Fiat 500 Collision Awareness Manual
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Fiat 500 Collision Awareness Manual

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See also: Workshop Manual , Owner's Manual
2012 FF
SAFETY NOTICE . . . . . . . . . . . . . . . . . . 2
USE OF HEAT DURING REPAIR . . . . . . . . . 2
WELD PROCESS . . . . . . . . . . . . . . . . . 12
BODY OPENING DIMENSIONS . . . . . . . . . 12
FRAME DIMENSIONS . . . . . . . . . . . . . . 19
GAP AND FLUSH DIMENSIONS. . . . . . . . . 22
PAINT CODES . . . . . . . . . . . . . . . . . . . 24
COLLISION INFORMATION

TABLE OF CONTENTS

page
COLLISION INFORMATION
RESTRAINT DEPLOYMENT . . . . . . . . . 25
BASECOAT/CLEARCOAT FINISH . . . . . . . . 28
POLISHING . . . . . . . . . . . . . . . . . . . 28
PAINT TOUCH­UP. . . . . . . . . . . . . . . . . 28
DECAL INSTALLATION . . . . . . . . . . . . . . 29
REPAIR . . . . . . . . . . . . . . . . . . . . . 32
WELDING AND WELD BONDING . . . . . . . . 39
PROCEDURES . . . . . . . . . . . . . . . . . 50
PROCEDURES . . . . . . . . . . . . . . . . . 59
WELDS . . . . . . . . . . . . . . . . . . . . . 68
CORROSION PROTECTION . . . . . . . . . . . 81
SOUND DEADENER LOCATIONS. . . . . . . . 83
LOCATIONS. . . . . . . . . . . . . . . . . . . 95
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  • Page 1: Table Of Contents

    2012 FF COLLISION INFORMATION COLLISION INFORMATION TABLE OF CONTENTS page page COLLISION INFORMATION STANDARD PROCEDURE WARNING SERVICE AFTER A SUPPLEMENTAL SAFETY NOTICE ....2 RESTRAINT DEPLOYMENT .

  • Page 2: Collision Information Warning Safety Notice

    2 COLLISION INFORMATION 2012 FF Collision Information Warning 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 non­automotive applications should be repaired in accordance with instructions supplied by the manufacturer of the total prod­...

  • Page 3: Specifications Vehicle Identification Number

    Side Inflatable Restraints Front Row C = Active Belts (ASP) Front Air Bags (OSP) With Side Inflatable Restraints All Rows FFA = 500 Pop, Left Hand Drive, Front Wheel Drive, 2 Door Hatchback FFB = 500 Sport, Left Hand Drive, Front Wheel...

  • Page 4: Standardized Steel Identification

    4 COLLISION INFORMATION 2012 FF VEHICLE IDENTIFICATION NUMBER DECODING CHART, continued POSITION INTERPRETATION CODE = DESCRIPTION Check Digit 0 through 9 or X Model Year C = 2012 Assembly Plant T = Toluca Assembly 12 thru 17 Vehicle Build Sequence 6 Digit Number Assigned by Assembly Plant STANDARDIZED STEEL IDENTIFICATION In an effort to reduce confusion over the large number of steel grades in use, and the repairability and weldability con­...
  • Page 5 2012 FF COLLISION INFORMATION • PL and PL­R ­ Some repairability depending upon the type of plastic involved, the degree of damage, and the com­ ponent function. Cosmetic components such as fascias (PL) have a higher degree of repair allowed than those com­ ponents which can carry components and loads.
  • Page 6 Fig. 1 BODY IN WHITE COMPONENT IDENTIFICATION ­ ENGINE BOX/FRONT END...
  • Page 7 Fig. 2 BODY IN WHITE COMPONENT IDENTIFICATION ­ DASH/COWL...
  • Page 8 Fig. 3 BODY IN WHITE COMPONENT IDENTIFICATION ­ BODY SIDE APERTURE...
  • Page 9 Fig. 4 BODY IN WHITE COMPONENT IDENTIFICATION ­ FLOOR...
  • Page 10 Fig. 5 BODY IN WHITE COMPONENT IDENTIFICATION ­ ROOF...
  • Page 11 Fig. 6 BODY IN WHITE COMPONENT IDENTIFICATION ­ REAR END...

  • Page 12: Weld Process

    12 COLLISION INFORMATION 2012 FF WELD PROCESS COMPONENT PARTS TRUCK FRAME BODYSHELL EXTERIOR & UNDERBODY PANELS Zinc and Zinc Iron Alloy coated sheet steels WELDING PROCESS GAS METAL FLUX GAS METAL MIG BRAZE GAS METAL FLUX CORED CORED (Note: 2) (Note: 1) (Note: 1) (Note: 1)
  • Page 13 DESCRIPTION FIGURE WINDSHIELD OPENING (Fig. 7) BODY SIDE APERTURE OPENINGS (Fig. 8) SUNROOF OPENING (500) (Fig. 9) ROOF OPENING (CABRIO) 1 of 2 (Fig. 10) ROOF OPENING (CABRIO) 2 of 2 (Fig. 11) LIFTGATE OPENING (500) (Fig.
  • Page 14 14 COLLISION INFORMATION 2012 FF Fig. 8 Body Side Opening...
  • Page 15 2012 FF COLLISION INFORMATION Fig. 9 Sunroof Opening...
  • Page 16 16 COLLISION INFORMATION 2012 FF Fig. 10 Cabrio Roof Opening (1 of 2)
  • Page 17 2012 FF COLLISION INFORMATION Fig. 11 Cabrio Roof Opening (2 of 2)
  • Page 18 18 COLLISION INFORMATION 2012 FF Fig. 12 Liftgate Opening (500)

  • Page 19: Frame Dimensions

    2012 FF COLLISION INFORMATION Fig. 13 Deck Lid Opening (Cabrio) FRAME DIMENSIONS NOTE: Frame dimensions are listed in metric scale millimeter (mm). All dimensions are from center to center of Principal Locating Point (PLP), or from center to center of PLP and fastener location. VEHICLE PREPARATION Position the vehicle on a level work surface.
  • Page 20 20 COLLISION INFORMATION 2012 FF Fig. 14 Underbody Dimensions...
  • Page 21 2012 FF COLLISION INFORMATION Fig. 15 Under Hood Dimensions...

