20. Hoodledge inner panel (RH/LH) 10. 2nd crossmember extension 6. Side dash (RH/LH) E 14. Hoodledge lower panel (RH/LH) 9. Front seat crossmember 18. Hoodledge rear reinforcement (RH/LH) 13. Cross-cab brace 21. subwoofer bracket 23. Front floor reinforcement 12. 2nd crossmember (RH/LH) F 16. Center pillar crossmember G 19. Rear floor H 22. Upper dash A 3. Front floor 17. Front seat crossmember B 5. Upper dash crossmember 2. Inner sill (RH/LH) 15.

Lock pillar reinforcement (RH/LH) Revision: August 2014 BRM-12 2015 Frontier NAM . BODY COMPONENT PARTS < REMOVAL AND INSTALLATION > King Cab LIIA2027E 1. Front roof rail (RH/LH) 6. Rear roof rail 3. 1 5. Roof bow No. Roof 2. 2 4. Roof bow No.

Rear strut inner (RH/LH) H 28. Hood 13. Bed side inner (RH/LH) 24. Rear door assembly (RH/LH) 21. Lock pillar inner (RH/LH) 8. Rear door inner (RH/LH) E 20. Body side panel (RH/LH) C 14. Front pillar inner. Front outer strut (RH/LH) 23. Rear strut outer (RH/LH) 29. Bed front panel 26. Floor board assembly 27. Front fender (RH/LH) 15. Front door inner (RH/LH) D 17. Bed side outer (RH/LH) F 22. Roof side rail (RH/LH) 10. upper (RH/LH) A 9. Tail gate I J BRM L M N O P Revision: August 2014 BRM-13 2015 Frontier NAM . Inner sill (RH/LH) 12. Rear panel G 25. Rear floor bolster assembly 30. Front door outer (RH/LH) 16. BODY COMPONENT PARTS < REMOVAL AND INSTALLATION > 7. Rear door (RH/LH) 19. Front door assembly (RH/LH) 18. Front pillar reinforcement (RH/LH) B 11.

BODY COMPONENT PARTS < REMOVAL AND INSTALLATION > Crew Cab LIIA2028E 1. Roof (with sunroof) 2. Roof bow No. 4 Revision: August 2014 BRM-14 2015 Frontier NAM . Rear roof rail 4. Roof 3.

Rear door inner (RH/LH) 22. Rear inner strut (RH/LH) BRM 34. Front door assembly (RH/LH) E 18. Floor board assembly 33. Roof bow No. Body side outer (RH/LH) G 23. Sunroof reinforcement 6. Roof bow No. Bed front panel J 31. Front pillar inner. Bed side inner (RH/LH) 32. Bed side outer panel (RH/LH) H 26. 3 A 7. Rear lock pillar inner (RH/LH) 24. Hood D 15. Rear door outer (RH/LH) 21. Front roof rail 10. Rear outer strut (RH/LH) 35. BODY COMPONENT PARTS < REMOVAL AND INSTALLATION > 5. Front pillar reinforcement (RH/LH) 13. Rear door assembly (RH/LH) F 20. Rear panel 30. Rear floor bolster assembly 36. Front outer strut (RH/LH) 27. Front door outer panel 19. upper (RH/LH) 11. Rear side inner reinforcement (RH/LH) 25. Roof side rail reinforcement (RH/LH) C 12. Front fender (RH/LH) 16. Front door inner (RH/LH) 17. Center pillar brace (RH/LH) 28. 2 8. Outer sill reinforcement (RH/LH) 14. Roof bow No. Tail gate L FRAME COMPONENT PARTS Crew Cab M N O P LIIA2102E Revision: August 2014 BRM-15 2015 Frontier NAM . 1 B 9. Center pillar inner (RH/LH) I 29.

