Page 1 DODGE NITRO BODY REPAIR MANUAL...
Page 2: Safety Notice
SAFETY NOTICE CAUTION ALL SERVICE AND REBUILDING INSTRUCTIONS CONTAINED HEREIN ARE APPLICABLE TO, AND FOR THE CONVENIENCE OF, THE AUTOMOTIVE TRADE ONLY. All test and repair procedures on components or assemblies in non-automotive applications should be repaired in accordance with instructions supplied by the manufacturer of the total product.
Page 3 Copies of the following Body Repair Manuals are available by calling 1-800-890-4038 • Chrysler 300 (81-316-0531CD) • Dodge Ram (81-316-0739-CD) • Chrysler Pacifica (81-316-0530-CD) • Dodge Sprinter Van (81-316-0533-CD) • Chrysler PT Convertible (81-316-0531-CD) • Jeep Compass (81-316-0738-CD) • Dodge Caliber (81-316-0737CD) • Jeep Commander (81-316-0636-CD) •...
Page 4 INTRODUCTION Dodge Nitro This manual has been prepared for use by all body technicians involved in the repair of the Dodge Nitro. This manual shows: - Typical panels contained in these vehicles - The types of welds for the panel...
Page 5 BODY CONSTRUCTION CHARACTERISTICS Definitions of Steels used in the Dodge Nitro: MS 66 - Represents an uncoated Hot Rolled Steel Sheet used mainly for interior braces and reinforcements. MS 67 - Represents an uncoated Cold Rolled Sheet structural steel used in areas where structural integrity is critical.
Page 6 BODY CONSTRUCTION CHARACTERISTICS The following measures have been implemented in order to provide maximum corrosion prevention and protection. 1. The use of galvannealed coatings throughout the body structure. 2. Ecoat is used on the complete body in all instances. 3. Body sealing. 4.
Page 7 Back to Index...
Page 8 HISTORY OF COLLISION REPAIR Time was, if you had an accident, the call went out to the insurance company - to the collision shop - or several shops - get the lowest bid and in no time at all, the vehicle was repaired. The facilities, training, and equipment were simple.
Page 9: Corrosion Protection
Corrosion Protection Factory Applied Corrosion Protection During the manufacturing of the unibody car, the manufacturer applies "corrosion protection" using specialized manufacturing processes. This system is not duplicated in the collision repair body shop. However, the body shop still has a responsibility to apply corrosion protection to the unibody vehicle. So, the collision repair shop must use alternative materials to do the corrosion protection job after the repair.
Page 10 Corrosion Protection Crevice corrosion is a form of localized attack that occurs in areas on metal surfaces exposed to the elements. Examples include spot weld lap joints, threaded or riveted connections, gasket fittings, porous welds, valve seats. Pitting is the corrosion of a metal surface at points or small areas which look like a small hole in the metal. Galvanic corrosion is the type that occurs when dissimilar metals are in electrical contact while immersed in an electrolyte.
Page 11 Corrosion Protection The penetration of corrosive solutions into these small areas, with widths that are typically a few thousandths of an inch, can result in various types of failures: the metal surface may become rusty in appearance, operating components may seize when protective coatings may have been removed from the metal surface.
Page 12 Corrosion Protection The types of materials used in rustproofing application include oil based materials, wax base materials, primers and color coats. The most important properties of rustproofing materials are adhesion, toughness, and the resistance to the environment. The best coating in the world is not effective unless it is present in the right place at the right time. Corrosion Protection Information When making the collision repair, refer to the manufacturer's information on where corrosion protection and sealants are applied.
Page 13 Corrosion Protection Spray Accessibility to the Repair Being able to achieve fog spray penetration into enclosed cavities as well as open areas requires application equipment, which includes an assortment of wands of various lengths and design. Some areas are more effectively treated by brush application of corrosion protection material before they are assembled.
Page 14 Corrosion Protection Desired Characteristics of Corrosion Protection Material 1. Corrosion prevention material- The material must displace water to prevent corrosion. This can be tested by spraying water on an open panel on the floor, then spraying the corrosion preventative material over the watered panel and observing if the material displaces the water.
Page 15 Back to Index...
Page 16 DODGE NITRO VEHICLE IDENTIFICATION NUMBER DESCRIPTION The Vehicle Identification Number (VIN) plate is located on the lower left A-pillar and is visible through the windshield. The VIN consists of 17 characters in a combination of letters and numbers that provide specific information about the vehicle.
Page 17 8 = Multipurpose Passenger Vehicle With Side Air Bags Gross Vehicle Weight Rating G = 5001-6000 Lbs. (2268-2721 Kg) Vehicle Line T = Nitro 4X2 (LHD) U = Nitro 4X4 (LHD) 9 = Nitro 4X4 (RHD) Series/Transmission 2 = Lowline...
Page 18 The Vehicle Identification Number (VIN) are unique identifying codes that have appeared on every vehicle sold on the United States since 1981. A VIN is 17 characters long, consisting of numbers and letters. Each character in a VIN has a specific meaning, and the VIN is broken up into sections. The following image (courtesy of howstuffworks.com) shows the 17 placeholders, described in detail below.
Page 19: Vehicle Certification Label
VEHICLE CERTIFICATION LABEL DESCRIPTION A vehicle certification label is attached to every DaimlerChrysler Corporation vehicle. The label certifies that the vehicle conforms to all applicable Federal Motor Vehicle Standards. The label also lists: • Month and year of vehicle manufacture. •...
Page 20 DODGE NITRO PAINT CODES EXTERIOR CODE COLOR Flame Red Clear Coat ARH/ARJ Inferno Red Crystal Pearl Coat Light Khaki Metallic Clear Coat Dark Khaki Pearl Coat Deep Beryl Green Pearl Coat Atlantic Blue Pearl Coat Midnight Blue Pearl Coat WSB/WS2...
Page 21 DODGE NITRO PAINT CODE LOCATION VEHICLE CERTIFICATION LABEL The vehicle certification label identifies the paint code. This label is located on the driver’s door shut face. Back to Index...
Page 22 Back to Index...
Page 23 WELDED PANEL REPLACEMENT Dodge Nitro The basic parts of the body structure are the welded panels. This section contains a brief description of the placement of some of the panels and their weld locations. Note: To ensure the strongest, most durable and cleanest welds possible, perform testing before and during all weld procedures.
Page 24 Explanation of Welding/Sealer Information The major construction of a unibody vehicle consists of welded panels that create the supporting structure for all com- ponents and assemblies of the vehicle. Here are some examples for replacement of these parts. Certain body components must use sealers to ensure proper assembly. Be sure to check the Body Sealing Locations and Structural Adhesive Sections for location and sealer type.
Page 25 Explanation of Welding Abbreviations Definitions Weld Type (ORD)=Ordinary Weld or Standard (CRT)=Critical Weld or Diamond (SAF)=Safety Weld PROJ=Projection Weld FCAW=Flex Core Arc Weld MFG=Manufacturing Weld S/WELD=Spot Welds /SD=Per Side Examples AA TO AB 5/SD S/WELDS (ORD)= PART AA WELDED TO PART AB 5 PER SIDE (5 RIGHT/5 LEFT) SPOT WELDS STANDARD AA TO AB 12 PROJ WELDS (CRT)= PART AA WELDED TO PART AB 12 PROJECTION WELDS CRITICAL OR DIAMOND Adhesives...
Page 26 WELD LOCATION OVERVIEW ZONES Back to Index...
Page 27 DODGE NITRO FRONT RAIL ASSEMBLY SECTION AA RAIL – FRT INR RT – AH REINF – U-CHANNEL RT – AR NUT/WELD.RD – ROUND.SPECIAL – TRANS AA RAIL – FRT INR LT – AH REINF – U-CHANNEL LT – TIEDOWN AB 55360616 – 17 RAIL – FRT OTR RT/LT AJ BRACKET –...
Page 28 PARTS IDENTIFICATION LEGEND, OVERVIEW 2 AA RAIL – FRT INR RT – AH REINF – U-CHANNEL RT – AR NUT/WELD.RD – ROUND.SPECIAL – TRANS AA RAIL – FRT INR LT – AH REINF – U-CHANNEL LT – TIEDOWN AB 55360616 – 17 RAIL – FRT OTR RT/LT AJ BRACKET –...
Page 29 WELD LAYOUT LOCATION GUIDE Back to Index...
Page 30 01 AB TO AA 30/SD S/WELDS (ORD) 02 AC TO AB TO AA 5/SD S/WELDS (ORD) Back to Index...
