Nissan Pathfinder: Body Repair - Removal and Installation

• Corrosion Protection
• Body Sealing
• Body Construction
• Replacement Operations

Corrosion Protection Nissan Pathfinder 2022

Description

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 anti-corrosive precoated steel sheet has been 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.

Nissan Genuine Service Parts are fabricated from galvannealed steel. Therefore, it is recommended that GENUINE NISSAN PARTS or equivalent be used for panel replacement to maintain the anti-corrosive performance built into the Nissan Pathfinder 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 employed on all body components.

CAUTION:

Confine paint removal during welding operations to an absolute minimum.

Nissan Genuine Service Parts are also treated in the same manner. Therefore, it is recommended that GENUINE NISSAN PARTS or equivalent be used for panel replacement to maintain anti-corrosive performance built into the Nissan Pathfinder vehicle at the factory.

Undercoating

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 preventive, soundproof, vibration-proof, shock-resistant, adhesive, and durable.

PRECAUTIONS IN UNDERCOATING

1. Do not apply undercoating unless specified. Avoid areas such as the areas above the muffler and three-way catalyst which are subjected to heat.

2. Do not undercoat the exhaust pipe or other parts which become hot.

3. Do not undercoat rotating parts.

4. Apply cavity wax after applying undercoating.

5. After putting seal on the Nissan Pathfinder vehicle, put undercoating on it.

UNDERCOATED AREAS

: Undercoated areas : Sealed portions

Body Sealing Nissan Pathfinder

Description

The following figure shows the areas which are sealed at the factory. Sealant which has been 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.

Front

C.	Roof (without panoramic roof glass) shown; roof (with panoramic roof glass) similar
.	Front

Front

Front

Body Construction Nissan Pathfinder Fifth generation

Body Construction

1.	Back pillar upper reinforcement	2.	Body side outer	3.	Back pillar
4.	Rear roof rail brace	5.	Rear pillar inner	6.	Rear pillar inner reinforcement
7.	Rear pillar seatbelt anchor	8.	Center pillar reinforcement	9.	Center pillar outer reinforcement
10.	Center pillar inner	11.	Front pillar upper reinforcement	12.	Dash side
13.	Front pillar upper hinge brace	14.	Lower hinge plate	15.	Rear wheelhouse inner
16.	Rear wheelhouse outer	17.	Sill outer reinforcement	18.	Sill outer reinforcement inner
19.	Sill inner reinforcement	20.	Sill outer reinforcement rear	21.	Sill inner extension
	Front

Fusible Insulator Applying Part

NOTE:

Service replacement fusible insulator material is available in varying thickness. Always check with the Parts Department for the latest parts information.

Apply the fusible insulator to prevent road noise, vibration and exhaust system heat inside the vehicle.

The service replacement material is cut-to-fit and not supplied in the same shape as original factory installed fusible insulator.

Place the fusible insulators in the positions shown in the figure and properly affix them to the vehicle surface.

Unit: mm (in)

	: Nissan Pathfinder Vehicle front
	: Fusible insulator thickness 3.0 (0.12)
	: Fusible insulator thickness 3.7 (0.15)

Unit: mm (in)

	: Nissan Pathfinder Vehicle front
	: Fusible insulator thickness 3.0 (0.12)
	: Fusible insulator thickness 3.7 (0.15)

Replacement Operations Nissan Pathfinder Fifth generation

Precautions for Body Repair

WARNING:

• The repair information in this section is intended for trained body repair technicians who have attained a high level of skill and experience (e.g. ASE Collision Repair Certification, I-CAR Professional Development Program [PDP] training, etc.) in repairing collision damaged Nissan Pathfinder vehicles using appropriate tools and equipment. Performing repairs without the proper training, tools or equipment could damage the Nissan Pathfinder vehicle or cause personal injury or death to you or others.

• The information in this Body Repair Manual is a guideline for repairing collision damaged Nissan Pathfinder vehicles. However, this information cannot cover all possible ways that a vehicle can be damaged. As such, the body repair technician is responsible for making sure that the repair does not affect the structural integrity or safety of the Nissan Pathfinder vehicle. Improper repair of a damaged vehicle may result in a collision, property damage, personal injury or death.

• Nissan recommends using only new genuine Nissan replacement body parts. Use of used, salvaged or aftermarket body parts is not recommended by Nissan. Non-genuine Nissan components may affect the Nissan Pathfinder vehicle's structural integrity and crash safety performance, which could result in serious personal injury or death in an accident.

Description

• Technicians are encouraged to read the Body Repair Manual (Fundamentals) in order to ensure that the original functions and quality of the Nissan Pathfinder vehicle are maintained. The Body Repair Manual (Fundamentals) contains additional information, including cautions and warnings, that are not included 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
"Number"	"Number" after symbol mark is the total number of welds to apply. Example 1: ■"4"A = 4 MAG plug welds for 3-panel plug weld method. Example 2: "1" x20 (0.79) = 1 MAG seam weld by length 20 mm (0.79 in).
	2-panel spot weld
	3-panel spot weld
	MAG plug weld
		For 3-panel plug weld method
	MAG seam weld / Point weld
	Rivet

• 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 Nissan Pathfinder vehicle.