4th crossmember gusset (RH/LH) 11. Front upper link mounting bracket (RH/LH) 6. 2nd cab mounting bracket (RH/LH) 12. 1st crossmember assembly 3. 2nd rear body mounting bracket (RH/LH) 16. Rear spring front bracket assembly (RH/LH) 15. (2wd) Center bearing bracket assembly. 3rd cab mounting bracket (RH/LH) 13. 1st crossmember assembly 3. 2nd crossmember assembly 26. Panhard rod reinforcement bracket (RH/LH) 10. 1st cab mounting bracket (RH/LH) 5. 5th rear body mounting bracket (RH/LH) 18. Rear shock absorber pin (RH/LH) 21. 3rd crossmember assembly 25. Frame assembly 2. 4th crossmember assembly 24. (4wd) 5th crossmember assembly 23. Front upper link mounting bracket (RH/LH) Revision: August 2014 BRM-16 2015 Frontier NAM . 4th crossmember gusset (RH/LH) 28. Front upper crossmember 20. Engine mounting bracket assembly (RH/LH) 27. Front brake hose bracket (RH/LH) 9. Frame assembly 2. BODY COMPONENT PARTS < REMOVAL AND INSTALLATION > 1. Front side member extension assembly (RH/LH) 5. 1st cab mounting bracket (RH/LH) 4. Bound bumper bracket (RH/LH) 8. Cab mounting bracket (RH/LH) 14. 9th crossmember assembly 19. Rear bound bumper bracket (RH/LH) 17. Front side member extension assembly (RH/LH) 4. Crossmember collar (RH/LH) King Cab LIIA2103E 1. Front shock absorber bracket (RH/LH) 7. 6th crossmember assembly 22.

6th crossmember assembly 22. 4th crossmember gusset (RH/LH) 28. Front upper crossmember F 21. 4th crossmember assembly G 24. (2wd) Center bearing bracket assembly. 9th crossmember assembly E 19. 1st rear body mounting bracket (RH/LH) 14. Front brake hose bracket (RH/LH) B 10. 4th crossmember gusset (RH/LH) 11. BODY COMPONENT PARTS < REMOVAL AND INSTALLATION > 6. Rear bound bumper bracket (RH/LH) 17. 2nd rear body mounting bracket (RH/LH) D 16. 2nd cab mounting bracket (RH/LH) 12. 3rd cab mounting bracket (RH/LH) C 13. 2nd crossmember assembly 26. Bound bumper bracket (RH/LH) A 8. Front shock absorber bracket (RH/LH) 7. Rear shock absorber pin (RH/LH) 20. Engine mounting bracket assembly (RH/LH) H 27. Panhard rod reinforcement bracket (RH/LH) 9. 5th rear body mounting bracket (RH/LH) 18. (4wd) 5th crossmember assembly 23. Rear spring front bracket assembly (RH/LH) 15. 3rd crossmember assembly 25. Crossmember collar (RH/LH) I J BRM L M N O P Revision: August 2014 BRM-17 2015 Frontier NAM .

PIIA0093E Phosphate Coating Treatment and Cationic Electrodeposition Primer A phosphate coating treatment and a cationic electrode position primer. PIIA0095E ANTI-CORROSIVE WAX To improve corrosion resistance. Therefore. which provide excellent corrosion protection. Therefore. NISSAN Genuine Service Parts are also treated in the same man- ner. which provides excellent and long term corrosion resistance with cationic electrode position primer. Accordingly. when replacing these parts. CAUTION: Confine paint removal during welding operations to an absolute minimum. NISSAN Genuine Service Parts are fabricated from galvannealed steel. the following anti-corrosive measures have been implemented in NISSAN production plants. CORROSION PROTECTION < REMOVAL AND INSTALLATION > CORROSION PROTECTION Corrosion Protection INFOID:0000000010713494 DESCRIPTION To provide improved corrosion prevention. be sure to apply anti-corrosive wax to the appropriate areas of Revision: August 2014 BRM-18 2015 Frontier NAM . When repairing or replacing body panels. Anti-corrosive Pre-coated Steel (Galvannealed Steel) To improve repairability and corrosion resistance. it is recommended that GENUINE NISSAN PARTS or equivalent be used for panel replacement to maintain the anti-cor- rosive performance built into the vehicle at the factory. anti-corrosive wax is applied inside the body sill and inside other closed sec- tions. Galvannealed steel is electroplated and heated to form Zinc-iron alloy. a new type of anti- corrosive pre-coated steel sheet has been adopted replacing con- ventional zinc-coated steel sheet. it is necessary to use the same anti-cor- rosive measures. are employed on all body components. it is recommended that GENUINE NISSAN PARTS or equivalent be used for panel replacement to maintain anti-corro- sive performance built into the vehicle at the factory.

