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Fiat 500 Abarth Collision Awareness Manual

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2012FFCOLLISIONINFORMATION1
COLLISIONINFORMATION
TABLEOFCONTENTS
page
COLLISIONINFORMATION
WARNING
SAFETYNOTICE..................2
USEOFHEATDURINGREPAIR.........2
SPECIFICATIONS
VEHICLEIDENTIFICATIONNUMBER.......3
STANDARDIZEDSTEELIDENTIFICATION....4
WELDPROCESS.................12
BODYOPENINGDIMENSIONS.........12
FRAMEDIMENSIONS..............19
GAPANDFLUSHDIMENSIONS.........22
PAINTCODES...................24
VEHICLECERTIFICATIONLABEL.......25
page
STANDARDPROCEDURE
SERVICEAFTERASUPPLEMENTAL
RESTRAINTDEPLOYMENT.........25
BASECOAT/CLEARCOATFINISH........28
FINESSESANDING,BUFFING,AND
POLISHING...................28
PAINTTOUCHUP.................28
DECALINSTALLATION..............29
NONSTRUCTURALSHEETMETAL
REPAIR.....................32
WELDINGANDWELDBONDING........39
SECTIONINGLOCATIONSAND
PROCEDURES.................50
BETAMATEREPLACEMENT
PROCEDURES.................59
ALUMINUMBRONZESEAMANDSLOT
WELDS.....................68
CORROSIONPROTECTION...........81
MATERIALLOCATIONS
SEALERSANDSOUNDDEADENERS.....82
SOUNDDEADENERLOCATIONS........83
STRUCTURALADHESIVE,FLEXIBLE
ADHESIVESANDSEAMSEALER
LOCATIONS...................95
2COLLISIONINFORMATION2012FF
CollisionInformation
Warning
SAFETYNOTICE
CAUTION:Allserviceandrebuildinginstructionscontainedhereinareapplicableto,andfortheconvenience
of,theautomotivetradeonly.Alltestandrepairproceduresoncomponentsorassembliesinnonautomotive
applicationsshouldberepairedinaccordancewithinstructionssuppliedbythemanufacturerofthetotalprod
uct.
Properserviceandrepairisimportanttothesafe,reliableoperationofallmotorvehicles.Theserviceproduces
recommendedanddescribedinthispublicationweredevelopedforprofessionalservicepersonnel,andareef
fectivemethodsforperformingvehiclerepair.Followingtheseprocedureswillhelpensureefficienteconomical
vehicleperformanceandservicereliability.Someserviceproceduresrequiretheuseofspecialtoolsdesigned
forspecificprocedures.Thesespecialtoolsshouldbeusedasrecommendedthroughoutthispublication.
Specialattentionshouldbeexercisedwhenworkingwithspringortensionloadedfastenersanddevicessuch
asEClips,Circlips,Snaprings,etc.,sincecarelessremovalmaycausepersonalinjury.Alwayswearsafety
goggleswhenworkingonvehiclesorvehiclecomponents.
ItisimportanttonotethatthispublicationcontainsvariousCautionsandWarnings.Theseshouldbereadcare
fullyinordertominimizeriskofpersonalinjuryorthepossibilitythatimproperservicemethodsmaydamage
thevehicleorrenderitunsafe.ItisimportanttonotethattheseCautionsandWarningscoveronlythesituations
andproceduresChryslerGroupLLChasencounteredandrecommended.ChryslerGroupLLCcannotpossibly
know,evaluate,andadvisetheservicetradeofallconceivablewaysinwhichservicemaybeperformed,orof
thepossiblehazardsofeach.Consequently,ChryslerGroupLLChasnotundertakenanysuchbroadservice
review.Accordingly,anyoneusesaserviceprocedureortoolthatisnotrecommendedinthispublicationmust
becertainthatneitherpersonalsafety,norvehiclesafety,willbejeopardizedbytheservicemethodstheyselect.
USEOFHEATDURINGREPAIR
WARNING:ChryslerGroupLLCengineering’spositionontheuseofheatduringcollisionrepairisasfollows:
•Anybodypanelorframecomponentdamagedwhichistoberepairedandreused,mustberepairedusing
the“coldstraightening”method.Noheatmaybeusedduringthestraighteningprocess.
•Duringroughstraighteningpriortopanelreplacement,damagedpanelsorframecomponentsmaybeheated
toassistinbody/framerealignment.Theapplicationofheatmustbeconstrainedtothepartswhichwillbe
replacedandnotallowedtoaffectanyothercomponents.