Page 31 03 AE TO AD TO AA 2/SD S/WELDS (ORD) 04 AE TO AA 8/SD S/WELDS (ORD) 05 AF TO AA 5/SD S/WELDS (ORD) 06 AG TO AA 5/SD S/WELDS (ORD) Back to Index...
Page 32 07 AE TO AB TO AA 2/SD S/WELDS (ORD) 08 AF TO AB TO AA 2/SD S/WELDS (ORD) 09 AH TO AB TO AA 2/SD S/WELDS (ORD) 10 AB TO AH 9/SD S/WELDS (ORD) 11 AH TO AC TO AB 4/SD S/WELDS (ORD) Back to Index...
Page 33 12 AJ TO AA 5/SD S/WELDS (ORD) 13 AD TO AA 14/SD S/WELDS (ORD) 14 AK TO AL 2/SD S/WELDS (ORD) 15 AK TO AB 3/SD S/WELDS (ORD) 16 AK TO AA 2/SD S/WELDS (ORD) Back to Index...
Page 34 17 AM TO AA 8/SD S/WELDS (ORD) 21 AN TO AM 1R S/WELDS (ORD) 18 AM TO AH TO AA 2/SD S/WELDS (ORD) 22 AP TO AM TO AA 1R S/WELDS (ORD) 19 AL TO AH TO AA 3/SD S/WELDS (ORD) 23 AR TO AM 2R PROJ WELDS (ORD) 20 AL TO AA 5/SD S/WELDS (ORD) 24 AR TO AH 1R PROJ WELD (ORD)
Page 35 25 AH TO AA 13/SD S/WELDS (ORD) 26 AP TO AA 4R S/WELDS (ORD) 27 AS TO AD 2/SD S/WELDS (ORD) 28 AT TO AD 2/SD S/WELDS (ORD) Back to Index...
Page 36 29 AP TO AA 4L S/WELDS (ORD) 30 AH TO AA 2/L S/WELDS (ORD) 31 AR TO AJ 1L PROJ WELD (ORD) 32 AR TO AM 2L PROJ WELDS (ORD) 33 AN TO AM 1L S/WELD (ORD) 34 AP TO AM TO AA 1L S/WELD (ORD) Back to Index...
Page 37 39 AK TO AA 1 FCAW (ORD) 35 AU TO AB 1/SD S/WELDS (ORD) 36 AV TO AB TO 2R S/WELDS (ORD) 40 AK TO AB 1 FCAW (ORD) 37 AU TO AC TO AB 8/SD S/WELDS (ORD) 41 AH TO AB 2 FCAW (ORD) 38 AC TO AB 4/SD S/WELDS (ORD) 42 AB TO AA 1 FCAW (ORD) Back to Index...
Page 38 43 AW TO AH 2/SD FCAW (ORD) 44 AW TO AP 4/SD FCAW (ORD) 45 AN TO AM 4/SD FCAW (ORD) Back to Index...
Page 39 46 AD TO AA 8/SD FCAW (ORD) 47 AP TO AA 2R FCAW (ORD) 48 AP TO AK 2L FCAW (ORD) 49 AV TO AK 2L S/WELDS (ORD) Back to Index...
Page 40 DODGE NITRO FRONT WHEELHOUSE ASSEMBLY SECTION AA WHEELHOUSE – FRT INR RT – AA WHEELHOUSE – FRT INR LT – AB REINF – FRT SHOCK ABSORBER TOWER UPR RT – AB REINF – FRT SHOCK ABSORBER TOWER UPR LT –...
Page 41 PARTS IDENTIFICATION LEGEND, OVERVIEW 3 AA WHEELHOUSE – FRT INR RT – AA WHEELHOUSE – FRT INR LT – AB REINF – FRT SHOCK ABSORBER TOWER UPR RT – AB REINF – FRT SHOCK ABSORBER TOWER UPR LT – AC REINF – FRT SHOCK ABSORBER TOWER LWR RT – AC REINF –...
Page 42 WELD LAYOUT LOCATION GUIDE Back to Index...
Page 43 01 AC TO AA 22R/23L S/WELDS (ORD) 02 AB TO AA TO AC 13/SD S/WELDS (ORD) 03 AD TO AC 2/SD S/WELDS (ORD) Back to Index...
Page 44 DODGE NITRO REAR RAIL ASSEMBLY SECTION AA RAIL – FRT RT – AG TORQUE BOX – RR RT – AR REINF – SPRING MTG – AA RAIL – FRT LT – AG TORQUE BOX – RR LT – AR REINF – SPRING MTG –...
Page 45 PARTS IDENTIFICATION LEGEND, OVERVIEW 4 AA RAIL – FRT RT – AG TORQUE BOX – RR RT – AR REINF – SPRING MTG – AA RAIL – FRT LT – AG TORQUE BOX – RR LT – AR REINF – SPRING MTG – AB RAIL –...
Page 46 WELD LAYOUT LOCATION GUIDE Back to Index...
Page 47 01 AC TO AA 8/SD S/WELDS (ORD) 02 AB TO AA TO AC 16/SD S/WELDS (ORD) 03 AC TO AB 16/SD S/WELDS (ORD) 04 AD TO AB 2R PROJ WELDS Back to Index...
Page 48 09 AG TO AA 1/SD S/WELDS (ORD) 05 AE TO AA 8/SD S/WELDS (ORD) 06 AE TO AF 3/SD S/WELDS (ORD) 10 AG TO AA 1L S/WELD (ORD) 07 AE TO AF TO AA 2/SD S/WELDS (ORD) 11 AF TO AA 12/SD S/WELD (ORD) 08 AG TO AE TO AA 3/SD S/WELDS (ORD) 12 AE TO AF TO AA 5/SD S/WELDS (ORD) Back to Index...
Page 49 13 AH TO AA 1 PROJ WELD 14 AH TO AB 1 PROJ WELD 15 AJ TO AA 5/SD S/WELDS (ORD) 16 AJ TO AG 5/SD S/WELDS (ORD) 17 AJ TO AA TO AK 1/SD S/WELDS (ORD) 18 AL TO AA 1 PROJ WELD Back to Index...
Page 50 19 AM TO AA TO AK 9R/7L S/WELDS (ORD) 23 AA TO AK 3/SD S/WELDS (ORD) 20 AM TO AN TO AA 1/SD S/WELD (ORD) 24 AM TO AA 6/SD S/WELDS (ORD) 21 AK TO AP TO AM 1/SD S/WELD (ORD) 25 AP TO AA TO AK 5/SD S/WELDS (ORD) 22 AN TO AM 7/SD S/WELDS (ORD) Back to Index...
Page 51 26 AK TO AA TO AR 7/SD S/WELDS (ORD) 27 AA TO AR 4/SD S/WELDS (ORD) 28 AK TO AA 5R/4L S/WELDS (ORD) 29 AN TO AR 4/SD S/WELDS (ORD) 30 AK TO AA TO AP 5/SD S/WELDS (ORD) 31 AA TO AP 2/SD S/WELDS (ORD) Back to Index...
Page 52 32 AA TO AK 12/SD S/WELDS (ORD) 33 AK TO AA TO AP 1/SD S/WELD (ORD) 34 AN TO AA TO AK 12/SD S/WELDS (ORD) Back to Index...
Page 53 35 AS TO AK 1L PROJ WELD 39 AS TO AK 2L PROJ WELD 36 AK TO AA 2L S/WELDS (ORD) 40 AP TO AA TO AK 1L S/WELD (ORD) 37 AH TO AK 1L PROJ WELD 41 AM TO AA TO AK 2/SD S/WELDS (ORD) 38 AK TO AA TO AP 1L PROJ WELD Back to Index...
Page 54 42 AK TO AP 27R/21L S/WELDS (ORD) 43 AS TO AK 1 PROJ WELD Back to Index...
Page 55 44 AS TO AK 3/SD S/WELDS (ORD) 45 AK TO AP 12R/18L S/WELDS (ORD) 46 AT TO AM TO AP 3/SD S/WELDS (ORD) 47 AS TO AK 1L PROJ WELD Back to Index...
Page 56 48 AU TO AJ 1R PROJ WELD 49 AV TO AA 2R PROJ WELD 50 AW TO AP 2R PROJ WELD 51 AU TO AA 1R PROJ WELD Back to Index...
Page 57 DODGE NITRO REAR FLOOR ASSEMBLY SECTION AA PAN – FLOOR RR – AB PLATE – COMPRESSION RR RT – AB PLATE – COMPRESSION RR LT – AC CROSSMEMBER – RR SEAT FRT RT – AD SUPPORT – FUEL TANK FRT –...
