Appendix 2 Parts Book

2.
Parts Book
ULSAB-AVC Engineering Report - Appendix - Section 2.0
2.1 Body Structure
2.1.1 C-Class
ULSAB-AVC Engineering Report - Appendix - Section 2.1.1
2.1.1.1 Parts List
ULSAB-AVC Engineering Report - Appendix - Section 2.1.1.1
2.1.1.1 Parts List - Body Structure - C-Class
ULSAB-AVC Body Structure Parts List C-Class

Blank No. Revision Level Gage (mm) 0.80 0.65 0.70 0.70 0.70 0.65 0.70 0.70 1.20 1.20 1.30 1.30 3.00 0.70 0.70 0.90 0.90 0.80 0.80 0.90 0.90 1.00 1.20 1.20 1.50 1.50 1.20 1.00 1.00 0.70 0.80 0.80 1.50 1.50 1.20 1.20 1.20 1.20 1.00 1.00 0.65 0.65 1.50 0.70 1.80 1.50 0.70 1.80 0.60 1.40 1.10 0.60 1.40 1.10 0.60 0.60 0.65 0.65 1.50 1.30 1.50 1.30 0.60 1.10 1.10 0.70 0.65 0.65 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 BH BH
Revision Level: A21

Grade (MPa) 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 500 500 350 350 500 500 450 450 700 260 700 700 260 700 500 700 700 500 700 700 280 280 300 300 500 500 500 500 210 350 350 700 210 210 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 340 340
Date: 27 JUL 01
Designed Mass (kg) C-Class 4.416 4.381 0.686 0.231 0.231 0.832 2.002 0.602 2.376 2.376 0.455 0.455 0.600 0.567 0.567 1.161 1.161 1.072 1.040 1.152 1.152 2.640 0.144 0.144 0.765 0.765 0.576 1.170 1.170 2.394 2.344 2.344 0.885 0.885 0.396 0.396 0.132 0.132 0.980 0.820 4.219 4.219 3.645 8.358 3.618 3.645 8.414 3.618 1.320 0.966 0.616 1.320 0.966 0.616 1.074 1.092 9.464 5.122 1.845 6.331 1.845 6.331 5.838 2.519 2.255 1.988 0.403 0.403
Number
Name
Date
Manuf. 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
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
2 2 2 2 2 2 AVC 2 2 AVC 2 2 2
AVC AVC AVC AVC AVC
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
AVC 2 1070 Gutter C-Pillar RH AVC 2 1071 Gutter C-Pillar LH
C01 C01
03-Feb-01 03-Feb-01
S S
2.1.1.1 Parts List - Body Structure - C-Class
ULSAB-AVC Body Structure Parts List C-Class

Blank No. Revision Level
Revision Level: A21

Grade (MPa)
Date: 27 JUL 01
Designed Mass (kg) C-Class 0.774 0.774 2.532 3.168 0.737 3.168 0.737 2.541 2.541 1.815 2.345 1.815 2.345 1.807 7.120 7.120 1.610 1.610 0.319 0.319 1.020 0.480 0.595 0.595 3.216 2.184 3.216 2.184 0.490 0.104 0.104 3.746 201.776
Number
Name
Date
Gage (mm) 0.65 0.65 0.60 1.80 1.10 1.80 1.10 0.70 0.70 1.50 0.70 1.50 0.70 0.65 1.00 1.00 0.70 0.70 1.10 1.10 0.60 1.20 0.70 0.70 1.20 1.40 1.20 1.40 0.70 0.80 0.80
Material Type 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
Yield Strength 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
Tensile Strength 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
Manuf. Process Code 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
AVC AVC AVC AVC AVC AVC AVC AVC
2 2 2 2 2 2 2 2 2 2
1072 1073 1074 1076
C-Pillar Inner RH C-Pillar Inner LH Back Panel Rail Rear RH
C04 C04 D00 B08 B08 C02 C02 B14 B14 E04 B03 B03 B03 B03 A00 A00 B00 A00 A02 A02 A05 A05
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
1077 Rail Rear LH 1080 Body Side Inner Rear RH 1081 Body Side Inner Rear LH 1086 Rocker Inner RH
1 2 1 2
AVC 2 1087 Rocker Inner LH AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC AVC 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
AVC 2 1221 Reinf B-Pillar Rocker Rear LH AVC 2 AVC 2 AVC 2 AVC TOTAL 1228 1232 1233 1900
1 2 1 2
Crossmember Roof A00 Reinf Waist B-Pillar Outer RH A00 Reinf Waist B-Pillar Outer LH A00 Brackets, Reinforcements and Hinges NOT Designed
Code S S/TWB HFT HFT/TWT S or HFS ST Code BH CP DP HSLA IF Mart TRIP
Manufacturing Process Stamped Stamped / Tailor Welded Blanks Hydroformed Tube Hydroformed Tube / Tailor Welded Tubes Stamped or Hydroformed Sheet Straight or Shaped Tube Steel Types Bake Hardenable Complex Phase Dual Phase High Strength, Low Alloy Interstitial-Free Martensitic Transformation-Induced Plasticity
* denotes DP Tube
2.1.1.2 Exploded View
2.1.1.2 Exploded View - Body Structure - C-Class
2.1.2 PNGV-Class
2.1.2.1 Parts List
2.1.2.1 Parts List - Body Structure - PNGV-Class
ULSAB-AVC Body Structure Parts List PNGV-Class

Blank No. Revision Level Gage (mm) 0.80 0.65 0.70 0.70 0.70 0.65 0.70 0.70 1.20 1.20 1.30 1.30 3.00 0.70 0.70 0.90 0.90 0.80 0.80 0.90 0.90 1.00 1.20 1.20 1.50 1.50 1.20 1.00 1.00 0.70 0.80 0.80 1.50 1.50 1.20 1.20 1.20 1.20 1.00 1.00 0.65 0.65 0.60 1.40 1.10 0.60 1.40 1.10 0.60 0.60 0.65 1.50 1.30 1.50 1.30 0.60 1.10 1.10 0.70 0.60 1.80 1.10 1.80 1.10 0.70 0.70 0.70 0.65 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 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
Revision Level: A21