  • Page 22: Gap And Flush Dimensions

    22 COLLISION INFORMATION 2012 FF GAP AND FLUSH DIMENSIONS...
  • Page 23 2012 FF COLLISION INFORMATION NOTE: All measurements are in millimeters. O/F = Over Flush U/F = Under Flush U/D = Up/Down F/A = Fore/Aft DIMENSION DESCRIPTION FLUSH Hood to Facia 4.0+/­ 1.0 Facia U/F 2.0+/­ 1.0 Parallel within 1.0 Fender to Hood 4.0+/­...

  • Page 24: Paint Codes

    24 COLLISION INFORMATION 2012 FF NOTE: All measurements are in millimeters. O/F = Over Flush U/F = Under Flush U/D = Up/Down F/A = Fore/Aft DIMENSION DESCRIPTION FLUSH Parallel within 1.5 Except 4.0 @ extreme sides Light Bar to Liftgate 0.0+/­...

  • Page 25: Vehicle Certification Label

    2012 FF COLLISION INFORMATION VEHICLE CERTIFICATION LABEL A vehicle certification label is attached to every Chrysler Group LLC vehicle. The label certifies that the vehicle con­ forms to all applicable Federal Motor Vehicle Standards. The label also lists: • Month and year of vehicle manufacture. •...
  • Page 26 26 COLLISION INFORMATION 2012 FF inspection. All other vehicle components should be closely inspected following any SRS component deployment, but are to be replaced only as required by the extent of the visible damage incurred. SQUIB CIRCUIT WIRING REPAIRS In addition to the preceding guidelines, be aware that the heat created by the initiator during an airbag or tensioner deployment will cause collateral damage to the connected wiring (squib circuits) and connector insulators.
  • Page 27 2012 FF COLLISION INFORMATION AIRBAG SQUIB STATUS IF THE ACTIVE DTC IS: CONDITIONS SQUIB STATUS Driver or Passenger Squib 1 AND Driver or Passenger Squib 2 open is NOT Squib 1 was used; Squib 2 is open an active code live.

  • Page 28: Basecoat/Clearcoat Finish

    28 COLLISION INFORMATION 2012 FF BASECOAT/CLEARCOAT FINISH The original equipment paint finish is a multi step process that involves cleaning, applying electro de­position (E­coat), anti­chip primer, basecoat, and clearcoat steps. CAUTION: Do not use abrasive chemicals, abrasive compounds or harsh alkaline based cleaning solvents on the painted surfaces of a vehicle.

  • Page 29: Decal Installation

    2012 FF COLLISION INFORMATION DECAL INSTALLATION Pre­Decal Application CAUTION: Dirt and defects located in the decal application area will adversely effect appearance and adhesion of the decal(s) NOTE: Vehicle body must be at least 21° C (70° F) during application process 1.
  • Page 30 30 COLLISION INFORMATION 2012 FF 3. Mix a 1/2 gallon water with 1/8 teaspoon dish soap and pour into spray bottle, this will be used as the de­ cal application solution. 4. With the use of the spray bottle (1), wet the vehicle surface area (2) with decal application solution.
  • Page 31 2012 FF COLLISION INFORMATION 12. With the use of a small squeegee (1), or equivalent start at the center of the decal and fan out to the edges using firm overlapping strokes. Repeat until entire de­ cal section area has been completed. NOTE: Extra care should be taken while removing the premask in pointed areas of the decal, as the corners may want to lift...

  • Page 32: Non­structural Sheet Metal Repair

    32 COLLISION INFORMATION 2012 FF 20. Use the squeegee (1) at the outer edge of the bubble to work the edges of the bubble slightly inward. Con­ tinue around the edges, moving the bubble gradually toward the center, until the center pin hole has been reached.
  • Page 33 2012 FF COLLISION INFORMATION NOTE: Structural adhesives that meet Chrysler Group LLC's approved replacement materials specifications include ­ Mopar #05083855AA, Fusor 112B and 3M 08116 Adhesive Types: • Acrylic Adhesives ­ Bond all types of bare metals and are excellent for cross bonding aluminum to steel. They have good NVH (Noise Vibration Harshness) properties and some offer anti­corrosion properties, so primers on bare metals are not necessary.
  • Page 34 34 COLLISION INFORMATION 2012 FF NOTE: Refer to the structural adhesives manufacturer for information on work, handling and curing times. 7. Apply a 10 ­ 13mm. (3/8 ­ 1/2in.) bead of structural adhesive to the bare metal mating surfaces of the backer panels. Evenly apply the adhesive over the complete bonding surface.
  • Page 35 2012 FF COLLISION INFORMATION Preparation: 1. Belt cut skins will require determining and cutting of the sectioning locations on the original panel and on the replacement panel. 2. Remove the door skin by grinding the outer edge (C) until the seam is perforated. 3.
  • Page 36 36 COLLISION INFORMATION 2012 FF 19. Weld the butt­joint with GMAW (Gas Metal Arc Welding), if a belt cut was used. Clean and dress welds accordingly. 20. Apply fiber­reinforced waterproof body filler to the section seam, as necessary. When cured sand and apply con­ ventional body filler and block sand.
  • Page 37 2012 FF COLLISION INFORMATION Fig. 17 Body Side Aperture 1 ­ SECTION JOINT WITH BACKER PANEL 2 ­ WELD BONDING (AREAS WHERE ACCESSIBLE) 3 ­ BODY SIDE APERTURE Preparation: NOTE: Be certain vehicle is evenly supported at normal suspension points. 1.
  • Page 38 38 COLLISION INFORMATION 2012 FF 9. With the aid of an assistant, dry fit the panel. Apply clamps to hold panel in place, making note of locations. Install screws where accessibility prohibits the use of clamps. This will aid in proper alignment during installation. 10.

