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16.1 BODY STRUCTURE

The ULSAB-AVC C-Class has achieved a mass reduction of 41.22 kg and the ULSAB-AVC PNGV-Class has achieved a mass reduction of 44.76 kg, compared to the average benchmark body structure mass.

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Table 16.1-1 shows that the targets for the design have been achieved. Table 16.1-1 Body structure targets
C-Class Component Name Target (kg) Body-in-White 183 (+25)* Results (kg) 201.776 Target (kg) 203 (+25)* Results (kg) 218.124 PNGV-Class

* estimated mass increase to ULSAB body structure due to more severe crash events

The C-Class body structure mass results show that the 25 kg anticipated for the more stringent target request could be offset by 6.3 kg. The PNGV-Class body structure shows that the 25 kg was offset by 10 kg. In comparison with the C-Class average benchmark body structure mass of 243 kg (see Chapter 2 - Program Targets), the ULSAB-AVC C-Class has achieved a mass reduction of 41.22 kg. In comparison with the PNGV-Class average benchmark body structure mass of 263 kg, the ULSAB-AVC PNGV-Class has achieved a mass reduction of 44.76 kg.

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16.2 Closure Structures

16.2.1. PNGV-Class Closures


Table 16.2.1-1 PNGV-Class Closure Structure
Closure Structures PNGV-Class Doors Front Doors Rear Hood Decklid Fenders Total Target PNGV-Class (kg) 27.0 22.0 16.0 10.0 4.0 79.0 PNGV-Class Results (kg) 19.186 18.556 9.534 10.270 3.216 60.762 Target Normalized Mass (kg) 15.5 15.5 8.0 8.0 NA PNGV-Class Normalized Mass Results (kg) 13.900 13.060 7.910 7.960 NA

Table 16.2.1-2 PNGV-Class closure structure assembly parts


Closure Assembly Parts PNGV-Class Doors Front Doors Rear Hood Decklid Electric Window Regulator (x4) Total Target PNGV-Class (kg) 8.0 4.0 1.0 4.0 8.0 25.0 PNGV-Class Results (kg) 5.114 4.354 1.190 2.610 7.640 20.908

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Table 16.2.1-3 PNGV-Class doors assembly parts


PNGV-Class Front Doors Results (kg) 0.820 1.478 0.740 0.940 0.260 0.280 0.080 0.016 0.500 5.114 PNGV-Class Rear Doors Results (kg) 0.820 1.478 0.740 0.940 0.280 NA 0.080 0.016 NA 4.354

Component Name

Check Strap (2x) Hinges Upper & Lower (2x) Latch (2x) Door Outside Handles (2x) Outer Belt Seal (2x) Mirror Flag Seal (2x) Boot Harness (2x) Interior Trim Brackets (4) Rearview Camera System, incl. Mirror Flag Patch (2) Total

Table 16.2.1-4 PNGV-Class hood assembly parts


PNGV-Class Results (kg) 0.680 0.470 0.040 1.190

Closure Assembly Parts Mounting Brackets Rear (Fixed Hood) Latches Spray Nozzels Total

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Table 16.2.1-5 PNGV-Class decklid assembly parts


PNGV-Class Results (kg) 1.100 0.700 0.520 0.250 0.040 2.610

Decklid Assembly Parts

Hinges Gas Struds & Attachment Latch & Striker Handle, incl. License Plate Lights Misc. Bolts & Clips Total

Table 16.2.1-6 PNGV-Class Closure Summary

Target PNGV-Class (kg) Structure Closures Assembly Parts Total 79.0 25.0 104.0

PNGV-Class Results (kg) 60.762 20.908 81.670

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16.2.2. C-Class Closures


Table 16.2.2-1 C-Class closure structure
Closure Structure C-Class Doors Front Hood Liftgate Fenders Total Target C-Class (kg) 26.0 16.0 10.0 4.0 56.0 C-Class Results (kg) 21.592 9.534 8.564 3.216 42.906 Target C-Class Normalized Mass (kg) 15.50 8.00 14.00 NA C-Classs Normalized Mass Results (kg) 13.328 7.910 11.180 NA

Table 16.2.2-2 C-Class closure assembly parts


Target C-Class C-Class Results (kg) (kg) 8.0 1.0 2.5 4.0 15.5 5.134 1.190 2.150 3.820 12.294

Closure Assembly Parts

Doors Front Hood Liftgate Electric Window Regulator Total

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Table 16.2.2-3 C-Class front doors (carry over parts ULSAC)


Target C-Class C-Class Front Doors Front Doors Assembly Parts Assembly Parts (kg) Results (kg) NA NA NA NA NA NA NA NA NA 8.000 0.820 1.478 0.740 0.940 0.280 0.280 0.080 0.016 0.500 5.134

Component Name

Check Strap (2x) Hinges Upper & Lower (2x) Latch (2x) Door Outside Handles (2x) Outer Belt Seal (2x) Mirror Flag Seal (2x) Boot Harness (2x) Interior Trim Brackets (4) Rearview Camera System, incl. Mirror Flag Patch (2) Total

