The first design priority was frontal crashworthiness performance, thereby establishing the general design and arrangement

of the front-end strcuture load paths and powertrain package.
6.1 BACKGROUND
One of the fundamental tasks for ULSAB-AVC was to develop two different vehicle-type body structures that met program targets including: • • • • • Crashworthiness Mass Structural performance Vehicle dimensions Common platform

6

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The first priority was frontal crashworthiness performance, thereby establishing the general design and arrangement of the front-end structure load paths for the selected powertrain package. Considering the stringent side impact crash demands, the focus of attention was then first set on the passenger compartment environment and next the rear end structure. Based on the philosophy that the structural performance in one region of a vehicle may, or will influence that of another, an holistic design approach was used for the development of the ULSAB-AVC body structure architecture.

ULSAB-AVC – PES Engineering Report June 2001 October 2001

Chapter 6 Page 1

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6.2. Common Platform Approach – Body Structure

Figure 6.2-1 Body structure – C-Class vehicle

Figure 6.2-2 Body structure - PNGV-Class vehicle
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ULSAB-AVC – PES Engineering Report June 2001 October 2001

Chapter 6 Page 2

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One very important aspect of the conceptual design approach to the ULSABAVC program, was the development of two different body structures as shown in Figures 6.2-1 and 6.2-2 (2-door hatchback, 4-door sedan) of two different vehicle classes (C-Class and PNGV-Class), while at the same time integrating as much common structure, individual parts, joints or complete sub-assemblies, into both structure variants. By integrating as many parts as possible, into both vehicle variants, cost-related benefits, such as part manufacturing costs, body assembly costs and vehicle assembly costs can be achieved. Figures 6.2-3 and 6.2-4 show the C-Class and PNGV-Class vehicles split to emphasize the common front end. In addition, the rear end structures also share some common parts and joints.

Figure 6.2-3 C-Class

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Figure 6.2-4 PNGV-Class

ULSAB-AVC – PES Engineering Report June 2001 October 2001

Chapter 6 Page 3

these parts can be manufactured using common dies. some areas of the body side outer panels.2-5 Common Platform features Apart from the body side outer panels. ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 4 . the front-end structure is virtually identical for both vehicle variants up to the B-pillar.2-7 show the exploded view of C-Class and PNGV-Class respectively.2-2 is the Parts List for both the C-Class and PNGV-Class body structures respectively. Although very different in design. are common. Inc. and all joints pertaining to it. Figure 6. body side members and rocker inner panels. Minor exceptions can be found at the front rail members. and front floor panels. The A-pillar.6 Body-In-White Concepts The program goals for a platform approach of both vehicle concepts have been accomplished. Engineering Services. body side members and rocker inner panels are similar. Figures 6.2-6 and 6. followed by similar trim operations respectively. tunnel.2-5 shows the features of the common platform approach.2-1. Nevertheless. Parts Numbers are identified according to the following convention in Table 6. Figure 6.. Table 6.

2-1 ULSAB-AVC part and CAD model number convention ULSAB-AVC Part and CAD Model Number Convention Number AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC 1 2 3 1 2 3 4 5 6 7 X X X X X X Criteria C-Class & PNGV-Class .Common Parts C-Class (only) . Package Structure Weld Assembly Typical Sections 0 0 0 to 9 9 9 Sub-Category Numbers Exploded View Part Identification The number of parts has been minimized in both vehicle variants due to the extensive utilization of advanced high strength steel materials and manufacturing technologies and joining processes.Unique Parts PNGV-Class (only) . such as tailor welded blanks. ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 5 .. hydroforming and laser welding. Inc.6 Body-In-White Concepts Table 6.Unique Parts Body Structure Closure Structure Glass / Hardware Front End Modules / Fascias / Interior Trim Etc. Engineering Services.

Figure 6. Inc..6 Body-In-White Concepts Engineering Services.2-6 Exploded view C-Class body structure ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 6 .

6 Body-In-White Concepts Engineering Services.2-7 Exploded view PNGV-Class body structure ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 7 . Figure 6. Inc..

344 2.144 0.838 2.40 1.70 0.231 0. Process Code S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S/TWB Designed Mass (kg) C-Class 4.20 1.80 0.381 0.00 0.60 1.65 1.70 1.980 0.765 0.70 1.567 0.144 0.376 0.455 0.80 0.394 2.144 0.616 1.170 2.80 0.152 2.820 4.344 0.60 1.50 1.20 1.331 1.20 1.60 0.80 0.144 0.567 1.885 0.885 0.820 Number Name Date AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 1008 1015 1045 1064 1065 1075 1082 1083 1088 1089 1116 1117 1128 1134 1135 1136 1137 1138 1139 1146 1147 1153 1168 1169 1182 1183 1190 1192 1193 1194 1196 1197 1202 1203 1216 1217 1224 1225 1226 1227 1016 1017 1020 Cowl Front Dash Header Front Support Header Front RH Support Header Front LH Crossmember Back Panel Crossmember Kick-Up Crossmember Tunnel Bulkhead Crash Box Dash RH Bulkhead Crash Box Dash LH Assy Reinf Rail Rear Suspension Attach RH Assy Reinf Rail Rear Suspension Attach LH Plate Crash Box Rail Front Attach (x2) Crossmember Support Front Seat Front RH Crossmember Support Front Seat Front LH Closeout Lower Crash Box Dash RH Closeout Lower Crash Box Dash LH Closeout Inner Crash Box Dash RH Closeout Inner Crash Box Dash LH A-Post Inner RH A-Post Inner LH Crossmember Rear Suspension Reinf Rail Rear Spring Attach RH Reinf Rail Rear Spring Attach LH Reinf Rail Rear Suspension C-Member RH Reinf Rail Rear Suspension C-Member LH Bracket Support Front Seat Rear (x2) Reinf Crash Box Dash RH Reinf Crash Box Dash LH Reinf Tunnel Closeout Outer Crash Box Dash RH Closeout Outer Crash Box Dash LH Reinf Waist B-Pillar Inner RH Reinf Waist B-Pillar Inner LH Bracket Member Body Side Inner Att Rear RH Bracket Member Body Side Inner Att Rear LH Bracket Crossmember Inst Panel Attach RH Bracket Crossmember Inst Panel Attach LH A-Brace Cowl Front A-Brace Cowl Rear Floor Front RH Floor Front LH Body Side Outer RH D03 C15 E01 D00 D00 C00 E04 B00 D01 D01 B01 B01 A00 C03 C03 C00 C00 A05 A05 A06 A06 D01 B01 B01 B01 B01 B01 A03 A03 C03 A10 A10 B02 B02 A02 A02 A00 A00 A00 A01 E01 E01 D05 05-Mar-01 22-Mar-01 09-Mar-01 06-Jan-01 06-Jan-01 24-Oct-00 27-Feb-01 17-Aug-00 04-Dec-00 04-Dec-00 21-Jul-00 21-Jul-00 30-Mar-00 09-Mar-01 09-Mar-01 05-Dec-00 05-Dec-00 20-Oct-00 20-Oct-00 11-Apr-01 11-Apr-01 19-Feb-01 03-Feb-01 03-Feb-01 16-Feb-01 16-Feb-01 06-Dec-00 25-Jan-01 25-Jan-01 05-Mar-01 25-Jan-01 25-Jan-01 21-Apr-01 21-Apr-01 15-Mar-01 15-Mar-01 27-Feb-01 27-Feb-01 05-Mar-01 22-Mar-01 28-Feb-01 28-Feb-01 11-Apr-01 AVC 2 1021 Body Side Outer LH D05 11-Apr-01 AVC 2 1036 Wheelhouse Inner RH C11 06-Mar-01 AVC 2 1037 Wheelhouse Inner LH C11 06-Mar-01 1 2 3 1 2 3 1 2 3 1 2 3 S/TWB S/TWB S/TWB AVC AVC AVC AVC AVC AVC AVC 2 2 2 2 2 2 2 2 2 2 2 1038 1039 1046 1049 1050 Wheelhouse Outer RH Wheelhouse Outer LH Roof Tunnel Member Rail Front RH D04 D04 D01 C07 C10 C10 B13 28-Feb-01 28-Feb-01 03-Feb-01 28-Feb-01 28-Feb-01 28-Feb-01 08-Mar-01 S S S or HFS S HFT/TWT HFT/TWT S/TWB 1051 Member Rail Front LH 1069 Floor Rear 1 2 1 2 1 2 3 4 Engineering Services.50 0.90 0.65 1.640 0.80 0.396 0.152 1.60 1.455 0.832 2.002 0.845 6.161 1.640 0.161 1.519 2.132 0.567 1.414 3.161 1.20 1.170 1.10 0.30 1.396 0.00 1.576 1.344 2.832 2.416 4.416 4.072 1.396 0.686 0.132 0.376 2.381 0.074 1.966 0.765 0.455 0.161 1.132 0.602 2.30 0.30 3.600 0.70 0.65 0.576 1.002 0.320 0.616 1.092 9.20 1.600 0.132 0.20 1.331 5.255 1.885 0.80 1.618 3.686 0.464 5.00 1.618 1.344 0.65 0.50 1.170 2.152 2.988 PNGVClass 4. ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 8 . Revision Level Grade (MPa) Gage (mm) 0.70 0.20 1.231 0.70 0.072 1.219 4.152 1.00 0.170 1.966 0.30 1.20 1.376 0.10 0.90 1.645 8.320 0.645 8.00 0.6 Body-In-White Concepts Table 6.396 0.10 1. Inc.70 Material Type DP DP IF DP DP DP DP HSLA DP DP DP DP DP CP CP DP DP DP DP DP DP DP HSLA HSLA HSLA HSLA DP DP DP Mart DP DP Mart Mart DP DP HSLA HSLA DP DP TRIP TRIP DP BH DP DP BH DP DP DP DP DP DP DP DP DP DP DP DP * DP * DP * DP * BH DP DP DP Yield Strength 500 280 300 280 280 280 700 350 700 700 500 500 700 700 700 500 500 400 400 700 700 700 350 350 350 350 500 400 400 950 400 400 1250 1250 500 500 350 350 500 500 450 450 700 260 700 700 260 700 500 700 700 500 700 700 280 280 300 300 500 500 500 500 210 350 350 700 Tensile Strength 800 600 420 600 600 600 1000 450 1000 1000 800 800 1000 800 800 800 800 700 700 1000 1000 1000 450 450 450 450 800 700 700 1200 700 700 1520 1520 800 800 450 450 800 800 800 800 1000 370 1000 1000 370 1000 800 1000 1000 800 1000 1000 600 600 500 500 800 800 800 800 340 600 600 1000 Date: 27 JUL 01 Manuf.50 1.122 1.2-2 ULSAB-AVC body structure parts list (C-Class and PNGV-Class) Revision Level: A21 Blank No.231 0.219 3.90 0.765 0.358 3.65 0.00 1.70 1.70 0.80 1.845 6.567 0..20 1.394 2.50 0.40 1.50 1.980 0.040 1.65 0.90 0.040 1.70 0.50 1.60 0.455 0.231 0.885 0.10 0.50 1.602 2.765 0.70 0.376 2.

