Fiat 500 Collision Awareness Manual page 40

40 COLLISION INFORMATION
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" panels spot welds must be removed using a spot weld cutting type tool, or equivalent.
On panels that are adhesive bonded or weld bonded it is acceptable to use heat up to 204°C. (400°F.), from a Non­Open
Flame heat source. This will loosen the bond, so less damage is inflicted to the mating surface. After panel is removed,
any remaining weld nugget should be ground smooth. Cut­off wheels should not be used, as there is potential to remove
material from the base material which would weaken the final repair. Place an air hammer with a flat bladed chisel bit
(or equivalent) in between panels and remove the panel. Care should be taken as to not damage mating flanges and
the surrounding components.
Key Points of a Welding Repair:
• Poor fit up will adversely affect weld quality and may result in a weld failure due to excessive metal stretching around
the nugget.
• Clamps should be used to bring parts together and hold them in position.
• Clamps should be insulated when using STRSW to control weld current shunting (This can be accomplished with
specialized clamps or by placing a insulating material such as cardboard between the clamp jaws and the panels.)
• Number, size and location of welds should closely duplicate the original assembly. Placement of the new weld should
NOT be within a 6mm. (0.25in.) of where the original weld was located. Placement of a new weld over an original
weld location may lead to metal fatigue or poor weld quality.
• Surface of the steel parts should be clean and free of scale, rust, paint, cured adhesives/sealers and any other con­
taminants that could adversely affect the quality of the weld joint. This includes the removal of any E­coat applied to
the service part within 25mm. (1in.) of any welds. (Proper corrosion protection must be installed when repairs are
complete.)
• If the joint originally had adhesive, all E­coat must be removed where the adhesive is to be reapplied.
• "Weld­thru" primers are not recommended anywhere STRSW or GMAW are used.
• Do not remove base material from the base panel when releasing welds.
NOTE: Chrysler Group LLC recommends the same quantity of welds as the original panel, but placement of the
new weld should NOT be within a 6mm. (0.25in.) of where the original welds were located. Placement of a new
weld over an original weld location may lead to metal fatigue or poor weld quality.
Requirements of a Welding Repair
The number one requirement of any welding repair is to restore the vehicle to its OEM condition. Materials and tech­
nologies should duplicate original OEM conditions as much as possible. To meet this requirement, the technician must
ensure the following:
• Panel layering (shingling) is the same as original
• Part fit up is correct
• Equivalent sealers and/or adhesives are utilized
• Welds are replaced in the same size, quantity and location
• "Weld­thru" primers are NOT recommended
• Structural adhesives and sealers must be replaced where they were located
A significant amount of structural adhesive is used at the OEM to improve joint strength. It may be difficult to determine
if the material between the panels is an adhesive or a sealer, and for this reason, the following guideline should be used:
If in doubt, use a two­component, corrosion inhibiting, structural adhesive. GMAW welding is not recommended
within 25mm. (1in.) of the adhesive as it creates heat that will destroy the adhesive. STRSW on the other hand, can
weld through the adhesive and will not destroy its properties.
NOTE: Structural adhesives that meet Chrysler materials recommendations for adhesive strength and corrosion
protection qualities include Mopar #05083855AA, Lord Fusor #112B and 3M #08816
Modified Lap Joint
NOTE: Parts shown for example purposes only. Emphasis is on joint design and proper plug weld placement
2012 FF