apply undercoating to that part. Revision: August 2014 BRM-19 2015 Frontier NAM . when such a panel is replaced or repaired. 3. Do not undercoat the exhaust pipe or other parts which become hot. vibration-proof. Do not undercoat rotating parts. noise and stone chip- ping. Do not apply undercoating to any place unless specified (such as the areas above the muffler and three way catalyst which are subjected to heat). A B C D E F G H I J BRM L M N LIIA1210E O UNDERCOATING The underside of the floor and wheelhouse are undercoated to prevent rust. vibration. Use an undercoat- ing which is rust preventive. Select an excellent anti-corrosive wax which will penetrate after application and has a long shelf life. CORROSION PROTECTION < REMOVAL AND INSTALLATION > the new parts. and durable. shock-resistant. 2. soundproof. Therefore. adhesive. P Precautions in Undercoating 1.

Apply bitumen wax after applying undercoating. CORROSION PROTECTION < REMOVAL AND INSTALLATION > 4. LIIA1211E Body Sealing INFOID:0000000010713495 DESCRIPTION Revision: August 2014 BRM-20 2015 Frontier NAM .

CORROSION PROTECTION < REMOVAL AND INSTALLATION > The following figure shows the areas which are sealed at the factory. B C D E F G H I J BRM L M N AWKIA1440GB O P Revision: August 2014 BRM-21 2015 Frontier NAM . Care should be taken not to apply an excess amount of A sealant and not to allow other unaffected parts to come into contact with the sealant. Sealant which has been applied to these areas should be smooth and free from cuts or gaps.

CORROSION PROTECTION < REMOVAL AND INSTALLATION > LIIA2002E Revision: August 2014 BRM-22 2015 Frontier NAM .

CORROSION PROTECTION < REMOVAL AND INSTALLATION > A B C D E F G H I J BRM L M N O LIIA2003E P Revision: August 2014 BRM-23 2015 Frontier NAM .

BODY CONSTRUCTION < REMOVAL AND INSTALLATION > BODY CONSTRUCTION Body Construction INFOID:0000000010713496 BODY CONSTRUCTION KING CAB LIIA1999E Revision: August 2014 BRM-24 2015 Frontier NAM .

BODY CONSTRUCTION < REMOVAL AND INSTALLATION > BODY CONSTRUCTION CREW CAB A B C D E F G H I J BRM L M N O LIIA2000E P Revision: August 2014 BRM-25 2015 Frontier NAM .

Revision: August 2014 BRM-26 2015 Frontier NAM . BODY ALIGNMENT < REMOVAL AND INSTALLATION > BODY ALIGNMENT Body Alignment INFOID:0000000010713497 BODY CENTER MARKS AWKIA1441GB A mark has been placed on each part of the body to indicate the vehicle center. When repairing parts dam- aged by an accident which might affect the vehicle frame (members. etc. pillars. more accurate and effective repair will be possible by using these marks together with body alignment specifications.).

more accurate and effective repair will be possible by using these marks together with body alignment specifications. When repairing parts A damaged by an accident which might affect the vehicle structure (members. pillars. etc.). Crew Cab B C D E F G H I J BRM L M N O P AWKIA1442GB Revision: August 2014 BRM-27 2015 Frontier NAM . BODY ALIGNMENT < REMOVAL AND INSTALLATION > PANEL PARTS MATCHING MARKS A mark has been placed on each body panel to indicate the parts matching positions.

BODY ALIGNMENT
< REMOVAL AND INSTALLATION >
King Cab

AWKIA1443GB

DESCRIPTION
• 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.

Revision: August 2014 BRM-28 2015 Frontier NAM

BODY ALIGNMENT
< REMOVAL AND INSTALLATION >
• The coordinates of the measurement points are the distances measured from the standard line of "X", "Y"
and "Z". A

B

C

D

E

LIIA1506E

ENGINE COMPARTMENT F

G

H

I

J

BRM

L

M

N

O

P

Revision: August 2014 BRM-29 2015 Frontier NAM

BODY ALIGNMENT
< REMOVAL AND INSTALLATION >
Measurement

AWKIA1576GB

Revision: August 2014 BRM-30 2015 Frontier NAM

BODY ALIGNMENT
< REMOVAL AND INSTALLATION >
Measurement Points
A

B

C

D

E

F

G

H

I

J

BRM

L

M

N

O

AWKIA1577GB

UNDERBODY P

Revision: August 2014 BRM-31 2015 Frontier NAM

BODY ALIGNMENT < REMOVAL AND INSTALLATION > Measurement LIIA2083E Revision: August 2014 BRM-32 2015 Frontier NAM .

