1.

Final Trim Line Assembly

ULSAB-AVC Engineering Report - Appendix - Section 1.0

ULSAB-AVC Assembly

Version 08/21/01

Later Rear Exhaust Tunnel Closeout Inst.

Bolt Battery Tray to Kick-up Crossmember Charcoal Canister + Fuel Line to C. C.

Interior Trim Assembly Area

2700 2 Parcel Shelf Support LH Install Rear Quarter Trim Panel LH Install Parcel Shelf Support RH Install Rear Quarter Trim Panel RH Install 2

Rear Bumper Installation

Start Assembly Line

Exhaust Tunnel Rear Installation

Quality Verification

Exhaust to Engine

Fuel Lines to Engine

2800 Headliner Install Support 2900 C Pillar Molding LH Install B Pillar Molding Lower LH Install 3000 1 B Pillar Molding Upper LH Install 3100 Rocker Molding 2 Install LH A Pillar Molding Lower LH Install 3200 A Pillar Molding Upper LH Install Sunvisor Install LH

Headliner Install

Hook-up of
Water Electric Air Heating/Air Conditioning

Quality Verification 2

C Pillar Molding RH Install B Pillar Molding Lower RH Install

2 (C-class) / 4 (PNGV-class) 6 (C-class) / 12 (PNGV-class)

B Pillar Molding Upper RH Install

1 2 Load assist 3 1 4400 4500 4700 4800

Body to Line

100

200

300

400

500

600

700

800

900

1000 1

1100 Installation of Front End Module Hose Hook-up Water, Oil, Intercooler 1 Drysump Tank to Subframe

1200

1300

1400

1500

1600

Shock to Body Quality Verification Front Cat. Conv. 1 Muffler Filler Neck Installation 1 1 man per side of line Quality Verification Coil Springs Quality Verification 990 980 970 960 950 940 930 2 1 2 920 910 1 905 1 1

ABS Unit Installation Connect Brake Actuator to ABS Unit

Electric Wiring Harness to Body Structure

Carpet Incl. Damping

2

Rocker Molding Install RH A Pillar Molding Lower RH Install

Seals and Sill Covers

1

Front Seat Unit Including Seat Belts on Seat Cross Member

Upper Front End Module Subassembly

Doors Front (C-class) / Front and Rear (PNGV-class)

3 Door Assembly Magazine incl. Glass Rear View Camera System Trim 2 4900 Quality Verification Cables Lock Electrical Hinges 1 1 1 1 2 1 2

Glazing Windshield Rear Quarter Glass

Hood to Body Structure + Fenders LH

Rear Fascia

Wheels / Tires 4x
1

Fueling + Filler Cap

Tests

Preparation for Shipping

A Pillar Molding Upper RH Install Sunvisor Install RH

Plastic Pan Heating and Air Conditioning Air Filter 4300 Fusebox

1700

Rear Seatbelt Locks to Rear Floor

Battery into Battery Tray

6500 Emissions 6600 6700 1 6800 6900 1 Seats and Belts 5 7000 7100 7200 1 Fluids 1 HVAC

Quality Verification Steering Race to Subframe

Air Conditioning Radiator to Subframe incl. Fan (Diesel + Intercooler)

3300 1 Rear Parcel Shelf Install

Interior Light and Coat Hook Install 3450 Wiper Fluid

Front Facia Module Inst. + Hook-up of Electrics (Bumper, Lights, Airducts)

Fuel Tank Installation

Mechanical Lifter

Exhaust System

Rear Axle Subassembly Installation from System Supplier

Brake Lines to Body F. Rear Susp.

Quality Verification Engine to Subframe installation (+ Driveshafts to Gearbox Installation)

Assembly Module to Body Structure 4000 4100 4150 4200 5000 5100 5200 5300 5400 5500 5600 5700 5800 5900 6000 6100 6150 6200 6300 6400

Pedal System to Body Structure

1800

1900

2000

2100

2200

2400

2500

2600

3400

3500

3600 3650

3700

3800

3900

Drive Off

3rd Brake Light 1 Bumper Lights 1 Quality Verification 1 1 4 Glazing Electrics Gas Struts Lock 3 1 From Paintshop 1 1 1

Subframe with Suspension + Brakes + Driveshaft + Engine Mounts from Systems Supplier
mechanical Lifter

Engine + Gearbox from Systems Supplier Incl. Engine Electric Wiring Harness
mechanical Lifter 1

Steering Shaft to Instrument Panel Steering Wheel

1

Bond Battery Tray into Structure

1

Rear Seat Unit

2 Load Assist

Wiper System Installation

Tunnel Trim Incl. Electronic Parking Brake

Latches to Body Structure

Filling
Water Oil Washer Fluid

Fenders RH

Door Fit Verification

Rear Lights

Exterior Trim and Decals

2 Final Inspection

Brake Lines to ABS Unit

Brake System Filling

2 load assist

Instrument Panel Complete Installation Incl. Air Bar Ducting + Heat Exchanger

Rear Hatch / Decklid

Station 99/111 16/20 Duration

100

200

300

400

500

600

700

800

900 to 990 10stations

1000

1100

1200

1300

1400

1500

1600

1700

1800

1900

2000

2100

2200

2400

2500

2600

2700 - 3300

3400

3500

3600

3700

3800

3900

4000

4100

4150

4200

4300

4400

4500

4600

4700

4800

4900

5000

5100

5200

5300

5400

5500

5600

5700

5800

5900

6000

6100

6150

6200

6300

6400

6500 - 6900

7000

7100

7200 Drive Off 5

1 1 1

2 2

3 2

13

4 1

3 1

6 / 12 2/4

3 1 3

1 1