Page 58 PARTS IDENTIFICATION LEGEND, OVERVIEW 5 AA PAN – FLOOR RR – AB PLATE – COMPRESSION RR RT – AB PLATE – COMPRESSION RR LT – AC CROSSMEMBER – RR SEAT FRT RT – AD SUPPORT – FUEL TANK FRT – AE NUT/WELD.RD –...
Page 59 WELD LAYOUT LOCATION GUIDE Back to Index...
Page 60 01 AB TO AA 22 S/WELDS (ORD) Back to Index...
Page 61 02 AC TO AA 10 S/WELDS (ORD) 03 AD TO AA 6 S/WELDS (ORD) Back to Index...
Page 62 04 AE TO AA 4 PROJ WELDS (ORD) 05 AF TO AA 2 PROJ WELDS (ORD) 06 AC TO AA 2 PROJ WELDS (ORD) Back to Index...
Page 63 WELD LOCATION OVERVIEW ZONES Back to Index...
Page 64 DODGE NITRO REAR FLOOR COMPLETE SECTION AA PAN – FLOOR RR – AM RAIL – RR RAIL SHORT RR LT – AB RAIL – RR RT – AN NUT/WELD.RD – ROUND – AB RAIL – RR LT – AP CROSSMEMBER – RR SUSPENSION TRACK AC PLATE –...
Page 65 PARTS IDENTIFICATION LEGEND, OVERVIEW 6 AA PAN – FLOOR RR – AM RAIL – RR RAIL SHORT RR LT – AB RAIL – RR RT – AN NUT/WELD.RD – ROUND – AB RAIL – RR LT – AP CROSSMEMBER – RR SUSPENSION TRACK AC PLATE –...
Page 66 WELD LAYOUT LOCATION GUIDE Back to Index...
Page 67 01 AC TO AA TO AB 30/SD S/WELDS (ORD) Back to Index...
Page 68 02 AA TO AE 2/SD S/WELDS (ORD) 03 AA TO AE TO AF 1/SD S/WELDS (ORD) 04 AA TO AF 5/SD S/WELDS (ORD) 05 AC TO AA TO AF 1/SD S/WELDS (ORD) 06 AC TO AA TO AD 2/SD S/WELDS (ORD) 07 AG TO AD 1 PROJ WELD Back to Index...
Page 69 08 AB TO AD 3/SD S/WELDS (ORD) 09 AH TO AB TO AD 2/SD S/WELDS (ORD) 10 AJ TO AA 4 PROJ WELDS 11 AK TO AA 1 PROJ WELD Back to Index...
Page 70 12 AD TO AL 2 S/WELDS (ORD) 13 AA TO AD 5/SD S/WELDS (ORD) 14 AA TO AL 1 S/WELD (ORD) 15 AA TO AK TO AD 31 S/WELDS (ORD) Back to Index...
Page 71 16 AA TO AB TO AM 4/SD S/WELDS (ORD) 17 AA TO AB 5/SD S/WELDS (ORD) 18 AN TO AL 1 PROJ WELD 19 AA TO AL TO AD 16 S/WELDS (ORD) Back to Index...
Page 72 24 AR TO AM 2R/1L S/WELDS (ORD) 20 AP TO AB 1/SD S/WELD (ORD) 25 AR TO AM TO AH 1/R S/WELD (ORD) 21 AP TO AB TO AH 3R/1L S/WELDS (ORD) 22 AP TP AM TO AB 1R S/WELD (ORD) 26 AA TO AR 18 S/WELDS (ORD) 23 AR TO AM TO AB 1/SD S/WELD (ORD) 27 AA TO AP 18 S/WELDS (ORD)
Page 73 28 AS TO AM TO AH 5L S/WELDS (ORD) 29 AP TO AB TO AH 2L S/WELDS (ORD) 30 AR TO AM TO AH 2/SD S/WELDS (ORD) 31 AA TO AM 11/SD S/WELDS (ORD) 32 AA TO AM TO AH 2/SD S/WELDS (ORD) Back to Index...
Page 74 33 AS TO AM 4R/2L S/WELDS (ORD) 34 AS TO AM TO AH 3R S/WELDS (ORD) 35 AA TO AS 31 S/WELDS (ORD) 36 AJ TO AA 2 PROJ WELDS Back to Index...
Page 75 37 AU TO AA 8 S/WELDS (ORD) 38 AK TO AU 4 PROJ WELDS 39 AU TO AA TO AM 3 S/WELDS (ORD) 40 AA TO AM TO AT 1/SD S/WELD (ORD) 41 AV TO AU 2 PROJ WELDS 42 AU TO AA TO AT 13 S/WELDS (ORD) Back to Index...
Page 76 43 AG TO AW 2 PROJ WELDS 44 AA TO AW 16 S/WELDS (ORD) 45 AA TO AX 5/SD S/WELDS (ORD) 46 AU TO AW 15 S/WELDS (ORD) Back to Index...
Page 77 47 AZ TO AT 1 PROJ WELD 51 AT TO AM 1/SD S/WELD (ORD) 48 AY TO AT 3/SD S/WELDS (ORD) 52 AX TO AY 2/SD S/WELDS (ORD) 49 AX TO AT TO AM 5/SD S/WELDS (ORD) 53 AW TO AT 16 S/WELDS (ORD) 50 AX TO AT 5/SD S/WELDS (ORD) 54 AY TO AT TO AM 2/SD S/WELDS (ORD) Back to Index...
Page 78 55 AU TO AA 1 STRUC ADH 56 AA TO AS 2 STRUC ADH 57 AA TO AR 1 STRUC ADH 58 AA TO AP 1 STRUC ADH 59 AD TO AA TO AL 1 STRUC ADH 60 AD TO AA TO AL 1 STRUC ADH 61 AA TO AM TO AB 2 STRUC ADH Back to Index...
Page 79 DODGE NITRO FRONT MISCELLANEOUS BODY SECTION AA CROSSMEMBER – FRT BUMPER FRT – AM STUD PLATE – AT REINF – B-PILLAR RT – AB CROSSMEMBR – FRT BUMPER RR – AM STUD PLATE – AT REINF – B-PILLAR LT –...
Page 80 PARTS IDENTIFICATION LEGEND, OVERVIEW 7 AA CROSSMEMBER – FRT BUMPER FRT – AM STUD PLATE – AT REINF – B-PILLAR RT – AB CROSSMEMBR – FRT BUMPER RR – AM STUD PLATE – AT REINF – B-PILLAR LT – AC REINF – HOOD LATCH STRIKER – AN STUD PLATE –...
Page 81 WELD LAYOUT LOCATION GUIDE Back to Index...
Page 82 01 AB TO AA 25 S/WELDS (ORD) Back to Index...
Page 83 02 AD TO AC 4 S/WELDS (ORD) Back to Index...
Page 84 03 AF TO AE 3/SD S/WELDS (ORD) 04 AH TO AG 2/SD S/WELDS (ORD) Back to Index...
Page 85 05 AL TO AJ 2/SD PROJ WELDS (ORD) 06 AL TO AK 2/SD PROJ WELDS (ORD) 07 AP TO AM 8 PROJ WELDS (ORD) 08 AP TO AN 8 PROJ WELDS (ORD) Back to Index...
Page 86 09 AS TO AR 9 S/WELDS (ORD) 10 AL TO AT 4/SD PROJ WELDS (ORD) Back to Index...
Page 87 11 AV TO AU 3/SD S/WELDS (ORD) 12 AV TO AU 1/SD MIG BRZ (ORD) 13 AW TO AU 2/SD S/WELDS (ORD) Back to Index...
Page 88 14 AY TO AX 2/SD S/WELDS (ORD) 15 AY TO AX 1/SD MIG BRZ Back to Index...
Page 89 16 BC TO AZ 1 PROJ WELD (ORD) 17 BB TO AZ 2 PROJ WELDS (ORD) 18 BC TO BA 2 PROJ WELDS (ORD) Back to Index...
Page 90 19 BE TO BD 18 S/WELDS (ORD) Back to Index...
Page 91 20 BF TO BD 4 FCAW (ORD) 21 BE TO BD 1 FCAW (ORD) 22 BE TO BD 13 FCAW (ORD) Back to Index...
Page 92 23 AS TO AR 1 STRUC ADH (ORD) 24 AS TO AR 2 STRUC ADH (ORD) 25 AS TO AR 1 STRUC ADH (ORD) 26 AS TO AR 1 STRUC ADH (ORD) 27 AS TO AR 2 STRUC ADH (ORD) 28 AS TO AR 1 STRUC ADH (ORD) Back to Index...
Page 93 Back to Index...
Page 94 WELD LOCATION OVERVIEW ZONES Back to Index...