Grade (MPa) 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 500 500 350 350 500 500 450 450 500 700 700 500 700 700 280 280 300 500 500 500 500 210 350 350 700 300 700 500 700 500 300 300 300 300 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 800 800 450 450 800 800 800 800 800 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
Date: 27 JUL 01
Designed Mass (kg) PNGVClass 4.416 4.381 0.686 0.231 0.231 0.832 2.002 0.602 2.376 2.376 0.455 0.455 0.600 0.567 0.567 1.161 1.161 1.072 1.040 1.152 1.152 2.640 0.144 0.144 0.765 0.765 0.576 1.170 1.170 2.394 2.344 2.344 0.885 0.885 0.396 0.396 0.132 0.132 0.980 0.820 4.459 4.459 1.356 0.966 0.660 1.356 0.966 0.660 1.134 1.146 5.252 1.845 6.604 1.845 6.604 7.932 3.135 2.882 2.002 2.172 3.168 1.408 3.168 1.408 0.336 0.336 0.938 8.905
Number
Name
Date
Manuf. 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
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 3 3 3
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 1036
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 Wheelhouse Inner 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 C10
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 06-Mar-01
AVC 3 1037 Wheelhouse Inner LH
C10
06-Mar-01
1 2 3 1 2 3
S/TWB
AVC AVC AVC AVC
3 3 3 3 3 AVC 3 3 AVC 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 3 1074 AVC 3 1076 3 AVC 3 1077 3 AVC 3 1124 AVC 3 1125 AVC 3 1126 AVC 3 1127
Back Panel Rail Rear RH Rail Rear LH Support Header Rear RH Support Header Rear LH Header Rear Roof
D00 B08 B08 E00 E00 E00 D00
04-Jan-01 02-Feb-01 02-Feb-01 03-Jan-01 03-Jan-01 03-Jan-01 06-Jan-01
S S/TWB S/TWB S S S S or HFS
2.1.2.1 Parts List - Body Structure - PNGV-Class
ULSAB-AVC Body Structure Parts List PNGV-Class

Blank No. Revision Level
Revision Level: A21

Grade (MPa)
Date: 27 JUL 01
Designed Mass (kg) PNGVClass 7.070 7.070 2.316 2.208 0.852 0.852 1.815 2.527 1.815 2.527 3.645 0.280 9.108 2.148 5.649 3.645 0.280 9.108 2.148 5.712 2.555 2.555 0.385 0.385 0.913 0.378 0.913 0.378 2.540 1.491 1.491 0.456 1.068 1.430 1.430 0.120 0.120 5.042 218.124
Number
Name
Date
Gage (mm) 1.00 1.00 0.60 0.60 1.20 1.20 1.50 0.70 1.50 0.70 1.50 0.70 1.80 1.20 0.70 1.50 0.70 1.80 1.20 0.70 0.70 0.70 0.70 0.70 1.10 0.60 1.10 0.60 1.00 0.70 0.70 1.20 0.60 1.00 1.00 0.80 0.80
Material Type DP * DP * DP DP IF IF 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 500 500 280 280 300 300 700 700 700 700 700 260 700 700 260 700 260 700 700 260 300 300 260 260 500 210 500 210 280 950 950 950 300 700 700 700 700
Tensile Strength 800 800 600 600 420 420 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. Process Code HFT HFT S S S S S/TWB S/TWB S/TWB
AVC AVC AVC AVC AVC AVC AVC
3 3 3 3 3 3 3
1130 1131 1156 1157 1160 1161 1162
Member Body Side Inner RH Member Body Side Inner LH Package Tray Upper Package Tray Lower Support Package Tray Lower RH Support Package Tray Lower LH Rocker Inner RH
B03 B03 C02 C00 C01 C01 A12 A12 B05
19-Feb-01 19-Feb-01 08-Jan-01 22-Dec-00 03-Jan-01 03-Jan-01 11-Apr-01 11-Apr-01 10-Apr-01
AVC 3 1163 Rocker Inner LH AVC 3 1170 Body Side Outer RH
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
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
AVC 3 1189 Rail Rear Outer Floor Extension LH AVC 3 AVC 3 AVC 3 AVC 3 AVC 3 AVC 3 AVC 3 AVC 3 AVC 3 AVC TOTAL 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
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, Reinforcements and Hinges NOT Designed
Code S S/TWB HFT HFT/TWT S or HFS ST Code BH CP DP HSLA IF Mart TRIP
Manufacturing Process Stamped Stamped / Tailor Welded Blanks Hydroformed Tube Hydroformed Tube / Tailor Welded Tubes Stamped or Hydroformed Sheet Straight or Shaped Tube Steel Types Bake Hardenable Complex Phase Dual Phase High Strength, Low Alloy Interstitial-Free Martensitic Transformation-Induced Plasticity
* denotes DP Tube
2.1.2.2 Exploded View - Body Structure - PNGV-Class
2.1.3 Parts Book Index
2.1.3 Parts Book Index - Body Structure
Part Number AVC 1 1008 AVC 1 1015 AVC 1 1045 AVC 1 1064 AVC 1 1075 AVC 1 1082 AVC 1 1083 AVC 1 1088 AVC 1 1116 AVC 1 1128 AVC 1 1134 AVC 1 1136 AVC 1 1138 AVC 1 1146 AVC 1 1153 AVC 1 1168 AVC 1 1182 AVC 1 1190 AVC 1 1192 AVC 1 1194 AVC 1 1196 AVC 1 1202 AVC 1 1216 AVC 1 1224 AVC 1 1226 AVC 1 1227 AVC 2 1016 AVC 2 1020 AVC 2 1036 AVC 2 1038 AVC 2 1046 AVC 2 1049 AVC 2 1050 AVC 2 1069 AVC 2 1070 AVC 2 1072 AVC 2 1074 AVC 2 1076 AVC 2 1080 AVC 2 1086 AVC 2 1115 Cowl Front Dash Header Front
Part Name
Revision D03 C15 E01 D00 C00 E04 B00 D01 B01 A00 C03 C00 A05 A06 D01 B01 B01 B01 A03 C03 A10 B02 A02 A00 A00 A01 E01 D05 C11 D04 D01 C07 C10 B13 C01 C04 D00 B08 C02 B14 E04
Date 05-Mar-01 22-Mar-01 09-Mar-01 06-Jan-01 24-Oct-00 27-Feb-01 17-Aug-00 04-Dec-00 21-Jul-00 30-Mar-00 09-Mar-01 05-Dec-00 20-Oct-00 11-Apr-01 19-Feb-01 03-Feb-01 16-Feb-01 06-Dec-00 25-Jan-01 05-Mar-01 25-Jan-01 21-Apr-01 15-Mar-01 27-Feb-01 05-Mar-01 22-Mar-01 28-Feb-01 11-Apr-01 06-Mar-01 28-Feb-01 03-Feb-01 28-Feb-01 28-Feb-01 08-Mar-01 03-Feb-01 06-Mar-01 12-Jan-01 02-Feb-01 10-Feb-01 11-Apr-01 22-Mar-01
Support Header Front RH Crossmember Back Panel Crossmember Kick-Up Crossmember Tunnel Bulkhead Crash Box Dash RH Assy Reinf Rail Rear Suspension Attach RH Plate Crash Box Rail Front Attach (x2) Crossmember Support Front Seat Front RH Closeout Lower Crash Box Dash RH Closeout Inner Crash Box Dash RH A-Post Inner RH Crossmember Rear Suspension Reinf Rail Rear Spring Attach RH Reinf Rail Rear Suspension C-Member RH Bracket Support Front Seat Rear (x2) Reinf Crash Box Dash RH Reinf Tunnel Closeout Outer Crash Box Dash RH Reinf Waist B-Pillar Inner RH Bracket Member Body Side Inner Att Rear RH Bracket Crossmember Inst Panel Attach RH A-Brace Cowl Front A-Brace Cowl Rear Floor Front RH Body Side Outer RH Wheelhouse Inner RH Wheelhouse Outer RH Roof Tunnel Member Rail Front RH Floor Rear Gutter C-Pillar RH C-Pillar Inner RH Back Panel Rail Rear RH Body Side Inner Rear RH Rocker Inner RH Header Rear
2.1.3 Parts Book Index - Body Structure C-Class/PNGV-Class
Part Number AVC 2 1132 AVC 2 1154 AVC 2 1188 AVC 2 1214 AVC 2 1215 AVC 2 1218 AVC 2 1220 AVC 2 1228 AVC 2 1232 AVC 3 1016 AVC 3 1036 AVC 3 1038 AVC 3 1049 AVC 3 1050 AVC 3 1069 AVC 3 1074 AVC 3 1076 AVC 3 1124 AVC 3 1126 AVC 3 1127 AVC 3 1130 AVC 3 1156 AVC 3 1157 AVC 3 1160 AVC 3 1162 AVC 3 1170 AVC 3 1172 AVC 3 1178 AVC 3 1188 AVC 3 1201 AVC 3 1208 AVC 3 1212 AVC 3 1214 AVC 3 1222 AVC 3 1230
Part Name Member Body Side Inner RH B-Pillar Inner RH Rail Rear Outer Floor Extension RH Support Back Panel Extension C-Member Kick-Up (x2) Reinf B-Pillar Lower RH Reinf B-Pillar Rocker Rear RH Crossmember Roof Reinf Waist B-Pillar Outer RH Floor Front RH Wheelhouse Inner RH Wheelhouse Outer RH Tunnel Member Rail Front RH Floor Rear Back Panel Rail Rear RH Support Header Rear RH Header Rear Roof Member Body Side Inner RH Package Tray Upper Package Tray Lower Support Package Tray Lower RH Rocker Inner RH Body Side Outer RH Body Side Inner Rear RH Gutter Deck Lid RH Rail Rear Outer Floor Extension RH Crossmember Package Tray B-Pillar Inner RH Extension C-Member Supt Front Seat Rr (x2) Support Back Panel Reinf B-Pillar Lower RH Reinf Waist B-Pillar Outer RH
Revision B03 B03 A00 B00 A00 A02 A05 A00 A00 E01 C10 D03 C07 C10 B10 D00 B08 E00 E00 D00 B03 C02 C00 C01 A12 B05 B03 B01 B03 B00 B01 A01 A01 B01 A00
Date 19-Feb-01 07-Mar-01 12-Jan-01 11-Jan-01 08-Mar-01 08-Mar-01 08-Mar-01 07-Mar-01 25-Apr-01 28-Feb-01 06-Mar-01 28-Feb-01 28-Feb-01 28-Feb-01 08-Mar-01 04-Jan-01 02-Feb-01 03-Jan-01 03-Jan-01 06-Jan-01 19-Feb-01 08-Jan-01 22-Dec-00 03-Jan-01 11-Apr-01 10-Apr-01 08-Mar-01 04-Jan-01 06-Jan-01 22-Dec-00 11-Apr-01 05-Jan-01 04-Jan-01 06-Jan-01 25-Apr-01
2.1.4 Parts Book Sheets - Body Structure
2.2 Closures Structure
2.2.1 Overview - C-Class
2.2.1.1 Parts Lists
2.2.1.1 Parts Lists - Closures Structure - C-Class - Front Door RH/LH
ULSAB-AVC - C-Class - Front Door RH/LH

