2753497 - INTRODUCTION - PANELS AND FRAME

General remarks

The topics are covered with particular attention to the new technical features required for passing the various tests introduced by new legislation. The descriptions and operating information provided are limited to a discussion of principles, rules and minimum precautions.For information on repair methods and vehicle specifications, see the specific sections on repair procedures.

Aerodynamics

The styling of the new car is designed to reflect great personality and originality and improves on the attributes of roominess, practicality and sturdiness achieved by previous models.The front, sides, rear and underbody were developed with particular attention to aerodynamics and allow outstanding drag coefficient values. The following values are an example:Version with basic specificationdrag coefficient Cd - 0.33drag coefficient by area Cd x A = 0.6738These values are the result of road testing and measurements carried out in a wind tunnel.These results contribute to the noiselessness of the vehicle and significantly reduce wind noise. They also allow fuel saving.

Safety

The main aim of car manufacturers is definitely the total safety of the driver and passengers.To adapt the vehicle to highly demanding European and international market regulations, the new vehicle was designed with great attention to detail in order to achieve an optimum response in all situations.

Specifications

The vehicle''s great torsional and flexural rigidity ensure good properties of passive strength and also offer a number of benefits:

  • low noise due to fewer vibrations;
  • no creaking from the trim;
  • better handling by maintaining the correct suspension angles and thus an absolutely controlled drive for a sensation of stability and comfort in general,
  • greater ability to withstand breakages caused by using the vehicle over particularly uneven road surfaces;
  • sensation of vehicle compactiness;
  • to ensure long-term overall vehicle quality.

Torsional rigidity

Diagram showing deformation due to torsion

Torsional rigidity

Torsional rigidity valuesBody with bonded windscreen: 60100 daNm/rad

Flexural rigidity

Diagram showing deformation due to bending

Flexural rigidity

Flexural rigidity valuesBody with bonded windscreen: 860 daN/mm

Preventive safety

This concerns all factors that determine comfortable driving conditions and prevent situations that could distract the driver''s attention:

  • very stiff body for greater driving safety;
  • optimised engine mountings (barycentric) to minimise vibration and noise transmission;
  • climate control system (where fitted) with activated charcoal pollen filter with balanced diffusion throughout the passenger compartment. Well-arranged ventilation outlets allow excellent air exchange and improved transpiration and thermal comfort;
  • an extensive glazed area allows optimum visibility;
  • the tail-lights are shaped to optimise the indicator light functions;
  • the arrangement of the pedals, steering wheel (height-adjustable as an option), main controls and warning lights has been carefully considered to achieve a good valance between driving position and ability to reach the controls;
  • the height-adjustable driver''s seat (where fitted) allows the best possible driving position to be achieved;
  • generous interior dimensions allow the vehicle occupants the necessary level of comfort;
  • abundant use of sound-absorbent materials and the adoption of specific vibration-proof fasteners to reduce mechanical noise and achieve a noiseless, welcoming environment;
  • interior trim that meets the toughest flame-retardant standards.

Active safety

This concerns features of the vehicle and specific components that help the driver overcome potential dangers while driving.The following features contribute to the vehicle''s active safety:outstanding stability during driving and in terms of the vehicle''s dynamic performance;excellent braking system;good pick-up;

The vehicle offers features that are mutually complementary:

  • the front suspension ensures great control of the vehicle during standard or sporty driving. It allows great driving precision and vehicle control over wet and slippery surfaces, a prompt, accurate response and an ability to absorb obstacles and roughness present on the road surface;
  • a torsion beam rear suspension designed to offer improved handling performance, the torsion beam assures the susension an ideal level of torsional rigidity for an excellent balance between vehicle front and rear.
  • smart bushes attaching the rear axle to the body for limited self-adjustment to steering modulated by the stiffness of the bushes
  • new design electric steering system (where fitted) designed for a crisp, prompt response in all situations;
  • braking system big enough to guarantee powerful, safe braking without fade, consisting of two independent cross-over circuits with an ABS/EBD system (the most advanced brake control system currently available) with four channels and four active sensors to reduce activation times, equipped with an EBD (Electronic Brake Distribution) device: that does away with the need for a load proportioning valve;
  • VDC integrated traction control system with ESP/ASR/HHC functions (where fitted).

Passive safety

Because in statistical terms head-on impacts account for 60% of accidents, side impacts account for 30% and the remaining 10% are accounted for by shunts, fires and rolls, the vehicle structure has been designed and developed to crumple in controlled manner in the case of impact and to absorb the energy developed without affecting the living areas of the passenger compartment.To safeguard the vehicle occupants, the seat anchorage points and seat belt attachment points (a three-part belt is also available on the central rear seat) have been reinforced.Front seat occupants are protected, as standard, by a system that includes a driver''s airbag and pyrotechnic seat belt pretensioners (electronically controlled). As an option, the safety system may be complemented by a passenger airbag (that can be deactivated manually by inserting the ignition key in a barrel on the right facia head), sidebags for the driver and front passenger and a head bag that extends under the moulded roof along the right and left sides to protect the heads of vehicle occupants from side impact.Particular attention was devoted to structural design to minimise damage and repair costs arising as a result of accidents
If the body is repaired, the structural reinforcements should always be replaced if deformed.