  

• 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.

  

• 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.

  

• 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.

Roof

ROOF (WITH PANORAMIC ROOF GLASS)

	Front
Replacement parts
•	Roof (with panoramic roof glass)
	For spot welding of steel plate of strength 980 MPa, observe the indicated welding conditions. Refer to Welding of Ultra High Strength Steel.

ROOF (WITHOUT PANORAMIC ROOF GLASS)

	Front
Replacement parts
•	Roof (without panoramic roof glass)
	For spot welding of steel plate of strength 980 MPa, observe the indicated welding conditions. Refer to Welding of Ultra High Strength Steel.

FRONT ROOF RAIL

Work after roof is removed.

	Front
Replacement parts
•	Front roof rail

REAR ROOF RAIL

Work after roof is removed.

	Front
Replacement parts
•	Rear roof rail

ROOF BOW 5TH

Work after roof is removed.

	Front
Replacement parts
•	Roof bow 5th

ROOF BOW 4TH [ROOF (WITHOUT PANORAMIC ROOF GLASS) ONLY]

Work after roof is removed.

	Front
Replacement parts
•	Roof bow 4th

ROOF BOW 2ND [ROOF (WITHOUT PANORAMIC ROOF GLASS) ONLY]

Work after roof is removed.

	Front
Replacement parts
•	Roof bow 2nd

Front Side Member Connector

	Front
Replacement parts
•	Front side member connector

Radiator Core Support Side

Work after front side member connector is removed.

	Front
Replacement parts
•	Radiator core support side

Hoodledge

HOODLEDGE REINFORCEMENT

Work after radiator core support side is removed.

	Front
Replacement parts
•	Hoodledge reinforcement

HOODLEDGE UPPER

Work after hoodledge reinforcement is removed.

	Front
Replacement parts
•	Hoodledge upper

BATTERY SUPPORT BRACKET

	Front
Replacement parts
•	Battery support bracket

HOODLEDGE LOWER FRONT

Work after hoodledge upper is removed.

A.	MAG weld
	Front
Replacement parts
•	Hoodledge lower front

HOODLEDGE LOWER REAR

Work after hoodledge lower front is removed.

	Front
Replacement parts
•	Hoodledge lower rear

Front Side Member

FRONT SIDE MEMBER CLOSING PLATE

Work after hoodledge lower rear is removed.

A.	MAG welds
	Front
Replacement parts
•	Front side member closing plate

FRONT SIDE MEMBER INNER

Work after front side member closing plate is removed.

	Front
Replacement parts
•	Front side member inner

SIDE MEMBER OUTRIGGER

Work after front side member inner is removed.

	Front
Replacement parts
•	Side member outrigger

FRONT SIDE MEMBER OUTRIGGER

Work after side member outrigger is removed.

	Front
Replacement parts
•	Front side member outrigger

Cowl Top

	Front
Replacement parts
•	Cowl top

Upper Dash

Work after cowl top is removed.

	Front
Replacement parts
•	Upper dash

Lower Dash

Work after upper dash and front side member stiffeners are removed.

	Front
Replacement parts
•	Lower dash

Front Floor

FRONT SIDE MEMBER STIFFENER

	Front
Replacement parts
•	Front side member stiffener

INSTRUMENT STAY BRACKET

	Front
Replacement parts
•	Instrument stay bracket

FRONT FLOOR PANEL

Work after lower dash, front side member stiffener and instrument stay bracket are removed.

	Front
Replacement parts
•	Front floor panel

Rear Panel

REAR FENDER BRACES

	Front
Replacement parts
•	Rear fender braces

REAR PANEL BRACKETS

	Front
Replacement parts
•	Rear fascia center brackets	•	Automatic back door warning buzzer bracket

REAR PANEL

Work after rear fender braces are removed.

	Front
Replacement parts
•	Rear panel

Rear Floor

REAR FLOOR BRACKETS AND LOWER SEATBACK SUPPORT

	Front
Replacement parts
•	Woofer bracket (front/rear)	•	Amplifier bracket	•	Lower seatback support

REAR FLOOR SIDES

	Front
Replacement parts
•	Rear floor sides

REAR FLOOR FRONT EXTENSION

Work after front floor is removed.

	Front
Replacement parts
•	Rear floor front extension

REAR FLOOR FRONT EXTENSION SIDES

Work after rear floor sides and rear floor front extension are removed.

	Front
Replacement parts
•	Rear floor front extension sides

REAR FLOOR PANEL

Work after rear floor front extension sides are removed.

	Front
Replacement parts
•	Rear floor panel

Body Side Outer

BODY SIDE OUTER FRONT

Work after hoodledge outer and roof panel are removed.

A.	Sectioning locations
	Front
Replacement parts
•	Body side outer front
	For spot welding of steel plate of strength 980 MPa, observe the indicated welding conditions. Refer to Welding of Ultra High Strength Steel.

BODY SIDE OUTER REAR

Work after roof panel is removed.