Blank No. Revision Level Grade (MPa) Gage (mm) 1.20 1.20 1.00 1.20 1.00 1.20 1.00 1.00 0.90 NA NA NA NA NA NA 0.60 0.60 1.00 1.00 1.50 1.00 0.60 0.60 1.20 1.20 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 Manuf. 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 Designed Designed Mass (kg) C-Class C-Class 0.648 0.648 0.648 0.648 0.500 0.500 0.384 0.384 0.500 0.500 0.384 0.384 0.330 0.330 0.330 0.330 0.028 0.028 0.246 0.246 0.084 0.084 0.044 0.044 0.160 0.160 0.040 0.040 0.140 0.140 4.542 4.542 4.542 4.542 0.610 0.610 0.610 0.610 3.450 3.450 1.860 1.860 0.696 0.696 0.696 0.696 0.060 0.060 0.060 0.060 21 592 21 592 21.592 21.592 PNGVClass
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 TOTAL TOTAL
1 2004 Hinge Tube - Front Door RH 1 2005 Hinge Tube - Front Door LH 1 2020 Inner Front - Front Door RH 1 2021 Inner Front - 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 - Front Door RH Mirror Flag Outer - Front Door LH Assy W-Reg Attach Upper - FD (0.007kg x4) Hinge Bushing - Front Door (0.041kg x6) Latch Bushing - Front Door (0.014kg x6) U-Clip M6 x 1.00 - Front Door (0.011kg x4) Hex Flange Head M6 x 15 - FD (0.040kg x4) Weld Stud M6 x 16 - Front Door (0.005kg x8) Adhesive Bond Lwr Tube - FD (0.070kg x2) Outer - Front Door RH Outer - Front Door LH Latch Tube - Front Door RH Latch Tube - Front Door LH Lower Tube - Front Door (x2) Outer Belt Reinforcement - Front Door (x2) Inner Rear - Front Door RH Inner Rear - Front Door LH Reinforcement Latch - Front Door RH Reinforcement Latch - 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
2.2.1.1 Parts Lists - Closures Structure - C-Class - Hood
ULSAB-AVC - C-Class - Hood