This“noheat”recommendationisduetotheextensiveuseofhighstrengthandadvancedhighstrengthsteels
inChryslerGroupLLCproducts.Highstrengthmaterialscanbesubstantiallyandnegativelyaffectedfromheat
inputwhichwillnotbeobviouslyknowntotherepairerorconsumer.
Ignoringtheserecommendationsmayleadtoseriouscompromisesintheabilitytoprotectoccupantsinafuture
collisionevent,reducetheengineeredqualitiesandattributes,ordecreasethedurabilityandreliabilityofthe
vehicle.
ThisstatementsupersedesanypreviouslyreleasedinformationbytheChryslerGroupLLC.
Failuretofollowtheseinstructionsmayresultinseriousorfatalinjury.
2012FFCOLLISIONINFORMATION3
Specifications
VEHICLEIDENTIFICATIONNUMBER
TheVehicleIdentificationNumber(VIN)label(1)is
attachedtothetopleftsideoftheinstrumentpanel.The
VINcontains17charactersthatprovidedataconcerning
thevehicle.Refertothedecodingcharttodeterminethe
identificationofavehicle.
Toprotecttheconsumerfromtheftandpossiblefraudthe
manufacturerisrequiredtoincludeaCheckDigitatthe
ninthpositionoftheVehicleIdentificationNumber.The
checkdigitisusedbythemanufacturerandgovernment
agenciestoverifytheauthenticityofthevehicleandoffi
cialdocumentation.Theformulatousethecheckdigitis
notreleasedtothegeneralpublic.
VEHICLEIDENTIFICATIONNUMBERDECODINGCHART
NOTE:
•ASP=AllSeatingPositions
•OSP=OutboardseatingPositions
POSITIONINTERPRETATIONCODE=DESCRIPTION
1,2,3
WMI(WorldManufacturerIdentifier)3C3ChryslerMexico
A=ActiveBelts(ASP)FrontAirBags(OSP)
WithoutSideInflatableRestraints
B=ActiveBelts(ASP)FrontAirBags(OSP)With
SideInflatableRestraintsFrontRow
4
RestraintSystem
C=ActiveBelts(ASP)FrontAirBags(OSP)With
SideInflatableRestraintsAllRows
FFA=500Pop,LeftHandDrive,FrontWheel
Drive,2DoorHatchback
FFB=500Sport,LeftHandDrive,FrontWheel
Drive,2DoorHatchback
FFC=500Lounge,LeftHandDrive,FrontWheel
Drive,2DoorHatchback
FFF=500Abarth,LeftHandDrive,FrontWheel
Drive,2DoorHatchback
FFD=500Pop,LeftHandDrive,FrontWheel
Drive,2DoorConvertible
5,6,7
VehicleLine,Series,BodyType
FFE=500Lounge,LeftHandDrive,FrontWheel
Drive,2DoorConvertible
H=1.4L4CYLGasolineTurbo(EAF)
8Engine
R=1.4L4CYLGasolineNonTurbo(EAB,
EAC,EAE,EAJ,EAK)
4COLLISIONINFORMATION2012FF
VEHICLEIDENTIFICATIONNUMBERDECODINGCHART ,continued
POSITIONINTERPRETATIONCODE=DESCRIPTION
9
CheckDigit
0through9orX
10ModelYear
C=2012
11AssemblyPlantT=T olucaAssembly
12thru17
VehicleBuildSequence
6DigitNumberAssignedbyAssemblyPlant
STANDARDIZEDSTEELIDENTIFICATION
Inanefforttoreduceconfusionoverthelargenumberofsteelgradesinuse,andtherepairabilityandweldabilitycon
cernsinvolvedwitheach,ChryslerGroupLLChasinstitutednewnomenclaturewhichisapplicabletomaterialcallouts
andBIWexplodedviewsreleasedforuseintherepairindustry.
Allmaterialslistedinthekeymaynotbeusedonagivenmodel,normayeverypanelbeidentifiedintheblowup(ex:
somegroupsdonotshowfascias).
WARNING:ChryslerGroupLLCengineering’spositionontheuseofheatduringcollisionrepairisasfollows:
•Anybodypanelorframecomponentdamagedwhichistoberepairedandreused,mustberepairedusing
the“coldstraightening”method.Noheatmaybeusedduringthestraighteningprocess.
•Duringroughstraighteningpriortopanelreplacement,damagedpanelsorframecomponentsmaybeheated
toassistinbody/framerealignment.Theapplicationofheatmustbeconstrainedtothepartswhichwillbe
replacedandnotallowedtoaffectanyothercomponents.
This“noheat”recommendationisduetotheextensiveuseofhighstrengthandadvancedhighstrengthsteels
inChryslerGroupLLCproducts.Highstrengthmaterialscanbesubstantiallyandnegativelyaffectedfromheat
inputwhichwillnotbeobviouslyknowntotherepairerorconsumer.
