3315517 - Introduction - BODYSHELL PANELS - REPLACING AND REPAIRING

INTRODUCTION

Introduction

Alfa Romeo has produced this collection of technical information to support the training programme for the new 166 model.The subjects have been developed, documenting, above all, the technical innovations, useful for overcoming the various tests set by the new legislation, assisting the description and teaching aspects, limited to providing minimal ideas, rules and precautions.For information on repair techniques and vehicle technical data, refer to the descriptions in the specific sections in the Repair Manual.

Aerodynamics

The style of the new car, featuring smooth lines which are modern yet, at the same time, recall styles of the past, contains all of the sporting tradition of Alfa Romeo plus the quality of a large saloon.The aims of adaptability, comfort, functionality and strength already achieved on previous models have all been consolidated.The front, the side panels with new and traditional perimeter trims, the side windows, the joined surfaces, the rear section and the underbody have been designed with special attention paid to the aerodynamic profile which, together with the typcial marque attitude, have made it possible to achieve an excellent drag coefficient and also reduce aerodynamic noise.

SAFETY

Introduction

The main aim of car manufacturers is undoubtedly the complete safety of the driver and passengers.To adapt the vehicle to market regulations, both European and world wide, which have become very exacting, the new Alfa Romeo has been designed with care taken over every detail in order to respond in the best possible way to all situations.Preventative safety

This involves all those factors which determine the comfort of driving conditions and allow situations which could distract the attention of the driver to be prevented:

  • extremely rigid bodyshell;
  • optimum engine mountings;
  • climate control system, equipped with devices such as, solar ray sensor, automatic switching off of recirculation for the exchange of air inside the passenger compartment, passenger compartment air filter, pollen filter, which allows a better exchange of air and better transpiration and thermal comfort and a balanced distribution throughout the passenger compartment thanks to the numerous vents, producing a significant development compared with conventional systems;
  • optimum visibility conditions thanks to the extensive glazed area and, on request, a windscreen with a rain sensor;
  • new adjustable headlamps which are automatically realigned, by means of a sophisticated system of signals coming from position sensors in the suspension and a longitudinal accelerometer (for pitching movements due to the vehicle accelerating or braking).The headlamps are available, on request, with exhaust gas (xenon) bulbs which have twice the intensity of normal halogen bulbs and allow better visibility;
  • the layout of the steering wheel, the pedals, the main controls and the warning lights has been carefully thought out to obtain a good balance between the driving position and the ease of reaching these controls allowing a sports driving style whilst maintaining a level of comfort which ensures the best possible control of the vehicle;
  • the generous dimensions of the interior spaces which make it possible to diversify the areas of activity inside the vehicle combined with the wraparound seats and, available on request for the front seats, electrical adjustments which allow the necessary comfort of the driver and the occupants of the vehicle;
  • abundant use of sound insulation materials and the adoption of special solutions for anti-vibration fixings to lower the mechanical noise and ensure quiet driving;
  • interior fittings which respond to the most stringent regulations governing flammability.
Active safetyThis involves all those measures which actively contribute to driving safety such as take-off and acceleration, solutions which guarantee stable and powerful braking and the dynamic behaviour of the vehicle

In this field, the Alfa 166, in addition to confirming the tradition of the marque, finds itself at the top end of the market, adopting solutions which include:

  • a dual crossover independent circuit braking system with ABS, fitted as standard on all models, with 4 channels and 4 active sensors which reduce the implementation times, equipped with electronic brake force distribution (E.B.D.);
  • an integrated drive control system (A.S.R. / T.C.S.), available on request;
  • a "high quadrilateral" front suspension, similar to those used in competitions, guarantees a high degree of control with both sports and normal driving.The advantages of this suspension are felt in: the driving precision and controlability of the vehicle, even in the wet and in poor grip conditions, an immediate and precise response and a capacity to absorb obstacles and uneven road conditions;
  • rear multilink type suspension with new geometry which combines the sophisticated performance of the multilink system with the relative design simplicity of the quadrilateral system and makes it possible to stabilize the vehicle during steering, guaranteeing excellent road holding properties and reactions to roll and pitching facilitating control ,even during extreme manoeuvres;
  • steering and power assisted steering designed with precision and immediate responsiveness in all situations in mind, with the conditions which sometimes give rise to noise during operation having been minimized.
Passive safetyPassive safety concerns the collection of solutions and features of devices which contribute to avoiding or lessening the consequences of an accident.Statistically about 60% of accidents involve frontal impacts, 30% side impacts and the remaining 10% include bumps, fires and overturning.The structure of the Alfa 166 has been designed and developed with the main objective being to safeguard the occupants from these impacts, to crumple in a controlled manner in the case of frontal, side and rear impacts and to absorb the energy from the impact without compromising the passenger survival chamber. The structure of the Alfa 166 has been designed and developed with the main objective being to safeguard the occupants from these impacts, to crumple in a controlled manner in the case of front, side and rear impacts and to absorb the energy from the impact without compromising the passenger survival chamber.Passive safety system main features

Both the basic version of the vehicle with twin air bags (driver and passenger), fitted as standard on all versions, and the version with a driver's air bag and a passenger side bag, have been successfully tested in accordance with the regulations governing the following situations:

  • offset frontal impacts at high speed - the front crumple zone and the strengthened passenger survival
  • dynamic side impacts - the structure of the side panel, the centre pillar and the reinforced door panels ensure conformity to the regulations;
  • overturning - the structure of the roof panel and the high resistance pillars ensure the survival cell;
  • prevention of the intrusion of the load transported in the luggage compartment - ensured by the partition behind the backrest and the links to the bodyshell;
  • resistance to rear impacts - ensured by the reinforced structure and the new rear side members;
  • impacts at low speed (4 - 15 kph) - special design features have made it possible to minimize damage, with considerable savings in repair costs;
  • front and rear bumpers which exceed the standards in the regulation (ECE 42) and pass the test without serious damage thanks to the optimum deformability and the presence of high density expanded material.
Fire safety

This is achieved through the FPS (Fire Prevention System) which consists of:

  • internal fire extinguishers which restrict the propagation speed of the flames;
  • an inertia switch to cut off the fuel pump;
  • a reflux valve and antimisfiring shields (overheating of the catalyzer on petrol versions);
  • a system protecting the cables through which high intensity currents flow;
  • no fuel leaks and retaining of the battery in the case of an impact or overturning;
  • fuel tank made from a plastic material which has high mechanical and fire resistant properties, located in front of the rear axle and firmly secured to the bodyshell;
  • steel pipes in the area of the spark out.

