Nissan Pickup 1993 User Manual

–BODY

BODY

BO–1

BO–2

–BODY General Information

GENERAL INFORMATION

If there is a possibility the body and/or parts may be dam– aged, first remove the danger before performing repair operations. Example:

1. Apply protection tape to the body adjacent to the body parts when removing and installing.

2. When prying off the body parts with a screwdriver or scraper etc., be sure to apply protection tape to the tip or blade to prevent damage to the paint film or body part.

If anti–rust agents are damaged while repairing other

parts, be sure to repair the anti–rust agent. Example:

1. If body sealant, paint film or undercoat are damaged by peeling, cracks, etc., be sure to repair each with an anti–rust agent.

2. If a hinge or exterior body panel is loosened or re– moved, be sure apply rust inhibitor after repairs.

–BODY Hood

HOOD

ADJUSTMENT OF HOOD

HINT: Since the centering bolt is used as the hood hinge set bolt, the hood cannot be adjusted with it on. Substi– tute the bolt with the washer for the centering bolt.

1. ADJUST HOOD IN FORWARD /REARWARD AND LEFT/RIGHT DIRECTIONS

Adjust the hood by loosening the hood side hinge bolts.

BO–3

2. ADJUST FRONT EDGE OF HOOD IN VERTICAL DIRECTION

Adjust the hood by turning the cushions.

3. REMOVE WIPER ARMS

4. REMOVE COWL PANEL

Remove two clips, three screws and the cowl panel.

5. ADJUST REAR EDGE OF HOOD IN VERTICAL DIRECTION

Adjust the hood by loosening the hood hinge bolts.

6. ADJUST HOOD LOCK

Adjust the lock by loosening the bolts.

BO–4

–BODY Front Door

FRONT DOOR

COMPONENTS

–BODY Front Door

COMPONENTS (Cont’d)

BO–5

BO–6

–BODY Front Door

ADJUSTMENT OF FRONT DOOR

1. ADJUST DOOR IN FORWARD/REARWARD AND VERTICAL DIRECTIONS

Using SST, adjust the door by loosening the body side hinge bolts. SST 09812–00010

2. ADJUST DOOR IN LEFT/RIGHT AND VERTICAL DIRECTIONS

Loosen the door side hinge bolts to adjust.

3. ADJUST DOOR LOCK STRIKER

(a) Check that the door fit and door lock linkages are

adjusted correctly.

(b) Adjust the striker position by slightly loosening the

striker mounting screws, and hitting the striker with a hammer.

DISASSEMBLY OF FRONT DOOR

(See pages BO–4 and 5)

1. (w/o Power Window) REMOVE REGULATOR HANDLE

Pull off the snap ring with a cloth and remove the regula– tor handle and plate.

2. REMOVE DOOR INSIDE HANDLE

(a) Remove the screw and slide the handle forward. (b) Disconnect the handle from the control link and re–

move the handle.

3. REMOVE INNER AND OUTER COVERS

(a) Using a screwdriver, pry loose a clip and remove the

inner cover.

HINT: Tape the screwdriver tip before use. (b) (w/ Ventilator Window or w/o Rear View Mirror)

Remove three screws and the outer cover.

–BODY Front Door

4. REMOVE REAR VIEW MIRROR (w/o Ventilator Window)

(a) (w/Remote Control Mirror)

Disconnect the connector.

(b) Remove three screws and the mirror.

(wI Ventilator Window)

(a) (w/ Remote Control Mirror)

Disconnect the connector.

(b) (w/o Remote Control Mirror)

Remove the mirror cover, two screws and the mir– ror. (w/ Remote Control Mirror) Remove the mirror cover, three screws and the mir– ror.

5. REMOVE DOOR TRIM

(a) (w/ Wide Armrest)

Remove two caps from the armrest.

(b) (w/ Wide Armrest)

Remove two screws from the armrest. (Semi Trim Type and Full Trim Type, wI Wide Arm– rest) Remove two screws and the armrest.

Remove the armrest panel by pulling upward, then disconnect the connectors.

(d) (w/ Wide Armrest)

Remove three clips. (Full Trim Type, w/o Wide Armrest) Remove the clip.

(e) Install the screwdriver between the retainers and

door trim to pry it loose.

BO–7

HINT: Tape the screwdriver tip before use. (f) Remove the door trim. (g) (w/ Power Window)

Remove nine screws and the armrest. (wI Wide armrest, w/o Power Window) Remove seven screws and the armrest.

(h) (w/ Wide Armrest)

Remove four screws and the door pocket.

(i) (Full Trim Type)

Remove the inner weatherstrip from the door trim.