Ignoringtheserecommendationsmayleadtoseriouscompromisesintheabilitytoprotectoccupantsinafuture
collisionevent,reducetheengineeredqualitiesandattributes,ordecreasethedurabilityandreliabilityofthe
vehicle.
ThisstatementsupersedesanypreviouslyreleasedinformationbytheChryslerGroupLLC.
Failuretofollowtheseinstructionsmayresultinseriousorfatalinjury.
NOTE:Corrosionprotectionmustberestoredafterrepair.
•LSGoodrepairabilityandweldability(leastsensitive
toheat).MaybeattachedusingthepreferredSqueeze
TypeResistanceSpotWelding(STRSW)process,weld
bondingwhereappropriate,orMIGwelding.Materials
haveatensilestrengthoflessthan270MPa.
•HSSomerepairabilityandgoodweldability(thehigher
thestrengthofthesteel,thegreaterthesensitivityto
heat).MaybeattachedusingSTRSW,weldbonding,
andMIGwelding.Materialtensilestrengthrangebe
tween270MPaand600MPaandincludesDP590.
•VHSVerylimitedrepairabilityandweldability(very
sensitivetoheat).AttachonlyatOEdefinedlocations
usingOEdefinedprocedures.Materialtensile
strengthsaregreaterthan600MPa.Thiscategory
includeshotstampedboronmaterialswhicharealso
termed“presshardened.”Specializedcuttersare
requiredwithmanymaterialsinthisgroup.
•LMGoodrepairabilityandweldability.Maybe
attachedusingSTRSW,weldbonding,andFluxCore
ArcWelding(FCAW).
•ALStampedaluminumsheetmetalpanelsmaybere
pairablewithspecializedtoolsandtechniques.
•MGMagnesiumnorepairability,replacementcomponentsonly.
2012FFCOLLISIONINFORMATION5
•PLandPLRSomerepairabilitydependinguponthetypeofplasticinvolved,thedegreeofdamage,andthecom
ponentfunction.Cosmeticcomponentssuchasfascias(PL)haveahigherdegreeofrepairallowedthanthosecom
ponentswhichcancarrycomponentsandloads.WherePLRcomponentsarebondedtosteelstructure,Chrysler
GroupLLCwillidentifytheproperadhesivetoattachthereplacementpanel.RepairmaterialsforPLarecommonly
availableinthecollisionrepairmarket.
•COCompositematerialsmaybefiberreinforced(ex:Kevlar)panelsorcomoldedassembliesofsteelandplastic.
Anyoftheserequirespecializedrepairmaterialsandprocesses.
AdditionalinformationonsectioningofcomponentswillalsobeidentifiedinpublicationssuchastheChryslerGroupLLC
NonStructuralSheetMetalRepairGuide(813160610)andStructuralSectioningGuide(813160859).
CALLOUTKEYDESCRIPTIONCOLOR
LSLowStrengthSteel
Black
HSHighStrengthSteelGreen
VHSVeryHighStrengthSteel
Red
LM
LaminatedSteelGrey
AL
SheetAluminium
Purple
MG
MagnesiumBrown
PLPlasticBlue
PLR
FiberReinforcedPlastic
Purple
COCompositeMaterial
Blue
6COLLISIONINFORMATION2012FF
Fig.1BODYINWHITECOMPONENTIDENTIFICATIONENGINEBOX/FRONTEND
2012FFCOLLISIONINFORMATION7
Fig.2BODYINWHITECOMPONENTIDENTIFICATIONDASH/COWL
8COLLISIONINFORMATION2012FF
Fig.3BODYINWHITECOMPONENTIDENTIFICATIONBODYSIDEAPERTURE
2012FFCOLLISIONINFORMATION9
Fig.4BODYINWHITECOMPONENTIDENTIFICATIONFLOOR
10COLLISIONINFORMATION2012FF
Fig.5BODYINWHITECOMPONENTIDENTIFICATIONROOF
2012FFCOLLISIONINFORMATION11
Fig.6BODYINWHITECOMPONENTIDENTIFICATIONREAREND
12COLLISIONINFORMATION2012FF
WELDPROCESS
COMPONENTPARTSTRUCKFRAMEBODYSHELLEXTERIOR&UNDERBODYPANELS
ZincandZincIronAlloycoatedsheetsteels
WELDINGPROCESSGASMETAL
ARC
(Note:1)
FLUX
CORED
ARC
GASMETAL
ARC
(Note:1)
MIGBRAZE
(Note:2)
GASMETAL
ARC
(Note:1)
FLUX
CORED
ARC
MaterialType
HighStrengthandStructuralQualitySteelswhichincludesHSLA,Marten
sitic,andDualPhasematerials
MaterialThickness
Range
2mm4mm0.6mm1.02mm>1.02mm3.0mm
ELECTRODETYPE
(AWSSPEC.A5.18)
AWS
CLASS.
