PF.

90088
CHARGE AIR HOSES AND PLUMBING PERFORMANCE STANDARD
ASSEMBLIES
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Date: 29-APR-2021

Change level Date Description of change

- 31-OCT-2014 Initial release
A 15-APR-2016 Added in table of contents Point 1.2.2 – Added in point 2 (REFERENCE)
the document number MS-50075 - Added in Table 1/Figure 2 Type G and
in Table 2/Figure 3 pressure class 4 – Updated in Table A-1 the EMEA
quantity.
B 10-OCT-2017 Added in Table 2 note 1-2 below – Updated the equipment (Table 4) in
expulsion test – Added note in Material Requirements 6.2.1 – Updated
acceptance criteria on Measurement of impurities 6.3.1
C 03-DEC-2020 Updated Minimum Reliability and Confidence demonstration in R90/C90.
- Eliminated old duration test on PV phase according to QR.00001
requirement (note under Figure 6). - Eliminated asterisks in Table A-1
and updated NOTE 1 NOTE 3.

D 29-APR-2021 Updated Acceptance criteria of point 9.3.3

For Information, please contact the following references:

For information, please contact author and co -author in the lateral

label of this document
For APAC, LATAM and Maserati contacts, please consult SD.00130

ANY PRINTED COPY IS TO BE DEEMED AS UNCHECKED; THEREFORE THE UPDATED COPY MUST BE CHECKED IN THE APPROPRIATE WEB SITE
CONFIDENTIAL
THIS DOCUMENT MUST NOT BE REPRODUCED OR CIRCULATED TO THIRD PARTIES WITHOUT PRIOR WRITTEN CONSENT BY THE
RELEVANT FCA COMPANY.
IN CASE OF DISPUTE, THE ONLY VALID REFERENCE IS THE ENGLISH EDITION
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CHARGE AIR HOSES AND PLUMBING ASSEMBLIES

TABLE OF CONTENTS
Updated Minimum Reliability and Confidence demonstration in R90/C90. - Eliminated old duration test on
PV phase according to QR.00001 requirement (note under Figure 6). - Eliminated asterisks in Table
A-1 and updated NOTE 1 NOTE 3. .......................................................................................................... 1
1 GENERAL/INTRODUCTION..................................................................................................... 4
1.1 Purpose ................................................................................................................................... 4
1.2 Component/Commodity Description ..................................................................................... 4
1.2.1 Classification .......................................................................................................................... 5
1.3 Application.............................................................................................................................. 6
1.3.1 Drawing data ........................................................................................................................... 6
1.4 Hazardous Material Control.................................................................................................... 6
1.5 Mandatory, Recommended or Specified Tests...................................................................... 7
1.6 Test Planning .......................................................................................................................... 7
1.7 Suggested, Recommended or Specified Components and/or Suppliers ............................. 7
2 REFERENCE ........................................................................................................................... 8
3 DEFINITIONS/ABBREVIATIONS/ACRONYMS/SYMBOLS...................................................... 8
4 SPECIAL TEST EQUIPMENT ................................................................................................ 10
5.1 Corrosion .............................................................................................................................. 10
6 APPEARANCE / PHYSICAL / MECHANICAL / ELECTRICAL REQUIREMENTS .................. 10
6.1 Appearance Requirements................................................................................................... 10
6.1.1 Ergonomics Requirements................................................................................................... 10
6.2 Physical Requirements......................................................................................................... 11
6.2.1 Material Requirements.......................................................................................................... 11
6.2.2 Dimensional Requirements .................................................................................................. 11
6.2.3 Weight Requirements ........................................................................................................... 11
6.2.4 Visual Inspection .................................................................................................................. 11
6.3 Mechanical Requirements .................................................................................................... 11
6.3.1 Measurement of impurities................................................................................................... 11
6.3.2 Part Identification and Marking ............................................................................................ 12
6.4 Electrical Requirement ......................................................................................................... 12
7 FUNCTIONAL REQUIREMENTS ........................................................................................... 12
7.1 Expulsion test ....................................................................................................................... 12
7.2 Resistance to pressure......................................................................................................... 12
7.3 Resistance to vacuum in temperature ................................................................................. 13
7.4 Burst test............................................................................................................................... 13
7.5 Insertion Effort test............................................................................................................... 13
7.6 Virtual Analysis..................................................................................................................... 14
7.6.1 FEM analysis (structural analysis)....................................................................................... 14
7.6.2 CFD analysis (Pressure Lost)............................................................................................... 14
7.6.3 Welding areas analysis......................................................................................................... 14
7.6.4 Mold cavity filling (injection or BM or other technologies) ................................................. 14
7.7 Pressure Leak Test only for Continuing Conformance....................................................... 14
7.8 Diameter expansion.............................................................................................................. 15
8 SAFETY AND REGULATORY REQUIREMENTS .................................................................. 15
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9 RELIABILITY / DURABILITY REQUIREMENTS..................................................................... 15