80 1.30 1.60 0.80 1.932 3.2-2 ULSAB-AVC body structures parts list (continued) ULSAB-AVC Body Structure Parts List Blank No.532 3.00 0.595 3.70 0.120 7.60 1.345 1.70 0.408 0.208 PNGVClass Number Name Date Manuf.336 0.408 3.737 3.50 0.316 2.20 1.480 0.50 0.604 1.20 1.00 1.20 0.65 0.216 2.70 0.00 0. ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 9 .168 1.70 1.40 1.65 1.10 1.10 0.774 2.70 0..60 1.10 0.403 0.403 0.70 0.541 2.459 4.10 1.168 0.002 2.146 5.60 1.184 0.60 Material Type BH BH DP DP DP DP DP DP DP IF IF DP DP DP DP DP DP * DP * Mart Mart DP DP DP Mart* DP DP DP DP DP DP DP DP DP TRIP TRIP DP DP DP DP DP DP DP DP DP DP * DP * DP * DP * BH DP DP DP DP DP DP DP DP IF IF IF DP DP * DP * DP DP Revision Level: A21 Grade (MPa) Yield Strength 210 210 500 500 300 700 500 700 500 300 300 700 700 700 700 350 500 500 950 950 500 500 300 950 700 700 700 700 700 700 700 700 700 450 450 500 700 700 500 700 700 280 280 300 500 500 500 500 210 350 350 700 300 700 500 700 500 300 300 300 300 500 500 280 280 Tensile Strength 340 340 800 800 500 1000 800 1000 800 420 420 1000 1000 1000 1000 600 800 800 1200 1200 800 800 500 1200 1000 1000 1000 1000 1000 1000 1000 1000 1000 800 800 800 1000 1000 800 1000 1000 600 600 500 800 800 800 800 340 600 600 1000 500 1000 800 1000 800 420 420 420 500 800 800 600 600 Date: 27 JUL 01 Designed Mass (kg) C-Class 0.70 0. Revision Level Gage (mm) 0.120 1.070 2.070 7.184 3.134 1.10 0.345 1.595 0.80 1.10 0.10 0.356 0.336 0.70 0.70 1.80 1.356 0.938 8.50 1.40 1.65 0.10 1.815 2.604 7.60 0.30 0.807 7.737 2.319 1.104 0.65 0.966 0. Inc.70 0.80 0.60 1.65 0.10 0.40 1.541 1.135 2.845 6.020 0. Process Code S S S S S S/TWB S/TWB S S S/TWB S/TWB S HFT HFT S S S S S ST S S S/TWB S/TWB S S S S S S/TWB AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC 2 2 2 2 2 2 2 2 2 2 2 2 1070 1071 1072 1073 1074 1076 Gutter C-Pillar RH Gutter C-Pillar LH C-Pillar Inner RH C-Pillar Inner LH Back Panel Rail Rear RH C01 C01 C04 C04 D00 B08 B08 C02 C02 B14 B14 E04 B03 B03 B03 B03 A00 A00 B00 A00 A02 A02 A05 A05 A00 A00 A00 E01 E01 C10 03-Feb-01 03-Feb-01 06-Mar-01 06-Mar-01 12-Jan-01 02-Feb-01 02-Feb-01 10-Feb-01 10-Feb-01 11-Apr-01 11-Apr-01 22-Mar-01 19-Feb-01 19-Feb-01 07-Mar-01 07-Mar-01 12-Jan-01 12-Jan-01 11-Jan-01 08-Mar-01 08-Mar-01 08-Feb-01 08-Mar-01 08-Mar-01 07-Mar-01 25-Apr-01 25-Apr-01 28-Feb-01 28-Feb-01 06-Mar-01 1077 Rail Rear LH 1080 Body Side Inner Rear RH 1081 Body Side Inner Rear LH 1086 Rocker Inner RH 1 2 1 2 2 1087 Rocker Inner LH 2 2 2 2 2 2 2 2 2 2 2 2 1115 1132 1133 1154 1155 1188 1189 1214 1215 1218 1219 1220 Header Rear Member Body Side Inner RH Member Body Side Inner LH B-Pillar Inner RH B-Pillar Inner LH Rail Rear Outer Floor Extension RH Rail Rear Outer Floor Extension LH Support Back Panel Extension C-Member Kick-Up (x2) Reinf B-Pillar Lower RH Reinf B-Pillar Lower LH Reinf B-Pillar Rocker Rear RH 1 2 1 2 2 1221 Reinf B-Pillar Rocker Rear LH 2 2 2 3 3 3 1228 1232 1233 1016 1017 1036 Crossmember Roof Reinf Waist B-Pillar Outer RH Reinf Waist B-Pillar Outer LH Floor Front RH Floor Front LH Wheelhouse Inner RH 1 2 1 2 AVC 3 1037 Wheelhouse Inner LH C10 06-Mar-01 1 2 3 1 2 3 S/TWB AVC AVC AVC AVC AVC AVC 3 3 3 3 3 3 3 3 3 1038 1039 1049 1050 Wheelhouse Outer RH Wheelhouse Outer LH Tunnel Member Rail Front RH D03 D03 C07 C10 C10 B10 28-Feb-01 28-Feb-01 28-Feb-01 28-Feb-01 28-Feb-01 08-Mar-01 1051 Member Rail Front LH 1069 Floor Rear 1 2 1 2 1 2 3 4 1 2 1 2 S S S HFT/TWT HFT/TWT S/TWB AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC 3 3 3 3 3 3 3 3 3 3 3 3 3 1074 Back Panel 1076 Rail Rear RH 1077 Rail Rear LH 1124 1125 1126 1127 1130 1131 1156 1157 Support Header Rear RH Support Header Rear LH Header Rear Roof Member Body Side Inner RH Member Body Side Inner LH Package Tray Upper Package Tray Lower D00 B08 B08 E00 E00 E00 D00 B03 B03 C02 C00 04-Jan-01 02-Feb-01 02-Feb-01 03-Jan-01 03-Jan-01 03-Jan-01 06-Jan-01 19-Feb-01 19-Feb-01 08-Jan-01 22-Dec-00 S S/TWB S/TWB S S S S or HFS HFT HFT S S Engineering Services.50 1.10 1.610 1.610 0.660 1.774 0.70 0.00 1.172 3.65 1.60 0.168 1.905 7.168 0.882 2.490 0.104 4.6 Body-In-White Concepts Table 6.70 1.966 0.845 6.40 0.65 1.80 0.459 1.65 0.216 2.252 1.70 1.660 1.65 0.815 2.60 1.60 1.319 0.