Page 95 DODGE NITRO DASH SECTION AA PANEL – DASH – AB REINF – ACCELERATOR PEDAL – AC REINF – BRAKE MASTER CYL – Back to Index...
Page 96 PARTS IDENTIFICATION LEGEND, OVERVIEW 9 AA PANEL – DASH – AB REINF – ACCELERATOR PEDAL – AC REINF – BRAKE MASTER CYL – Back to Index...
Page 97 WELD LAYOUT LOCATION GUIDE Back to Index...
Page 98 01 AA TO AC 16 S/WELDS (ORD) 02 AA TO AB 4 S/WELDS (ORD) Back to Index...
Page 99 DODGE NITRO PLENUM ASSEMBLY SECTION AA PANEL – PLENUM BAFFLE – AB PANEL – PLENUM CLOSURE RT – AC PANEL – PLENUM LWR – AD PANEL – PLENUM CLOSURE LT – AE PANEL – PLENUM RR – AF REINF – STEERING COLUMN MOUNTING –...
Page 100 PARTS IDENTIFICATION LEGEND, OVERVIEW 10 AA PANEL – PLENUM BAFFLE – AB PANEL – PLENUM CLOSURE RT – AC PANEL – PLENUM LWR – AD PANEL – PLENUM CLOSURE LT – AE PANEL – PLENUM RR – AF REINF – STEERING COLUMN MOUNTING – AG TAPPING PLATE –...
Page 101 WELD LAYOUT LOCATION GUIDE Back to Index...
Page 102 01 AC TO AB 2 S/WELDS (ORD) 02 AC TO AA 7 S/WELDS (ORD) 03 AD TO AC 2 S/WELDS (ORD) Back to Index...
Page 103 04 AE TO AC 30 S/WELDS (ORD) 05 AF TO AE TO AC 10 S/WELDS (ORD) Back to Index...
Page 104 06 AF TO AE TO AA 3 S/WELDS 07 AE TO AA 9 S/WELDS (ORD) Back to Index...
Page 105 08 AF TO AC 4 S/WELDS (ORD) 09 AD TO AC 2 S/WELDS (ORD) 10 AS TO AA 2 S/WELDS (ORD) 11 AB TO AA 1 S/WELD (ORD) 12 AB TO AC 1 S/WELD (ORD) Back to Index...
Page 106 13 AG TO AE 2 PROJ WELDS (ORD) Back to Index...
Page 107 14 AC TO AA 1 STRUC ADH (ORD) 15 AD TO AC 1 STRUC ADH (ORD) 16 AC TO AA 1 STRUC ADH (ORD) 17 AC TO AB 1 STRUC ADH (ORD) Back to Index...
Page 108 WELD LOCATION OVERVIEW ZONES Back to Index...
Page 109 DODGE NITRO FRONT FLOOR SECTION AA PAN – FLOOR FRT – AB REINF – TUNNEL FRT – AC BRACKET – OCCUPANT RESTRAINT CONTROLLER MODULE – AD PLATE – COMPRESSION FRT FLOOR CTR RT – AD PLATE – COMPRESSION FRT FLOOR CTR LT –...
Page 110 PARTS IDENTIFICATION LEGEND, OVERVIEW 11 AA PAN – FLOOR FRT – AB REINF – TUNNEL FRT – AC BRACKET – OCCUPANT RESTRAINT CONTROLLER MODULE – AD PLATE – COMPRESSION FRT FLOOR CTR RT – AD PLATE – COMPRESSION FRT FLOOR CTR LT – AE CROSSMEMBER –...
Page 111 WELD LAYOUT LOCATION GUIDE Back to Index...
Page 112 01 AB TO AA 4/SD S/WELDS (ORD) 02 AC TO AA 11 S/WELDS (SAF) Back to Index...
Page 113 01 AB TO AA 4/SD S/WELDS (ORD) 03 AA TO AE TO AD 1/SD S/WELD (ORD) 04 AD TO AA 3/SD S/WELDS (ORD) 05 AE TO AA 14/SD S/WELDS (ORD) Back to Index...
Page 114 06 AF TO AA 5 S/WELDS (ORD) 07 AG TO AA 24 S/WELDS (ORD) Back to Index...
Page 115 DODGE NITRO REAR WHEELHOUSE SECTION AA PANEL – RR WHEELHOUSE INR RT – AB EXTENSION – RR WHEELHOUSE INR RT – AC BRACKET – WHEELHOUSE TRIM INR – AC BRACKET – WHEELHOUSE TRIM INR – AD PANEL – RR WHEELHOUSE INR LT –...
Page 116 PARTS IDENTIFICATION LEGEND, OVERVIEW 12 AA PANEL – RR WHEELHOUSE INR RT – AB EXTENSION – RR WHEELHOUSE INR RT – AC BRACKET – WHEELHOUSE TRIM INR – AC BRACKET – WHEELHOUSE TRIM INR – AD PANEL – RR WHEELHOUSE INR LT – AE EXTENSION –...
Page 117 WELD LAYOUT LOCATION GUIDE Back to Index...
Page 118 01 AB TO AA 12 S/WELDS (ORD) 02 AC TO AA 2 S/WELDS (ORD) Back to Index...
Page 119 03 AC TO AD 2 S/WELDS (ORD) 04 AE TO AD 20 S/WELDS (ORD) Back to Index...
Page 120 DODGE NITRO FENDER ASSEMBLY SECTION AA FENDER – FRT RT – AA FENDER – FRT LT – AB REINF – FENDER RR UPR RT – AB REINF – FENDER RR UPR LT – AC REINF – FENDER FRT UPR RT –...
Page 121 PARTS IDENTIFICATION LEGEND, OVERVIEW 13 AA FENDER – FRT RT – AA FENDER – FRT LT – AB REINF – FENDER RR UPR RT – AB REINF – FENDER RR UPR LT – AC REINF – FENDER FRT UPR RT – AC REINF –...
Page 122 01 AB TO AA 7/SD S/WELDS (ORD) 02 AC TO AA 6/SD S/WELDS Back to Index...
Page 123 WELD LOCATION OVERVIEW ZONES Back to Index...
Page 124 DODGE NITRO FRONT FLOOR/DASH/PLENUM SECTION AA PANEL – PLENUM BAFFLE – AB PANEL – PLENUM LWR – AC REINF – BRAKE MASTER CYLINDER – AD PANEL – DASH – AE PAN – FLOOR FRT – Back to Index...
Page 125 PARTS IDENTIFICATION LEGEND, OVERVIEW 16 AA PANEL – PLENUM BAFFLE – AB PANEL – PLENUM LWR – AC REINF – BRAKE MASTER CYLINDER – AD PANEL – DASH – AE PAN – FLOOR FRT – Back to Index...
Page 126 WELD LAYOUT LOCATION GUIDE Back to Index...
Page 127 01 AA TO AB TO AC 6 S/WELDS (ORD) 02 AA TO AB TO AD 13 S/WELDS (ORD) 03 AB TO AD 4 S/WELDS (ORD) Back to Index...
Page 128 04 AD TO AE 37 S/WELDS (ORD) Back to Index...
Page 129 05 AD TO AE 1 STRUC ADH Back to Index...
Page 130 DODGE NITRO UNDERBODY COMPLETE SECTION AA PANEL – FENDER INR RT – AN BRACKET – FRT RAIL TO CROSSMEMBER – AY CROSSMEMBER – FRT SEAT FRT LT – AA PANEL – FENDER INR LT – AN BRACKET – FRT RAIL TO CROSSMEMBER –...
Page 131 PARTS IDENTIFICATION LEGEND, OVERVIEW 17 AA PANEL – FENDER INR RT – AN BRACKET – FRT RAIL TO CROSSMEMBER – AY CROSSMEMBER – FRT SEAT FRT LT – AA PANEL – FENDER INR LT – AN BRACKET – FRT RAIL TO CROSSMEMBER – AY CROSSMEMBER –...
Page 132 WELD LAYOUT LOCATION GUIDE Back to Index...
Page 133 01 AD TO AC TO AA 2/SD S/WELDS (ORD) 02 AD TO AC TO AB 5/SD S/WELDS (ORD) 03 AG TO AE 5/SD S/WELDS (ORD) 04 AE TO AA 6/SD S/WELDS (ORD) 05 AF TO AE TO AA 4/SD S/WELDS (ORD) 06 AG TO AA 4/SD S/WELDS (ORD) Back to Index...
Page 134 07 AH TO AC TO AA 1/SD S/WELD (ORD) 08 AC TO AA 1/SD S/WELD (ORD) 09 AH TO AB TO AA 8/SD S/WELDS (ORD) 10 AH TO AB 5/SD S/WELDS (ORD) 11 AJ TO AB 3/SD S/WELDS (ORD) Back to Index...