9.1 System and Vehicle Level Requirement .............................................................................. 15
9.2 Design Failure Modes and Effects Analysis (DFMEA) ........................................................ 16
9.3 Pressure Cycling Test .......................................................................................................... 16
9.3.1 Heavy duty Requirements .................................................................................................... 16
9.3.2 Air leakage test ..................................................................................................................... 17
9.3.3 Standard Duty Requirements ............................................................................................... 17
10 PRODUCT ASSURANCE....................................................................................................... 20
10.1 Approved Best Practices...................................................................................................... 20
11 WARRANTY RETURNED PARTS TEST AND ANALYSIS PROCEDURES ........................... 20
Annex A 20
Annex B 22
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1 GENERAL/INTRODUCTION

1.1 Purpose

This standard covers the environmental, physical, electrical, mechanical, functional, regulatory and
durability requirements for charge air hoses and plumbing assemblies.

1.2 Component/Commodity Description

The purpose of the charge air cooler plumbing assembly is to provide a reliable leak-free method of
transferring pressurized air from charging system in hot state to the charge air cooler and return cooler
pressurized air to the engine. Peak air temperature distribution is shown in table 1.
It must also prevent oil from permeating through the hose.

Figure 1 - Charge air cooler system diagram

In this system, there are 2 groups of CAC plumbing – CAC hot side plumbing and CAC cold side
plumbing. The CAC hot side plumbing allows charged air to flow through it from the air compressor on the
engine to the charge air cooler. The CAC cold side plumbing allows charged air to flow back from the
charge air cooler to the engine to be feed into the engine cylinders.
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1.2.1 Classification

In function of use, pressures, temperatures of both driven fluid and environmental radiance, hoses are
subdivided and classified by type according to what shown in the following tables:

Table 1 - Type hoses

Max working Stiffening
temperature Min Material (1) material
(inside/outside) (°C) working
Type Use (as indication (as
temp.
Continua (°C) only) indication
Peak only)
tive
Section from compressor 150 °C 160 °C -40 °C Para
A AEM
to intercooler (302 °F) (320 °F) (-104 °F) Aramyde

Section from compressor 200 °C 220 °C -40 °C Meta

B VMQ
to intercooler (392 °F) (428 °F) (-104 °F) Aramyde

Section from compressor 200 °C 220 C° -40 °C VMQ/FVMQ Meta

B-0
to intercooler (392 °F) (428 °F) (-104 °F) VMQ/FPM Aramyde

-40 °C Para
Section between 100 °C 110 °C
C CR;CM Aramyde /
intercooler and engine (212 °F) (230 °F) (-104 °F) polyester

-40 °C Para
Section between 120 °C 130 °C NBR/CSM
D Aramyde /
intercooler and engine (248 °F) (266 °F) (-104 °F) (CM)
polyester
-25 °C (2)
(2)
Section from compressor 180 °C 190 ° C (-13 °F) HT-ACM Meta/Para
E
to intercooler (356 °F) (374 °F) -40 °C HT-AEM Aramyde
(-104 °F)
Section from compressor 170 °C 180 °C -40 °C Meta
F HT-AEM
to intercooler (338 °F) (356 °F) (-104 °F) Aramyde
Section from compressor 220°C 240 °C -40 °C MVQ/FPM Meta
G
to intercooler (428 °F) (464 °F) (-104 °F) wrapped Aramyde