Revision Level Blank No. Grade (MPa) Gage (mm) Material Type Yield Strength 0.60 0.60 2.50 1.50 1.50 Mild DP Mild Mild Mild 140 350 140 140 140 Tensile Strength 270 600 270 270 270 Manuf. Process Code C-Class C-Class S S or HFS S S S 3.408 3.408 5.676 5.676 0.070 0.070 0.070 0.070 0.310 0.310 9.534 9.534 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 Designed Designed Mass (kg)
Number
Name
Date
PNGVClass
AVC AVC AVC AVC AVC TOTAL
1 2600 Inner - Hood 1 2601 Outer - Hood 1 x Striker Assembly - Hood 1 x Reinforcement Striker - Hood 1 x Reinforcement Hinge - Hood (x2)
B01 B00
10-Apr-01 09-Feb-01
Ref: ULSAC Phase-1 Ref: ULSAC Phase-1 Ref: ULSAC Phase-1
2.2.1.1 Parts Lists - Closures Structure - C-Class - Liftgate
ULSAB-AVC - C-Class - Liftgate

Blank No. Revision Level Grade (MPa) Gage (mm) 0.60 0.60 0.70 1.50 Material Type Mild DP Mild * Mild Yield Strength 140 350 140 140 Tensile Strength 270 600 270 270 Manuf. Process Code S S or HFS HFT S Designed Designed Mass (kg) C-Class C-Class 2.796 2.796 3.408 3.408 2.240 2.240 0.120 0.120 8.564 8.564 PNGVClass
Number
Name
Date
AVC AVC AVC AVC TOTAL
2 2400 Inner - Liftgate 2 2401 Outer - Liftgate 2 2402 Member Aperture - Liftgate 2 x Reinforcement Latch - Liftgate
B03 B03 B00
14-Feb-01 14-Feb-01 02-Feb-01
Ref: ULSAC Phase-1
* denotes Tube
2.2.1.2 Exploded View - Closures Structure - C-Class
2.2.2 Overview - PNGV-Class
2.2.2.1 Parts Lists
2.2.2.1 Parts Lists - Closures Structure - PNGV-Class - Front Door RH/LH
ULSAB-AVC - PNGV-Class - Front Door RH/LH

Blank No. Revision Level Grade (MPa) Gage (mm) 1.20 1.20 1.00 1.20 1.00 1.20 0.90 NA NA NA NA NA NA 1.00 1.00 1.00 1.00 1.50 1.00 0.60 0.60 0.60 0.60 1.20 1.20 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 Manuf. 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 Designed Mass (kg) Designed C-Class C-Class PNGVClass 0.648 0.648 0.500 0.384 0.500 0.384 0.028 0.246 0.084 0.044 0.160 0.040 0.140 0.330 0.330 0.620 0.620 2.580 1.600 3.792 3.792 0.798 0.798 0.060 0.060 19.186
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 TOTAL
1 2004 Hinge Tube - Front Door RH 1 2005 Hinge Tube - Front Door LH 1 2020 Inner Front - Front Door RH 1 2021 Inner Front - 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 - FD (0.007kg x4) Hinge Bushing - Front Door (0.041kg x6) Latch Bushing - Front Door (0.014kg x6) U-Clip M6 x 1.00 - Front Door (0.011kg x4) Hex Flange Head M6 x 15 - FD (0.040kg x4) Weld Stud M6 x 16 - Front Door (0.005kg x8) Adhesive Bond Lwr Tube - FD (0.070kg x2) Mirror Flag Outer - Front Door RH Mirror Flag Outer - Front Door LH Latch Tube - Front Door RH Latch Tube - Front Door LH Lower Tube - Front Door (x2) Outer Belt Reinforcement - Front Door (x2) Outer - Front Door RH Outer - Front Door LH Inner Rear - Front Door RH Inner Rear - Front Door LH Reinforcement Latch - Front Door RH Reinforcement Latch - 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
* denotes Tube
2.2.2.1 Parts Lists - Closures Structure - PNGV-Class - Rear Door RH/LH
ULSAB-AVC - PNGV-Class - Rear Door RH/LH

Blank No. Revision Level Grade (MPa) Gage (mm) 0.90 NA NA NA NA 0.60 0.60 1.00 1.20 1.00 1.20 0.60 0.60 1.20 1.20 1.00 1.00 1.50 1.00 1.10 1.10 1.20 1.20 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 Manuf. 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 Designed Mass (kg) C-Class PNGVClass 0.028 0.246 0.084 0.040 0.140 3.792 3.792 0.430 0.408 0.430 0.408 1.062 1.062 0.744 0.744 0.850 0.850 1.560 1.480 0.143 0.143 0.060 0.060 18.556
Number
Name
Date
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 - FD (0.007kg x4) Hinge Bushing - Front Door (0.041kg x6) Latch Bushing - Front Door (0.014kg x6) Weld Stud M6 x 16 - Front Door (0.005kg x8) Adhesive Bond Lwr Tube - FD (0.070kg x2) Outer - Rear Door RH Outer - Rear Door LH 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 - 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 - Rear Door RH Inner Rear - Rear Door LH Hinge Tube - Rear Door RH Hinge Tube - Rear Door LH Latch Tube - Rear Door RH Latch Tube - Rear Door LH Lower Tube - Rear Door (x2) Outer Belt Reinforcement - Rear Door (x2) Reinf Belt Hinge Tube - Rear Door RH Reinf Belt Hinge Tube - Rear Door LH Reinforcement Latch - Rear Door RH Reinforcement Latch - Rear Door LH
1 2 1 2
* denotes Tube
2.2.2.1 Parts Lists - Closures Structure - PNGV-Class - Hood
ULSAB-AVC - PNGV-Class - Hood

Revision Level Blank No. Grade (MPa) Gage (mm) Material Type Yield Strength 0.60 0.60 2.50 1.50 1.50 Mild DP Mild Mild Mild 140 350 140 140 140 Tensile Strength 270 600 270 270 270 Manuf. Process Code Designed Mass (kg) Designed
Number
Name
Date
PNGVClass 3.408 5.676 0.070 0.070 0.310 9.534
1 2600 Inner - Hood 1 2601 Outer - Hood 1 x Striker Assembly - Hood 1 x Reinforcement Striker - Hood 1 x Reinforcement Hinge - Hood (x2)
B01 B00
10-Apr-01 09-Feb-01
S S or HFS S S S
* denotes Tube
2.2.2.1 Parts Lists - Closures Structure - PNGV-Class - Deck Lid
ULSAB-AVC - PNGV-Class - Deck Lid