BODY ALIGNMENT < REMOVAL AND INSTALLATION > Measurement Points A B C D E F G H I J BRM L M N O AWKIA1578GB P Revision: August 2014 BRM-33 2015 Frontier NAM .

BODY ALIGNMENT < REMOVAL AND INSTALLATION > LIIA2085E Revision: August 2014 BRM-34 2015 Frontier NAM .

BODY ALIGNMENT < REMOVAL AND INSTALLATION > Measurement (Crew Cab Long Bed) A B C D E F G H I J BRM L M N O LIIA2721E P Revision: August 2014 BRM-35 2015 Frontier NAM .

BODY ALIGNMENT < REMOVAL AND INSTALLATION > Measurement Points (Crew Cab Long Bed) LIIA2722E Revision: August 2014 BRM-36 2015 Frontier NAM .

BODY ALIGNMENT < REMOVAL AND INSTALLATION > A B C D E F G H I J BRM L M N O AWKIA1446GB PASSENGER COMPARTMENT P Measurement Revision: August 2014 BRM-37 2015 Frontier NAM .

BODY ALIGNMENT < REMOVAL AND INSTALLATION > Crew Cab AWKIA1447GB Revision: August 2014 BRM-38 2015 Frontier NAM .

BODY ALIGNMENT < REMOVAL AND INSTALLATION > King Cab A B C D E F G H I J BRM L M N O AWKIA1448GB P Revision: August 2014 BRM-39 2015 Frontier NAM .

BODY ALIGNMENT < REMOVAL AND INSTALLATION > Crew Cab AWKIA1449GB Revision: August 2014 BRM-40 2015 Frontier NAM .

BODY ALIGNMENT < REMOVAL AND INSTALLATION > King Cab A B C D E F G H I J BRM L M N O AWKIA1450GB P Revision: August 2014 BRM-41 2015 Frontier NAM .

BODY ALIGNMENT < REMOVAL AND INSTALLATION > Measurement Points AWKIA1451GB Revision: August 2014 BRM-42 2015 Frontier NAM .

BODY ALIGNMENT < REMOVAL AND INSTALLATION > A B C D E F G H I J BRM L M N O AWKIA1452GB P Revision: August 2014 BRM-43 2015 Frontier NAM .

BODY ALIGNMENT < REMOVAL AND INSTALLATION > LIIA2092E REAR BODY Revision: August 2014 BRM-44 2015 Frontier NAM .

BODY ALIGNMENT < REMOVAL AND INSTALLATION > Measurement A B C D E F G H I J BRM L M N O AWKIA1453GB P Revision: August 2014 BRM-45 2015 Frontier NAM .

BODY ALIGNMENT < REMOVAL AND INSTALLATION > Measurement Points AWKIA1454GB PICKUP BED Measurements Revision: August 2014 BRM-46 2015 Frontier NAM .

BODY ALIGNMENT < REMOVAL AND INSTALLATION > Crew Cab A B C D E F G H I J BRM L M N O LIIA2095E P Revision: August 2014 BRM-47 2015 Frontier NAM .

BODY ALIGNMENT < REMOVAL AND INSTALLATION > King Cab LIIA2096E Revision: August 2014 BRM-48 2015 Frontier NAM .

the bushings and insulators have paint marks that are to be installed facing out- ward. BODY ALIGNMENT < REMOVAL AND INSTALLATION > Measurement points A B C D E F G H I J BRM L M N O AWKIA1455GB Body Mounting INFOID:0000000010713498 P • When removing. be sure to replace bolts and nuts (sealant applied bolts or self-lock nuts are used for all positions). Revision: August 2014 BRM-49 2015 Frontier NAM . • Unless otherwise noted.

BODY ALIGNMENT < REMOVAL AND INSTALLATION > Crew Cab LIIA2100E 1. Upper bushing 3. Upper bushing without paint mark 7. Shim Revision: August 2014 BRM-50 2015 Frontier NAM . Black washer 5. Lower bushing 4. Washer 6. Body mount insulator 8. Body washer 9. Gold washer 2.