NOTE 1: The materials indicated in the table are referred to the inner conduit in contact with the fluid; for the intermediate part and
the cover can be used alternative materials. To see section 3 for all abbreviations.
NOTE 2: -25 °C (33,8 °F) is lower limit of this material.
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Table 2 - Pressures
Class Continuative working pressure (bar) Peak pressure (bar)
1 1,5 1,8
2 1,8 2,1
3 2,2 2,5
4 2,5 2,8
NOTE1: The indicated pressures are to be considered as relative pressures.
NOTE2: In case of a parameter of pressure or temperature turned out ≥ than those reported in the tables (tolerances included) it is
necessary to move to the next classification.

Classification is given by combination between working temperature and pressure, for instance: Type A/2
Where:
A= pipelines with continuative temperature of 150 °C (302 °F) and possible peak at 160 °C (320 °F).
2= pipelines with continuative pressure of 1,8 bar and possible peak of 2,1 bar.
Shouldn't the Class be indicated, it has to be intended as Class 1.
Note: as the silicon compound (Type B) can cause oil sweating on the external surface, should a perfect permeability
is required, a fluoroelastometer or fluorosilicon layer, fastened by adhesive to the inner duct, is necessary; in
this case, the Class to be used is “B -0”.

NOTE1: The indicated pressures are to be considered as relative pressures.

NOTE2: In case of a parameter of pressure or temperature turned out ≥ than those reported in the tables (tolerances included ) it is
necessary to move to the next Class.

1.2.2 Compound Material

Compound Material used must be according to MS.90058

1.3 Application
This standard is limited in its application to those CAD files (such as CATIA/NX), drawings or engineering
illustrations which call out this standard number, or refer to this standard within some other standard or
specification.

1.3.1 Drawing data

- The number of this Proc. Spec. is indication of the Type (e.g.: PF.90088 B-0/2). Should the class not
be indicated on the drawing, Class 1 shall be used;
- Indication of pressures/temperatures, if different from the ones required in the Proc. Spec.; the peak
pressure is to be intended as always equal to continuative working pressure increase of 0,3 bar;
- Vacuum resistance value if different from 0,03 bar (Abs).

1.4 Hazardous Material Control

Products and processes used to manufacture the products listed in this standard must conform to the
employee and consumer health, employee safety, regulated substances, recycling and environmental
reporting requirements.

NOTE: Please refer to the specifications in Annex B where you will find a list of FCA and/ or international specifications that can
apply to the requirement listed in this section.
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1.5 Mandatory, Recommended or Specified Tests

Mandatory or suggested tests if any provided within this standard are meant to assure compliance to the
specification but do not relieve the responsible entity from ensuring that the component or system meets
all environmental, physical, electrical, mechanical, functional, regulatory and durability requirements
including all applicable system interface requirements as described in the standard for the entire duration
of specified useful life.
1.6 Test Planning
A test plan (DVP&R) shall be developed to verify and validate all required functions specified in this
standard. The responsible entity shall provide any addi tional testing that’s deemed necessary to meet
functional requirements; the tables at the end of this document provide summary of all the requirements,
and shall be used to develop the test planning.
Samples utilized for Design Verification (DV) shall meet specified drawings tolerance range. Samples for
Production Validation (PV) shall meet statistical capabilities for machine and manufacturing processes.
Where necessary, each line item of the test plan (DVP&R) must be supported by a comprehensive test or
laboratory procedure. A test plan (DVP&R) agreement by FCA does not relieve the responsible entity
from ensuring that the component or system meets all environmental, physical, electrical, mechanical,
functional, regulatory and durability requirements including all applicable system interface requirements,
in the entity’s area of responsibility, as described in the standard for the specified useful life.

NOTE: For DV and PV, please refer to the specifications in Annex B where you will find a list of FCA and/ or international
specifications that can apply to the requirements listed in this section.