  • Page 39: Welding And Weld Bonding

    2012 FF COLLISION INFORMATION WELDING AND WELD BONDING Safety Notice CAUTION: All Service and rebuilding instructions contained herein are applicable to, and for the convenience of, the automotive repair industry only. The service procedures recommended and described in this publication were developed for professional service per­ sonnel, and are effective methods for performing vehicle repair.
  • Page 40 40 COLLISION INFORMATION 2012 FF Panel Removal WARNING: Always Wear Safety Goggles, Work Gloves, Hearing Protection and a Dust Mask when removing welded panels this way. Failure to follow these instructions could result in serious or fatal injury. When removing panels and components for replacement, care must be taken not to damage the underlying component. On welded and "Weld Bonded"...
  • Page 41 2012 FF COLLISION INFORMATION The repair joint is a combination lap­joint (1) and butt­joints (2) – the panels are lapped in the flat areas and butted in contoured locations and at weld flanges. The graphic bet­ ter illustrates this process. Fig.
  • Page 42 42 COLLISION INFORMATION 2012 FF Plug Weld Layout 1 ­ MIG PLUG WELDS 2 ­ MIG SEAM WELD The MIG plug welds, or "puddle welds" should be made after drilling 8 mm (5/16 in) holes and should be staggered 12.5 mm (0.5 in) apart following the centerline of the lap and should be alternating above and below the centerline 9.5 mm (3/8 in.).
  • Page 43 2012 FF COLLISION INFORMATION • GMAW is an arc welding process where the electrode wire is fed through a weld gun and is surrounded by a shielding gas. The term MIG comes from early uses on aluminum where argon was used as shielding gas and the process was referred to as Metal Inert Gas welding.
  • Page 44 44 COLLISION INFORMATION 2012 FF Preparation CAUTION: All NVH foam must be removed from the repair area of the vehicle, as material is flammable. • Prior to making repairs with STRSW, weld coupons must be created for testing. The test joint must be an exact duplicate of the original joint, including layering and adhesive application.
  • Page 45 2012 FF COLLISION INFORMATION Weld Process, continued COMPONENT PARTS TRUCK FRAME BODY SHELL EXTERIOR & UNDERBODY PANELS WIRE FEED SPEED 245­250 110 Vertical 95­115 All 150­155 Flat 245­250 110 Vertical (in/min) Vertical Down Welds & Horizontal Vertical Down Down Down 70­90 Flat &...
  • Page 46 46 COLLISION INFORMATION 2012 FF Application • Weld bonding is the STRSW welding process utilizing structural adhesive between the panels that are resistance welded together. The adhesive creates a very stiff structure, while the welding eliminates concerns of the adhesives' peel strength.
  • Page 47 2012 FF COLLISION INFORMATION Same Current Level Used For Both Welds Fig. 20 Current Level Low for Both Welds 1­ STRUCTURAL ADHESIVE 2 ­ WELD TOO SMALL 3 ­ WELD NON­EXISTENT Fig. 21 Current Level Medium for Both Welds 1 ­ STRUCTURAL ADHESIVE 2 ­...
  • Page 48 48 COLLISION INFORMATION 2012 FF Fig. 22 Current Level High for Both Welds 1 ­ STRUCTURAL ADHESIVE 2 ­ WELD HAS HEAVY EXPULSION OF METAL AND SURFACE MARKINGS 3 ­ WELD CORRECT SIZE Current Level Adjusted to Provide Acceptable Welds Fig.
  • Page 49 2012 FF COLLISION INFORMATION Fig. 24 Current Level Medium for Both Welds 1 ­ STRUCTURAL ADHESIVE 2 ­ WELD CORRECT SIZE 3 ­ WELD TOO SMALL 1. Select the proper spot welding "arm" which provides the best access to the areas of the vehicles where the spot welds are to be made.

  • Page 50: Sectioning Locations And Procedures

    50 COLLISION INFORMATION 2012 FF Final Weld Preparation CAUTION: All NVH foam must be removed from the repair area of the vehicle, as material is flammable. 1. Visually verify that mating flanges are free of scale, rust, dirt, paint and cured adhesives/sealers, as well as wrinkles. If cracked, wrinkled or scored metal exists the condition needs to be corrected at this time.
  • Page 51 Service assemblies for body components may be disassembled if utilization of the subcomponents is more appropriate to the repair or to reduce vehicle disruption. The structural and non­structural metal on the Fiat 500 (FF) may be sectioned in several areas providing the prescribed methods below are adhered to.
  • Page 52 52 COLLISION INFORMATION 2012 FF Upper Load Path Beam Fig. 26 Upper Load Path Beam NOTE: Right side shown, left side typical 1 ­ OUTER LOAD PATH BEAM 2 ­ INNER LOAD PATH BEAM 3 ­ COWL TAB (DO NOT CUT) 4 ­...
  • Page 53 2012 FF COLLISION INFORMATION On the inner area of the Inner Load Path Beam (2) cut along the sectioning cut line (4), once again using care not to damage the Cowl Tab. Cut the replacement part in the same location. A Butt­joint with Mig seam weld is to be used for the sectioning joint Front Frame Rail Fig.
  • Page 54 54 COLLISION INFORMATION 2012 FF 3 ­ REMOVE SPOT WELDS AFT 4 ­ SECTIONING CUT LINE (FRONT RAIL LOWER OUTER) Remove the spot welds that join the Reinforcement Bracket (2) to the Lower Rail Outer (1). Remove spot welds from point of reference (3) to the cut line (4).
  • Page 55 2012 FF COLLISION INFORMATION NOTE: The Cowl Side Hinge Pillar area is dedicated to where it is to be sectioned, as compared to the general locations within the outlined areas. Collision Information SIDE APERTURE (OUTER) 2 ­ OUTER COWL SIDE HINGE PILLAR SECTIONING LOCATION The body side aperture has many areas in which it may be sectioned in.
  • Page 56 56 COLLISION INFORMATION 2012 FF Cowl Side Reinforcement Fig. 29 Cowl Side Reinforcement 1 ­ A­PILLAR CUT LINE 2 ­ ROCKER PANEL CUT LINE 3 ­ COWL SIDE REINFORCEMENT When replacing the Cowl Side Reinforcement (3) it will be necessary to cut the outer A­pillar (1) high enough and cut the Rocker Panel (2) back far enough to access to the Cowl Side Reinforcement (3).
  • Page 57 2012 FF COLLISION INFORMATION Rear Floor Fig. 30 Rear Floor Section 1 ­ REAR FLOOR 2 ­ DRAWN LINE / SERVICE FLOOR PAN CUT LINE 3 ­ ORIGINAL FLOOR PAN CUT LINE 1. Draw a line (2) on the original and replacement floor pan, where indicated in the above diagram. 2.
  • Page 58 58 COLLISION INFORMATION 2012 FF Rear Rail CAUTION: Care must be taken to cut only through the Outer Rail. Do not cut into the Inner Reinforcement which is located directly beneath the Rear Outer Rail 1 ­ RIGHT REAR RAIL 2 ­...