Page 135 12 AL TO AG 3/SD FCAW (ORD) 13 AL TO AK TO AG 4/SD S/WELDS (ORD) 14 AK TO AG 3/SD S/WELDS (ORD) 15 AN TO AM 3/SD S/WELDS (ORD) 16 AL TO AG 3/SD S/WELDS (ORD) Back to Index...
Page 136 17 AR TO AE 6/SD S/WELDS (ORD) 18 AS TO AE 4/SD S/WELDS (ORD) 19 AP TO AK 2/SD FCAW (ORD) 20 AP TO AL 1/SD FCAW (ORD) 21 AK TO AL TO AE 10/SD S/WELDS (ORD) 22 AP TO AK TO AL 3/SD S/WELDS (ORD) Back to Index...
Page 137 23 AV TO AT 2/SD S/WELDS (ORD) 24 AE TO AT 1/SD S/WELDS (ORD) 25 AE TO AH TO AT 1/SD S/WELD (ORD) 26 AE TO AH 6R/3L S/WELDS (ORD) 27 AU TO AT 8/SD S/WELDS (ORD) Back to Index...
Page 138 28 AW TO AE TO AH 3L S/WELDS (ORD) 29 AX TO AB 14/SD S/WELDS (ORD) 30 AU TO AX 6/SD S/WELDS (ORD) Back to Index...
Page 139 31 AX TO AT 19/SD S/WELDS (ORD) 32 AY TO AX 4/SD S/WELDS (ORD) 33 AZ TO AX TO AT 3/SD S/WELDS (SAF) 34 AY TO AX TO AT 2/SD S/WELDS (SAF) 35 BA TO AX 6/SD S/WELDS (ORD) Back to Index...
Page 140 36 AX TO BB 8/SD S/WELDS (ORD) 37 AX TO BC 1/SD S/WELD (ORD) 38 BC TO BB 18R/19L S/WELDS (ORD) 39 BA TO BC TO BB 1/SD S/WELD (ORD) 40 AT TO AX TO BB 1/SD S/WELD (ORD) Back to Index...
Page 141 45 AK TO BD TO AT 6/SD S/WELDS (ORD) 41 BE TO AL TO AT 2/SD S/WELDS (SAF) 46 AK TO AT 4/SD S/WELDS (ORD) 42 AL TO AY TO AT 2/SD S/WELDS (SAF) 47 AK TO AY TO AT 2/SD S/WELDS (SAF) 43 AL TO BD TO AT 6/SD S/WELDS (ORD) 48 BE TO AK TO AT 2/SD S/WELDS (SAF) 44 AV TO BD TO AT 2/SD S/WELDS (ORD)
Page 142 49 AZ TO BE TO AT 2/SD S/WELDS (ORD) 50 BF TO BE TO AT 2/SD S/WELDS (ORD) 51 BF TO BE TO AT 2/SD S/WELDS (SAF) 52 AZ TO BE TO AT 4/SD S/WELDS (SAF) 53 BE TO AT 14/SD S/WELDS (ORD) Back to Index...
Page 143 54 BG TO BE TO AL 3/SD S/WELDS (SAF) 58 AL TO BE 6/SD S/WELDS (SAF) 55 BH TO BG 2R/2L S/WELDS (SAF) 59 BH TO BG TO AK 1L S/WELD (SAF) 56 BH TO BG TO AL 1R S/WELD (SAF) 60 BG TO BE TO AK 3/SD S/WELDS (SAF) 57 AX TO BE 2/SD S/WELDS (SAF) 61 BH TO BG 1/SD S/WELD (ORD)
Page 144 62 BB TO AT 24 S/WELDS (ORD) 63 BE TO BB TO AT 2R/2L S/WELDS (ORD) Back to Index...
Page 145 64 BE TO AT 1/SD STRUC ADH (ORD) 65 BE TO AT 1/SD STRUC ADH (ORD) 66 AL TO AT 1/SD STRUC ADH (ORD) 67 AK TO AT 1/SD STRUC ADH (ORD) 68 BE TO AT 1/SD STRUC ADH (ORD) 69 BA TO AT 1/SD STRUC ADH (ORD) Back to Index...
Page 146 70 BB TO AT 1 STRUC ADH (ORD) Back to Index...
Page 147 71 BC TO BB 1R STRUC ADH (ORD) 72 BC TO BB 1L STRUC ADH (ORD) Back to Index...
Page 148 DODGE NITRO BODY SIDE APERTURE INNER SECTION AA 55360732/3 PANEL-BODY SIDE INR RT/LT AF REINF – SHOULDER BELT – AB REINF – A-PILLAR INR LWR RT – AG REINF – SEAT & SHOULDER BELT RR – AB REINF – A-PILLAR INR LWR LT –...
Page 149 PARTS IDENTIFICATION LEGEND, OVERVIEW 18 AA 55360732/3 PANEL-BODY SIDE INR RT/LT AF REINF – SHOULDER BELT – AB REINF – A-PILLAR INR LWR RT – AG REINF – SEAT & SHOULDER BELT RR – AB REINF – A-PILLAR INR LWR LT – AJ PANEL –...
Page 150 WELD LAYOUT LOCATION GUIDE Back to Index...
Page 151 01 AB TO AA 27/SD S/WELDS (ORD) 02 AC TO AB TO AA 1/SD S/WELDS (SAF) 03 AC TO AA 2/SD S/WELDS (ORD) 04 AD TO AA 4/SD S/WELDS (ORD) Back to Index...
Page 152 05 AG TO AA 2/SD S/WELDS (SAF) 06 AE TO AA 2/SD S/WELDS (ORD) 07 AE TO AB TO AA 1/SD S/WELD (ORD) 08 AF TO AA 7/SD S/WELDS (ORD) Back to Index...
Page 153 09 AK TO AA 4/SD S/WELDS (ORD) 10 AL TO AA 4/SD S/WELDS (SAF) 11 AJ TO AA 16 S/WELDS (ORD) 12 AM TO AA 21 S/WELDS (ORD) 13 AJ TO AA 9R S/WELDS (ORD) Back to Index...
Page 154 14 AP TO AN 3L S/WELDS (ORD) 15 AN TO AA 14L S/WELDS (ORD) 16 AP TO AA 6L S/WELDS (ORD) Back to Index...
Page 155 DODGE NITRO BODY SIDE APERTURE OUTER SECTION AA REINF – FENDER INR RT – AH 55360722/3AA PANEL – BODY SIDE OTR RT/LT AA REINF – FENDER INR LT – AJ GUSSET – FRT FENDER INR RT – AB REINF – BODY SIDE APERTURE EXTENSION RT –...
Page 156 PARTS IDENTIFICATION LEGEND, OVERVIEW 19 AA REINF – FENDER INR RT – AH 55360722/3AA PANEL – BODY SIDE OTR RT/LT AA REINF – FENDER INR LT – AJ GUSSET – FRT FENDER INR RT – AB REINF – BODY SIDE APERTURE EXTENSION RT – AJ GUSSET –...
Page 157 WELD LAYOUT LOCATION GUIDE Back to Index...
Page 158 01 AC TO AA 3/SD S/WELDS (ORD) 02 AC TO AA TO AB 2/SD S/WELDS (ORD) 03 AD TO AA 4/SD S/WELDS (ORD) 04 AE TO AA 2/SD S/WELDS (ORD) 05 AF TO AA 2/SD S/WELDS (ORD) 06 AG TO AA 2/SD S/WELDS (ORD) Back to Index...
Page 159 11 AA TO AH 4/SD /SWELDS (ORD) 07 AJ TO AH 3/SD S/WELDS (ORD) 12 AA TO AK TO AB 1/SD S/WELD (ORD) 08 AJ TO AA TO AH 4/SD S/WELDS (ORD) 13 AK TO AH 3/SD S/WELDS (ORD) 09 AB TO AH 6/SD S/WELDS (ORD) 10 AA TO AB TO AH 2/SD S/WELDS (ORD) Back to Index...
Page 160 14 AL TO AH 8/SD S/WELDS (ORD) Back to Index...
Page 161 15 AM TO AH 2/SD S/WELDS (ORD) 16 AN TO AH 8/SD S/WELDS (ORD) Back to Index...
Page 162 17 AQ TO AH 14/SD S/WELDS (ORD) 18 AP TO AH 5/SD S/WELDS (ORD) 19 AN TO AQ 6/SD S/WELDS (ORD) Back to Index...
Page 163 20 AK TO AH 1/SD STRUC ADH (ORD) 21 AN TO AQ TO AH 1/SD STRUC ADH (ORD) 22 AN TO AQ 1/SD STRUC ADH (ORD) 23 AN TO AH 1/SD STRUC ADH (ORD) Back to Index...