6. REMOVE SERVICE HOLE COVER 7–1. (wI Ventilator Window)

REMOVE VENTILATOR WINDOW

(a) Remove the bolt and two screws. (b) Remove the ventilator window by pulling it upward.

BO–8

–BODY Front Door

7–2. (w/o Ventilator Window) REMOVE FRONT LOWER FRAME

Remove the bolt and the frame.

8. REMOVE REAR LOWER FRAME

Remove the bolt and the frame.

9–1. (Semi Trim type) REMOVE INNER AND OUTER WEATHERSTRIP

Pry loose the clips from the edge of the panel and remove the weatherstrip.

9–2. (Full Trim type) REMOVE OUTER WEATHERSTRIP

In the same manner, remove the outer weatherstrip.

10. REMOVE GLASS RUN

11. REMOVE INSIDE LOCKING KNOB

Disconnect the link and remove the inside locking knob.

12. REMOVE OUTSIDE HANDLE WITH LOCK CYLINDER AND DOOR LOCK

(a) Disconnect the links from the outside handle with

the lock cylinder.

(b) (w/Power Door Lock)

Disconnect the connectors, remove three screws, the bolt and the door lock with the motor. (w/o Power Door Lock) Remove three screws and the door lock.

cylinder.

(d) Remove the snap ring and the lock cylinder.

13. REMOVE DOOR GLASS AND WINDOW REGULATOR

(a) Remove two glass channel mounting bolts. (b) Place the glass in the door cavity.

Remove two equalizer arm bracket mounting bolts.

(d) (wI Power Window)

Disconnect the connectors, then remove four regu– lator mounting bolts. (wIo Power Window)

Remove three regulator mounting bolts. (e) Remove the regulator through the service hole. (f) Remove the glass by pulling it upward.

–BODY Front Door

BO–9

REPLACEMENT OF GLASS

1. REMOVE GLASS CHANNEL WITH SCREWDRIVER OR LIKE OBJECT

2. APPLY SOAPY WATER TO INSIDE OF WEATHER– STRIP

3. INSTALL CHANNEL BY TAPPING IT WITH PLASTIC HAMMER

ASSEMBLY OF FRONT DOOR

(See pages BO–4 and 5)

1. BEFORE INSTALLING PARTS, COAT THEM WITH MP GREASE

(a) Apply MP grease to the sliding surface and the gears

of the window regulator.

NOTICE: Do not apply MP grease to the spring of the window regulator.

(b) Apply MP grease to the sliding surface of the door

lock.

2. INSTALL WINDOW REGULATOR AND DOOR GLASS

(a) Place the glass in the door cavity. (b) Place the regulator through the service hole. (c) (wI Power Window)

Install the four regulator mounting bolts, then con– nect the connector. (w/o Power Window) Install the three regulator mounting bolts.

(d) (w/o Ventilator Window)

Install the equalizer arm and temporarily tighten two equalizer arm mounting bolts.

(e) Attach the glass to the window regulator with two

bolts.

BO–10

–BODY Front Door

3. INSTALL OUTSIDE HANDLE WITH LOCK CYLINDER AND DOOR LOCK

(a) Install the lock cylinder with the snap ring to the out–

side handle.

(b) Install the outside handle and lock cylinder with two

bolts.

Install the door lock and motor with three screws and the bolt, then connect the connector. (w/o Power Door Lock) Install the door lock with three screws.

(d) Connect the links to the outside handle.

4. INSTALL INSIDE LOCKING KNOB

Install the locking knob and connect the control links.

5. INSTALL GLASS RUN

6. INSTALL REAR LOWER FRAME

7–1. (w/o Ventilator Window) INSTALL FRONT LOWER FRAME 7–2. (w/Ventilator Window) INSTALL VENTILATOR WINDOW

(a) Install the ventilator window. (b) Install the bolt and two screws.

8. (w/o Ventilator Window) ADJUST DOOR GLASS

Adjust the equalizer arm up or down and tighten if where–

dimensions A and B, as shown are equal.

9. INSTALL REAR VIEW MIRROR

10. INSTALL INNER AND OUTER COVERS

11. INSTALL SERVICE HOLE COVER

(a) Seal the service hole cover with adhesive. (b) Install the lower edge of the service hole cover into

the panel slit.

–BODY Front Door

NOTICE: Do not block the trim clip seating with the tape.

12–1.(Semi Trim type)

INSTALL OUTER AND INNER WEATHERSTRIP

Install the claw of the clips into the upper panel slit and push the weatherstrip onto the panel.

12–2.(Full Trim type)

INSTALL OUTER WEATHERSTRIP

In the same manner, install the outer weatherstrip.