  • Page 59: Betamate Replacement Procedures

    Weld and Weld Bonding section, (Refer to Collision Information ­ Standard Procedure). DESCRIPTION INFORMATION Sill Reinforcement / Rocker Sill Reinforcement / Rocker Center Roof Bow (500 Only) Center Roof Bow (500) B­pillar Inner Reinforcement / B­Pillar Outer Reinforcement Inner B­pillar Reinforcement / Outer B­pillar Reinforcement Quarter Panel Extension / B­pillar...
  • Page 60 60 COLLISION INFORMATION 2012 FF Sill Reinforcement / Rocker 1 ­ SILL REINFORCEMENT 2 ­ INNER B­PILLAR REINFORCEMENT D ­ BETAMATE ADHESIVE 1. With the use of a grinder equipped with a 50 grit grinding disc, remove all contaminants and coatings off of the mating surfaces within 25mm (1in.) of the area where Betamate was originally applied.
  • Page 61 2012 FF COLLISION INFORMATION Center Roof Bow (500) 1 ­ ROOF BOW 2 ­ B­PILLAR REINFORCEMENT (BOW PERCH) D ­ BETAMATE ADHESIVE CAUTION: Procedure will require overhead welds within the interior, Extreme care needs be taken to protect the interior and exterior from weld splatter and sparks 1.
  • Page 62 62 COLLISION INFORMATION 2012 FF Inner B­pillar Reinforcement / Outer B­pillar Reinforcement 1 ­ INNER B­PILLAR REINFORCEMENT D ­ BETAMATE ADHESIVE 1. With the use of a grinder equipped with a 50 grit grinding disc, remove all contaminants and coatings off of the mating surfaces within 25mm (1in.) of the area where Betamate was originally applied.
  • Page 63 2012 FF COLLISION INFORMATION Quarter Panel Extension / B­Pillar Reinforcement 1 ­ QUARTER PANEL EXTENSION 2 ­ OUTER B­PILLAR REINFORCEMENT D ­ BETAMATE ADHESIVE 1. With the use of a grinder equipped with a 50 grit grinding disc, remove all contaminants and coatings off of the mating surfaces within 25mm (1in.) of the area where Betamate was originally applied.
  • Page 64 64 COLLISION INFORMATION 2012 FF Quarter Panel Extension / C­Pillar Reinforcement 1 ­ C­PILLAR REINFORCEMENT 2 ­ QUARTER PANEL EXTENSION 3 ­ B­PILLAR REINFORCEMENT OUTER D ­ BETAMATE ADHESIVE 1. With the use of a grinder equipped with a 50 grit grinding disc, remove all contaminants and coatings off of the mating surfaces within 25mm (1in.) of the area where Betamate was originally used.
  • Page 65 2012 FF COLLISION INFORMATION B­Pillar Reinforcement / C­Pillar Reinforcement 1 ­ C­PILLAR REINFORCEMENT D ­ BETAMATE ADHESIVE The Betamate Adhesive that was originally applied in the C­pillar Reinforcement to the B­pillar Reinforcement lap joint will be completely deleted. Substitute Betamate Adhesive with the use of additional plug welds.
  • Page 66 66 COLLISION INFORMATION 2012 FF 1 ­ B­PILLAR REINFORCEMENT 2 ­ C­PILLAR REINFORCEMENT 3 ­ ORIGINAL FACTORY WELD LOCATIONS 4 ­ ADDITIONAL WELDS LOCATIONS The three original factory welds (3) used in the joint, will be accompanied with six additional welds. The six additional welds (4) will be 5mm plug welds, placed in locations as shown.
  • Page 67 2012 FF COLLISION INFORMATION Inner Wheelhouse 1 ­ INNER QUARTER PANEL 2 ­ INNER WHEELHOUSE D ­ BETAMATE ADHESIVE 1. With the use of a grinder equipped with a 50 grit grinding disc, remove all contaminants and coatings off of the mating surfaces within 25mm (1in.) of the area where Betamate was originally applied.