120 5.50 0.815 2.042 218.645 0.60 1.80 0.2-2 ULSAB-AVC body structures parts list (continued) ULSAB-AVC Body Structure Parts List Revision Level Revision Level: A21 Grade (MPa) Date: 27 JUL 01 Designed Mass (kg) C-Class PNGVClass 1.70 1.124 Blank No.385 0.20 0.6 Body-In-White Concepts Table 6.527 3.378 0.70 0.430 1.70 1.60 1.645 0.20 0.108 2.540 1. Number Name Date Gage (mm) 1. ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 10 .70 0.776 Manufacturing Process Stamped Stamped / Tailor Welded Blanks Hydroformed Tube Hydroformed Tube / Tailor Welded Tubes Stamped or Hydroformed Sheet Straight or Shaped Tube Miscellaneous Steel Types Bake Hardenable Complex Phase Dual Phase High Strength.555 2.068 1.120 0.148 5.70 1.50 0.80 1. Inc.555 0.456 1.60 1.527 1.50 0.70 0.913 0.491 0. Low Alloy Interstitial-Free Martensitic Transformation-Induced Plasticity * denotes Tube S S/TWB HFT HFT/TWT S or HFS ST Misc Code BH CP DP HSLA IF Mart TRIP Engineering Services.70 1.280 9.70 1.280 9.70 0.491 1. Process Code S/TWB S/TWB S/TWB AVC AVC AVC 3 1162 Rocker Inner RH 3 1163 Rocker Inner LH 3 1170 Body Side Outer RH A12 A12 B05 11-Apr-01 11-Apr-01 10-Apr-01 AVC 3 1171 Body Side Outer LH B05 10-Apr-01 1 2 1 2 1 2 3 4 5 1 2 3 4 5 S/TWB AVC AVC AVC AVC AVC AVC 3 3 3 3 3 1172 1173 1178 1179 1188 Body Side Inner Rear RH Body Side Inner Rear LH Gutter Deck Lid RH Gutter Deck Lid LH Rail Rear Outer Floor Extension RH B03 B03 B01 B01 B03 B03 08-Mar-01 08-Mar-01 04-Jan-01 04-Jan-01 06-Jan-01 06-Jan-01 22-Dec-00 11-Apr-01 11-Apr-01 05-Jan-01 04-Jan-01 06-Jan-01 06-Jan-01 25-Apr-01 25-Apr-01 3 1189 Rail Rear Outer Floor Extension LH 1201 1208 1209 1212 1214 1222 1223 1230 1231 1900 1 2 1 2 S S S S S/TWB S/TWB ST S S ST S S S S S Misc AVC 3 AVC 3 AVC 3 AVC 3 AVC 3 AVC 3 AVC 3 AVC 3 AVC 3 AVC TOTAL Code Crossmember Package Tray B00 B-Pillar Inner RH B01 B-Pillar Inner LH B01 Extension C-Member Supt Front Seat Rr (x2) A01 Support Back Panel A01 Reinf B-Pillar Lower RH B01 Reinf B-Pillar Lower LH B01 Reinf Waist B-Pillar Outer RH A00 Reinf Waist B-Pillar Outer LH A00 Brackets.50 0. Reinforcements and Hinges NOT Designed 3.00 0.70 1.80 1.746 201.70 1.430 0.815 2.70 0.649 3.913 0.10 0.20 0..712 2.00 1.00 0.108 2.148 5.378 2.385 0.80 Material Type DP DP DP DP DP BH DP DP BH DP BH DP DP BH IF IF BH BH DP BH DP BH DP * Mart Mart Mart* DP DP DP DP DP Yield Strength 700 700 700 700 700 260 700 700 260 700 260 700 700 260 300 300 260 260 500 210 500 210 280 950 950 950 300 700 700 700 700 Tensile Strength 1000 1000 1000 1000 1000 370 1000 1000 370 1000 370 1000 1000 370 420 420 370 370 800 340 800 340 600 1200 1200 1200 500 1000 1000 1000 1000 Manuf.10 0.

2. These include the front header panel.1.2.2. Common Parts Figure 6. spring. Figure 6.1-1 ULSAB-AVC common parts (C-Class & PNGV-Class) exploded view The two rear end structures share several essential common sub-structures or joints that have evolved through intense development. The entire kick-up structure inboard of the rocker inner panels is identical. and shock absorber attachments.2. two support panels. 6.1-2 shows the common parts and their relative locations.6 Body-In-White Concepts Engineering Services. The kick-up crossmember panel (AVC# 11082) is common for both vehicle variants. as a result of the identical suspension trailing arm.2. and two B-pillar inner reinforcements. Figure 6. shown for the C-Class vehicle and listed in Table 6.1-1 illustrates the common parts for both ULSAB-AVC vehicle structures in an exploded view. Inc..1-1. The upper structure incorporates several common parts. although 85-mm different in longitudinal body position. ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 11 . The suspension crossmember is identical for both variants. Using the same rear suspension system has resulted in common joints and parts in the rear rail environment.

2. Inc.. Figure 6.1-2 Exploded view of common parts ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 12 .6 Body-In-White Concepts Engineering Services.

344 2.65 0. Process Code S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S Designed Mass (kg) C-Class 4.396 0.20 1.152 2.344 0.80 1.765 0.00 1.20 1.885 0.765 0.765 0.231 0.90 1.376 2.144 0.90 0.394 2.00 1.416 4.394 2.885 0.885 0.20 1.602 2.161 1.344 0.30 3..80 0. ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 13 .455 0.1-1 ULSAB-AVC body structure common parts list (C-Class & PNGV-Class) Revision Level: A21 Blank No.832 2.600 0.00 0.002 0.396 0.132 0.376 2.152 1.376 0.455 0.455 0.072 1.90 0.396 0.70 0.002 0.20 1.640 0.381 0.170 1.344 2.602 2.040 1.820 Number Name Date AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1008 1015 1045 1064 1065 1075 1082 1083 1088 1089 1116 1117 1128 1134 1135 1136 1137 1138 1139 1146 1147 1153 1168 1169 1182 1183 1190 1192 1193 1194 1196 1197 1202 1203 1216 1217 1224 1225 1226 1227 Cowl Front Dash Header Front Support Header Front RH Support Header Front LH Crossmember Back Panel Crossmember Kick-Up Crossmember Tunnel Bulkhead Crash Box Dash RH Bulkhead Crash Box Dash LH Assy Reinf Rail Rear Suspension Attach RH Assy Reinf Rail Rear Suspension Attach LH Plate Crash Box Rail Front Attach (x2) Crossmember Support Front Seat Front RH Crossmember Support Front Seat Front LH Closeout Lower Crash Box Dash RH Closeout Lower Crash Box Dash LH Closeout Inner Crash Box Dash RH Closeout Inner Crash Box Dash LH A-Post Inner RH A-Post Inner LH Crossmember Rear Suspension Reinf Rail Rear Spring Attach RH Reinf Rail Rear Spring Attach LH Reinf Rail Rear Suspension C-Member RH Reinf Rail Rear Suspension C-Member LH Bracket Support Front Seat Rear (x2) Reinf Crash Box Dash RH Reinf Crash Box Dash LH Reinf Tunnel Closeout Outer Crash Box Dash RH Closeout Outer Crash Box Dash LH Reinf Waist B-Pillar Inner RH Reinf Waist B-Pillar Inner LH Bracket Member Body Side Inner Att Rear RH Bracket Member Body Side Inner Att Rear LH Bracket Crossmember Inst Panel Attach RH Bracket Crossmember Inst Panel Attach LH A-Brace Cowl Front A-Brace Cowl Rear D03 C15 E01 D00 D00 C00 E04 B00 D01 D01 B01 B01 A00 C03 C03 C00 C00 A05 A05 A06 A06 D01 B01 B01 B01 B01 B01 A03 A03 C03 A10 A10 B02 B02 A02 A02 A00 A00 A00 A01 05-Mar-01 22-Mar-01 09-Mar-01 06-Jan-01 06-Jan-01 24-Oct-00 27-Feb-01 17-Aug-00 04-Dec-00 04-Dec-00 21-Jul-00 21-Jul-00 30-Mar-00 09-Mar-01 09-Mar-01 05-Dec-00 05-Dec-00 20-Oct-00 20-Oct-00 11-Apr-01 11-Apr-01 19-Feb-01 03-Feb-01 03-Feb-01 16-Feb-01 16-Feb-01 06-Dec-00 25-Jan-01 25-Jan-01 05-Mar-01 25-Jan-01 25-Jan-01 21-Apr-01 21-Apr-01 15-Mar-01 15-Mar-01 27-Feb-01 27-Feb-01 05-Mar-01 22-Mar-01 Engineering Services.132 0.70 0.161 1.686 0.20 1.567 1.416 4.20 1.567 0.576 1.00 Material Type DP DP IF DP DP DP DP HSLA DP DP DP DP DP CP CP DP DP DP DP DP DP DP HSLA HSLA HSLA HSLA DP DP DP Mart DP DP Mart Mart DP DP HSLA HSLA DP DP Yield Strength 500 280 300 280 280 280 700 350 700 700 500 500 700 700 700 500 500 400 400 700 700 700 350 350 350 350 500 400 400 950 400 400 1250 1250 500 500 350 350 500 500 Tensile Strength 800 600 420 600 600 600 1000 450 1000 1000 800 800 1000 800 800 800 800 700 700 1000 1000 1000 450 450 450 450 800 700 700 1200 700 700 1520 1520 800 800 450 450 800 800 Date: 27 JUL 01 Manuf.567 0.040 1.144 0.00 0.170 2.161 1.231 0.231 0.50 1.640 0.70 0.80 0.70 1.50 1.396 0.50 1.686 0.80 0.144 0.132 0.980 0.50 1.765 0.6 Body-In-White Concepts Table 6.170 2.65 0.231 0.376 0.072 1. Revision Level Grade (MPa) Gage (mm) 0.455 0.132 0.00 1.161 1.70 0.576 1.885 0.80 0.90 0.152 2. Inc.144 0.381 0.70 0.567 1.980 0.600 0.70 0.820 PNGVClass 4.30 1.70 0.832 2.20 1.152 1.170 1.20 1.20 1.2.