13. INSTALL THE DOOR TRIM

(a) (Full Trim Type)

Install the inner weatherstrip to the door trim.

(b) (wI Wide Armrest)

Install the door pocket with four screws to the door trim.

Install the armrest with nine screws to the door trim. (wI Wide Armrest, w/o Power Window) Install the armrest with seven screws to the door trim.

(d) Install the door trim with retainers to the inside panel

by tapping.

(e) (wI Power Window)

Connect the connectors and install the armrest panel.

(f) (w/ Wide Armrest)

Install three crips. (Full Trim Type, w/o Wide Armrest) Install the clip.

(g) (w/ Wide Armrest)

Install two screws to the armrest. (Semi Trim Type and Full Trim Type, wI Wide Arm– rest) Install the armrest with two screws.

(h) (w/ Wide Armrest)

Install two caps to the armrest.

BO–11

BO–12

–BODY Front Door

14. INSTALL DOOR INSIDE HANDLE (See step 2 on page BO–6)

(a) Connect the handle to the control links. (b) Push the inside handle in the door panel and slide it

rearward.

15. (w/o Power Window) INSTALL REGULATOR HANDLE

With door window fully closed, install the plate and the regulator handle with the snap ring as shown.

–BODY Moulding

MOULDING Windshield Moulding

COMPONENTS

BO–13

Type I Applicable Models

Frame No. Frame No.

REMOVAL OF WINDSHIELD MOULDING

LOCATION OF CLIPS AND FASTENER

• For vehicles in the table below which have black moul– ding, refer to diagram type 1.

• For other vehicles which have black or metallic mould– ing, refer to diagram Type 11.

• However, if all clips and fasteners are replaced, either diagram Type I or Type 11 may be referred to.

Vehicle Code

VZN 100, VZN 105 RN101, RN106

RN80, RN85, RN90 VZN80, VZN85, VZN90, VZN 110

Vehicle Code

VZN95

VZN100,VZN105

RN110

BO–14

–BODY Moulding

1. REMOVE WIPER ARMS

2. REMOVE COWL LOUVER AND WEATHERSTRIP

3. REMOVE LOWER MOULDING WITH LOWER JOINT COVERS

(a) Remove five screws from the clips. (b) Pry up a scraper to loosen the clips from the body. HINT: Tape the scraper tip before use. (c) Remove the moulding with lower joint covers and

clips.

4. REMOVE SIDE MOULDING WITH UPPER JOINT COVERS

(a) Install the tip of a scraper between the body and

moulding.

HINT: Tape the scraper tip before use. (b) Pry up the scraper to loosen the moulding from the

claws of the clips and fasteners.

5. REMOVE UPPER MOULDING

(a) Using a knife, cut off the upper moulding as shown. (b) Cut off the old adhesive around the upper moulding

installation area.

NOTICE: Do not damage the body and glass.

REPLACEMENT OF FASTENER

REPLACE FASTENER

(a) Remove the damaged fastener. (b) Cut off the old adhesive around the fastener instal–

lation area.

NOTICE: Be carefully not to damage the body.

–BODY Moulding

BO–15

INSTALLATION OF WINDSHIELD MOULDING

1. INSTALL CLIP INTO MOULDING (See page BO–13)

Install the clip to the appropriate place on the moulding.

2. APPLY ADHESIVE AT CLIP INSTALLATION AREA

(a) Cut out the old adhesive around the clip installation

area.

NOTICE: Do not damage the body and fastener.

(b) Apply adhesive at the clip installation area so water

does not collect there.

3. APPLY ADHESIVE AT UPPER MOULDING INSTALLA– TION AREA

4. INSTALL NEW UPPER MOULDING

Place the moulding onto the body and tap it by hand.

5. INSTALL SIDE MOULDING WITH UPPER JOINT COVERS

(a) Place the moulding with upper joint covers onto the

body. (b) Tap the moulding by hand to install it. (c) Pry up the clips on the body side, and install them to

the moulding.

6. INSTALL LOWER MOULDING WITH LOWER JOINT COVERS

(a) Place the moulding with lower joint covers onto the

body.

(b) Align the clips of the moulding with the body holes,

and push the moulding on the body.

7. INSTALL COWL LOUVER AND WEATHERSTRIP

(See page BO–13)

8. INSTALL WIPER ARMS

(See page BO–13)

BO–16

–BODY Moulding

Wheel Arch Moulding

COMPONENTS

REPLACEMENT OF FRONT WHEEL ARCH MOULDING

1. REMOVE FRONT WHEEL ARCH MOULDING

(a) Remove five screws. (b) Using a screwdriver, pry up the wheel arch mould–

ing, and remove it.