Blank No. Revision Level Grade (MPa) Gage (mm) 0.60 0.60 1.50 1.50 1.20 Material Type Mild DP Mild Mild Mild Yield Strength 140 350 140 140 140 Tensile Strength 270 600 270 270 270 Designed Mass (kg) Designed Manuf. Process PNGVCode C-Class C-Class Class S S or HFS S S S 3.768 6.072 0.070 0.040 0.320 10.270
Number
Name
Date
3 2500 Inner - Deck Lid 3 2501 Outer - Deck Lid 3 x Striker Assembly - Decklid 3 x Reinforcement Striker - Decklid 3 x Reinforcement Hinge - Decklid (x2)
C01 C00
10-Apr-01 12-Jan-01
* denotes Tube
2.2.2.2 Exploded View - Closures Structure - PNGV-Class
2.2.3 Front Doors - C-Class/PNGV-Class
2.2.3.1 Parts Book Index
2.2.3.1 Parts Book Index - Front Doors Structure - C-Class/PNGV-Class
Pa rt Numbe r AVC 1 2004 AVC 1 2020 AVC 1 2026 AVC 1 2045 AVC 1 2047 AVC 1 2056 AVC 1 2057 AVC 1 2058 AVC 2 2000 AVC 2 2006 AVC 2 2008 AVC 2 2010 AVC 2 2022 AVC 2 2050 AVC 3 2006 AVC 3 2008 AVC 3 2010 AVC 3 2028 AVC 3 2030 AVC 3 2052
Pa rt Na me Hinge Tube - Front Door RH Inner Front - Front Door RH Mirror Flag Outer - Front Door RH Assy W-Reg Attach Upper - Front Dr (x2 / door) Hinge Bushing - Front Door (x3 / door) Latch Bushing - Front Door (x3 / door) U-Clip M6 x 1.00 - Front Door (x2 / door) Hex Flange Head M6 x 15 - Front Dr (x2 / door) Outer - Front Door RH Latch Tube - Front Door RH Lower Tube - Front Door (x2) Outer Belt Reinforcement - Front Door (x2) Inner Rear - Front Door RH Reinforcement Latch - Front Door RH Latch Tube - Front Door RH Lower Tube - Front Door (x2) Outer Belt Reinforcement - Front Door (x2) Outer - Front Door RH Inner Rear - Front Door RH Reinforcement Latch - Front Door RH
Re visio n C02 B03 B03 A00 A00 A00 A00 A00 C04 C02 D00 D00 B02 A00 C02 D00 D00 B05 B02 A00
Da te 09-Apr-01 10-Apr-01 04-Apr-01 09-May-01 09-May-01 09-May-01 09-May-01 09-May-01 08-Apr-01 09-Apr-01 04-Apr-01 05-Apr-01 11-Apr-01 02-Apr-01 10-Apr-01 04-Apr-01 05-Apr-01 08-Apr-01 10-Apr-01 02-Apr-01
2.2.3.2 Parts Book Sheets
2.2.3.2 Parts Book Sheets - Front Doors Structure - C-Class/PNGV-Class
2.2.4 Rear Door - PNGV-Class
2.2.4.1 Parts Book Index - Rear Door Structure - PNGV-Class
Pa rt Numbe r AVC 1 2045 AVC 1 2047 AVC 1 2056 AVC 3 2032 AVC 3 2034 AVC 3 2038 AVC 3 2040 AVC 3 2042 AVC 3 2044 AVC 3 2046 AVC 3 2048 AVC 3 2054
Pa rt Na me Assy W-Reg Attach Upper - Rear Dr (x2 / door) Hinge Bushing - Rear Door (x3 / door) Latch Bushing - Rear Door (x3 / door) Outer - Rear Door RH Inner Front - Rear Door RH Inner Rear - Rear Door RH Hinge Tube - Rear Door RH Latch Tube - Rear Door RH Lower Tube - Rear Door (x2) Outer Belt Reinforcement - Rear Door (x2) Reinf Belt Hinge Tube - Rear Door RH Reinforcement Latch - Rear Door RH
Re visio n A00 A00 A00 B02 B02 B02 B02 B02 C00 C00 B02 A00
Da te 09-May-01 09-May-01 09-May-01 05-Apr-01 12-Apr-01 12-Apr-01 12-Apr-01 12-Apr-01 04-Apr-01 05-Apr-01 12-Apr-01 02-Apr-01
2.2.4.2 Parts Book Sheets - Rear Door Structure - PNGV-Class
2.2.5 Hood - C-Class/PNGV-Class
2.2.5.1 Parts Book Index - Hood Structure - C-Class/PNGV-Class
Pa rt Numbe r AVC 1 2600 AVC 1 2601 Inner - Hood Outer - Hood
Pa rt Na me
Re visio n B01 B00
Da te 10-Apr-01 09-Feb-01
2.2.5.2 Parts Book Sheets - Hood Structure
2.2.5.2 Parts Book Sheets - Hood Structure
2.2.6 Liftgate - C-Class
2.2.6.1 Parts Book Index - Liftgate Structure - C-Class
Pa rt Numbe r AVC 2 2400 AVC 2 2401 AVC 2 2402 Inner - Liftgate Outer - Liftgate
Pa rt Na me
Re visio n B03 B03 B00
Da te 14-Feb-01 14-Feb-01 02-Feb-01
Member Aperture - Liftgate
2.2.6.2 Parts Book Sheets - Liftgate Structure - C-Class
2.2.7 Deck Lid - PNGV-Class
2.2.7.1 Parts Book Index - Deck Lid Structure - PNGV-Class
Pa rt Numbe r AVC 3 2500 AVC 3 2501 Inner - Deck Lid Outer - Deck Lid
Pa rt Na me
Re visio n C01 C00
Da te 10-Apr-01 12-Jan-01
2.2.7.2 Parts Book Sheets - Deck Lid Structure - PNGV-Class
2.2.7.2 Parts Book Sheets - Deck Lid Structure - PNGV-Class
2.3 Ancillary Closures Structure
2.3.1 Parts List
2.3.1 Parts Lists - Ancillary Closures Structure
ULSAB-AVC - C-Class / PNGV-Class - Ancillary Closures RH/LH