Gold washer 2. Upper bushing 3. BODY ALIGNMENT < REMOVAL AND INSTALLATION > King Cab A B C D E F G H I J BRM L LIIA2101E 1. Washer 6. Shim N O P Revision: August 2014 BRM-51 2015 Frontier NAM . Black washer 5. Body mount insulator 8. Body washer 9. Upper bushing without paint mark 7. Lower bushing M 4.

use a saw to avoid weakening surrounding areas due to heat. precautions in repairing automotive bodies made of high strength steel are described below: HIGH STRENGTH STEEL (HSS) USED IN NISSAN VEHICLES Tensile strength NISSAN/INFINITI designation Major applicable parts • Front inner pillar upper 373 N/mm2 • Front pillar hinge brace SP130 (38kg/mm2. use caution in pulling any HSS panel. allow a minimum margin of 50 mm (1.97in). When heating is unavoidable.022°F). do not heat HSS parts above 550°C (1.) PIIA0115E • When straightening body panels. REPAIRING HIGH STRENGTH STEEL < REMOVAL AND INSTALLATION > REPAIRING HIGH STRENGTH STEEL Precaution in Repairing High Strength Steel INFOID:0000000010713499 High strength steel is used for body panels in order to reduce vehicle weight. Verify heating temperature with a thermometer. In this case.54klb/sq in) • Outer front pillar reinforcement • Other reinforcements 785-981N/mm2 • Outer sill reinforcement (80-100kg/mm2 SP150 • Main back pillar 114-142klb/sq in) SP130 is the most commonly used HSS. PIIA0116E • When cutting HSS panels. and carefully pull the HSS panel. PIIA0117E Revision: August 2014 BRM-52 2015 Frontier NAM . Instead. avoid gas (torch) cutting if possible. Because HSS is very strong. (Crayon-type and other similar type thermometer are appropri- ate. SP150 HSS is used only on parts that require much more strength. Read the following precautions when repairing HSS: 1. Additional points to consider • The repair of reinforcements (such as side members) by heat- ing is not recommended since it may weaken the component. Accordingly. pulling may cause deformation in adjacent portions of the body. If gas (torch) cutting is unavoidable. increase the number of measuring points.

200 rpm) to increase drill bit durability and facilitate the operation. PIIA0145E 2.G. use spot welding whenever possi- ble in order to minimize weakening surrounding areas due to A heat. therefore. when cutting spot welds on a HSS panel. used as rein- forcement in the door guard beams. the assembly parts G must be replaced. Do not use gas (torch) welding because it is inferior in welding strength. L M N PIIA0147E O P Revision: August 2014 BRM-53 2015 Frontier NAM . • SP150 HSS panels with a tensile strength of 785 to 981 N/ F mm2 (80 to 100 kg/mm2. leaving no gaps. use a low E speed high torque drill (1. REPAIRING HIGH STRENGTH STEEL < REMOVAL AND INSTALLATION > • When welding HSS panels. If spot welding is impossible. the outer panels also sustain substantial damage. Therefore. 114 to 142 klb/sq in). is too strong to repair.I.000 to 1. welding. Precautions in spot welding HSS H This work should be performed under standard working condi- tions. Always note the following when spot welding HSS: • The electrode tip diameter must be sized properly according to I the metal thickness. B C PIIA0144E D • The spot weld on HSS panels is harder than that of an ordi- nary steel panel. J PIIA0146E BRM • The panel surfaces must fit flush to each other. When these HSS parts are damaged. use M.

8 (0.0 (0.063) 27 (1.71) or over 1.024) 10 (0.47) or over 1.6 (0. Unit: mm (in) Thickness (T) Minimum pitch (L) 0.6 (0.047) 20 (0.06) or over 1.79) or over 1.39) or over 0.8 (0.22) or over JSKIA0781ZZ Revision: August 2014 BRM-54 2015 Frontier NAM . REPAIRING HIGH STRENGTH STEEL < REMOVAL AND INSTALLATION > • Follow the specifications for the proper welding pitch.071) 31 (1.2 (0.039) 18 (0.031) 12 (0.