  • Page 68: Aluminum Bronze Seam And Slot Welds

    68 COLLISION INFORMATION 2012 FF Drain Trough Cabrio Collision Information SIDE APERTURE 2 ­ DRAIN TROUGH 3 ­ CROSSMEMBER 4 ­ C­PILLAR 5 ­ BODY SIDE APERTURE EXTENSION D ­ BETAMATE ADHESIVE 1. With the use of a grinder equipped with a 50 grit grinding disc, remove all contaminants and coatings off of the mating surfaces within 25mm (1in.) of the area where Betamate was originally applied.
  • Page 69 2012 FF COLLISION INFORMATION Replacement of these welds can be achieved with the use of a MIG welder, as used as normal in low / high strength steel panel replacement. Proper welding equipment set up can be found in the Weld Process Chart, (Refer to Collision Information ­...
  • Page 70 70 COLLISION INFORMATION 2012 FF Fig. 31 Front Lower Rail NOTE: Left Side Shown, Right Side Typical 1 ­ RAIL END 2 ­ FRONT FRAME RAIL (LOWER) A ­ ALUMINUM BRONZE SEAM WELDS...
  • Page 71 2012 FF COLLISION INFORMATION Fig. 32 Upper Load Path Beam NOTE: Right Side Shown, Left Side Typical 1 ­ INNER LOAD PATH BEAM 2 ­ OUTER LOAD PATH BEAM A ­ ALUMINUM BRONZE SEAM WELDS B ­ ALUMINUM BRAZE SLOT WELDS...
  • Page 72 72 COLLISION INFORMATION 2012 FF Fig. 33 Upper Plenum Panel 1 ­ UPPER PLENUM PANEL B ­ ALUMINUM BRAZE SLOT WELDS...
  • Page 73 2012 FF COLLISION INFORMATION Fig. 34 Cowl Side Reinforcement NOTE: Left Side Shown, Right Side Typical 1 ­ COWL SIDE REINFORCEMENT B ­ ALUMINUM BRAZE SLOT WELDS...
  • Page 74 74 COLLISION INFORMATION 2012 FF Fig. 35 Cabrio Front Header Collision Information SIDE APERTURE 2 ­ FRONT HEADER PANEL A ­ ALUMINUM BRONZE SEAM WELDS...
  • Page 75 2012 FF COLLISION INFORMATION Fig. 36 Rear Seat Crossmember NOTE: Left Side Shown, Right Side Typical NOTE: 500 Shown, Cabrio Typical 1 ­ REAR FLOOR 2 ­ REAR SEAT CROSSMEMBER 3 ­ FRONT FLOOR A ­ ALUMINUM BRONZE SEAM WELDS...
  • Page 76 76 COLLISION INFORMATION 2012 FF Fig. 37 Sill Reinforcement NOTE: Left Side Shown, Right Side Typical 1 ­ INNER SILL PANEL 2 ­ SILL REINFORCEMENT 3 ­ INNER B­PILLAR A ­ ALUMINUM BRONZE SEAM WELDS...
  • Page 77 2012 FF COLLISION INFORMATION Fig. 38 B­Pillar Reinforcement NOTE: Right Side Shown, Left Side Typical 1 ­ OUTER B­PILLAR REINFORCEMENT 2 ­ INNER B­PILLAR REINFORCEMENT B ­ ALUMINUM BRONZE SLOT WELDS...
  • Page 78 78 COLLISION INFORMATION 2012 FF Fig. 39 Quarter Panel Extension NOTE: Right Side Shown, Left Side Typical 1 ­ QUARTER PANEL EXTENSION 2 ­ INNER QUARTER PANEL A ­ ALUMINUM BRONZE SEAM WELD...
  • Page 79 2012 FF COLLISION INFORMATION Fig. 40 Rear Header (Cabrio) NOTE: Right Side Shown, Left Side Typical 1 ­ REAR HEADER BRACKET 2 ­ BODY SIDE APERTURE A ­ ALUMINUM BRONZE SEAM WELD...
  • Page 80 80 COLLISION INFORMATION 2012 FF Fig. 41 Taillamp Pocket (1 of 2) NOTE: Right Side Shown, Left Side Typical 1 ­ TAILLAMP POCKET 2 ­ BODY SIDE APERTURE B ­ ALUMINUM BRONZE SLOT WELD...

  • Page 81: Corrosion Protection

    2012 FF COLLISION INFORMATION Fig. 42 Taillamp Pocket (2 of 2) NOTE: Left Side Shown, Right Side Typical 1 ­ TAILLAMP POCKET B ­ ALUMINUM BRONZE SLOT WELDS CORROSION PROTECTION Corrosion Protection Restoration "Corrosion protection" encompasses all the materials and coatings which protect a vehicle from corrosion and include: •...

  • Page 82: Material Locations Sealers And Sound Deadeners

    82 COLLISION INFORMATION 2012 FF prevent intrusions of contaminates, such as water and road salt, into seams causing corrosion. Lap joints, hem flanges, and any panel mating locations need to be addressed during the repair and treated to duplicate the original vehicle build. All bare metal should be etch primed prior to applying seam sealer, following the refinish material provider's instructions for doing so, unless the manufacture of the sealer specifically states otherwise.