Blank No. Revision Level Grade (MPa) Gage (mm) 0.60 0.60 0.60 0.60 0.50 0.50 0.60 0.50 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 Manuf. Process Code S S or HFS S or HFS S S S S S S Designed Mass (kg) C-Class 0.348 1.608 1.608 0.090 1.290 1.290 PNGVClass 0.348 1.608 1.608
Number
Name
Date
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 - Roof Side Rail RH Applique - Roof Side Rail LH Fuel Filler Lid Applique - Roof Side Rail RH Applique - 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
6.234 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
0.090 1.430 1.430 6.514
2.3.2 Exploded View
2.3.2 Exploded View - Ancillary Closures Structure
2.3.3 Parts Book Index
2.3.3 Parts Book Index - Ancillary Closures Structure
Part Number AVC 1 2300 AVC 1 2602 AVC 2 2301 AVC 2 2700 AVC 3 2302 AVC 3 2702
Part Name Engine Service Lid Fender RH Fuel Filler Lid Applique - Roof Side Rail RH Fuel Filler Lid Applique - Roof Side Rail RH
Revision A00 B01 A00 A02 A00 A02
Date 20-Feb-01 19-Feb-01 20-Feb-01 19-Feb-01 20-Feb-01 19-Feb-01
2.3.4 Parts Book Sheets
2.3.4 Parts Book Sheets - Ancillary Closures Structure
2.4 Ancillary Structure
2.4.1 Front Seat Structure
2.4.1.1 Parts List
2.4.1.1 Parts List - Front Seat Structure
ULSAB-AVC - Front Seat RH/LH

Blank No. Revision Level Grade (MPa) Gage (mm) 1.20 1.00 1.00 1.00 1.00 1.00 1.00 1.50 1.50 1.50 1.50 1.00 1.00 0.70 0.70 2.00 2.00 2.00 2.00 2.00 2.00 1.00 1.00 Assy Assy Material Type Mart * DP * DP * DP * DP * DP * HSLA TRIP TRIP TRIP TRIP DP DP Mild * Mild * HSLA HSLA HSLA HSLA HSLA HSLA Mild Mild Assy Assy Yield Strength 950 350 350 350 350 350 350 450 450 450 450 500 500 140 140 350 350 350 350 350 350 140 140 Assy Assy Tensile Strength 1200 600 600 600 600 600 450 800 800 800 800 800 800 270 270 450 450 450 450 450 450 270 270 Assy Assy Manuf. Process Code ST ST ST ST ST ST S S S S S S S ST ST S S S S S S S S Designed Mass (kg) C-Class 2.568 1.120 1.120 0.300 0.300 0.500 0.400 0.510 0.510 0.135 0.135 0.710 0.710 0.931 0.931 0.760 0.480 0.260 0.260 0.100 0.100 1.320 1.300 1.952 1.952 19.364 PNGVClass 2.568 1.120 1.120 0.300 0.300 0.500 0.400 0.510 0.510 0.135 0.135 0.710 0.710 0.931 0.931 0.760 0.480 0.260 0.260 0.100 0.100 1.320 1.300 1.952 1.952 19.364
Number
Name
Date
AVC 1 AVC 1 AVC 1 AVC 1 AVC 1 AVC 1 AVC 1 AVC 1 AVC 1 AVC 1 AVC 1 AVC 1 AVC 1 AVC 1 AVC 1 AVC 1 AVC 1 AVC 1 AVC 1 AVC 1 AVC 1 AVC 1 AVC 1 AVC 1 AVC 1 TOTAL Code S ST ROD Code DP HSLA Mart Mild TRIP
1184 1400 1401 1402 1403 1404 1405 1406 1407 1408 1409 1410 1411 1412 1413 1414 1415 1416 1417 1418 1419 1420 1421 1422 1423
Crossmember Support Front Seat Rear Frame Member Back Support Front Seat RH Frame Member Back Support Front Seat LH Diagonal Member Back Supt Front Seat RH Diagonal Member Back Supt Front Seat LH Crossmember Back Support Front Seat (x2) Bracket Head Support Attach Front Seat (x2) Bracket Retractor Attachment Front Seat RH Bracket Retractor Attachment Front Seat LH Reinf Retractor Attachment Front Seat RH Reinf Retractor Attachment Front Seat LH Retainer Spring Back Support Front Seat RH Retainer Spring Back Support Front Seat LH Frame Member Seat Support Front Seat RH Frame Member Seat Support Front Seat LH Bracket Back Supt Attach Outer Frt Seat (x2) Bracket Back Supt Attach Inner Frt Seat (x2) Bracket Seat Attach Outer Front Seat RH Bracket Seat Attach Outer Front Seat LH Bracket Seat Attach Inner Front Seat RH Bracket Seat Attach Inner Front Seat LH Frame Cushion Support Front Seat (x2) Reinf Cushion Support Front Seat (x2) Assy Tilt Mech Cushion Supt Front Seat RH Assy Tilt Mech Cushion Supt Front Seat LH
C00 A01 A01 A01 A01 A01 A01 A01 A01 A01 A00 A01 A01 A00 A00 A01 A01 A01 A01 A00 A00 A00 A00 A01 A01
03-Nov-00 10-May-01 10-May-01 10-May-01 10-May-01 10-May-01 09-May-01 10-May-01 10-May-01 10-May-01 04-May-01 10-May-01 10-May-01 04-May-01 04-May-01 10-May-01 10-May-01 10-May-01 10-May-01 04-May-01 04-May-01 04-May-01 04-May-01 09-May-01 09-May-01
Manufacturing Process Stamped Straight or Shaped Tube Straight or Shaped Rod Steel Types Dual Phase High Strength, Low Alloy Martensitic Mild Steel Transformation-Induced Plasticity
* denotes tube
2.4.1.2 Exploded View - Front Seat Structure
2.4.1.3 Parts Book Index - Front Seat Structure
Part Number AVC 1 1184 AVC 1 1400 AVC 1 1402 AVC 1 1404 AVC 1 1405 AVC 1 1406 AVC 1 1408 AVC 1 1410 AVC 1 1412 AVC 1 1414 AVC 1 1415 AVC 1 1416 AVC 1 1418 AVC 1 1420 AVC 1 1421 AVC 1 1422
Part Name Crossmember Support Front Seat Rear Frame Member Back Support Front Seat RH Diagonal Member Back Supt Front Seat RH Crossmember Back Support Front Seat (x2) Bracket Head Support Attach Front Seat (x2) Bracket Retractor Attachment Front Seat RH Reinf Retractor Attachment Front Seat RH Retainer Spring Back Support Front Seat RH Frame Member Seat Support Front Seat RH Bracket Back Supt Attach Outer Frt Seat (x2) Bracket Back Supt Attach Inner Frt Seat (x2) Bracket Seat Attach Outer Front Seat RH Bracket Seat Attach Inner Front Seat RH Frame Cushion Support Front Seat (x2) Reinf Cushion Support Front Seat (x2) Assy Tilt Mech Cushion Supt Front Seat RH
Revision C00 A01 A01 A01 A01 A01 A01 A01 A00 A01 A01 A01 A00 A00 A00 A01
Date 03-Nov-00 10-May-01 10-May-01 10-May-01 09-May-01 10-May-01 10-May-01 10-May-01 04-May-01 10-May-01 10-May-01 10-May-01 04-May-01 04-May-01 04-May-01 09-May-01
2.4.1.4 Parts Book Sheets - Front Seat Structure
2.4.2 Rear Seat Structure
2.4.2.1 Parts List
2.4.2.1 Parts List - Rear Seat Structure
ULSAB-AVC - Rear Seat