C Technicians are also encouraged to read Body Repair Manual (Fundamentals) in order to ensure that the orig- inal functions and quality of the vehicle can be maintained. The Body Repair Manual (Fundamentals) contains additional information. that are not including in this manual. certain procedures may not apply in some regions or countries. REPLACEMENT OPERATIONS < REMOVAL AND INSTALLATION > REPLACEMENT OPERATIONS A Replacement Operation INFOID:0000000010713500 DESCRIPTION B This section is prepared for technicians who have attained a high level of skill and experience in repairing col- lision-damaged vehicles and also use modern service tools and equipment. including cautions and warnings. E F G H I J BRM L M N O P Revision: August 2014 BRM-55 2015 Frontier NAM . and as such. The symbols used in this section for cutting and welding / brazing operations are as shown. Persons unfamiliar with body repair techniques should not attempt to repair collision-damaged vehicles by using this section. D Please note that this information is prepared for worldwide usage. Technicians should refer to both manuals to ensure proper repairs.

REPLACEMENT OPERATIONS < REMOVAL AND INSTALLATION > PIIA0149E Revision: August 2014 BRM-56 2015 Frontier NAM .

N PIIA0153E O HOODLEDGE LH Side P Revision: August 2014 BRM-57 2015 Frontier NAM . Cut outer front pillar over 60 mm above inner front pillar cut position. Refer to the front pillar section. REPLACEMENT OPERATIONS < REMOVAL AND INSTALLATION > • Front pillar butt joint can be determined anywhere within shaded area as shown in the figure. Also. M 3. Clamp jig to pillar. Align cutting line with notch on jig. I J BRM PIIA0152E • An example of cutting operation using a cutting jig is as follows. Use this distance when cutting the service part. (At position A) 4. A: Cut position of outer pillar B: Cut position of inner pillar 2. Cut outer pillar along groove of jig. Mark cutting lines. this will H permit service part to be accurately cut at joint position. The best location for the butt joint is at A position A due to the construction of the vehicle. Cut inner pillar at position B in same manner. L 1. E F G PIIA0151E • Prepare a cutting jig to make outer pillar easier to cut. 5. Remove jig and cut remaining portions. B C PIIA0150E D • Determine cutting position and record distance from the locating indent.

AWKIA1456GB RH Side Revision: August 2014 BRM-58 2015 Frontier NAM . REPLACEMENT OPERATIONS < REMOVAL AND INSTALLATION > • Work after radiator core support has been removed.

REPLACEMENT OPERATIONS < REMOVAL AND INSTALLATION > • Work after radiator core support has been removed. A B C D E F G H I J BRM L M N O AWKIA1457GB P Revision: August 2014 BRM-59 2015 Frontier NAM .

REPLACEMENT OPERATIONS < REMOVAL AND INSTALLATION > FRONT PILLAR AWKIA1458GB Revision: August 2014 BRM-60 2015 Frontier NAM .

REPLACEMENT OPERATIONS < REMOVAL AND INSTALLATION > CENTER PILLAR (CREW CAB ONLY) A B C D E F G H I J BRM L M N O AWKIA1459GB OUTER SILL P King Cab Revision: August 2014 BRM-61 2015 Frontier NAM .

REPLACEMENT OPERATIONS < REMOVAL AND INSTALLATION > Work with front pillar outer. AWKIA1460GB Crew Cab Revision: August 2014 BRM-62 2015 Frontier NAM . and rear pillar outer removed. front pillar reinforcement.

center pillar reinforcement. front pillar reinforcement. center pillar outer. REPLACEMENT OPERATIONS < REMOVAL AND INSTALLATION > Work with front pillar outer. A B C D E F G H I J BRM L M N O AWKIA1461GB P REAR CAB PILLAR Revision: August 2014 BRM-63 2015 Frontier NAM . and rear pillar outer removed.

REPLACEMENT OPERATIONS < REMOVAL AND INSTALLATION > King Cab AWKIA1462GB Revision: August 2014 BRM-64 2015 Frontier NAM .

REPLACEMENT OPERATIONS < REMOVAL AND INSTALLATION > A B C D E F G H I J BRM L M N O AWKIA1463GB P Revision: August 2014 BRM-65 2015 Frontier NAM .

REPLACEMENT OPERATIONS < REMOVAL AND INSTALLATION > Crew Cab AWKIA1464GB Revision: August 2014 BRM-66 2015 Frontier NAM .

REPLACEMENT OPERATIONS < REMOVAL AND INSTALLATION > A B C D E F G H I J BRM L M N O AWKIA1465GB P Revision: August 2014 BRM-67 2015 Frontier NAM .