  • Page 83: Sound Deadener Locations

    • Equalize 2K Products according to adhesive manufacturer's recommendations. • Always follow manufacturer's recommendations for storage, usage and application to achieve best performance of the product. SOUND DEADENER LOCATIONS DESCRIPTION FIGURE PUR FOAM LOCATIONS (500) (Fig. 43) PUR FOAM LOCATIONS (CABRIO) (Fig. 44) HOOD (Fig. 45) DASH PANEL (OUTER) (Fig.
  • Page 84 84 COLLISION INFORMATION 2012 FF Fig. 43 500 PUR Foam NOTE: Left side shown, right side typical 1 ­ A PILLAR 2 ­ LOWER HINGE PILLAR 3 ­ C PILLAR 4 ­ REAR CLOSEOUT...
  • Page 85 2012 FF COLLISION INFORMATION Fig. 44 Cabrio PUR Foam NOTE: Left side shown, right side typical 1 ­ A PILLAR 2 ­ LOWER HINGE PILLAR 3 ­ C PILLAR 4 ­ REAR CLOSEOUT...
  • Page 86 86 COLLISION INFORMATION 2012 FF Fig. 45 Hood 1 ­ HOOD 2 ­ HOOD SILENCER PAD...
  • Page 87 2012 FF COLLISION INFORMATION Fig. 46 Dash Panel (Outer) 1 ­ DASH PANEL 2 ­ DASH PANEL / ENGINE COMPARTMENT SILENCER PAD...
  • Page 88 88 COLLISION INFORMATION 2012 FF Fig. 47 Dash Panel (Inner) (1 of 2) 1 ­ DASH PANEL 2 ­ DASH PANEL / COWL SILENCER PAD...
  • Page 89 2012 FF COLLISION INFORMATION Fig. 48 Dash Panel Inner (2 of 2) 1 ­ DASH PANEL 2 ­ RIGHT AND LEFT MASTIC PADS...
  • Page 90 90 COLLISION INFORMATION 2012 FF Fig. 49 Cowl Sides 1 ­ LEFT SIDE COWL 2 ­ RIGHT SIDE COWL 3 ­ SIDE PANEL SILENCER PADS...
  • Page 91 2012 FF COLLISION INFORMATION Fig. 50 HVAC 1 ­ HVAC 2 ­ HVAC STUFFER FOAM...
  • Page 92 92 COLLISION INFORMATION 2012 FF Fig. 51 Floor 1 ­ FRONT FLOOR 2 ­ REAR FLOOR 3 ­ MASTIC PADS...
  • Page 93 2012 FF COLLISION INFORMATION Fig. 52 Door / Body Side Aperture 1 ­ DOOR 2 ­ BODY SIDE APERTURE 3 ­ MASTIC PAD 4 ­ BETA BRACE PATCH...
  • Page 94 94 COLLISION INFORMATION 2012 FF Fig. 53 Roof 1 ­ ROOF 2 ­ MASTIC PADS (BASE ROOF ONLY) 3 ­ MASTIC PAD (BASE ROOF, FIXED GLASS ROOF AND SUNROOF MODELS)