1-3 and 6.2.2.2.. Figure 6.1-4 PNGV-Class common parts body structure ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 14 .1-4). Inc.2.6 Body-In-White Concepts The percentage of common parts by the body structure mass are 23% and 21% for the C-Class and PNGV-Class respectively (Figures 6. Figure 6.1-3 C-Class common parts body structure Engineering Services.

The two large rear floor panels are very similar in design.2-1 show parts with the potential to be manufactured using common dies. The PNGV-Class floor is extended by 85 mm at its rear end compared with the C-Class floor. Figure 6. The area of the part. The distance between kick-up and rear axle center is identical. Actual verification requires a detailed design phase working together with the tool and die and the part manufacturers. Figures 6. resulting in almost identical parts in this environment.2-1 C-Class and PNGV-Class parts from common dies ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 15 . Inc. of the C-Class rail.2. 6.6 Body-In-White Concepts Engineering Services. Similarly.2. which undergoes different trim operations is indicated (red). Parts Manufactured from Common Dies Parts manufactured from common dies are defined as parts using the same stamping or hydroforming tool followed by different trim operations to adjust the parts for a difference in size for both vehicle variants.2.2.. the PNGV-Class longitudinal rail is a rear extended version.

2-2 with common parts shown in red and parts manufactured from common dies shown in blue.6 Body-In-White Concepts Engineering Services. Inc. ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 16 . the floor joints result in a common rear crossmember panel. The results of the common platform approach is summarized for the C-Class in Figure 6. The tubes terminate above the rear longitudinal rails using a common attachment bracket. The tubular hydroformed body side members are laser welded to the wheelhouse inner panels..2. the wheelhouse inner panels require only one small different trim operation. Although not identical. At the rear ends.

common parts shown in red) ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 17 . Figure 6..2. Inc.2-2 ULSAB-AVC common parts and parts manufactured with common dies (common dies shown in blue.6 Body-In-White Concepts Engineering Services.

6 Body-In-White Concepts Engineering Services.C-Class and PNGV-Class 6. The two crash boxes are designed as two-piece stampings. The front and rear tube material thicknesses are 1.1.3.1-1 Bumper subframe attachment to rails ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 18 . and welded to the bumper. Underbody .Front Frontal crash energy management is achieved with load distribution into the two tubular longitudinal rails. Frontal crash loads are transferred through the rails via the bumper beam and crash box.3.3 mm respectively. Inc. Figure 6.5 mm / 1. 15km/h frontal impact).3. which is used for attachment of the front fascia module to the vehicle structure. The engine/suspension subframe four-point attachment to the front rails and the attachments of the bumper to the rails are shown in Figure 6. This eliminates an upper longitudinal load path. Front End Structure . Each rail is tubular hydroformed from two tailorwelded 100 mm diameter DP 500/800 MPa tubes.1-1. a front shock tower is not required in the body structure. 6. Due to the suspension design concept with a transverse leaf spring and a subframe incorporating the upper shock attachment.3. and absorb energy in case of low speed impact (0 degree..

Integrating the front rails and upper tunnel. In a frontal crash. thereby minimizing cockpit intrusion. the subframe rear attachments are designed and positioned to allow movement of the engine inside the tunnel. Inc. while forming a cross-car connection between the rocker and front floor crossmember. the tunnel crossmember is an important component within this environment. a-pillar. the longitudinal rails represent the backbone of the entire underbody structure. it forms a cross-car connection between the two front seat support crossmembers.6 Body-In-White Concepts Engineering Services. upper tunnel. The tunnel crossmember is also a critical component.3. The floor is laser welded to the lower outboard rail surface providing enhanced underbody aerodynamic efficiency. front rail longitudinal loads are transferred to the rocker.1-2 shows the front floor panel.3. Integrating the front rails and upper tunnel reinforcement. and lower tunnel. Figure 6. which is laser welded to the tubular hydroformed longitudinal front rails. Terminating within the kick-up crossmember box-section. Figure 6..1-2 Bottom view of front and rear floor panels ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 19 . Rear of the front subframe attachments.

Figure 6. ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 20 . It also incorporates an upper diagonal reinforcement for load transfer between rail and A-pillar. it provides a good load path. tunnel and cowl.6 Body-In-White Concepts Engineering Services. Furthermore.3. Front End Load Distribution The front end forward of the A-post has been designed primarily to absorb energy in a frontal crash..3. Figure 6. Inc. The dash crash box incorporates an inner lower diagonal bulkhead and lower closeout panel that transfer loads between rail and rocker. lateral loads are transferred into the dash crossmember.3. 6. The structure achieves a good compromise between the very different and stringent demands imposed by the 100% frontal and 40% offset crash events.2.2-2 shows the common front end structure in front view. Additionally.2-1 shows the common front end structure of both vehicles in front isometric view and in a top view identifying the load distribution from the front rails into the structure. Figure 6.2-3 shows it in side view.3. The front rail to dash crash box joints are two of the most significant joints in the vehicle structure.

Figure 6.6 Body-In-White Concepts Engineering Services. Inc.3.2-1 Front load paths ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 21 ..

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Figure 6.3.2-2 Front end structure front view

Figure 6.3.2-3 Front-end structure side view
Engineering Services, Inc..

ULSAB-AVC – PES Engineering Report June 2001 October 2001

Chapter 6 Page 22

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Integrated into the dash and cowl structure are both upper and lower crossmembers, connected by a two-piece stamped A-brace at the center of the vehicle. The lower crossmember and A-brace provide a good foundation for the tunnel and tunnel reinforcement joint. Packaged within the engine cover module (forward of the dash above the engine), is the HVAC unit. This location provides additional package space within the passenger compartment. As shown in Sec-A, Figure 6.3.2-4, air is transferred from the HVAC between the A-brace diagonal structure, to the air distribution unit incorporated within the instrument panel. Additional lateral support is provided by the front floor closeout panel, creating a closed box section rear of the dash panel inboard of the crash box.

Figure 6.3.2-4 Front-end structure rear view
ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 23

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6.4 Side Structure
The rocker structure as shown in Figure 6.4-1 for C-Class and 6.4-2 for PNGVClass is identical forward of the C-Class B-pillar reinforcement and forward of PNGV-Class lower B-pillar reinforcement. To optimize the rocker and A-post sections to reduce part count, and to eliminate unnecessary joints, there are no inner rocker and a-post reinforcements or bulkheads. To compensate, the rocker inner and body side outer panels are manufactured from tailor welded blanks. Furthermore, the door hinges incorporate the hinge stem passing through the A-post, and welded to the A-post inner and body side outer panels.

Figure 6.4-1 Rocker with kick-up crossmember C-Class
ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 24

the PNGV-Class front rails. front floor and tunnel are extended by 85 mm. whereas the forward vertical wall and top surface is part of the tailor welded four-blank rear floor. The rear vertical wall is a single stamped part. Nevertheless. The kick-up crossmember incorporates a rectangular closed box section. the PNGVClass kick-up is 85 mm further rearward in vehicle.4-2 Rocker with front seat rear crossmember PNGV-Class ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 25 . Between the rocker inner panels. Figure 6. due to package criteria. the kick-up crossmember structure is identical for C-Class and PNGV-Class. The front rails and tunnel pass through the box section.6 Body-In-White Concepts Engineering Services. providing weld joints front and rear. To maintain the same joint structure for both body variants. Inc..