HINT: Tape the screwdriver tip before use.

2. INSTALL FRONT WHEEL ARCH MOULDING

(a) Tap the wheel arch moulding by hand to install it. (b) Install five screws.

REPLACEMENT OF REAR WHEEL ARCH MOULDING

1. REMOVE REAR WHEEL ARCH MOULDING

(a) Remove six screws. (b) Using a screwdriver, pry up the wheel arch mould

ing, and remove it.

HINT: Tape the screwdriver tip before use.

2. INSTALL REAR WHEEL ARCH MOULDING

(a) Tap the wheel arch moulding by hand to install it. (b) Install six screws.

–BODY Windshield

WINDSHIELD (Adhesive Type)

PREPARE ITEMS LISTED

BO–17

Part name and No.

Adhesive set 08850–00070 (0 – 150C or 32 – 59’F) 08850–00080

(15 – 351C or 59 – 951F) 08850–00090 (35 – 450C or 95 – 1131F)

Dam kit 04562–30040

Ambient temperature

Part No.

Contents of set

Main agent 500g (17.64 oz.) hardening agent 75g (2.65 oz.) Primer G (for glass) 20g (

0. 71 oz.) Primer M (for body) 20g (0.71 oz.) Sponge (for applying primer) Piano wire 0.6 mm dia. x 1 m (0.024 x 39.37 in.) Cartridge

Dam Double–stick tape (for sticking on dam)

Sealant gun (for applying adhesive Glass or steel sheet (for mixing adhesive) Putty spatula (for mixing adhesive and correcting adhered parts) Cleaner (for cleaning adhering surface)

Part name

1. CHOOSE SUITABLE ADHESIVE SET

Use an adhesive set suitable for the ambient tempera– ture.

Quantity

1 1 1 1 2 1 1

800120

10 20 30 40 Ambient Temperature

2. CHECK ADHESIVE USABLE TIME

After mixing the main and hardening agents, finish glass installation within the specified time as shown. Example: For glass installation in ambient temperature

!C (77!F), apply adhesive set No.35 within 45 min–

of 25 utes.

3. CHECK ADHESIVE SETTING TIME

First, mix the main and hardening agents. Then, perform a leak test only after the setting time has elapsed. Example: The setting time for adhesive set No.35 with an ambient temperature of 25

NOTICE: Do not drive the vehicle until at least double the setting time has elapsed.

!C (77!F) is 2.5 hours.

BO–18

–BODY Windshield

COMPONENTS

REMOVAL OF WINDSHIELD

1. REMOVE FOLLOWING PARTS:

• Inner rear view mirror

• Sun visors and holders

• Wiper arms

• Cowl louver

• Front pillar garnishes

• Assist grip

2. REMOVE WINDSHIELD MOULDING (See page BO–13)

3. REMOVE CLIPS

Be careful not to damage the side moulding clips, when removing them from around the glass. HINT: It is not necessary to remove the fasteners but any damaged fasteners should be replaced.

–BODY Windshield

4. REMOVE WINDSHIELD GLASS

(a) Push piano wire through from the interior. (b) Tie both wire ends to the wooden blocks or like ob–

jects. HINT: Apply adhesive tape to the outer surface to keep the surface from being scratched.

NOTICE: When separating, take care not to damage the

paint and interior and exterior ornaments.

To prevent scratching the safety pad when removing the windshield, place a plastic sheet between the piano wire and safety pad. Cut the adhesive by pulling the piano wire around it. (d) Remove the glass.

NOTICE: Leave as much of the adhesive layer on the

body as possible when cutting off the glass.

BO–19

PREPARATION FOR INSTALLATION

1. CLEAN AND SHAPE CONTACT SURFACE OF BODY

(a) Remove any dam remaining on the body. (b) Cut away any rough areas with a knife. HINT: Leave as much of the adhesive layer on the body as possible. (c) Clean the cutting surface of the adhesive with a

piece of cloth saturated in cleaner. HINT: Even if all the adhesive has been removed, clean the body.

2. IF NECESSARY, REPLACE FASTENERS (See page BO–14)

3. CLEAN REMOVED GLASS BEFORE INSTALLATION

(a) Using a scraper, remove the adhesive sticking to the

glass. (b) Using the cleaner, clean the glass.

4. POSITION GLASS

(a) Place the glass in correct position. (b) Check that all contacting parts of the glass rim are

perfectly even, and do not make contact with the

fasteners. (c) Mark reference marks between the glass and body. (d) Remove the glass.

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