Bending and torsional strength

The high bending and torsional strength of the Alfa 166 bodyshell, in addition to endowing the vehicle with impressive passive resistance qualities, also translates into multiple advantages:

  • less noise thanks to fewer vibrations;
  • improved driveability, keeping the suspension angles correct;
  • extremely precise driving with a sensation of a firm ride and great comfort;
  • increased resistance to breaking caused by the use of the vehicle over particularly uneven roads;
  • the sensation of a compact car;
  • also ensuring that the overall qualities of the vehicle are maintained for a longer period of time.

Resistance to frontal impacts

In the case of operations to the bodyshell, if the structural reinforcements are distorted they must always be replaced.
The differentiated strength bodyshell has strengthening reinforcements for the survival chamber to resist the stringent frontal impact tests to ensure the rigidity and indestructibility of the passenger compartment offering maximum protection to the occupants and keeping the effect of the impact to a minimum.

The following are the main operations which have been carried out to the bodyshell to achieve the proposed objectives:

  • the reinforcements in the struts, designed to crumple in a pre-set fashion absorbing and distributing the force of the impact thanks to the connecting front crossmember which also allows non central impacts to be absorbed.There is also a further element which absorbs the impact of the rigid foam;
  • reinforcements in the side members and the side pillars connected by a box section crossmember under the windscreen which ensures the transverse rigidity of the passenger compartment joining the side panels at waist height;
  • reinforcements under the floor panel and on the gear lever support which increase the solidity and strength of the floor, limiting the deformation of the pedals, as far as possible;
  • adoption of bonnet lid retaining hooks and a new system for fixing the dashboard.
A further function of absorbing and distributing the force of the impact is carried out by the engine frame which discharges the forces to the box sections under the floor and avoids excessive loads on the passenger compartment.These devices in the box sections, in conjunction with the presence of rigid foam, retaining systems and internal energy absorbing parts allow the Alfa 166 to pass the tests with flying colours.
1.REINFORCEMENTS IN THE STRUTS 2.LOWER FRONT CROSSMEMBER 3.UPPER FRONT CROSSMEMBER 4.REINFORCEMENTS IN SIDE PILLARS 5.REINFORCEMENTS IN SIDE MEMBERS 6.BOX SECTION CROSSMEMBER UNDER THE WINDSCREEN 7.LONGITIDUNAL REINFORCEMENTS UNDER THE FLOOR 8.REINFORCEMENTS UNDER THE FLOOR 9.GEAR LEVER SUPPORT REINFORCEMENT 10.BONNET LID RETAINING HOOK 11.STRUCTURAL FOAM

Resistance to side impacts

As far as resistance to side impacts is concerned, the bodyshell has been designed to conform to the mos recent European regulations and is capable of guaranteeing a high level of safety with special crumple zones in the case of an impact which ensure the passenger survival cell protecting the occupants.

The above has been achieved by:

  • reinforcing the side members under the door inserting beams with a high degree of transverse rigidity to maintain the resistance to deformation properties between the front pillars and the centre pillars forming an ideal door seal;
  • reinforcing the centre pillars along their entire length, inserting a high resistance diaphragm reinforced where the seat belts are mounted and in the area of the lock strikers;
  • adopting a central reinforcement for the floor, which includes the reinforcement for the tunnel for the gear lever support and the crossmember joining the side members under the door with controlled deformation to optimize the distribution of the forces;
  • inserting a multi-thickness box section connecting beam between the centre pillars in the side panels under the high resistance roof panel.
A further essential element in the resistance to side impacts consists of the doors which are discussed in the paragraph which follows.
1.UNDERDOOR SIDE MEMBER REINFORCEMENT 2.COMPLETE CENTRE PILLAR REINFORCEMENT DIAPHRAGM 3.GEAR LEVER SUPPORT TUNNEL REINFORCEMENT 4.REINFORCEMENT CROSSMEMBER BETWEEN THE UNDERDOOR SIDE MEMBERS 5.CENTRE PILLAR CONNECTING BOX SECTION BEAM

Structure of the doors

The structure of the doors is of fundamental importance for the safety of the passengers in the case of side impacts and has therefore been designed with optimum geometry and rigidity of the door panels to complete the capacity to maintain the survival cell and keep possible injury of the occupants to a minimum.The structure of the doors allows them to be opened after the most severe frontal and rear impacts.

This has been achieved by:

  • adopting tubular impact beams and waist reinforcements which follow the line of the pillars, completing the seal of the high resistance door;
  • adopting high resistance locks and strikers;
  • using energy absorption internal door liners with no sharp corners, designed to ensure the minimum impact with the body in the case of an accident;
  • adopting opening devices with bowden cables which ensure operation even in the case of a side impact.
1.REAR DOOR 2.FRONT DOOR 3.REAR WAIST REINFORCEMENT 4.WAIST REINFORCEMENT 5.PILLAR REINFORCEMENT 6.TUBULAR IM
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