Fiat 500 Abarth Collision Awareness Manual

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)3C3ChryslerMexico

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.

•LSGoodrepairabilityandweldability(leastsensitive

toheat).MaybeattachedusingthepreferredSqueeze

TypeResistanceSpotWelding(STRSW)process,weld

bondingwhereappropriate,orMIGwelding.Materials

haveatensilestrengthoflessthan270MPa.

•HSSomerepairabilityandgoodweldability(thehigher

thestrengthofthesteel,thegreaterthesensitivityto

heat).MaybeattachedusingSTRSW,weldbonding,

andMIGwelding.Materialtensilestrengthrangebe

tween270MPaand600MPaandincludesDP590.

•VHSVerylimitedrepairabilityandweldability(very

sensitivetoheat).AttachonlyatOEdeﬁnedlocations

usingOEdeﬁnedprocedures.Materialtensile

strengthsaregreaterthan600MPa.Thiscategory

includeshotstampedboronmaterialswhicharealso

termed“presshardened.”Specializedcuttersare

requiredwithmanymaterialsinthisgroup.

•LMGoodrepairabilityandweldability.Maybe

attachedusingSTRSW,weldbonding,andFluxCore

ArcWelding(FCAW).

•ALStampedaluminumsheetmetalpanelsmaybere

pairablewithspecializedtoolsandtechniques.

•MGMagnesiumnorepairability,replacementcomponentsonly.

2012FFCOLLISIONINFORMATION5

•PLandPLRSomerepairabilitydependinguponthetypeofplasticinvolved,thedegreeofdamage,andthecom

ponentfunction.Cosmeticcomponentssuchasfascias(PL)haveahigherdegreeofrepairallowedthanthosecom

ponentswhichcancarrycomponentsandloads.WherePLRcomponentsarebondedtosteelstructure,Chrysler

GroupLLCwillidentifytheproperadhesivetoattachthereplacementpanel.RepairmaterialsforPLarecommonly

availableinthecollisionrepairmarket.

•COCompositematerialsmaybeﬁberreinforced(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.1BODYINWHITECOMPONENTIDENTIFICATIONENGINEBOX/FRONTEND

2012FFCOLLISIONINFORMATION7

Fig.2BODYINWHITECOMPONENTIDENTIFICATIONDASH/COWL

8COLLISIONINFORMATION2012FF

Fig.3BODYINWHITECOMPONENTIDENTIFICATIONBODYSIDEAPERTURE

2012FFCOLLISIONINFORMATION9

Fig.4BODYINWHITECOMPONENTIDENTIFICATIONFLOOR

10COLLISIONINFORMATION2012FF

Fig.5BODYINWHITECOMPONENTIDENTIFICATIONROOF

2012FFCOLLISIONINFORMATION11

Fig.6BODYINWHITECOMPONENTIDENTIFICATIONREAREND

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

2mm4mm0.6mm1.02mm>1.02mm3.0mm

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

0.0350.0450.0230.0250.0350.0350.045

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)

1/25/83/81/21/25/85/83/41/25/83/81/2

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

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Fiat 500 Abarth Collision Awareness Manual

Fiat 500 Abarth Collision Awareness Manual

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