A.	Sectioning locations
	Front
Replacement parts
•	Body side outer rear
	For spot welding of steel plate of strength 980 MPa, observe the indicated welding conditions. Refer to Welding of Ultra High Strength Steel.

Front Pillar Outer (Partial)

Work after hoodledge outer is removed.

A.	Sectioning location
	Front
Replacement parts
•	Front pillar outer (partial)

For spot welding of steel plate of strength 980 MPa, observe the indicated welding conditions. Refer to Welding of Ultra High Strength Steel.

Front Pillar Upper Hinge Brace

Work after front pillar outer (partial) is removed.

	Front
Replacement parts
•	Front pillar upper hinge brace

Center Pillar Outer (Partial)

Unit: mm (in)

A.	Sectioning location	B.	180.0 (7.09)	C.	140.0 (5.51)	D.	110.0 (4.33)
	Front
Replacement parts
•	Center pillar outer (partial)

Center Pillar Reinforcement

Work after center pillar outer (partial) is removed.

	Front
Replacement parts
•	Center pillar reinforcement

Sill Outer (Partial)

A.	Sectioning location
	Front
Replacement parts
•	Sill outer (partial)

For spot welding of steel plate of strength 980 MPa, observe the indicated welding conditions. Refer to Welding of Ultra High Strength Steel.

Sill Outer Reinforcement

Work after sill outer (partial) is removed.

A.	MAG welds
	Front
Replacement parts
•	Sill outer reinforcement

For spot welding of steel plate of strength 980 MPa, observe the indicated welding conditions. Refer to Welding of Ultra High Strength Steel.

Rear Fender (Partial)

A.	Sectioning location
	Front
Replacement parts
•	Rear fender (partial)

For spot welding of steel plate of strength 980 MPa, observe the indicated welding conditions. Refer to Welding of Ultra High Strength Steel.

Rear Fender Extension (Partial)

Work after rear panel is removed.

A.	Sectioning location
	Front
Replacement parts
•	Rear fender extension (partial)

Rear Combination Lamp Base

Work after body side outer rear is removed.

	Front
Replacement parts
•	Rear combination lamp base	•	Rear fascia bracket

Back Pillar Outer

Work after rear combination lamp base is removed.

	Front
Replacement parts
•	Back pillar outer

Sill Outer Reinforcement Rear

Work after sill outer reinforcement is removed.

	Front
Replacement parts
•	Sill outer reinforcement rear

Back Pillar Inner

Work after back pillar outer is removed.

	Front
Replacement parts
•	Back pillar inner

Roof Side Rail

ROOF SIDE RAIL OUTER REINFORCEMENT

Work after center pillar reinforcement is removed.

	Front
Replacement parts
•	Roof side rail outer reinforcement

ROOF SIDE RAIL INNER

Work after roof side rail outer reinforcement is removed.

A.	MAG welds
	Front
Replacement parts
•	Roof side rail inner

Dash Side Inner

Work after roof side rail inner is removed.

	Front
Replacement parts
•	Dash side inner

Center Pillar Inner Reinforcement

Work after roof side rail inner is removed.

A.	MAG welds
	Front
Replacement parts
•	Center pillar inner reinforcement

Rear Pillar Inner

REAR PILLAR INNER REINFORCEMENT

Work after roof side rail outer is removed.

	Front
Replacement parts
•	Rear pillar inner reinforcement

REAR PILLAR INNER

Work after rear pillar inner reinforcement is removed.

	Front
Replacement parts
•	Rear pillar inner

Rear Wheelhouse

REAR WHEELHOUSE OUTER

Work after sill outer reinforcement rear and rear pillar inner are removed.

A.	MAG welds
	Front
Replacement parts
•	Rear wheelhouse outer

REAR WHEELHOUSE INNER

Work after rear wheelhouse outer is removed.

A.	MAG weld
	Front
Replacement parts
•	Rear wheelhouse inner

7th Crossmember

Work after rear floor panel is removed.

	Front
Replacement parts
•	7th crossmember

5th Crossmember

Work after rear floor panel is removed.

	Front
Replacement parts
•	5th crossmember

Rear Side Member

Work after 7th crossmember and 5th crossmember are removed.

	Front
Replacement parts
•	Rear side member

Rear Seat Belt Anchor Inner Reinforcement

Work after rear side member is removed.

	Front
Replacement parts
•	Rear seat belt anchor inner reinforcement

2nd Crossmember

Work after front floor panel is removed.

	Front
Replacement parts
•	2nd crossmember

Front Side Member Center Extension

Work after 2nd crossmember is removed.

	Front
Replacement parts
•	Front side member center extension

Sill Inner Reinforcement

Work after front side member center extension is removed.

	Front
Replacement parts
•	Sill inner reinforcement

3rd Crossmember

Work after sill inner reinforcement is removed.

	Front
Replacement parts
•	3rd crossmember

Back Door Outer

A.	Adhesive
	Front
Replacement parts
•	Back door outer

NOTE:

• Always follow proper procedure for door hemming. Refer to Door Hemming.

• Use commercially available panel bonding adhesive for door hemming:

  <Adhesive>

  3M™ 08115 Panel Bonding Adhesive or equivalent