1-1).5. The tank is packaged on the right side of vehicle between the kick-up and suspension crossmember. the design provides adequate package space for the fuel tank (see Figure 6. the C-Class (no rear door) uses the b-pillar/rocker reinforcement to do this. Inc.1. and mass reduction. The floor panel forms the upper and (upper) inside wall. Rear End Structure 6. C-Class The rear longitudinal rails consist primarily of three components – rear floor.5. While maintaining a smooth and consistent transition from rocker to rear rail.5.6 Body-In-White Concepts Engineering Services. is the suspension trailing arm attachment reinforcement. crashworthiness. all three parts are manufactured from tailor welded blanks. and the wheelhouse panel forms the outer vertical wall of the rear rail. ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 26 . Unlike the 4-door PNGV-Class rocker that uses the body side outer panel to close the rocker section rear of the b-pillar. To optimize for body stiffness. rear rail and wheelhouse inner. the rocker panel forms the lower and inside wall. Integrated within the rail section. 6..

creating a closed box section below the floor.5. this joint is one of the most significant on the entire body structure. and directly above it. due to the attachment of the body side member directly above the rail at this connection. Within the joint and rail section. Inc. are two important reinforcements.. ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 27 Engineering Services.1-1 C-Class rear floor structure (top view) The U-profile suspension crossmember is laser welded to the rear floor. . Here the suspension spring attachment reinforcement is laser welded to the rail lower surface. Furthermore.6 Body-In-White Concepts Figure 6. The crossmember creates an important load path between the rails.

but they are an extended version. ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 28 . Both vehicle variants have a rear floor extension. the floor extension forms the outside vertical wall of the rail section. and closing off the section. The rails consist primarily of three components – rear floor.2-1) employs the same joint and design parameters as the C-Class structure.6 Body-In-White Concepts Engineering Services. Inc. such as kick-up crossmember. and all rear suspension attachment reinforcements. Identical in design to the front bumper crash box.. In principle.all three components using tailor welded blank technology for optimum rail performance.2. and the body side member attachment bracket reinforces the section from above. the kick-up crossmember. suspension crossmember. the PNGV-Class extension is considerably longer. to provide backup for suspension spring loads. suspension crossmember.5. The inner rail reinforcement is designed to maintain rail section.5. PNGV-Class PNGV-Class rear body structure (see Figure 6. but shorter due to different package and crash behavior requirements. rear crossmember. Using the same joint and design principles. rear crossmember. and is tailor welded. rear rail and wheelhouse inner . the rear bumper crash box is a two-piece stamping used for attachment of the fascia module to the rails and back panel. Rear crash loads are transferred through the rails via the bumper beam and rear crash box (not shown). replacing that of the wheelhouse. back panel and rails is the L-profile rear crossmember. Separating the wheelhouse from back panel. 6. the longitudinal rear rails have similar characteristics as C-Class structure. and all rear suspension attachment reinforcements are common parts used on both C-Class and PNGV-Class structure. Connecting the rear floor.

6 Body-In-White Concepts Figure 6. Inc.2-1 PNGV-Class rear floor structure (top and isometric view) Engineering Services.5.. ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 29 .

loads are transferred from the front rails through the dash crash box into the members at the A-post. a larger weld surface is created at the A-post joint.1-2 show the two tubular hydroformed body side members located in the C-Class body structure. In this area. for both structural and manufacturing reasons. by a reinforcement incorporated within the rail section. with material types DP 350/600 and DP 700/1000 and material thicknesses of 1.1 mm and 1. reinforces the transition from rocker to rear rail.6 Body-In-White Concepts Engineering Services. as the tubes incorporate the A-pillar. C-Class The most distinct aspect of the upper structure is the two tubular body side members designed to transfer loads between the A-post and rear longitudinal rails.0 mm. At the front end.6. are the rear floor panel and wheelhouse inner panels. 6.6. the suspension trailing arm is attached to the lower surface of the rail. It forms a connection between the wheelhouse inner-outer slip plane weld flange and the rocker inner panel.6. . Inc. Upper Structure 6. and closing off the rail section as it transitions rearward.8 mm.8 mm. roof side rail and partial C-pillar structure.1-1 and 6.forward of this the outer panel blank thickness is 1. A vertical wall portion of the quarter inner panel. Complimenting this. The front tailor welded blank is manufactured from DP 700/1000 with a thickness of 1. The tube diameter is expanded and material axially fed into the tool during the manufacturing process (tubular hydroforming).6. with a material thickness of 1. This portion of the outer panel is manufactured from DP 700/1000. with a thickness 1. is the rail inner panel. In this way. ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 30 . Each member is hydroformed from an 85 mm diameter DP 500/800 tube. The 5-blank tailor welded body side outer panel closes off the outside of the rocker rear end. Welded to this inside wall.2 mm..1.4-mm respectively. Figures 6.

6..6. Figure 6. Inc.1-2 C-Class tubular hydroformed body side members 3/4 front view ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 31 .1-1 C-Class tubular hydroformed body side members 3/4 rear view Figure 6.6 Body-In-White Concepts Engineering Services.

At the rear.. loads are transferred from the suspension spring and the shock absorber attachments from the outside into the longitudinal rails and the body side members. is the suspension spring reinforcement. the body side members are attached on the top surface of the rear floor (upper part of the longitudinal rails) with a bracket connecting both longitudinal rails and rear rail upper surface (see Figure 6.6. With this arrangement. Positioned directly below the body side member.1-3).6 Body-In-White Concepts Engineering Services. and are reinforced by the member attachment bracket. The suspension shock absorber attachment bushings are integrated into the tube. Inc. and attached to the inner reinforcement on the rail lower surface. ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 32 .

6.6 Body-In-White Concepts Engineering Services. Inc. Figure 6.1-3 C-Class Rear end upper structure ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 33 ..

front adhesive bonded and rear welded to the roof panel.. The header panel. much consideration was given to the rear header to C-pillar joint concept as shown in Figure 6.6. but provides a welding base for the roof panel. For improved body stiffness and for manufacturing reasons.1-4.1-4 C-Class rear end structure ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 34 . not only creates a good joint. The two body side members are as essential to the ULSAB-AVC upper structure architecture as the front longitudinal rails are to the underbody structure. Figure 6.6 Body-In-White Concepts Engineering Services. Inc. creates a closed box section at each end.6. This design.

Inc. while using the same components for joining of the body side member to the rear (see Figure 6.2-1 and 6..2-1 PNGV-Class tubular hydroformed body side member 3/4 rear view ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 35 . as the tubes include the A-pillar.2-2). the body side member terminates at the rear rail in an identical manner as its C-Class counterparts.6. Although different at the rear end. roof side rail.2. Figure 6.6. designed to transfer loads between the a-post and rear longitudinal rails. Each member is hydroformed from an 85 mm diameter DP tube 500/800.6. loads are transferred from the front rails though the dash crash box into the body side members.2-3). The design concept also integrates the package tray structure.6. with a material thickness of 1.6 Body-In-White Concepts Engineering Services. the PNGV-Class upper structure employs two hydroformed members (see Figures 6.6. 6.0 mm. and partial C-pillar structure. At the lower a-pillar. PNGV-Class Identical in principle as the C-Class concept.

The roof panel is joined to the structure during final assembly. and redirect towards the rear longitudinal rails. Figure 6.. Inc. provide a good structural platform and weld surface for the roof panel.6. with the application of one continuous laser weld on both sides of the vehicle structure. ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 36 . the rear header support panels.6 Body-In-White Concepts Engineering Services.2-2 PNGV-Class tubular hydroformed body side members 3/4 front view At the juncture at which the body side members deflect from the roof panel. which are laser welded to the side members.

both cushions tilt forward independently in the vehicle.6. For this reason.. The package tray crossmember consists of a 72 mm square DP tube 280/600 with a material thickness of 1. The crossmember vertical walls are aligned with those of the body side members. it was imperative to develop a package tray concept without either diagonal braces or a sheer wall that would otherwise restrict access.6 Body-In-White Concepts Figure 6.6. and are supported by the package tray support brackets that are laser welded to the body side members and to the package tray crossmember. Inc. The package tray assembly is shown in Figure 6.2-3 Upper structure PNGV-Class 3/4 front view Much attention has been given to the package tray design concept. . This provides package space and access from the rear of the vehicle. and is laser welded forward in the vehicle ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 37 Engineering Services.2-4. The tray upper is an inverted U-profile stamping that provides the rear glass attachment surface. The rear seating arrangement employs a 60/40 split seat back and seat cushion. allowing the back rests to tilt and lay flat.0 mm. Similar to that of C-Class.

closes the U-section package tray upper from underneath. which is laser welded to the crossmember top surface. Figure 6.6 Body-In-White Concepts Engineering Services. Inc. to the body side members above the crossmember joints. which is important for torsional rigidity of the structure.2-4 Package tray ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 38 .. which incorporates the package tray crossmember provides a cross-vehicle load path.6. This package tray design. The package tray lower panel.