Table 16.2.4-4 C-Class liftgate assembly parts


Target C-Class C-Class Liftgate Liftgate Assembly Parts Assembly Parts Results (kg) (kg) NA NA NA NA NA 2.500 0.640 0.520 0.700 0.250 0.040 2.150
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Component Name

Hinge (2x), incl. 4 Bolts Latch & Striker Gas Struds & Attachments (2x) Handle, incl. License Plate Lights
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Misc. Bolts & Nuts Total

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Program Achievement Summary

Table 16.2.4-5 C-Class closure summary

Target C-Class (kg) Structure Closures Assembly Parts Total 56.0 15.5 71.5

C-Class Results (kg) 42.906 12.294 55.200

16.3. Glazing
Table 16.3-1 Glazing
Component Name Target C-Class (kg) 12.3 15.0 NA 4.8 32.1 Target PNGV-Class (kg) 12.3 NA 14.7 5.8 32.8 C-Class Results (kg) 9.695 10.374 NA 3.806 23.875 PNGV-Class Results (kg) 9.695 NA 11.458 5.298 26.451

Front Side 2 Door Side 4 Door Rear Total

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16.4. Chassis / Suspension


Table 16.4-1 Chassis / Suspension Mass
Target C-Class C-Class and PNGVand Class Results PNGV-Class (kg) (kg) 50.0 42.0 44.236 25.761 6.720 5.7 NA 2.113 NA 20.0 26.2 16.0 8.5 15.5 14.5 1.000 198.5 182.053 Replacement for spare wheel tire 36.865 16.208 26.000 23.150 electrohydraulic brake system w/ steel disc brakes Wheel size 5x14 including bolts (12) 175/65 R14 Adjustable pedal system

Component Name Front Suspension incl.. Subframe Rear Suspension incl. Subframe Pedals Main Brake Cylinder Parking Brake Gear Shift Wheels (4) Tires (4) Steering incl. Power System Brake System hydraulic/ABS Front Brake System Rear Brake System Tire fit kit Total *

Remarks

* Total mass does not include drive shafts

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16.5. Engine

Component Name

Engine Gasoline 113 135.00 8.0 2.6 10.0 3.5 15.0 10.910 20.0 0.75 2.5 NA 1.0 NA 143.5 183.5 184.5 144.5 150.896 NA 1.0 NA 1.750 0.850 2.595 2.5 3.500 0.8 0.700 21.0 0.700 3.500 1.750 0.850 2.595 122.096 152.496 0.700 3.500 1.750 0.850 2.595 16.0 13.310 12.510 3.5 4.035 4.035 10.0 5.426 5.426 2.6 0.815 0.815 8.0 7.315 6.115 7.315 0.815 5.426 4.035 (135.0) 83 113

Engine Diesel

Table 16.5-1 Engine

Cooling System

Fuel Pump

Fuel Tank incl. Filler

Fuel System incl. Fuel lines and Air Filter Exhaust System incl. Catalytic Converter

Exhaust System Diesel

Active Carbon Filter

Heat Shield Exhaust System

Dry Sump Oil Tank incl. Hoses

Engine Electrical Control Unit

Engine Mounts

Total Gasoline

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Total Diesel

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C-Class Target C-Class (kg) Diesel Results (kg) Gasoline Results (kg) Diesel Results (kg) Target PNGV-Class (kg) 100.0 83 6.115 0.815 5.426 4.035 PNGV-Class Gasoline Results (kg)

100.0

14.910 0.700 3.500 1.750 0.850 2.595 123.696

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16.6. Transmission
Table 16.6-1 Transmission
Component Name Target C-Class and PNGV-Class (kg) 40.00 10.00 50.00 C-Class Diesel Results (kg) 36.000 8.064 44.064 Gasoline Results (kg) 36.000 7.064 43.064 PNGV-Class Diesel Results (kg) 36.000 8.064 44.064 Gasoline Results (kg) 36.000 7.064 43.064

Transmission incl. Electrical Actuator Drive Shafts Total

16.7. Interior
Table 16.7-1 Interior
Component Name Carpets Instrument Panel Restraint system Interior Panels Seat system F & R Heating & Ventilation Sound Damping Air Conditioning Total Target C-Class (kg) Target PNGV-Class (kg) C-Class Diesel Results (kg) 64.825 Gasoline Results (kg) 64.825 PNGV-Class Diesel Results (kg) 72.175 Gasoline Results (kg) 72.175

65.0

73.0

63.0 14.0 16.6 16.2 174.8

69.0 14.0 20.0 16.2 192.2

47.260 9.160 19.180 12.080 152.505

47.260 9.160 19.180 12.080 152.505

47.260 9.160 19.740 12.080 160.415

47.260 9.160 19.740 12.080 160.415

16.8. Exterior
Table 16.8-1 Exterior
C-Class Exterior Target C-Class (kg) Target PNGVClass (kg) Diesel Results (kg) 2.580 1.500 0.130 4.210 Gasoline Results (kg) 2.580 1.500 0.130 4.210 PNGV-Class Diesel Results (kg) 2.860 1.500 0.130 4.490 Gasoline Results (kg) 2.860 1.500 0.130 4.490