1.7 Suggested, Recommended or Specified Components and/or Suppliers

Suggested, recommended or specified components and/or suppliers, if any, are still required to comply to
the specification and do not relieve the responsible entity from ensuring that the component or system
utilizing these suggested, recommended or specified components and/or suppliers meets all
environmental, physical, electrical, mechanical, functional, regulatory and durability requirements
including all applicable system interface requirements, in the entity’s area of responsibility, as described
in the standard for the specified useful life.
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2 REFERENCE
Table 3 - Referred Documents
Document Number Document Title
QR-10012 DIMENSIONAL QUALITY REQUIREMENTS.
MS-3881 FLUID – RUBBER ASSEMBLY – WETTING AGENT IN WATER.
Installation dimension of charged air hoses and fittings of engine charging
CS.00028
system and for pneumatic control solenoid valve. Design directives.
Engine cooling pipes/sleeves couplings, pipe unions, filling and seal checking
2.00102/06
of circuit.
MS.90089 Various metallic part painting.
Plastic tanks for power steering circuit fluids: definition of the quality/size of
7.G2183
inner scraps/impurities.
50180 Corrosion tests.
WARRANTY RETURNED PARTS TESTING AND ANALYSIS
PS-11346
PROCEDURES.
71085 Operative Procedure for Chargeback.
07740 Qualification of production parts new components (buy).
MS-PM-3-1 PAINT - IDENTIFICATION COATING.
HOSE - TURBO CHARGER APPLICATIONS - SILICONE COVER/ FLUROCARBON LINED -
MS-50075 META ARAMID REINFORCEMENT

3 DEFINITIONS/ABBREVIATIONS/ACRONYMS/SYMBOLS

ABS Acrylonitrile Butadiene Styrene

AEM Ethylene Acrylate
BM Blow Molding
CAC Charge Air Cooler
CAD Computer-Aided Drafting / Computer-Aided Design
CATIA Computer Aide Three dimensional Interactive Application
CFD Computational Fluid Dynamics
CMVSS Canadian Motor Vehicle Safety Standards
Continuing Post capability continuing conformance test program may be implemented after
Conformance successful completion of the continuing conformance requirements. Tests must be
(Post- completed with production parts on a continuing basis. Samples for these tests must
Capability) be selected on a random basis to represent the entire production population as much
as possible. In the event that any portion of these tests is not met, the reaction plan
specified in the Supplier control plan shall be invoked.
Continuing Continuing conformance tests are used to demonstrate process compliance and must
Conformance be completed using production castings, tooling, and processes. Continuing
(Pre-Capability) conformance tests are t
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o be done at the specified frequency, until process capability or confidence is

demonstrated per the defined test criteria. Continuing conformance tests are to be
conducted at the specified frequency, for a minimum of three production days, or nine
production runs, whichever is more stringent.
CSM Chlorosulfonated Polyethylene
DFMEA Design Failure Mode and Effect Analysis
DV Design Validation
DVP&R Design Verification Plan & Report
ECE Economic Commission for Europe
EM Electro-Mechanical
FDV Final Design Validation
FEM FINITE METHOD ANALYSIS
FMEA Failure Mode and Effect Analysis
FMVSS Federal Motor Vehicle Safety Standards
FPM Fluorinated propylene monomer
FVMQ Fluorosilicone
HMSR Endurance Test - STRUCTURAL DURABILITY ROAD Proving Ground
Job 1 Production start up
L4S Vehicle Endurance Test STRUCTURAL DURABILITY ROAD Proving Ground
NBR Nitrile rubber
NVH Noise, Vibration and Harness
MS-PM-31 PAINT – IDENTIFICATION COATING
PG STRUCTURAL DURABILITY ROAD Proving Ground
PPAP Production Part Approval Process
PS PS can mean pre-serial production
PT-7 Powertrain Endurance Test - STRUCTURAL DURABILITY ROAD Proving Ground
PV Product Validation
QRE Quality & Reliability Engineer/ Engineering
SXV Vehicle Endurance Test - STRUCTURAL DURABILITY ROAD Proving Ground
TFO FCA Design and Organization Procedures
TTF Test to failure
VMQ Silicone
VP Verification Process
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4 SPECIAL TEST EQUIPMENT

Table 4 - Special Test Equipment

Section
Function Tested Test Equipment Specified
Number(s)
Note: Value of ‘‘D" is equal to nominal diameter
of the spigot on which the same sleeve shall be
mounted, while value of ‘‘L" is the insertion depth.
Both dimensions shall be got from Standard
CS.00028.