Page 164 WELD LOCATION OVERVIEW ZONES Back to Index...
Page 165 DODGE NITRO BODY SIDE APERTURE COMPLETE SECTION AH REINF – BODY SIDE DOOR HINGE UPR LT – AA 55360722AA/55360721AA – PANEL – BODY SIDE OTR RT/LT AJ REINF – BODY SIDE FRT DOOR LWR HINGE RT – AB 55360732AA/55360733AA – PANEL – BODY SIDE AJ REINF –...
Page 166 PARTS IDENTIFICATION LEGEND, OVERVIEW 20 AH REINF – BODY SIDE DOOR HINGE UPR LT – AA 55360722AA/55360721AA – PANEL – BODY SIDE AJ REINF – BODY SIDE FRT DOOR LWR HINGE RT – OTR RT/LT AJ REINF – BODY SIDE FRT DOOR LWR HINGE LT – AB 55360732AA/55360733AA –...
Page 167 WELD LAYOUT LOCATION GUIDE Back to Index...
Page 168 01 AF TO AB TO AD 2/SD S/WELDS (ORD) 02 AF TO AB 1/SD S/WELD (ORD) 03 AB TO AE TO AD 1/SD S/WELD (ORD) 04 AC TO AB TO AA 3/SD S/WELDS (ORD) 05 AD TO AB TO AA 4/SD S/WELDS (ORD) Back to Index...
Page 169 06 AA TO AB TO AF 43/SD S/WELDS (ORD) 07 AG TO AB TO AF 2/SD S/WELDS (ORD) Back to Index...
Page 170 08 AH TO AB TO AA 2/SD S/WELDS (ORD) 09 AJ TO AB TO AA 2/SD S/WELDS (ORD) 10 AB TO AA 8/SD S/WELDS (ORD) Back to Index...
Page 171 11 AA TO AK TO AB 39/SD S/WELDS (ORD) 12 AB TO AA 4/SD S/WELDS (ORD) Back to Index...
Page 172 13 AM TO AB TO AA 1/SD S/WELD (ORD) 14 AB TO AA 23/SD S/WELDS (ORD) Back to Index...
Page 173 15 AB TO AA 5/SD S/WELDS (ORD) 16 AL TO AA 13/SD S/WELDS (ORD) 17 AR TO AA TO AL 1/SD S/WELD (ORD) 18 AB TO AL TO AA 2/SD S/WELDS (ORD) Back to Index...
Page 174 19 AB TO AA 34/SD S/WELDS (ORD) Back to Index...
Page 175 20 AP TO AA 2/SD S/WELDS (ORD) 21 AP TO AN 2/SD S/WELDS (ORD) 22 AN TO AB 12/SD S/WELDS (ORD) 23 AB TO AA 2/SD S/WELDS (ORD) Back to Index...
Page 176 24 AL TO AA 1 STRUC ADH Back to Index...
Page 177 DODGE NITRO BODY IN WHITE WITHOUT ROOF SECTION AA REINF – FENDER INR RT – AH REINF – BODY SIDE ARPERTURE EXTENSION LT – AV EXTENSION – RR WHEELHOUSE INR RT – AA REINF – FENDER INR LT – AJ 55360732/3 – BODY SIDE RT & LT – INR AV EXTENSION –...
Page 178 PARTS IDENTIFICATION LEGEND, OVERVIEW 21 AA REINF – FENDER INR RT – AH REINF – BODY SIDE ARPERTURE EXTENSION LT – AV EXTENSION – RR WHEELHOUSE INR RT – AA REINF – FENDER INR LT – AJ 55360732/3 – BODY SIDE RT & LT – INR AV EXTENSION –...
Page 179 WELD LAYOUT LOCATION GUIDE Back to Index...
Page 180 01 AA TO AB 16/SD S/WELDS (ORD) 02 AA TO AB TO AD 5/SD S/WELDS (ORD) 03 AC TO AD TO AB 4/SD S/WELDS (ORD) 04 AE TO AA TO AB 3/SD S/WELDS (ORD) 05 AA TO AB TO AF 1/SD S/WELDS (ORD) Back to Index...
Page 181 06 AM TO AG TO AJ 1/SD S/WELDS (ORD) 11 AL TO AA 2R/1L S/WELDS (ORD) 07 AN TO AM TO AG 1/SD S/WELDS (ORD) 12 AL TO AJ TO AH 1/SD S/WELDS (ORD) 08 AJ TO AL TO AM 1R S/WELD (ORD) 13 AA TO AK 1/SD S/WELDS (ORD) 09 AL TO AJ TO AA 1/SD S/WELDS (ORD) 14 AA TO AP TO AJ 2/SD S/WELDS (ORD)
Page 182 16 AR TO AJ TO AP 35/SD S/WELDS (ORD) 17 AK TO AJ TO AP 9/SD S/WELDS (ORD) 18 AR TO AS TO AP 3/SD S/WELDS (ORD) Back to Index...
Page 183 19 AR TO AJ 3/SD S/WELDS (ORD) 20 AR TO AJ TO AP 17/SD S/WELDS (ORD) 21 AT TO AJ TO AP 8/SD S/WELDS (ORD) Back to Index...
Page 184 22 AJ TO AU 5/SD S/WELDS (ORD) 23 AJ TO AV 5/SD S/WELD (ORD) 24 AJ TO AW 10/SD S/WELDS (ORD) Back to Index...
Page 185 25 AU TO AY TO AX 4/SD S/WELDS (ORD) 29 AX TO AY TO BA 2/SD S/WELDS (ORD) 26 AU TO AZ TO AY 1/SD S/WELDS (ORD) 30 AX TO AY 1/SD S/WELDS (ORD) 27 AX TO AZ TO BB 5/SD S/WELDS (ORD) 31 AP TO AY 1/SD S/WELDS (ORD) 28 AX TO BA TO BB 1/SD S/WELDS (ORD) 32 AP TO AY TO AJ 2/SD S/WELDS (ORD)
Page 186 33 AP TO AV 12L S/WELDS (ORD) 34 BD TO AX 1/SD S/WELDS (ORD) 35 BD TO AJ TO AX 1/SD S/WELDS (ORD) 36 BC TO AX 1/SD S/WELDS (ORD) Back to Index...
Page 187 37 BC TO BD 12/SD S/WELDS (ORD) 38 BD TO AJ 4/SD S/WELDS (ORD) 39 BC TO BD TO AJ 1/SD S/WELDS (ORD) 40 BE TO AJ 6/SD S/WELDS (ORD) 41 BE TO AG 3/SD S/WELDS (ORD) 42 BF TO AG 3/SD S/WELDS (ORD) Back to Index...
Page 188 43 AJ TO BD 1/SD STRUC ADH 44 AJ TO AU 1/SD STRUC ADH 45 AW TO AX 1/SD STRUC ADH 46 AJ TO AR 1/SD STRUC ADH 47 AT TO AV TO AW TO AJ 1R STRUC ADH Back to Index...
Page 189 48 AM TO AL TO AJ 1/SD STRUC ADH 49 AJ TO AK 1/SD STRUC ADH 50 AJ TO AR 1/SD STRUC ADH 51 AT TO AV TO AW TO AJ 1L STRUC ADH Back to Index...
Page 190 WELD LOCATION OVERVIEW ZONES Back to Index...
Page 191 DODGE NITRO BODY IN WHITE COMPLETE SECTION AA PANEL – ROOF W/O SUNROOF – AB 55360732 AC REINF – A-PILLAR INR LWR RT – AD HEADER – ROOF FRT LWR – AE STUD.WELD/EXTERNAL – NO.FIN.PILOT.PT SPECIAL – SIDE AIR BAG CURTAIN ATTACH...
Page 192 PARTS IDENTIFICATION LEGEND, OVERVIEW 22 AA PANEL – ROOF W/O SUNROOF – AB 55360732 AC REINF – A-PILLAR INR LWR RT – AD HEADER – ROOF FRT LWR – AE STUD.WELD/EXTERNAL – NO.FIN.PILOT.PT SPECIAL – SIDE AIR BAG CURTAIN ATTACH AF 55360722 AG 55360840/41 AH HEADER –...
Page 193 WELD LAYOUT LOCATION GUIDE Back to Index...
Page 194 01 AD TO AA 21 S/WELDS (ORD) 02 AD TO AC TO AA 1/SD S/WELD (ORD) 03 AC TO AB TO AA 1/SD S/WELD (ORD) 04 AE TO AC 2/SD PROJ WELDS (ORD) Back to Index...
