Nissan Frontier D40 Full Body Repair Manual

A complete practical guide to repairing and restoring the Nissan Frontier Navara D40 2005-2021 car body.

Includes: Information about the materials from which the body elements are made. Description of damage types (dents, scratches, corrosion, etc.). Diagnostics of body damage. Detailed instructions for removing and installing parts such as doors, hood, fenders, bumpers, glass, etc.

Fastening diagrams and sequence of work.

Description of methods for restoring damaged parts (straightening, welding, replacement). Preparing the surface for painting. Adjusting the gaps between body panels. Wiring in body elements:

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Body corrosion:

One of the most common problems is corrosion, especially on wheel arches, sills and underbody. This is especially true for cars used in regions with a humid climate or where road salt is actively used.

Metal rots in places where dirt accumulates, so regularly washing the underbody of the car will extend the life of the body.

Bumper cracks and damage:

Paint chips on bumpers are common for Nissan Frontier D40

Plastic bumpers can crack or break with minor impacts. This is due to the material and design of the bumpers, which do not always withstand even minor collisions.

Door hinge wear:

Over time, door hinges can wear out, which leads to sagging doors. This causes difficulties when closing them and can damage the paint on the body.

Fading and loss of gloss of paint:

On some models, paint may fade over time, especially if the car is frequently exposed to the sun. This may be due to poor quality coating or lack of regular maintenance.

Issues with seals and glass tightness:

Seals on doors and glass may lose elasticity over time, leading to water leaks into the interior, especially during heavy rain.

Weak body fastenings:

Some owners report problems with fastenings, such as mirror fastenings or body trims, which may become loose over time and require repair or replacement.