  • Page 95: Structural Adhesive, Flexible Adhesives And Seam Sealer Locations

    2012 FF COLLISION INFORMATION Fig. 54 Wheelhouses (Inner) 1 ­ LEFT WHEELHOUSE 2 ­ RIGHT WHEELHOUSE 3 ­ MASTIC PAD STRUCTURAL ADHESIVE, FLEXIBLE ADHESIVES AND SEAM SEALER LOCATIONS Structural adhesives, flexible adhesives and seam sealers should only be applied by trained technicians. Follow the manufactures instructions for proper applications of products.
  • Page 96 Decklid (Cabrio) (Fig. 60) Gas Door Pocket / Bodyside (Fig. 61) 500 Roof (Exterior) (Fig. 62) Front Roof Header (500 w/ Sunroof and Cabrio) (Fig. 63) 500 Roof (Interior) (Fig. 64) Lower Front Rail / Strut Tower (Fig. 65) Lower Rail (Front) (Fig.
  • Page 97 (Fig. 93) Rear Wheelhouse (2 of 4) (Fig. 94) Rear Wheelhouse (3 of 4) (Fig. 95) Rear Wheelhouse (4 of 4) (Fig. 96) Drain Trough (500) (Fig. 97) Drain Trough (Cabrio) (Fig. 98) Rear Header (Cabrio) (Fig. 99) Taillamp Housing (Fig.
  • Page 98 98 COLLISION INFORMATION 2012 FF Fig. 55 Hood NOTE: Double row seam sealer represents factory appearance of seam sealer. Single row represents discrete application to seal and protect yet maintain factory appearance of no sealer. NOTE: Drain holes must remain clear of obstructions from adhesives and sealers. 1 ­...
  • Page 99 2012 FF COLLISION INFORMATION Fig. 56 Fender NOTE: Right side shown, left side typical 1 ­ FENDER A ­ STRUCTURAL ADHESIVE...
  • Page 100 100 COLLISION INFORMATION 2012 FF Fig. 57 Door (1 of 2) NOTE: Left side shown, right side typical NOTE: Double row seam sealer represents factory appearance of seam sealer. Single row represents discrete application to seal and protect yet maintain factory appearance of no sealer. NOTE: Drain holes must remain clear of obstructions from adhesives and sealers.
  • Page 101 2012 FF COLLISION INFORMATION Fig. 58 Door (2 of 2) NOTE: Left side shown, right side typical 1 ­ DOOR (REPAIR PANEL) A ­ STRUCTURAL ADHESIVE B ­ ANTI­FLUTTER ADHESIVE...
  • Page 102 102 COLLISION INFORMATION 2012 FF Fig. 59 Liftgate (500) NOTE: Double row seam sealer represents factory appearance of seam sealer. Single row represents discrete application to seal and protect yet maintain factory appearance of no sealer. NOTE: Drain holes must remain clear of obstructions from adhesives and sealers.
  • Page 103 2012 FF COLLISION INFORMATION Fig. 60 Decklid (Cabrio) NOTE: Double row seam sealer represents factory appearance of seam sealer. Single row represents discrete application to seal and protect yet maintain factory appearance of no sealer. NOTE: Drain holes must remain clear of obstructions from adhesives and sealers. 1 ­...
  • Page 104 104 COLLISION INFORMATION 2012 FF Fig. 61 Gas Door Housing NOTE: Right side shown, left side typical 1 ­ GAS DOOR HOUSING A ­ STRUCTURAL ADHESIVES C ­ SEAM SEALER...
  • Page 105 2012 FF COLLISION INFORMATION Fig. 62 500 Roof (Exterior) NOTE: Right side shown, left side typical Collision Information SIDE APERTURE 2 ­ ROOF (FRONT) 3 ­ ROOF (REAR) C ­ SEAM SEALER...
  • Page 106 106 COLLISION INFORMATION 2012 FF Fig. 63 Front Roof Header (500 with Sunroof and Cabrio) NOTE: Right side shown left side typical NOTE: 500 with sunroof shown, Cabrio typical 1 ­ FRONT ROOF HEADER 2 ­ BODY SIDE APERTURE (FRONT)
  • Page 107 2012 FF COLLISION INFORMATION Fig. 64 500 Roof (Interior) WARNING: Betamate Adhesive is not typical structural adhesive and requires welding procedure duplicate strength of the joint. NOTE: 1 ­ FRONT HEADER 2 ­ CENTER ROOF BOW 3 ­ REAR ROOF HEADER C ­...
  • Page 108 108 COLLISION INFORMATION 2012 FF Fig. 65 Lower Front Rail / Strut Tower 1 ­ RIGHT FRONT LOWER RAIL 2 ­ LEFT FRONT LOWER RAIL 3 ­ STRUT TOWER C ­ SEAM SEALER...
  • Page 109 2012 FF COLLISION INFORMATION Fig. 66 Lower Rail NOTE: Right side shown, left side typical 1 ­ FRONT LOWER RAIL 2 ­ CRADLE MOUNT 3 ­ CRADLE MOUNT (ENGINE COMPARTMENT VIEW) C ­ SEAM SEALER...
  • Page 110 110 COLLISION INFORMATION 2012 FF Fig. 67 Front Wheelhouse (1 of 3) NOTE: Right side shown, left side typical 1 ­ FENDER 2 ­ FRONT WHEELHOUSE (LOWER) 3 ­ FRONT LOWER RAIL C ­ SEAM SEALER...
  • Page 111 2012 FF COLLISION INFORMATION Fig. 68 Front Wheelhouse (2 of 3) NOTE: Right side shown, left side typical 1 ­ FENDER 2 ­ DASH PANEL C ­ SEAM SEALER...
  • Page 112 112 COLLISION INFORMATION 2012 FF Fig. 69 Front Wheelhouse (3 of 3) Sprayed NOTE: Right side shown, left side typical 1 ­ FENDER C ­ SEAM SEALER (SPRAYABLE)
  • Page 113 2012 FF COLLISION INFORMATION Fig. 70 Strut Tower / Dash NOTE: Right side shown, left side typical 1 ­ STRUT TOWER 2 ­ DASH PANEL 3 ­ FRONT LOWER RAIL 4 ­ (UPPER VIEW) LOWER RAIL C ­ SEAM SEALER...
  • Page 114 114 COLLISION INFORMATION 2012 FF Fig. 71 Cowl Top / Strut Tower NOTE: Right side shown, left side typical 1 ­ COWL TOP 2 ­ STRUT TOWER 3 ­ INNER LOAD PATH BEAM C ­ SEAM SEALER...
  • Page 115 2012 FF COLLISION INFORMATION Fig. 72 Strut Tower Reinforcement NOTE: Right side shown, left side typical 1 ­ STRUT TOWER REINFORCEMENT 2 ­ STRUT TOWER 3 ­ DASH PANEL C ­ SEAM SEALER...
  • Page 116 116 COLLISION INFORMATION 2012 FF Fig. 73 Cowl / Dash NOTE: Left side shown, right side typical 1 ­ COWL 2 ­ STRUT TOWER 3 ­ DASH 4 ­ REINFORCEMENT C ­ SEAM SEALER...
  • Page 117 2012 FF COLLISION INFORMATION Fig. 74 Body Side Aperture / Cowl Side Reinforcement NOTE: Right side shown, left side typical 1 ­ COWL SIDE REINFORCEMENT A ­ STRUCTURAL ADHESIVE...
  • Page 118 118 COLLISION INFORMATION 2012 FF Fig. 75 Cowl Side Reinforcement / Inner Load Path Beam NOTE: Right side shown, left side typical 1 ­ COWL SIDE REINFORCEMENT 2 ­ INNER LOAD PATH BEAM A ­ STRUCTURAL ADHESIVE...
