1. Final Trim Line Assembly

ULSAB-AVC Engineering Report - Appendix - Section 1.0

Interior TrimAssembly Area

Rear SeatbeltLocks to

Rear Floor

Rear SeatUnit

WiperSystem

Installation

Front Seat Unit Including SeatBelts on Seat Cross MemberBody to Line

Start Assembly Line

Fuel TankInstallation

Filler NeckInstallation

LaterRear Exhaust Tunnel

Closeout Inst.

Exhaust TunnelRear Installation

ExhaustSystem

Front Cat. Conv.

Muffler

Rear AxleSubassembly

Installation fromSystem Supplier

Coil Springs

Shock to Body

Quality Verification

Brake Linesto Body F.Rear Susp.

Subframe with Suspension +Brakes + Driveshaft + Engine

Mounts from Systems Supplier

Engine + Gearbox fromSystems Supplier Incl.Engine Electric Wiring

Harness

Engine to Subframeinstallation (+ Driveshaftsto Gearbox Installation)

910 Quality Verification

Steering Raceto Subframe

930 Quality Verification

Air Conditioning Radiatorto Subframe incl. Fan(Diesel + Intercooler)

Quality Verification

Drysump Tank toSubframe

Quality Verification

Hose Hook-up Water,Oil, Intercooler

Quality Verification

Installation ofFront EndModule

Exhaust toEngine

Bolt Battery Tray toKick-up CrossmemberCharcoal Canister +Fuel Line to C. C.

Version 08/21/01

Fuel Linesto Engine

Pedal System toBody Structure

Quality Verification

ABS Unit InstallationConnect Brake

Actuator to ABS Unit

BrakeLines toABS Unit

Electric WiringHarness to

Body Structure

Brake SystemFilling

Battery intoBattery Tray

Carpet Incl.Damping

Instrument Panel CompleteInstallation Incl. Air Bar

Ducting + Heat Exchanger

Steering Shaft toInstrument Panel

SteeringWheel

Parcel Shelf SupportLH Install

Parcel Shelf SupportRH Install

Rear Quarter TrimPanel LH Install

Rear Quarter TrimPanel RH Install

Headliner InstallSupport

HeadlinerInstall

C Pillar MoldingLH Install

C Pillar MoldingRH Install

B Pillar MoldingLower LH Install

B Pillar MoldingLower RH Install

B Pillar MoldingUpper LH Install

B Pillar MoldingUpper RH Install

Rocker MoldingInstall LH

Rocker MoldingInstall RH

A Pillar MoldingLower LH Install

A Pillar MoldingLower RH Install

A Pillar MoldingUpper LH Install

A Pillar MoldingUpper RH Install

SunvisorInstall LH

SunvisorInstall RH

Rear ParcelShelf Install

Interior Light andCoat Hook Install

Quality Verification

Seals andSill Covers

Bond BatteryTray intoStructure

Upper FrontEnd Module

Subassembly

Air Filter

Fusebox

Wiper Fluid

Plastic Pan

Heating and AirConditioning

Assembly Moduleto Body Structure

Hook-up ofWaterElectricAirHeating/Air Conditioning

Front Facia ModuleInst. + Hook-up ofElectrics (Bumper,Lights, Airducts)

Tunnel TrimIncl. ElectronicParking Brake

Quality Verification

Latches toBody

Structure

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

Door Assembly -Magazine incl. Glass

Rear View Camera System

Trim

Hinges

Cables

Lock

Rear Hatch/ Decklid

Lock

Gas Struts

Electrics

Glazing

Bumper Lights

3rd Brake Light

Door Fit Verification

GlazingWindshieldRear Quarter Glass

Fenders RH

From Paintshop

Hood to BodyStructure +Fenders LH

Rear Fascia

RearLights

Wheels /Tires 4x

FillingWaterOilWasher Fluid

Fueling +Filler Cap

Tests

HVAC

Emissions

Fluids

Electrical

Seats and Belts

Preparationfor

Shipping

ExteriorTrim andDecals Final Inspection

Drive Off

ULSAB-AVC Assembly

100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600

1700

1800 1900 2000 2100 2200 25002400 2600

2700

2800

2900

3000

3400 3500 3600 3700 3800 3900 40004100 4200

4300

4400 4500 4700 4800

4900

5000 5100 5200 5300 5400 5500 5600 5700 5800 5900 6000 6100 6200 6300 6400

6500

7000

6600

6700

6800

6900

7100

72002

1

2

1

1

1

1

1

1

1 2

1

1

2

2

1

2

2

2

1

3100

3200

3300

2

2

1

4

1

2

2 3

1

2

1

2

4

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

3

1

1

1

2

1

1

2

2

2

1

1

1

1

15

1

1

Rear BumperInstallation

1

2

1

1

1

1

1

3 1 1

Station 100 200 300 400 500 600 700 800 900 to 990 10stations 1000 1100 1200 1300 1400 1500 1600 1800 1900 2000 2100 2200 25002400 2600 3400 3500 3600 3700 3800 3900 4000 4100 4200 5000 5100 5200 5300 5400 5500 5600 5700 5800 5900 6000 6100 6200 6300 6400 7000 710049004400 4500 4600 4700 480043001700Drive Off

72006500 - 6900

1

1 1

2 1

2

2 3

2

1 1 1 1 1 1 2 1 4 2 1

2700 - 3300

13 4

1

1 2 1 3

1

2 1 2 4 6 / 12 3

1 3

1 1

1 1

1 2 1 1 2 5 2 2 599/111

16/20

Duration

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

2 / 4

Mechanical Lifter

1 1 man per side of line

2

mechanical Lifter mechanical Lifter

920

940

960

980

905

950

990

970

2

load assist

3650

1

1

4

Load Assist

2

Load assist

4150

1

4150

6150

6150

1

1

3450