C-Class In the C-Class B-pillar design (see Figure 6. resulting in a very different approach for C-Class than for PNGV-Class.5 mph side impact event.7. between the lower B-pillar joint and wheelhouse. A U-profile B-pillar inner panel connects the rocker to the body side member. 6. The B-pillar design concept contributes largely towards meeting the stringent demands imposed by these crash events. Side Pole crash event and the Roof Crush. the absence of a rear door presented a challenge. Inc.6 Body-In-White Concepts Engineering Services. Figure 6. B-Pillar Structure 6. Creating a closed section. the design criteria included the US-SINCAP 38.1-1).7.1-1 C-Class B-Pillar structure partial exploded view ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 39 .1. a full-length B-pillar inner reinforcement is incorporated into the rocker section. Unlike the PNGV-Class structure..7.7.

The opposing outer reinforcement is welded to the B-pillar reinforcement.6 Body-In-White Concepts Engineering Services. To restrict major B-pillar bending and deformation in Side Impact. occupying the space created by increasing the lateral section. They are positioned at the transition from lower pillar structure to upper glass-support structure. two U-profile reinforcements (AVC# 11202 and AVC 21232) are incorporated within the closed B-pillar section as shown in Figure 6. Inc. Passing through the reinforcement laterally is the kick-up crossmember extension is a 55-mm square section Mart tube 950/1200 with a material thickness of 1. creating a sheer plane between the lower rocker weld flange. This tube transfers load in the side crash events into the kick-up crossmember.2 mm (see Figure 6.7.7.1-3).. below the waist. extending the length of the transition. and the door aperture seal attachment weld flange. ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 40 . The reinforcements are not aligned due to the door latch packaging constraints of the 2-door hatchback. The lower joint has a flat reinforcement.1-2. The inner reinforcement is welded to the B-pillar inner panel.

6 Body-In-White Concepts Figure 6.7. Inc. ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 41 .1-2 B-Pillar structure C-Class Engineering Services..

7.7.7. the PNGV-Class B-pillar (see Figure 6. Figure 6. Inc.2-1 PNGV-Class B-pillar structure partial exploded view ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 42 ..1-3 Section through Kick-up crossmember extension 6.7. PNGV-Class Although equally as important as the C-Class B-pillar.2-1) is different in design as a result of the requirements for a 4-door sedan.6 Body-In-White Concepts Engineering Services. Figure 6.2.

as well as potential reduction in both part-count and in manufacturing costs. the C-Class design uses a square tube (with the same material specifications) to transfer loads into the kick-up crossmember.7.6 Body-In-White Concepts Engineering Services.7.2-2. vertical rocker weld flange and both door aperture seal attachment weld flanges. The outer B-pillar portion of the complex body side outer blank is dual phase steel. in the PNGV-Class B-pillar design. and that is welded to both the B-pillar inner panel and body side outer panel.2-3. a 5-blank tailor welded body side outer panel replaces the full-length b-pillar inner reinforcement. To restrict major b-pillar bending and deformation at the waist. The similar outer reinforcement is welded to the body side outer panel instead of the C-Class full length reinforcement. ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 43 . this tube is aligned with the front seat rear crossmember matching its 60 mm size. Two U-profile reinforcements are incorporated within the closed b-pillar section. the lower joint has a flat reinforcement that creates a sheer plane between the lower.8 mm blank thickness of the body side outer panel. The reinforcement joined to the inner panel is common to both vehicle variants.8 mm thickness. A section through the seat crossmember and the seat crossmember extension is shown in Figure 6. Whereas. Passing through the flat reinforcement laterally is an octagonal extension Mart tube 950/1200 with a material thickness of 1.. Similar in principle to C-Class and shown in Figure 6. and 1. The door attachment system for the rear door is identical to that of the front door. this concept results in increased body structure stiffness. with a 700 MPa yield strength.7.2 mm and has the same dimensions as the seat crossmember of 60 mm.2-2 as C-Class. a U-profile B-pillar inner panel connects the rocker inner panel to the body side member. As in the C-Class. The hinge body incorporates a stem that passes through the B-pillar. PNGV-Class employs the same concept shown in Figure 6. Both arrangements result in good side impact performance. However. Inc. In conjunction with the 1. in the PNGV-Class design.

6 Body-In-White Concepts Figure 6. Figure 6..7.7. Inc.2-3 PNGV-Class seat crossmember section ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 44 .2-2 B-Pillar structure PNGV-Class Engineering Services.

. Closure Structures A comprehensive detailed description of development of criteria pertaining to doors. hood. Inc. Closure structures for ULSAB-AVC represent concept designs.8-2 C-Class closure structures including glass 3/4 rear view ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 45 . Figure 6. structural performances will have to be verified in a detail design phase.8.6 Body-In-White Concepts Engineering Services. therefore. liftgate and decklid can be found in the ULSAC Phase-1 & ULSAC Phase-2 Engineering Reports.8-1 C-Class closure structures including glass 3/4 front view Figure 6. 6.

Inc.8-4 PNGV-Class closure structures including glass 3/4 rear view ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 46 .6 Body-In-White Concepts Engineering Services.8-3 PNGV-Class closure structures including glass 3/4 front view Figure 6. Figure 6..

8-5 Exploded view C-Class closures structure ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 47 . Inc. Figure 6..6 Body-In-White Concepts Engineering Services.

Inc..6 Body-In-White Concepts Engineering Services.8-6 Exploded view PNGV-Class closures structure ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 48 . Figure 6.

6. the same conceptual design approach. For the ULSAB-AVC program.1-1) is an extended version of the PNGV-Class door (see Figure 6. Inc. connected by straight upper and lower longitudinal tubes.8. In keeping with the ULSAC design.1-2). both doors employ tubular hydroformed front and rear vertical members for hinge and latch attachment. Completing the basic structure are partial front and rear inner panels.. except the mirror flag panel is replaced by partial front-end waist reinforcement.8.8. Figure 6. and latch reinforcement.8. and technologies were used on the current ULSAB-AVC program. The PNGV-Class rear door is very similar to the front door. The C-Class door (see Figure 6. mirror flag panel.6 Body-In-White Concepts Engineering Services.1-1 Exploded view of C-Class Door Structure ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 49 .1. Doors – C-Class and PNGV-Class In principle. as were used during ULSAC Validation Phase. an outer panel. two front doors were developed.

Front Door RH Mirror Flag Outer . Process Code HFT HFT S/TWB S/TWB S S S NA NA NA NA NA NA S orHFS S or HFS HFT HFT ST ST S S S S AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC TOTAL 1 2004 Hinge Tube .696 0.FD (0.450 1.90 NA NA NA NA NA NA 0.084 0.20 1.00 1.040kg x4) Weld Stud M6 x 16 .384 0.00 0.041kg x6) Latch Bushing .60 1.Front Door RH 1 2021 Inner Front .6 Body-In-White Concepts Table 6.140 4.542 0.648 0.040 0.Front Door (x2) Inner Rear .500 0.Front Door LH Lower Tube .20 Material Type IF * IF * Mild Mild Mild Mild Mild Mild Mild NA NA NA NA NA NA DP DP IF * IF * DP * DP * Mild Mild Mild Mild Yield Strength 260 260 140 140 140 140 140 140 140 NA NA NA NA NA NA 350 350 260 260 500 500 140 140 140 140 Tensile Strength 410 410 270 270 270 270 270 270 270 NA NA NA NA NA NA 600 600 410 410 800 800 270 270 270 270 Date: 27 JUL 01 Designed Mass (kg) C-Class 0.330 0.50 1.20 1.FD (0.Front Door LH 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2026 2027 2045 2047 2056 2057 2058 2059 2060 2000 2001 2006 2007 2008 2010 2022 2023 2050 2051 Mirror Flag Outer .8.028 0.060 21.60 0. ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 50 .00 .Front Door (0.Front Door RH Inner Rear .00 1.Front Door (x2) Outer Belt Reinforcement .FD (0.1-1 Parts list C-Class .Front Door LH C02 C02 B03 B03 B03 B03 A00 A00 A00 A00 A00 A00 A00 C04 C04 C02 C02 D00 D00 B02 B02 A00 A00 09-Apr-01 09-Apr-01 10-Apr-01 10-Apr-01 04-Apr-01 04-Apr-01 09-May-01 09-May-01 09-May-01 09-May-01 09-May-01 09-May-01 09-May-01 08-Apr-01 08-Apr-01 09-Apr-01 09-Apr-01 04-Apr-01 05-Apr-01 11-Apr-01 11-Apr-01 02-Apr-01 02-Apr-01 1 2 1 2 Code S S/TWB HFT S or HFS ST Code DP IF Mild Manufacturing Process Stamped Stamped / Tailor Welded Blanks Hydroformed Tube Stamped or Hydroformed Sheet Straight or Shaped Tube Steel Types Dual Phase Interstitial-Free Mild Steel * denotes Tube Engineering Services.044 0.Front Door RH 1 2005 Hinge Tube .Front Door RH/LH File Revision Level: A14 Blank No.Front Door RH Reinforcement Latch .060 0.610 0.330 0.014kg x6) U-Clip M6 x 1. Revision Level Grade (MPa) Gage (mm) 1.Front Door LH Assy W-Reg Attach Upper .070kg x2) Outer .Front Door LH 1 2020 Inner Front .Front Door (0.00 0.00 1.Front Door (0.20 1.007kg x4) Hinge Bushing .20 1.592 PNGVClass Number Name Date Manuf.246 0.860 0.20 1.648 0.160 0.Front Door RH Latch Tube .542 4.500 0.Front Door (0.610 3.60 0.005kg x8) Adhesive Bond Lwr Tube .384 0.60 1..Front Door LH Latch Tube .00 1.Front Door LH Reinforcement Latch .00 1.Front Door RH Outer .696 0.011kg x4) Hex Flange Head M6 x 15 . Inc.