General specifications

The body is made up of differential crumple zones and is fitted with reinforcements to strengthen the survival cell. These enable the car to withstand head-on impact by ensuring the passenger compartment remains intact to offer the greatest protection to its occupants and minimise the effects of impact.

The main actions taken on the body to achieve the required aims are as follows:

  • front structure with differential crumple zones designed to crumple at pre-established points to absorb and distribute the impact force over the structure due to a front sacrificial beam bolted to a crash box that can absorb even off-centre impact.
  • reinforcements on the side pillars connected to a high-strength tubular steel structure under the facia that ensures a sturdy connection between the pillars and also with the floor, to which it is connected by a cradle anchored to the tunnel. This configuration contributes significantly to ensuring the non-deformability of the entire front area of the passenger compartment during head-on and side impacts. Because it also acts as a support structure for the steering column, it prevents the steering wheel moving back and upwards during all types of frontal impact.
  • reinforcements under the floorpan that increase the solidity and stiffness of the floor to limit deformation as much as possible;
  • adoption of bonnet retaining hooks on the bonnet hinges and a collapsible telescopic steering column.
Impact forces are further absorbed and distributed by the engine attachments that discharge the forces to the front reinforcement and prevent excessive load on the passenger compartment.These features of the structure, together with the fastening systems and the interior energy absorbing parts allow the vehicle to achieve a high level of safety and pass all the tests imposed by standards.

Composition

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1 Front sacrificial crossmember2 Bonnet hinge reinforcements3 Outer element of central pillar reinforcements4 Inner element of central pillar reinforcements5 Reinforcements on side pillars

General specifications

The body complies with all the most recent European standards on side impact and is able to assure a high level of occupant safety by crumpling in a controlled fashion to prevent damage to the survival cell.

The above has been achieved by:

  • reinforcing the underdoor reails between the front pillars and the central pillars;
  • reinforcing the central and rear pillars at the rail attachment points, at the seat belt anchorage points and in the lock striker areas;
  • inserting a box section reinforcement beam between the underdoor rails.
the doors described below contribute significantly to the vehicle''s ability to withstand side impact.

Composition

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1 Underdoor rail reinforcement2 Reinforcement beam between underdoor rails

General specifications

The door structure is of fundamental importance to the safety of passengers in the case of side impact and the door panel geometry and stiffness is therefore designed to maintain survival spaces at the sides and minimise possible injury to passengers.

The above has been achieved by:

  • fitting tubular side impact bars, using reinforcements at the waistline and along the pillars to make up an ideal high-strength door ring;
  • fitting high-strength locks and strikers;
  • fitting energy-absorbing interior door trim without sharp corners designed to ensure minimum impact against the body in the event of an accident.

Composition

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1 Pillar reinforcement2 Tubular side-impact bar

General specifications

The specific structure of the ceiling makes the passenger compartment more rigid and contributes to passenger safety in the event of side impact or roll-over which, despite being much less likely to occur than the other types of impact, is one of the most dangerous accidents.

The following features increase the solidity of the passenger compartment structure:

  • high-resistance steel box section crossmembers connecting the side panels at the upper part of the windscreen, tailgate and in a central position between the upper ends of the pillars;
  • structural adhesive sections along the edges of the upper box section beams of the windscreen compartment and tail-gate compartment.
These features allow outstanding levels of strength to be achieved during the static and dynamic crushing and rollover tests required by European standards.

Composition

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1 Upper windscreen box section beam2 Upper tailgate box section beam3 Roof panel4 Box section beam connecting central pillars

General specifications

The vehicle''s resistance to rear impact is very high and passes the tests specified by the toughest standards in force in Europe.

This performance is ensured by:

  • a reinforced rear box section beam;
  • reinforcements on the attachments between the rear beam and pillars;
  • tailgate with reinforced ribbing;
  • reinforced side and rear tailgate ribbing.

Composition

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1 Left rear rail2 Right rear rail3 Rail connection beam4 Rear beam

WINDSCREEN AND WINDOWS

The fixed windows further contribute to safety. The windscreen is bonded to the body and this increases the structural rigidity of the vehicle.To increase the vehicle safety level, the windscreen is in laminated glass. This solution prevents the glass from shattering if struck by stones or gravel to assure visibility at all times and above all to offer a high level of protection if struck with the head.The windscreen is bonded to the body. The seal flush with the body helps reduce wind noise due to the vehicle''s progress.

Safety against fires

This is achieved by a FPS (Fire Prevention System) consisting of:

  • fireproof interiors, all trim meets the toughest US flame-retardant standards and will not catch fire if it accidentally touches a heat source (e.g. a cigarette) and limits the flame propagation rate;
  • inertia switch to cut off the fuel pump;
  • antimisfiring shields (overheating of the catalytic converter, for petrol versions) that insulate the catalytic converter and protect the brake and fuel pipes;
  • electrical equipment protected by maxifuses that cut off the fuel flow in the case of short-circuit or overheating that could occur in the event of fire;
  • battery secured in the event of impact or roll-over;
  • cut-off valve to prevent fuel leaks if the vehicle rolls over;
  • plastic fuel tank with high mechanical strength and fire-resistance, secured firmly to the body in a shielded position;
  • arrangement of the electrical equipment, fuel pipes and brakes desig
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