ER70S6
AWS
CLASS.
E71T11
(Note3)
AWS
CLASS.
ER70S6
AWS
CLASS.
ERCuSi
ASilicon
Bronze
AWS
CLASS.
ER70S6
AWS
CLASS.
E71T11
(Note3)
ELECTRODESIZE
0.0350.0450.0230.0250.0350.0350.045
ELECTRODEMAKERLincoln®Lincoln®
NR211MP
Lincoln®Lincoln®Lincoln®
NR211MP
WIREFEEDSPEED
(in/min)
245250
Vertical
Down
110Vertical
Down
95115All
Welds
150155Flat
&Horizontal
245250
Vertical
Down
110Vertical
Down
7090Flat&
Horizontal
7090Flat&
Horizontal
7090Flat&
Horizontal
7090Flat&
Horizontal
TRAVELSPEED
(in/min)
10
VOLTAGE
192015181619181919201518
POLARITYDCEPDCENDCEPDCEPDCEPDCEN
GASFLOW(cfh)
2535
N/A
253525352535
N/A
ELECTRICAL
STICKOUT(in)
1/25/83/81/21/25/85/83/41/25/83/81/2
GASTYPE75%ArN/A75%Ar100%Ar75%ArN/A
25%CO225%CO225%CO2
TYPEOFARC
TRANSFER
ShortCircuitShortCircuit
Pulse
ShortCircuit
TheseProcedureSpecificationsareappropriateasofthispublication.Proceduresmaybesuperceededwithnewspec's
atalaterdate.
Alwaysprocesstothethinnermaterialthickness(TMT)
Allpersonsperformingweldingmustbequalifiedtoweldinallpositions.
NOTE:
1.MustremoveZincCoatingonbothsidesofmetalattheweldzone.
2.MIGBrazeweldingprocessrequiresuseofPulseArc®orSTT®weldingmachine.
3.MustuseLincoln®productsinceE71T11productdiffersfromothersuppliers.
BODYOPENINGDIMENSIONS
NOTE:Bodyopeningdimensionsarelistedinmetricscalemillimeter(mm).PrincipalLocatingPoints(PLP),
fastenerlocations,andholesaremeasuredtocenter,unlessnotedotherwise.
2012FFCOLLISIONINFORMATION13
VEHICLEPREPARATION
Positionthevehicleonalevelworksurface.Removeanyweatherstrips,doorstrikersoranyotherpartsthatmayinter
ferewiththereferencepoint.
DESCRIPTIONFIGURE
WINDSHIELDOPENING(Fig.7)
BODYSIDEAPERTUREOPENINGS(Fig.8)
SUNROOFOPENING(500)(Fig.9)
ROOFOPENING(CABRIO)1of2(Fig.10)
ROOFOPENING(CABRIO)2of2(Fig.11)
LIFTGATEOPENING(500)(Fig.12)
DECKLIDOPENING(CABRIO)(Fig.13)
Fig.7WindshieldOpening
14COLLISIONINFORMATION2012FF
Fig.8BodySideOpening
2012FFCOLLISIONINFORMATION15
Fig.9SunroofOpening
16COLLISIONINFORMATION2012FF
Fig.10CabrioRoofOpening(1of2)
2012FFCOLLISIONINFORMATION17
Fig.11CabrioRoofOpening(2of2)
18COLLISIONINFORMATION2012FF
Fig.12LiftgateOpening(500)
2012FFCOLLISIONINFORMATION19
Fig.13DeckLidOpening(Cabrio)
FRAMEDIMENSIONS
NOTE:Framedimensionsarelistedinmetricscalemillimeter(mm).Alldimensionsarefromcentertocenter
ofPrincipalLocatingPoint(PLP),orfromcentertocenterofPLPandfastenerlocation.
VEHICLEPREPARATION
Positionthevehicleonalevelworksurface.Usingscreworbottlejacks,adjustthevehiclePLPheightstothespecified
dimensionabovealevelworksurface.Verticaldimensionscanbetakenfromtheworksurfacetothelocationsindicated
wereapplicable.
INDEX
DESCRIPTIONFIGURE
UnderBodyDimensions
(Fig.14)
UnderHood
(Fig.15)
NOTE:Underbodycrossandlengthpointtopointmeasurementsaretakenfromanevenplane(plum).
20COLLISIONINFORMATION2012FF
Fig.14UnderbodyDimensions
/