.8. ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 51 .1-2 Exploded view of PNGV-Class front and rear door structure Engineering Services.6 Body-In-White Concepts Figure 6. Inc.

00 1.005kg x8) Adhesive Bond Lwr Tube .Front Door (0. Revision Level Grade (MPa) Gage (mm) 0.556 Number Name Date Manuf.Rear Door LH Hinge Tube .Front Door RH/LH File Revision Level: A14 Blank No.Front Door RH Mirror Flag Outer .330 0.480 0.648 0.Front Door RH Reinforcement Latch .070kg x2) Outer .798 0.Front Door RH 1 2005 Hinge Tube .Rear Door LH Reinforcement Latch .. Code S S/TWB HFT S or HFS ST Code DP IF Mild Manufacturing Process Stamped Stamped / Tailor Welded Blanks Hydroformed Tube Stamped or Hydroformed Sheet Straight or Shaped Tube Steel Types Dual Phase Interstitial-Free Mild Steel * denotes Tube ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 52 .50 1. Revision Level Grade (MPa) Gage (mm) 1.620 0.600 3.00 1.560 1.00 1.500 0.Front Door (x2) Outer .430 0.246 0.850 0.90 NA NA NA NA NA NA 1.143 0.084 0.00 1.60 0.005kg x8) Adhesive Bond Lwr Tube .00 1.062 1.00 1.384 0.430 0.060 0.50 1.007kg x4) Hinge Bushing .140 0.60 0.20 Material Type IF * IF * Mild Mild Mild Mild Mild NA NA NA NA NA NA Mild Mild IF * IF * DP * DP * DP DP Mild Mild Mild Mild Yield Strength 260 260 140 140 140 140 140 NA NA NA NA NA NA 140 140 260 260 500 500 350 350 140 140 140 140 Tensile Strength 410 410 270 270 270 270 270 NA NA NA NA NA NA 270 270 410 410 800 800 600 600 270 270 270 270 Date: 27 JUL 01 Designed Mass (kg) C-Class PNGVClass 0.60 1.798 0.Rear Door RH Reinf Belt Hinge Tube .007kg x4) Hinge Bushing .Front Door LH 1 1 1 1 1 1 1 1 1 3 3 3 3 3 3 3 3 3 3 2045 2047 2056 2057 2058 2059 2060 2026 2027 2006 2007 2008 2010 2028 2029 2030 2031 2052 2053 Assy W-Reg Attach Upper .648 0.792 0.140 3.792 3.160 0.00 1.00 1.744 0.Rear Door LH Lower Tube .20 Material Type Mild NA NA NA NA DP DP Mild Mild Mild Mild Mild Mild IF * IF * IF * IF * DP * DP * Mild Mild Mild Mild Yield Strength 140 NA NA NA NA 350 350 140 140 140 140 140 140 260 260 260 260 500 500 140 140 140 140 Tensile Strength 270 NA NA NA NA 600 600 270 270 270 270 270 270 410 410 410 410 800 800 270 270 270 270 Date: 27 JUL 01 Designed Mass (kg) C-Class PNGVClass 0.FD (0.60 0.028 0.Front Door (0.580 1.384 0.Rear Door LH 1 2 1 2 Engineering Services.408 1.FD (0.028 0.Rear Doors RH/LH File Revision Level: A14 Blank No.Front Door RH Outer .Front Door LH Inner Rear .792 3.408 0.850 1.Rear Door RH Hinge Tube .8.8.20 1.60 1.Rear Door RH Outer . Process Code HFT HFT S/TWB S/TWB S NA NA NA NA NA NA S S HFT HFT ST ST S or HFS S or HFS S S S S AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC TOTAL 1 2004 Hinge Tube .744 0.10 1.Front Door (0.620 2.90 NA NA NA NA 0.Rear Door (x2) Outer Belt Reinforcement .20 0.00 0.20 1.Front Door (0.Front Door RH Inner Rear .041kg x6) Latch Bushing .00 .20 1.060 0.040kg x4) Weld Stud M6 x 16 .00 1.011kg x4) Hex Flange Head M6 x 15 .Front Door LH Reinforcement Latch .186 Number Name Date Manuf.330 0.Rear Door LH 3 3 3 3 3 3 3 3 3 3 3 3 2038 2039 2040 2041 2042 2043 2044 2046 2048 2049 2054 2055 Inner Rear .60 0.040 0.10 1.084 0.014kg x6) Weld Stud M6 x 16 .Rear Door LH Latch Tube .246 0.Front Door (x2) Outer Belt Reinforcement .143 0.Front Door RH Latch Tube .060 19.Front Door (0.Rear Door RH Reinforcement Latch .Rear Door RH Inner Rear .044 0.Front Door (0.20 1.Front Door LH 1 2020 Inner Front .014kg x6) U-Clip M6 x 1.Front Door RH 1 2021 Inner Front .Rear Door RH A00 A00 A00 A00 A00 B02 B02 B02 B02 B02 B02 B02 B02 B02 B02 C00 C00 B02 B02 A00 A00 09-May-01 09-May-01 09-May-01 09-May-01 09-May-01 05-Apr-01 05-Apr-01 12-Apr-01 12-Apr-01 12-Apr-01 12-Apr-01 12-Apr-01 10-Apr-01 12-Apr-01 12-Apr-01 04-Apr-01 05-Apr-01 12-Apr-01 12-Apr-01 02-Apr-01 02-Apr-01 3 2035 Inner Front .Front Door (0.20 1.20 1.FD (0.20 0.60 0.Rear Door (x2) Reinf Belt Hinge Tube .Front Door LH Latch Tube .20 1.Rear Door LH Inner Front .070kg x2) Mirror Flag Outer .Front Door LH C02 C02 B03 B03 A00 A00 A00 A00 A00 A00 A00 B03 B03 C02 C02 D00 D00 B05 B05 B02 B02 A00 A00 09-Apr-01 09-Apr-01 10-Apr-01 10-Apr-01 09-May-01 09-May-01 09-May-01 09-May-01 09-May-01 09-May-01 09-May-01 04-Apr-01 04-Apr-01 10-Apr-01 10-Apr-01 04-Apr-01 05-Apr-01 08-Apr-01 08-Apr-01 10-Apr-01 10-Apr-01 02-Apr-01 02-Apr-01 1 2 1 2 Code S S/TWB HFT S or HFS ST Code DP IF Mild Manufacturing Process Stamped Stamped / Tailor Welded Blanks Hydroformed Tube Stamped or Hydroformed Sheet Straight or Shaped Tube Steel Types Dual Phase Interstitial-Free Mild Steel * denotes Tube Table 6. Inc.00 1.20 1.500 0.00 1. Process Code S NA NA NA NA S or HFS S or HFS S/TWB S/TWB S S HFT HFT HFT HFT ST ST S S S S AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC TOTAL 1 1 1 1 1 3 3 3 2045 2047 2056 2059 2060 2032 2033 2034 Assy W-Reg Attach Upper .60 1.Front Door LH Lower Tube .060 18.6 Body-In-White Concepts Table 6.Rear Door RH Latch Tube .1-3 Parts list PNGV-Class .FD (0.792 0.040 0.041kg x6) Latch Bushing .1-2 Parts list PNGV-Class .FD (0.062 0.

as well as the HVAC system incorporated into the engine cover module. as were developed in the ULSAC Program. the ULSAB-AVC hood design (see Figure 6. 6.2. the hood provides access to an additional stowage compartment. Due to the engine/suspension compact design concept. Inc. Figure 6.8.. Hood – C-Class and PNGV-Class The same principles were used to develop the ULSAB-AVC hood.6 Body-In-White Concepts Engineering Services.8. Common for both AVC vehicle variants.8.2-1 Exploded view of C-Class & PNGV-Class hood structure ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 53 . The hood is attached to the body at the rear and latched at the front to the engine cover module in two locations.2-1) features a stamped or sheet hydroformed outer panel attached to a stamped inner panel.