Page 195 05 AF TO AA 6/SD S/WELDS (ORD) 06 AF TO AB TO AA 6/SD S/WELDS (ORD) Back to Index...
Page 196 07 AJ TO AG TO AA 2 S/WELDS (ORD) 08 AH TO AG TO AA 4 S/WELDS (ORD) 09 AJ TO AH TO AA 15 S/WELDS (ORD) Back to Index...
Page 197 10 AE TO AA 5/SD PROJ WELDS (ORD) 11 AE TO AB 7R/5L PROJ WELDS (ORD) Back to Index...
Page 198 12 AJ TO AA 1 STRUC ADH (ORD) 13 AK TO AA 3 STRUC ADH (ORD) 14 AD TO AA 1 STRUC ADH (ORD) 15 AF TO AA 1/SD STRUC ADH (ORD) 16 AK TO AA 3 STRUC ADH (ORD) Back to Index...
Page 199 DODGE NITRO HOOD ASSEMBLY SECTION AA 55360879AA PANEL – HOOD OTR AB 55360881AA PANEL – HOOD INR AC REINF – HOOD LATCH STRIKER – AD REINF – HOOD HINGE – Back to Index...
Page 200 PARTS IDENTIFICATION LEGEND, OVERVIEW 23 AA 55360879AA PANEL – HOOD OTR AB 55360881AA PANEL – HOOD INR AC REINF – HOOD LATCH STRIKER – AD REINF – HOOD HINGE – Back to Index...
Page 201 WELD LAYOUT LOCATION GUIDE Back to Index...
Page 202 01 AD TO AB 10 S/WELDS (ORD) Back to Index...
Page 203 02 AC TO AB 31 S/WELDS (ORD) Back to Index...
Page 204 06 AB TO AA 27 STRUC ADH Back to Index...
Page 205 04 AB TO AA 16 STRUC ADH Back to Index...
Page 206 05 AC TO AA 4 STRUC ADH 06 AB TO AA 1 STRUC ADH 07 AB TO AA 1 STRUC ADH Back to Index...
Page 207 WELD LOCATION OVERVIEW ZONES Back to Index...
Page 208 DODGE NITRO FRONT DOOR ASSEMBLY SECTION AF CHANNEL – FRT DOOR GLASS RT – AA PANEL – FRT DOOR INR RT – AA PANEL – FRT DOOR INR LT – AF CHANNEL – FRT DOOR GLASS LT – AB BEAM – IMPACT FRT DOOR RT –...
Page 209 PARTS IDENTIFICATION LEGEND, OVERVIEW 24 AA PANEL – FRT DOOR INR RT – AF CHANNEL – FRT DOOR GLASS RT – AF CHANNEL – FRT DOOR GLASS LT – AA PANEL – FRT DOOR INR LT – AG STUD PLATE – AB BEAM –...
Page 210 WELD LAYOUT LOCATION GUIDE Back to Index...
Page 211 01 AB TO AA 9/SD S/WELDS (SAF) 02 AC TO AA 9/SD S/WELDS (ORD) 03 AD TO AA 2/SD S/WELDS (ORD) Back to Index...
Page 212 04 AE TO AA 7/SD S/WELDS (ORD) 05 AF TO AA 15/SD S/WELDS (ORD) Back to Index...
Page 213 06 AG TO AA 2/SD S/WELDS (ORD) 07 AH TO AA 2/SD S/WELDS (ORD) 08 AJ TO AA 11/SD PROJ WELDS Back to Index...
Page 214 09 AK TO AA 1/SD STRUC ADH (ORD) Back to Index...
Page 215 10 AB TO AK 3/SD STRUC ADH (ORD) 11 AE TO AK 5/SD STRUC ADH (ORD) 12 AF TO AK 1/SD STRUC ADH (ORD) 13 AF TO AK 1/SD STRUC ADH (ORD) 14 AF TO AK 1/SD STRUC ADH (ORD) 15 AF TO AK 1/SD STRUC ADH (ORD) Back to Index...
Page 216 DODGE NITRO REAR DOOR ASSEMBLY SECTION AA PANEL – RR DOOR INR RT – AE REINF – FRT DOOR LATCH LT – AA PANEL – RR DOOR INR LT – AF STUD PLATE – AB CHANNEL – RR DOOR GLASS –...
Page 217 PARTS IDENTIFICATION LEGEND, OVERVIEW 25 AA PANEL – RR DOOR INR RT – AE REINF – FRT DOOR LATCH LT – AA PANEL – RR DOOR INR LT – AF STUD PLATE – AB CHANNEL – RR DOOR GLASS – AF STUD PLATE –...
Page 218 WELD LAYOUT LOCATION GUIDE Back to Index...
Page 219 01 AC TO AA 3/SD S/WELDS (ORD) 02 AB TO AA 17/SD S/WELDS (ORD) Back to Index...
Page 220 03 AD TO AA 5/SD S/WELDS (SAF) 04 AE TO AA 5/SD S/WELDS (ORD) 05 AE TO AA 3/SD S/WELDS (ORD) 06 AC TO AA 4/SD S/WELDS (ORD) 07 AD TO AA 4/SD S/WELDS (SAF) Back to Index...
Page 221 08 AG TO AA 2/SD S/WELDS (ORD) 09 AF TO AA 2/SD S/WELDS (ORD) 10 AH TO AA 10/SD PROJ WELDS Back to Index...
Page 222 11 AD TO AJ 2/SD STRUC ADH (ORD) 12 AC TO AJ 1/SD STRUC ADH (ORD) 13 AC TO AJ 1/SD STRUC ADH (ORD) 14 AC TO AJ 3/SD STRUC ADH (ORD) Back to Index...
Page 223 15 AJ TO AA 1/SD STRUC ADH (ORD) 16 AJ TO AA 1/SD STRUC ADH (ORD) 17 AJ TO AA 1/SD STRUC ADH (ORD) 18 AJ TO AA 1/SD STRUC ADH (ORD) Back to Index...
Page 224 DODGE NITRO LIFTGATE ASSEMBLY SECTION AA PANEL – LIFTGATE INR – AB REINF – LIFTGATE LATCH – AC NUT/WELD.RD – NO.FIN.SPECIAL – REAR WIPER AC NUT/WELD.RD – NO.FIN.SPECIAL – GRAB HANDLE AD TAPPING PLATE – LIFTGATE INR PANEL HINGE MOUNTING – HINGE MOUNTING AD TAPPING PLATE –...
Page 225 PARTS IDENTIFICATION LEGEND, OVERVIEW 26 AA PANEL – LIFTGATE INR – AB REINF – LIFTGATE LATCH – AC NUT/WELD.RD – NO.FIN.SPECIAL – REAR WIPER AC NUT/WELD.RD – NO.FIN.SPECIAL – GRAB HANDLE AD TAPPING PLATE – LIFTGATE INR PANEL HINGE MOUNTING – HINGE MOUNTING AD TAPPING PLATE –...
Page 226 WELD LAYOUT LOCATION GUIDE Back to Index...
Page 227 01 AB TO AA 16 S/WELDS (ORD) 02 AC TO AA 5 PROJ WELDS Back to Index...
Page 228 03 AD TO AA 4/SD S/WELDS (ORD) Back to Index...
Page 229 04 AE TO AA 6/SD S/WELDS (ORD) Back to Index...
Page 230 05 AE TO AA 6 STRUC ADH (ORD) 06 AE TO AA 1 STRUC ADH (ORD) 07 AE TO AA 2 STRUC ADH (ORD) Back to Index...
Page 231 08 AE TO AA 1 STRUC ADH (ORD) 09 AE TO AA 2 STRUC ADH (ORD) 10 AE TO AA 1 STRUC ADH (ORD) Back to Index...
Page 232 Back to Index...
Page 233 Deadener Locations Dodge Nitro This section shows the different locations for Sealers, Sound Deadeners and Structural Adhesives and has been pre- pared for use by all body technicians involved in the repair of Dodge Nitro. Body/Paint Sealer Locations..............Structural Adhesive Locations..............
Page 234 SEALER INFORMATION SEALER AMOUNT/BEAD SIZE 4mm DIA* X 1000mm PUMPABLE * = DIAMETER APPLICATION RECOMMENDATIONS ALL REPAIRS WHERE PANELS WERE REPLACED HAVE VOIDS THAT MUST BE FILLED WITH SEALANT. SEALANT SHOULD BE APPLIED TO ALL SKIPS, PIN HOLES, IN SEALERS AND WELD BURN THROUGH HOLES ON THE INTE- RIOR AND EXTERIOR OF TH VEHICLE THAT WOULD PERMIT LEAKAGE OF WATER, AIR OR EXHAUST FUMES.