Applique Side Roof Rails Applique B-pillar with seal Fuel Filler lid with hinge

NA NA NA 4.5

NA NA NA 6.5

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Total

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16.9. Electrics
Table 16.9-1 Electrics
Target C-Class (kg) 6.0 7.5 13.0 12.3 2.9 41.7 Target PNGV-Class (kg) 3.8 7.5 15.0 12.3 2.9 41.5 C-Class Results (kg) 6.180 5.200 10.412 12.300 2.590 36.682 PNGV-Class Results (kg) 4.370 5.200 11.032 12.300 2.590 35.492

Component Name

Windshield Wipers (Front & Rear) Lights (Front & Rear) Electrics & Cables Batteries (36 AH/ILV) Radio (2 Speakers & Antenna) Total

16.10. Automotive Fluids


Table 16.10-1 Automotive fluids
Target C-Class (kg) 5.0 5.0 27.0 30.0 2.5 1.5 41.0 44.0 Target PNGV-Class (kg) 5.0 5.0 27.0 30.0 2.5 1.5 41.0 44.0 C-Class Results (kg) 5.0 5.0 27.0 30.0 1.4 1.5 39.9 42.9 PNGV-Class Results (kg) 5.0 5.0 27.0 30.0 1.4 1.5 39.9 42.9

Component Name

Oil Cooling Water 36 L Gasoline* 36 L Diesel* Gear Oil Washing Water Total Gasoline Total Diesel

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Specific average mass of gasoline = 0.75 kg/L Specific average mass of Diesel = 0.84 kg/L

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Program Achievement Summary

16.11. Other Concept Related Components


Table 16.11-1 Other concept related components
C-Class Other Concept Related Components Diesel Results (kg) 20.087 9.524 0.548 1.100 9.853 41.112 Gasoline Results (kg) 19.587 9.524 0.548 1.100 9.853 40.612 PNGV-Class Diesel Results (kg) 20.087 9.524 0.548 1.100 11.479 42.738 Gasoline Results (kg) 19.587 9.524 0.548 1.100 11.479 42.238

Front End Module Engine cover with service box Service lid with hinge and lock Wheelhouse covers rear Bumper with fascia rear Total

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Component Name 183 (+25) 71.5 32.1 198.5 183.5 50.0 173.0 4.5 41.7 44.0 NA 16.0 16.000 15.00 998 (+25)* 955 (+25)* 966.263 NA 41.112 41.0 42.900 36.682 36.682 39.900 40.612 16.000 15.00 932.963 1077 (+25)* 1034 (+25)* 44.0 NA 4.200 4.200 152.505 152.505 44.064 43.064 143.5 150.896 122.096 184.5 182.053 182.053 198.5 144.5 50.0 192.0 6.5 41.5 41.0 NA 20.0 23.875 23.875 32.8 55.200 55.200 104.0 201.776 201.776 203 (+25) 218.124 81.670 26.451 182.053 152.496 44.064 160.415 4.490 35.492 42.900 42.738 20.000 20.00 1030.893

Body Stucture

Closures Structure incl. Fenders

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Program Achievement Summary


Target C-Class Diesel (kg) Gasoline (kg) Diesel (kg) Gasoline (kg) Diesel (kg) Gasoline (kg) Diesel (kg) C-Class Results Target PNGV-Class PNGV-Class Results Gasoline (kg) 218.124 81.670 26.451 182.053 123.696 43.064 160.415 4.490 35.492 39.900 42.238 20.000 20.00 997.593

Glazing

Chassis

Engine incl. mounting brackets and bearings

16.12. Main Component Summary

Gear Box

Interior

Table 16.12-1 Main Component Summary

Exterior

Electrics

Automotive Fluid

Other Concept Related

Paint

Brackets and Undercover, aerodynamic devices

ULSAB-AVC PES Engineering Report June 2001 October 2001

Total

* estimated mass increase to ULSAB body structure due to more severe crash events

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16.13. Vehicle Dimensions


Table 16.13-1 Vehicle Dimensions
ECIE Index SAE Index Exterior C-Class Target 4100 +100 1750 +50 1400 +50 1530 +20 1530 +20 TBD < 2.0 1402 >1350 > VW Golf IV > VW Golf IV 5 <11 PNGV-Class Target 4750 1822 +50 1374 1529 +20 1529 +20 > 2743 <2.0 1402 1389 2.7 0.44 5 TBD C-Class Result 4179 1766 1455 1540 1540 2950 2.02 1448 1402 > VW Golf 2.98/1186 5 10.7 PNGV-Class Result 4744 1765 1455 1540 1540 3035 2.02 1448 1402 NA 0.57 5 10.9

L103 W103 H100 W101 W102 L101 -W3 W4 ---

L103 W103 H100 W101 W102 L101 -W3 W4 ---

Overall Length [mm] Overall Width [mm] Overall Height [mm] Track - Front [mm] Track - Rear [mm] Wheelbase [mm] Frontal Area [m2] Shoulder Room Front [mm] Shoulder Room Rear [mm] Interior Volume [m3] Luggage Compartment Volume [m3] Passenger Capacity Turning Circle

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