Blank No. Revision Level Grade (MPa) Gage (mm) 4.00 4.00 1.50 2.00 2.00 2.00 0.80 0.80 1.00 1.00 1.00 1.00 1.00 1.00 Material Type Mild Mild Mild HSLA HSLA HSLA DP DP HSLA HSLA HSLA HSLA HSLA HSLA Yield Strength 140 140 140 350 350 350 350 350 350 350 350 350 350 350 Tensile Strength 270 270 270 450 450 450 600 600 450 450 450 450 450 450 Manuf. Process Code ROD ROD S S S S S S S S S S S S Designed Designed Mass (kg) C-Class C-Class 0.745 0.745 0.531 0.531 0.045 0.045 0.300 0.300 0.280 0.280 0.280 0.280 3.136 3.136 1.984 1.984 0.380 0.380 0.380 0.380 0.380 0.380 0.380 0.380 0.950 0.950 0.380 0.380 10.151 10.151 PNGVClass 0.745 0.531 0.045 0.300 0.280 0.280 3.136 1.984 0.380 0.380 0.380 0.380 0.950 0.380 10.151
Number
Name
Date
AVC 1 AVC 1 AVC 1 AVC 1 AVC 1 AVC 1 AVC 1 AVC 1 AVC 1 AVC 1 AVC 1 AVC 1 AVC 1 AVC 1 TOTAL Code S ST ROD Code DP HSLA Mart Mild TRIP
1424 1425 1426 1427 1428 1429 1430 1431 1432 1433 1434 1435 1436 1437
Assy Seat Support 60% Rear Seat Assy Seat Support 40% Rear Seat Bracket Seat Support Attach Rear Seat (x4) Bracket Back Supt Inner Floor Attach Rr Seat Brkt Back Supt Outer Floor Atach Rr Seat RH Brkt Back Supt Outer Floor Atach Rr Seat LH Back Support 60% Rear Seat Back Support 40% Rear Seat Reinf Back Support Outer Rear Seat RH Reinf Back Support Outer Rear Seat LH Reinf Back Support Inner Rear Seat RH Reinf Back Support Inner Rear Seat LH Bracket Head Support Attach 60% Rear Seat Bracket Head Support Attach 40% Rear Seat
A00 A00 A00 A00 A00 A00 A00 A00 A00 A00 A00 A00 A00 A00
30-May-01 30-May-01 30-May-01 30-May-01 30-May-01 30-May-01 30-May-01 30-May-01 30-May-01 30-May-01 30-May-01 30-May-01 30-May-01 30-May-01
Manufacturing Process Stamped Straight or Shaped Tube Straight or Shaped Rod Steel Types Dual Phase High Strength, Low Alloy Martensitic Mild Steel Transformation-Induced Plasticity
* denotes tube
2.4.2.2 Exploded View - Rear Seat Structure
2.4.2.3 Parts Book Index - Rear Seat Structure
Part Number AVC 1 1424 AVC 1 1425 AVC 1 1426 AVC 1 1427 AVC 1 1428 AVC 1 1430 AVC 1 1431 AVC 1 1432 AVC 1 1434 AVC 1 1436 AVC 1 1437
Part Name Assy Seat Support 60% Rear Seat Assy Seat Support 40% Rear Seat Bracket Seat Support Attach Rear Seat (x4) Bracket Back Supt Inner Floor Attach Rr Seat Brkt Back Supt Outer Floor Atach Rr Seat RH Back Support 60% Rear Seat Back Support 40% Rear Seat Reinf Back Support Outer Rear Seat RH Reinf Back Support Inner Rear Seat RH Bracket Head Support Attach 60% Rear Seat Bracket Head Support Attach 40% Rear Seat
Revision A00 A00 A00 A00 A00 A00 A00 A00 A00 A00 A00
Date 30-May-01 30-May-01 30-May-01 30-May-01 30-May-01 30-May-01 30-May-01 30-May-01 30-May-01 30-May-01 30-May-01
2.4.2.4 Parts Book Sheets - Rear Seat Structure
2.4.3 Instrument Panel Structure
2.4.3.1 Parts List
2.4.3.1 Parts List - Instrument Panel Structure
ULSAB-AVC Instrument Panel Structure Parts List

Blank No. Revision Level Gage (mm) 2.50 2.00 2.00 2.00 2.00 2.00 Material Type Mild DP * Mild Mild Mild * Mild
Revision Level: A05

Grade (MPa) Yield Strength 140 350 140 140 140 140 Tensile Strength 270 600 270 270 270 270
Date:30 JULY 01 30 JULY

Designed Mass (kg) Designed C-Class C-Class 1.775 1.775 3.260 3.260 0.220 0.220 0.220 0.220 0.720 0.720 0.120 0.120 6.315 6.315 PNGVClass 1.775 3.260 0.220 0.220 0.720 0.120 6.315
Number
Name
Date
Manuf. Process Code S ST S S ST S
AVC 1 AVC 1 AVC 1 AVC 1 AVC 1 AVC 1 TOTAL Code S ST Code DP Mild
1302 1303 1304 1305 1306 1307
Bracket Steering Column Attachment Crossmember Instrument Panel Bracket C-Member Inst Panel Support RH Bracket C-Member Inst Panel Support LH Brace C-Member Inst Panel Support (x2) Plate C-Member Inst Panel Attachment (x2)
A02 A01 A00 A00 A00 A01
22-Mar-01 20-Mar-01 27-Feb-01 27-Feb-01 28-Feb-01 20-Mar-01
Manufacturing Process Stamped Straight or Shaped Tube Steel Types Dual Phase Mild Steel
* denotes tube
2.4.3.2 Exploded View - Instrument Panel Structure
2.4.3.3 Parts Book Index - Instrument Panel Structure
Part Number AVC 1 1302 AVC 1 1303 AVC 1 1304 AVC 1 1306 AVC 1 1307
Part Name Bracket Steering Column Attachment Crossmember Instrument Panel Bracket C-Member Inst Panel Support RH Brace C-Member Inst Panel Support (x2) Plate C-Member Inst Panel Attachment (x2)
Revision A02 A01 A00 A00 A01
Date 22-Mar-01 20-Mar-01 27-Feb-01 28-Feb-01 20-Mar-01
2.4.3.4 Parts Book Sheets - Instrument Panel Structure
2.4.4 Bumper Beam Structure
2.4.4.1 Parts List
2.4.4.1 Parts List - Bumper Beam Structure
ULSAB-AVC Bumper Beam Structure Parts List