Page 235 BODY SEALER LOCATIONS DESCRIPTION FIGURE A-PILLAR REINFORCEMENT, BODY SIDE APERTURE AND PLENUM UPPER PLENUM BAFFLE LOWER DASH, FRONT FLOOR AND COWL SIDE UPPER DASH, PLENUM AND COWL SIDE UPPER DASH, AND LOWER PLENUM DASH AND FRONT FLOOR FRONT FLOOR PAN, BODY SIDE SILL AND COWL SIDE FRONT FLOOR PAN AND REAR FLOOR PAN FLOOR PAN AND BODY SIDE SILL REAR FLOOR PAN AND REAR WHEELHOUSE...
Page 236 BODY SEALER LOCATIONS Figure 1. A-PILLAR REINFORCEMENT, BODY SIDE APERTURE AND PLENUM Back to Index...
Page 237 BODY SEALER LOCATIONS Figure 2. UPPER PLENUM BAFFLE Back to Index...
Page 238 BODY SEALER LOCATIONS Figure 3. LOWER DASH, FRONT FLOOR AND COWL SIDE Back to Index...
Page 239 BODY SEALER LOCATIONS Figure 4. UPPER DASH, PLENUM AND COWL SIDE Back to Index...
Page 240 BODY SEALER LOCATIONS Figure 5. UPPER DASH AND LOWER PLENUM Back to Index...
Page 241 BODY SEALER LOCATIONS Figure 6. DASH AND FRONT FLOOR Back to Index...
Page 242 BODY SEALER LOCATIONS Figure 7. FRONT FLOOR PAN, BODY SIDE SILL AND COWL SIDE Back to Index...
Page 243 BODY SEALER LOCATIONS Figure 8. FRONT FLOOR PAN AND REAR FLOOR PAN Back to Index...
Page 244 BODY SEALER LOCATIONS Figure 9. FLOOR PAN AND BODY SIDE SILL Back to Index...
Page 245 BODY SEALER LOCATIONS Figure 10. REAR FLOOR PAN AND REAR WHEELHOUSE Back to Index...
Page 246 BODY SEALER LOCATIONS Figure 11. BODY SIDE INNER AND REAR WHEELHOUSE INNER/OUTER Back to Index...
Page 247 BODY SEALER LOCATIONS Figure 12. REAR WHEELHOUSE OUTER AND REAR FLOOR Back to Index...
Page 248 BODY SEALER LOCATIONS Figure 13. REAR WHEELHOUSE OUTER AND BODY SIDE OUTER Back to Index...
Page 249 BODY SEALER LOCATIONS Figure 14. BODY SIDE APERTURE AND ROOF Back to Index...
Page 250 BODY SEALER LOCATIONS Figure 15. LIFTGATE DRAIN TROUGH AND BODY SIDE APERTURE Back to Index...
Page 251 BODY SEALER LOCATIONS Figure 16. TAIL LAMP MOUNTING AND BODY SIDE APERTURE Back to Index...
Page 252 BODY SEALER LOCATIONS Figure 17. TAIL LAMP CAN Back to Index...
Page 253 BODY SEALER LOCATIONS Figure 18. LIFTGATE DRAIN TROUGH AND TAIL LAMP OPENING Back to Index...
Page 254 BODY SEALER LOCATIONS Figure 20. FLOOR PAN, BODY INNER AND D-PILLAR REINFORCEMENT Back to Index...
Page 255 DODGE NITRO STRUCTURAL ADHESIVE LOCATIONS Back to Index...
Page 256 STRUCTURAL ADHESIVE LOCATION INDEX NOTE: Structural Adhesives used are a high strength epoxy and a high expansion lower strength antiflutter material. High strength epoxy is used on all areas. DESCRIPTION FIGURE SUNROOF PLENUM ASSEMBLY FLOOR PAN/DASH/PLENUM REAR FLOOR COMPLETE UNDERBODY COMPLETE (1 OF 3) UNDERBODY COMPLETE (2 OF 3) UNDERBODY COMPLETE (3 OF 3) OUTER BODY SIDE APERTURE...
Page 257 STRUCTURAL ADHESIVE LOCATIONS Figure 1. SUNROOF Back to Index...
Page 258 STRUCTURAL ADHESIVE LOCATIONS Figure 2. PLENUM ASSEMBLY Back to Index...
Page 259 STRUCTURAL ADHESIVE LOCATIONS Figure 3. FRONT FLOOR/DASH/PLENUM Back to Index...
Page 260 STRUCTURAL ADHESIVE LOCATIONS Figure 4. REAR FLOOR COMPLETE Back to Index...
Page 261 STRUCTURAL ADHESIVE LOCATIONS Figure 5. UNDERBODY COMPLETE (1 OF 3) Back to Index...
Page 262 STRUCTURAL ADHESIVE LOCATIONS Figure 6. UNDERBODY COMPLETE (2 OF 3) Back to Index...
Page 263 STRUCTURAL ADHESIVE LOCATIONS Figure 7. UNDERBODY COMPLETE (3 OF 3) Back to Index...
Page 264 STRUCTURAL ADHESIVE LOCATIONS Figure 8. OUTER BODY SIDE APERTURE Back to Index...
Page 265 STRUCTURAL ADHESIVE LOCATIONS Figure 9. BODY SIDE APERTURE COMPLETE Back to Index...
Page 266 STRUCTURAL ADHESIVE LOCATIONS Figure 10. BODY IN WHITE WITHOUT ROOF (1 OF 2) Back to Index...
Page 267 STRUCTURAL ADHESIVE LOCATIONS Figure 11. BODY IN WHITE WITHOUT ROOF (2 OF 2) Back to Index...
Page 268 STRUCTURAL ADHESIVE LOCATIONS Figure 12. BODY IN WHITE COMPLETE Back to Index...
Page 269 Dodge Nitro SOUND DEADENER LOCATIONS Back to Index...
Page 270 DODGE NITRO SOUND DEADENER LOCATIONS DESCRIPTION FIGURE FLOOR PAN (1 OF 3) FLOOR PAN (2 OF 3) FLOOR PAN (3 OF 3) DASH PANEL Back to Index...
Page 271 SOUND DEADENER LOCATIONS Figure 1. FLOOR PAN (1 OF 3) Back to Index...
Page 272 SOUND DEADENER LOCATIONS Figure 2. FLOOR PAN (2 OF 3) Back to Index...
Page 273 SOUND DEADENER LOCATIONS Figure 3. FLOOR PAN (3 OF 3) Back to Index...
Page 274 SOUND DEADENER LOCATIONS Figure 4. DASH PANEL Back to Index...
Page 275 DODGE NITRO FRAME/BODY DIMENSIONS Back to Index...
Page 276 FRAME DIMENSIONS Frame dimensions are listed in metric scale. All dimensions are from center of Principal Locating Point (PLP), or from center to center of PLP and transfer location. Vertical dimensions can be taken from the work surface to the locations indicated.
Page 277 FRAME/BODY DIMENSIONS Figure 1. PLAN VIEW Back to Index...
Page 278 FRAME/BODY DIMENSIONS Figure 2. SIDE VIEW Back to Index...
Page 279 OPENING DIMENSIONS DESCRIPTION FIGURE ENGINE BOX OPENING WINDSHIELD OPENING FRONT DOOR OPENING REAR DOOR OPENING QUARTER WINDOW OPENING LIFTGATE OPENING LIFTGATE WINDOW OPENING Back to Index...
Page 280 FRAME/BODY DIMENSIONS Figure 1. ENGINE BOX OPENING Back to Index...
Page 281 FRAME/BODY DIMENSIONS Figure 2. WINDSHIELD OPENING Back to Index...
Page 282 FRAME/BODY DIMENSIONS Figure 3. FRONT DOOR OPENING Back to Index...
Page 283 FRAME/BODY DIMENSIONS Figure 4. REAR DOOR OPENING Back to Index...
Page 284 FRAME/BODY DIMENSIONS Figure 5. QUARTER WINDOW OPENING Back to Index...
Page 285 FRAME/BODY DIMENSIONS Figure 6. LIFTGATE OPENING Back to Index...
Page 286 FRAME/BODY DIMENSIONS Figure 7. LIFTGATE WINDOW OPENING Back to Index...
Page 287 GAP AND FLUSH DIMENSIONS Back to Index...
Page 288 GAP AND FLUSH DIMENSIONS Back to Index...
Page 289 Back to Index...

Dodge NITRO Repair Manual

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Summary of Contents for Dodge NITRO

Page 2: Safety Notice

Page 9: Corrosion Protection

Page 19: Vehicle Certification Label

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