REPLACEMENT OPERATIONS < REMOVAL AND INSTALLATION > REAR PANEL AWKIA1466GB REAR FLOOR REAR Revision: August 2014 BRM-68 2015 Frontier NAM .

REPLACEMENT OPERATIONS < REMOVAL AND INSTALLATION > King Cab A B C D E F G H I J BRM L M N O AWKIA1467GB P Revision: August 2014 BRM-69 2015 Frontier NAM .

REPLACEMENT OPERATIONS < REMOVAL AND INSTALLATION > Crew Cab AWKIA1468GB PICKUP BED Revision: August 2014 BRM-70 2015 Frontier NAM .

REPLACEMENT OPERATIONS < REMOVAL AND INSTALLATION > King Cab A B C D E F G H I J BRM L M N O AWKIA1469GB P Revision: August 2014 BRM-71 2015 Frontier NAM .

REPLACEMENT OPERATIONS < REMOVAL AND INSTALLATION > AWKIA1470GB Revision: August 2014 BRM-72 2015 Frontier NAM .

REPLACEMENT OPERATIONS < REMOVAL AND INSTALLATION > A B C D E F G H I J BRM L M N O AWKIA1472GB P Revision: August 2014 BRM-73 2015 Frontier NAM .

REPLACEMENT OPERATIONS < REMOVAL AND INSTALLATION > AWKIA1473GB Revision: August 2014 BRM-74 2015 Frontier NAM .

REPLACEMENT OPERATIONS < REMOVAL AND INSTALLATION > A B C D E F G H I J BRM L M N O AWKIA1474GB P Revision: August 2014 BRM-75 2015 Frontier NAM .

REPLACEMENT OPERATIONS < REMOVAL AND INSTALLATION > Crew Cab AWKIA1475GB Revision: August 2014 BRM-76 2015 Frontier NAM .

REPLACEMENT OPERATIONS < REMOVAL AND INSTALLATION > A B C D E F G H I J BRM L M N O LIIA2021E P Revision: August 2014 BRM-77 2015 Frontier NAM .

REPLACEMENT OPERATIONS < REMOVAL AND INSTALLATION > AWKIA1476GB Revision: August 2014 BRM-78 2015 Frontier NAM .

REPLACEMENT OPERATIONS < REMOVAL AND INSTALLATION > A B C D E F G H I J BRM L M N O AWKIA1477GB P Revision: August 2014 BRM-79 2015 Frontier NAM .

REPLACEMENT OPERATIONS < REMOVAL AND INSTALLATION > AWKIA1478GB Revision: August 2014 BRM-80 2015 Frontier NAM .

do not choose partial replacement method. REPLACEMENT OPERATIONS < REMOVAL AND INSTALLATION > Rear Crossmember A B C D E F G H I J BRM L M N O AWKIA1479GB P CRUSH HORN CAUTION: When replacing a damaged crush horn on N50 model. such as cutting and butt-joint welding the crush horn. Revision: August 2014 BRM-81 2015 Frontier NAM .

Use the following procedure(s) to replace any factory-installed foam insulators. LIIA2148E Foam Repair INFOID:0000000010713501 During factory body assembly. REPLACEMENT OPERATIONS < REMOVAL AND INSTALLATION > Be sure to replace the entire crush horn when the crush horn has damage at the back of the body mounting bracket. foam insulators are installed in certain body panels and locations around the vehicle. URETHANE FOAM APPLICATIONS Revision: August 2014 BRM-82 2015 Frontier NAM .

Fill procedures before installation of service part. NOTE: Fill in enough to close gap with service part while avoiding flange H area. Fill foam material on wheelhouse outer side. . Install service part. . Clean area in which foam was removed. Read instructions on product for fill procedures. REPLACEMENT OPERATIONS < REMOVAL AND INSTALLATION > Use commercially available spray foam for sealant (foam material) repair of material used on vehicle. . Clean area in which foam was removed. . Fill procedures after installation of service part. Install service part. B . G . . D E F LIIA1081E 2. NOTE: Refer to label for information on working times. Remove foam material remaining on vehicle side. Insert nozzle into hole near fill area and fill foam material or fill in enough to close gap with the service C part. . Remove foam material remaining on vehicle side. I J LIIA1082E BRM L M N O P Revision: August 2014 BRM-83 2015 Frontier NAM . A FILL PROCEDURES 1.