Fiat 500 Collision Awareness Manual page 58

58 COLLISION INFORMATION
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 ­ RIGHT INNER REINFORCEMENT (Do Not Cut)
3 ­ RIGHT RAIL CUT LINE
4 ­ LEFT REAR RAIL
5 ­ LEFT INNER REINFORCEMENT (Do Not Cut)
6 ­ LEFT RAIL CUT LINE
The Rear Rail is to be sectioned along the forward edge of the square Principle Location Point (PLP). The Rail Inner
Reinforcement will be utilized as the weld backer.
1. Cut the existing Outer Rear Rail at the forward edge of the of the PLP. Use a reciprocating saw or equivalent to cut
only through the Outer Rail.
2. Cut the service part (Outer Rear Rail) 1.6 mm. (1/16 in.) rearward of the forward edge of the PLP.
3. With the use of a spot weld cutter or equivalent, chamfer the spot welds from the cut line rearward.
4. Separate the rearward portion of the outer rail from the inner reinforcement with an air chisel or equivalent.
5. Determine if access will allow for Squeeze Type Resistance Spot Welds (STRW) to replace the original spot welds.
6. If access will not allow, drill 8 mm. (5/16 in.) holes in the same locations on the service part as they were located on
the original Outer Rail to the Inner Reinforcement.
7. Remove any coatings from within 25 mm (1 in.) of the cut edge of the service rail, original rail, reinforcement and
locations of spot welds or plug welds.
8. Leaving a 1.6 mm. (1/16 in.) gap where the butt joint will be placed, clamp the service part firmly into place.
9. Apply MIG weld to the butt­joint location and plug welds or STRSW to the predetermined locations.
2012 FF