incorporates an upper frame.534 Number Name Date Manuf. are the liftgate inner and outer panels. manufactured from a hydroformed tube.408 5.070 0.676 0. Creating the lower structure.6 Body-In-White Concepts Table 6.Hood (x2) B01 B00 10-Apr-01 09-Feb-01 Ref: ULSAC Phase-1 Ref: ULSAC Phase-1 Ref: ULSAC Phase-1 Code S S/TWB HFT S or HFS ST Code DP IF Mild Manufacturing Process Stamped Stamped / Tailor Welded Blanks Hydroformed Tube Stamped or Hydroformed Sheet Straight or Shaped Tube Steel Types Dual Phase Interstitial-Free Mild Steel * denotes Tube 6.60 0.Hood 1 x Reinforcement Striker .50 Material Type Mild DP Mild Mild Mild Yield Strength 140 350 140 140 140 Tensile Strength 270 600 270 270 270 Date: 27 JUL 01 Designed Mass (kg) C-Class 3.50 1.070 0.8.Hood 1 2601 Outer . shown in Figure 6.408 5. Process Code S S or HFS S S S AVC AVC AVC AVC AVC TOTAL 1 2600 Inner .Hood 1 x Striker Assembly . The liftgate.534 PNGVClass 3.8. The liftgate features a stamped or sheet hydroformed outer panel attached to a stamped inner panel. ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 54 . as were used during the ULSAC Program.Hood 1 x Reinforcement Hinge . and encapsulating the two lower tube ends.070 0.3.2-2 Parts list C-Class and PNGV-Class – Hood File Revision Level: A14 Blank No. Liftgate – C-Class The same principles were used to develop the C-Class liftgate.676 0.3-1.070 0. Revision Level Grade (MPa) Gage (mm) 0..310 9. Engineering Services.8.310 9.50 1.60 2. Inc.

6 Body-In-White Concepts Figure 6.8.3-1 Exploded view of C-Class liftgate structure Table 6.Liftgate B03 B03 B00 14-Feb-01 14-Feb-01 02-Feb-01 Ref: ULSAC Phase-1 Code S S/TWB HFT S or HFS ST Manufacturing Process Stamped Stamped / Tailor Welded Blanks Hydroformed Tube Stamped or Hydroformed Sheet Straight or Shaped Tube Steel Types Dual Phase Interstitial-Free Mild Steel * denotes Tube Engineering Services.120 8.60 0.240 0. Process Code S S or HFS HFT S AVC AVC AVC AVC TOTAL 2 2400 Inner .796 3.8.408 2. Inc.3-1 Parts list liftgate .70 1.50 Material Type Mild DP Mild * Mild Yield Strength 140 350 140 140 Tensile Strength 270 600 270 270 Date: 27 JUL 01 Designed Mass (kg) C-Class 2.564 PNGVClass Number Name Date Manuf.Liftgate 2 2402 Member Aperture .60 0.. Revision Level Grade (MPa) Gage (mm) 0.Liftgate 2 x Reinforcement Latch .C-Class File Revision Level: A14 Blank No. Code DP IF Mild ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 55 .Liftgate 2 2401 Outer .

8.070 0.4. Revision Level Grade (MPa) Gage (mm) 0.8.072 0.50 1.20 Material Type Mild DP Mild Mild Mild Yield Strength 140 350 140 140 140 Tensile Strength 270 600 270 270 270 Date: 27 JUL 01 Designed Mass (kg) C-Class PNGVClass 3.768 6. Inc.Deck Lid 3 2501 Outer . Figure 6.Decklid 3 x Reinforcement Hinge .6 Body-In-White Concepts 6.Decklid 3 x Reinforcement Striker . The design principal features a stamped or sheet hydroformed outer panel attached to a stamped inner panel.320 10.4-1 Parts list PNGV-Class . Code S S/TWB HFT S or HFS ST Code DP IF Mild Manufacturing Process Stamped Stamped / Tailor Welded Blanks Hydroformed Tube Stamped or Hydroformed Sheet Straight or Shaped Tube Steel Types Dual Phase Interstitial-Free Mild Steel * denotes Tube ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 56 .4-1 Exploded view of PNGV-Class decklid structure Table 6.Decklid (x2) C01 C00 10-Apr-01 12-Jan-01 Ref: ULSAC Phase-1 Ref: ULSAC Phase-1 Ref: ULSAC Phase-1 Engineering Services.Deck Lid File Revision Level: A14 Blank No..Deck Lid 3 x Striker Assembly .270 Number Name Date Manuf. Decklid – PNGV-Class The same principle technologies were used to develop the PNGV-Class decklid. Process Code S S or HFS S S S AVC AVC AVC AVC AVC TOTAL 3 2500 Inner .60 1.50 1.040 0. as were used during the ULSAC Program.8.60 0.

9.6 Body-In-White Concepts Engineering Services.9-1 Exploded view of ancillary closures ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 57 . Ancillary Closures Figure 6. 6. Inc..

60 0.60 0. Inc. They are mechanically attached to the A-post at the rear.430 6. The lower and front openings are mechanically attached to the upper engine cover module.090 1.Roof Side Rail LH Fuel Filler Lid Applique .50 0..60 0.Roof Side Rail RH Applique .430 1.608 1.234 Manufacturing Process Stamped Stamped / Tailor Welded Blanks Hydroformed Tube Stamped or Hydroformed Sheet Straight or Shaped Tube Steel Types Dual Phase Interstitial-Free Mild Steel * denotes Tube 0.1.50 0.290 1.9.608 0.9.60 0.9.60 0.50 Material Type Mild DP DP Mild Mild Mild Mild Mild Mild Yield Strength 140 350 350 140 140 140 140 140 140 Tensile Strength 270 600 600 270 270 270 270 270 270 Date: 27 JUL 01 Designed Mass (kg) C-Class 0. Process Code S S or HFS S or HFS S S S S S S AVC AVC AVC AVC AVC AVC AVC AVC AVC TOTAL 1 1 1 2 2 2 3 3 3 2300 2602 2603 2301 2700 2701 2302 2702 2703 Engine Service Lid Fender RH Fender LH Fuel Filler Lid Applique . The fenders are common for both vehicle variants.514 Code S S/TWB HFT S or HFS ST Code DP IF Mild 6.090 1. Engineering Services.9-1 Parts list Ancillary Closures File Revision Level: A14 Blank No. The fenders are manufactured utilizing stamping or sheet hydroforming.348 1.348 1.6 Body-In-White Concepts Table 6. Figure 6.50 0.Roof Side Rail LH A00 B01 B01 A00 A02 A02 A00 A02 A02 20-Feb-01 19-Feb-01 19-Feb-01 20-Feb-01 19-Feb-01 19-Feb-01 20-Feb-01 19-Feb-01 19-Feb-01 6.608 Number Name Date Manuf. the front fenders (see Figure 6.1-1) are relatively small and basic in design. Fenders Due to the wrap-over design of the hood that encompasses much of the wheelhouse. Revision Level Grade (MPa) Gage (mm) 0.1-1 C-Class & PNGV-Class vehicles right side fender ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 58 .290 PNGVClass 0.608 1.Roof Side Rail RH Applique .

Roof Side Rail Appliques In principle. the roof side rail appliques have both functional and decorative purposes.9. Fuel Filler Lids The fuel filler lids (see Figure 6.9. ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 59 . Figure 6. In part.2-1) were designed as one-piece stampings.9. hemmed edges.9. 6. Inc. special decorative paint treatments and coatings may be applied to the post body paint shop appliques. the appliques are used to cover the laser-welded joints.3.2-1 View of C-Class & PNGV-Class fuel filler lids 6.2.. First.6 Body-In-White Concepts Engineering Services. thereby providing the customer with exterior trim and color options. Second. Visible laser-welded joints exist on the a-pillar and roof side rail surfaces. tailor welded blanks are used to manufacture both C-Class and PNGVClass body side outer panels. and flanged according to hinge attachment requirements.

Inc.6 Body-In-White Concepts Engineering Services.3-1 View of C-Class roof side rail appliques exposing the body side outer laser welded joints and roof side rail joints.9. Figure 6. ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 60 .3-2 View of PNGV-Class roof side rail appliques exposing the body side outer laser welded joints and roof side rail joints.. Figure 6.9.

6 Body-In-White Concepts Figure 6. ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 61 .9.3-3 Roof side rail applique section Engineering Services. Inc..

9.4-1 Location of engine service lid (closed) Engineering Services. the service lid is integrated into the front of the hood and into the rear of the front fascia module. Figure 6. Inc. Figure 6. engine coolant filler. Engine Service Lid The engine service lid provides easy access to the engine oil filler. the lid is common for both vehicle variants. hemmed edge.6 Body-In-White Concepts 6.9. and windshield washer liquid filler. Manufactured from a one-piece stamping.9. Although a separate component. and flanged according to hinge attachment requirements.4-2 Engine service compartment ULSAB-AVC – PES Engineering Report June 2001 October 2001 Chapter 6 Page 62 ..4.

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