Blank No. Revision Level Gage (mm) 1.10 1.00 1.00 1.00 0.80 0.80 0.80 0.80 Material Type DP Mart Mart HSLA Mart Mart Mart Mart
Revision Level: A02

Grade (MPa) Yield Strength 400 1250 1250 350 1250 1250 1250 1250 Tensile Strength 700 1520 1520 450 1520 1520 1520 1520
Date: 22 MAR 01 0
Designed Mass (kg) C-Class 1.408 1.940 2.640 0.920 1.312 2.064 PNGVClass 1.408 1.940 2.640 0.920
Number
Name
Date
Manuf. Process Code S RF S S RF S RF S
AVC 1 AVC 1 AVC 1 AVC 1 AVC 2 AVC 2 AVC 3 AVC 3 TOTAL Code S RF Code DP HSLA Mart
1009 1012 1013 1206 1047 1048 1047 1048
Assy Crash Box Bumper Front (x2) Bumper Beam Front Inner Bumper Beam Front Outer Assy Crash Box Bumper Rear (x2) Bumper Beam Rear Inner Bumper Beam Rear Outer Bumper Beam Rear Inner Bumper Beam Rear Outer
D01 E01 F01 B02 F00 G00 F00 G00
31-Oct-00 25-Jan-01 25-Jan-01 24-Jan-01 24-Jan-01 24-Jan-01 24-Jan-01 24-Jan-01
10.284 Manufacturing Process Stamped Roll Formed Steel Types Dual Phase High Strength, Low Alloy Martensitic
1.536 2.336 10.780
2.4.4.2 Exploded View - Bumper Beam Structure
2.4.4.3 Parts Book Index - Bumper Beam Structure
Part Number AVC 1 1009 AVC 1 1012 AVC 1 1013 AVC 1 1206 AVC 2 1047 AVC 2 1048 AVC 3 1047 AVC 3 1048
Part Name Assy Crash Box Bumper Front (x2) Bumper Beam Front Inner Bumper Beam Front Outer Assy Crash Box Bumper Rear (x2) Bumper Beam Rear Inner Bumper Beam Rear Outer Bumper Beam Rear Inner Bumper Beam Rear Outer
Revision D01 E01 F01 B02 F00 G00 F00 G00
Date 31-Oct-00 25-Jan-01 25-Jan-01 24-Jan-01 24-Jan-01 24-Jan-01 24-Jan-01 24-Jan-01
2.4.4.4 Parts Book Sheets - Bumper Beam Structure

Appendix 2 Parts Book

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Appendix 2 Parts Book

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2.

ULSAB-AVC Engineering Report - Appendix - Section 2.0

2.1 Body Structure

ULSAB-AVC Engineering Report - Appendix - Section 2.1

ULSAB-AVC Engineering Report - Appendix - Section 2.1.1

2.1.1.1 Parts List

ULSAB-AVC Engineering Report - Appendix - Section 2.1.1.1

2.1.1.1 Parts List - Body Structure - C-Class

ULSAB-AVC Body Structure Parts List C-Class

Revision Level: A21

Manuf. 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

AVC 2 1021 Body Side Outer LH

AVC 2 1036 Wheelhouse Inner RH

AVC 2 1037 Wheelhouse Inner LH

AVC AVC AVC AVC AVC

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

AVC 2 1070 Gutter C-Pillar RH AVC 2 1071 Gutter C-Pillar LH

ULSAB-AVC Engineering Report - Appendix - Section 2.1.1.1

2.1.1.1 Parts List - Body Structure - C-Class

ULSAB-AVC Body Structure Parts List C-Class

Revision Level: A21

Material Type 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

AVC AVC AVC AVC AVC AVC AVC AVC

1072 1073 1074 1076

C-Pillar Inner RH C-Pillar Inner LH Back Panel Rail Rear RH

Code S S/TWB HFT HFT/TWT S or HFS ST Code BH CP DP HSLA IF Mart TRIP

ULSAB-AVC Engineering Report - Appendix - Section 2.1.1.1

2.1.1.2 Exploded View

ULSAB-AVC Engineering Report - Appendix - Section 2.1.1.2

2.1.1.2 Exploded View - Body Structure - C-Class

ULSAB-AVC Engineering Report - Appendix - Section 2.1.1.2

ULSAB-AVC Engineering Report - Appendix - Section 2.1.2

2.1.2.1 Parts List

ULSAB-AVC Engineering Report - Appendix - Section 2.1.2.1

2.1.2.1 Parts List - Body Structure - PNGV-Class

ULSAB-AVC Body Structure Parts List PNGV-Class

Revision Level: A21

Manuf. 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

AVC 3 1037 Wheelhouse Inner LH

AVC AVC AVC AVC

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

S S S HFT/TWT HFT/TWT S/TWB

D00 B08 B08 E00 E00 E00 D00

04-Jan-01 02-Feb-01 02-Feb-01 03-Jan-01 03-Jan-01 03-Jan-01 06-Jan-01

S S/TWB S/TWB S S S S or HFS

ULSAB-AVC Engineering Report - Appendix - Section 2.1.2.1

2.1.2.1 Parts List - Body Structure - PNGV-Class

ULSAB-AVC Body Structure Parts List PNGV-Class

Revision Level: A21

Material Type DP * DP * DP DP IF IF 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

Manuf. Process Code HFT HFT S S S S S/TWB S/TWB S/TWB

AVC AVC AVC AVC AVC AVC AVC

1130 1131 1156 1157 1160 1161 1162

B03 B03 C02 C00 C01 C01 A12 A12 B05

19-Feb-01 19-Feb-01 08-Jan-01 22-Dec-00 03-Jan-01 03-Jan-01 11-Apr-01 11-Apr-01 10-Apr-01