  • Page 119 2012 FF COLLISION INFORMATION Fig. 76 Inner Cowl Side NOTE: Right side shown, left side typical 1 ­ COWL SIDE A ­ STRUCTURAL ADHESIVE...
  • Page 120 120 COLLISION INFORMATION 2012 FF Fig. 77 A­pillar NOTE: Right side shown, left side typical 1 ­ A­PILLAR (INNER) 2 ­ COWL PANEL C ­ SEAM SEALER...
  • Page 121 2012 FF COLLISION INFORMATION Fig. 78 Upper Plenum 1 ­ UPPER PLENUM A ­ STRUCTURAL ADHESIVE...
  • Page 122 122 COLLISION INFORMATION 2012 FF Fig. 79 Sill Reinforcement WARNING: Betamate Adhesive is not typical structural adhesive and requires welding procedure duplicate strength of the joint. NOTE: Right side shown, left side typical 1 ­ SILL REINFORCEMENT 2 ­ INNER B­PILLAR REINFORCEMENT D ­...
  • Page 123 2012 FF COLLISION INFORMATION Fig. 80 Cowl / Dash / Front Floor (Interior) 1 ­ COWL PANEL 2 ­ DASH PANEL 3 ­ FRONT FLOOR 4 ­ TUNNEL C ­ SEAM SEALER...
  • Page 124 124 COLLISION INFORMATION 2012 FF Fig. 81 Rear Floor (Interior) NOTE: Right side shown, left side typical 1 ­ FRONT FLOOR 2 ­ REAR FLOOR C ­ SEAM SEALER...
  • Page 125 2012 FF COLLISION INFORMATION Fig. 82 Lower Deck (Interior) NOTE: Left side shown, right side typical 1 ­ LOWER DECK 2 ­ REAR FLOOR C ­ SEAM SEALER...
  • Page 126 126 COLLISION INFORMATION 2012 FF Fig. 83 Front Floor / Dash (Exterior) 1 ­ LOWER RAIL 2 ­ FRONT FLOOR C ­ SEAM SEALER...
  • Page 127 2012 FF COLLISION INFORMATION Fig. 84 Front Floor / Sill / Tunnel NOTE: Right side shown, left side typical 1 ­ FRONT FLOOR 2 ­ TUNNEL 3 ­ SILL / FLOOR SIDE VIEW DETAIL 4 ­ DO NOT COVER PROTRUSION WITH SEALER C ­...
  • Page 128 128 COLLISION INFORMATION 2012 FF Fig. 85 Front Floor / Rear Floor (Exterior) 1 ­ FRONT FLOOR 2 ­ REAR FLOOR 3 ­ CROSSMEMBER C ­ SEAM SEALER...
  • Page 129 2012 FF COLLISION INFORMATION Fig. 86 Rear Floor (Exterior) 1 ­ REAR FLOOR CROSSMEMBER 2 ­ REAR FLOOR 3 ­ LEFT REAR RAIL C ­ SEAM SEALER...
  • Page 130 130 COLLISION INFORMATION 2012 FF Fig. 87 Front Floor / Rear Floor Sprayable NOTE: Componant moutinng surfaces should remain free of sealer 1 ­ FRONT FLOOR 2 ­ REAR FLOOR 3 ­ FRONT FLOOR WRAP AROUND 4­ ­ REAR FLOOR WRAP AROUND C ­...
  • Page 131 WARNING: Betamate Adhesive is not typical structural adhesive and requires welding procedure duplicate strength of the joint. NOTE: Left side shown, right side typical NOTE: 500 shown, Cabrio typical 1 ­ INNER BODY SIDE 2 ­ INNER WHEELHOUSE D ­ BETA MATE ADHESIVE (FOLLOW ALL WARNINGS AND PROCEDURES) Betamate joint requires separate welding requirements that can be found in Betamate Replacement Procedures as found in, (Refer to Collision Information ­...
  • Page 132 WARNING: Betamate Adhesive is not typical structural adhesive and requires welding procedure duplicate strength of the joint. NOTE: Right side shown, left side typical NOTE: 500 shown, Cabrio typical 1 ­ INNER QUARTER PANEL 2 ­ B­PILLAR REINFORCEMENT A ­ STRUCTURAL ADHESIVE D ­...
  • Page 133 Fig. 90 C­ Pillar Reinforcement WARNING: Betamate Adhesive is not typical structural adhesive and requires welding procedure duplicate strength of the joint. NOTE: Cabrio shown, 500 typical NOTE: Right side shown, left side typical 1 ­ C PILLAR REINFORCEMENT D ­ BETAMATE ADHESIVE (FOLLOW ALL WARNINGS AND PROCEDURES Betamate joint requires separate welding requirements that can be found in Betamate Replacement Procedures as found in, (Refer to Collision Information ­...
  • Page 134 134 COLLISION INFORMATION 2012 FF Fig. 91 Lower Body Side Extension NOTE: Right side shown, left side typical Collision Information SIDE APERTURE (REAR) 2 ­ LOWER EXTENSION 3 ­ INNER WHEELHOUSE (REAR) 4 ­ BACKSIDE CORNER DETAIL C ­ SEAM SEALER...
  • Page 135 2012 FF COLLISION INFORMATION Fig. 92 Rear Inner Wheelhouse NOTE: Right side shown, left side typical 1 ­ INNER WHEELHOUSE (REAR) 2 ­ LOWER RAIL (REAR) C ­ SEAM SEALER...
  • Page 136 136 COLLISION INFORMATION 2012 FF Fig. 93 Rear Wheelhouse (1 of 4) NOTE: Left side shown, right side typical 1 ­ OUTER WHEELHOUSE 2 ­ INNER VIEW C ­ SEAM SEALER...
  • Page 137 2012 FF COLLISION INFORMATION Fig. 94 Rear Wheelhouse (2 of 4) NOTE: Right side shown, left side typical 1 ­ INNER WHEELHOUSE (REAR) 2 ­ OUTER WHEELHOUSE C ­ SEAM SEALER...
  • Page 138 138 COLLISION INFORMATION 2012 FF Fig. 95 Rear Wheelhouse (3 of 4) NOTE: Right side shown, left side typical 1 ­ OUTER WHEELHOUSE C ­ SEAM SEALER...
  • Page 139 2012 FF COLLISION INFORMATION Fig. 96 Rear Wheelhouse (4 0f 4) Sprayable NOTE: Right side shown, left side typical 1 ­ REAR WHEELHOUSE C ­ SEAM SEALER (SPRAYABLE)
  • Page 140 140 COLLISION INFORMATION 2012 FF Fig. 97 Drain Trough (500) NOTE: Right side shown, left side typical 1 ­ DRAIN TROUGH 2 ­ TAIL LAMP POCKET C ­ SEAM SEALER...
  • Page 141 2012 FF COLLISION INFORMATION Fig. 98 Drain Trough (Cabrio) WARNING: Betamate Adhesive is not typical structural adhesive and requires welding procedure duplicate strength of the joint. NOTE: Right side shown, left side typical Collision Information SIDE APERTURE 2 ­ DRAIN TROUGH 3 ­...
  • Page 142 142 COLLISION INFORMATION 2012 FF Fig. 99 Rear Header (Cabrio) 1 ­ REAR HEADER 2 ­ BODY SIDE APERTURE C ­ SEAM SEALER...
  • Page 143 2012 FF COLLISION INFORMATION Fig. 100 Tail Lamp Housing NOTE: Right side shown, left side typical 1 ­ TAIL LAMP HOUSING 2 ­ BODY SIDE APERTURE A ­ STRUCTURAL ADHESIVE C ­ SEAM SEALER...
  • Page 144 144 COLLISION INFORMATION 2012 FF Fig. 101 Liftgate Opening Lower Panel NOTE: Right side shown, left side typical 1 ­ TAIL LAMP POCKET 2 ­ LIFTGATE OPENING LOWER PANEL C ­ SEAM SEALER...

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