7.1 Expulsion test

5 ENVIRONMENTAL REQUIREMENTS
All pressures specified in this norm are relative to atmosphere (gauge pressures).
Charge air hoses and plumbing assemblies shall withstand environmental stresses without any
degradation to functional requirements for pressure cycling in § 9.3 throughout its design life.

5.1 Corrosion
In case of metallic contents, unless validated separately, the components must meet the functional and
appearance requirements specified in CS.00081, the coating or painting must be checked according to
the drawing indications.

6 APPEARANCE / PHYSICAL / MECHANICAL / ELECTRICAL REQUIREMENTS

6.1 Appearance Requirements

6.1.1 Ergonomics Requirements

Definition of Ergonomics: It is the study of relations existing among man, objects, machines and
environment during any activity, in order to improve efficiency, safety and welfare state.
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6.2 Physical Requirements

Supplier shall demonstrate dimensional capability for all key dimensional characteristics, identified on
CAD files (such as CATIA/NX), during DV and PV phases including physical interface requirements e.g.:
Fastening points; Interface constrains; Interface materials etc.

6.2.1 Material Requirements

The charge air hoses and plumbing assemblies shall meet the material requirements specified in the
released engineering drawing and according SSTS document.
Compound Material used must be according to MS.90058

6.2.2 Dimensional Requirements

The charge air hoses and plumbing assemblies shall meet the dimensional requirements specified in the
released engineering drawing and shall adhere to the procedures and guidelines identified in Chrysler
QR-10012, Dimensional Quality Requirements.

6.2.3 Weight Requirements

The charge air hoses and plumbing assemblies shall meet the weight requirements specified in the
released engineering drawing and according SSTS document.

6.2.4 Visual Inspection

Every component must be free of roughness, pitting, holes, tears, cracks, initial detachment between sub-
layer and coating, between sub-layer and intermediate layer and any other defect that can compromise its
function, must be checked present of the caps and drawings requirements.

6.3 Mechanical Requirements

6.3.1 Measurement of impurities

Procedure
A. Carry out the measurement with the equipment and procedures set by Standard 7.G2183 and check
that the measured values are within the set limit.

Note: In case of components consisting of several elements (plastic, metal or rubber pipes, fast co uplings, etc.), the test must be
carried out on the supply assy.
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Acceptance Criteria

MASS DIMENSION
Metal < 500 μm
< 1 mg/dm2 Plastic < 700 μm
Fibers < 90 x 3000 μm

6.3.2 Part Identification and Marking

All components/assemblies installed on FCA motor vehicles as original equipment, spare parts or
Accessories must be marked to typify the component as “GENUINE” and express brand image and
“DISTINCTIVENESS”.

NOTE 1: For part identification and making requirements, please refer to the specifications in Annex B where you will find a list of
FCA and/ or international specifications that could apply to the requirements listed in this section.

NOTE 2: Indelibility for any reference or circumferential marks should be according to MS-PM-3-1 included in Annex B.

6.4 Electrical Requirement

Not applicable.

7 FUNCTIONAL REQUIREMENTS

7.1 Expulsion test

Procedure
A. Put 2 metal plugs on both ends of rubber pipe (see special tool equipment table 4) and tighten the
hose making use of the clamps required by design.

Note: in case use is made of clamps with cutting-head screw, close at the maximum speed required by design.

B. Connect one of the 2 pipe unions to a bench that can pressurize the inside of the tested hose with air.
C. Send a pneumatic pressure with increase of 2 bar/min until measuring the expulsion pressure; verify
that the measured value meets what required.

Acceptance Criteria
≥ 3 bar.

7.2 Resistance to pressure

Procedure
A. Mount the hose or assembly simulating the mounting on vehicle (with clamps and tightening torque
as per design).
B. Foreseen continuative peak pressure (see classification § 1.2.1) and keep it there for a period of 5
min; during test and at the end comparing it with what required in acceptance criteria.
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C. Put the same hose or assembly into the environmental chamber at foreseen continuative working
temperature (see classification § 1.2.1) and keep it there for a period of 70 h.
D. After aging time and at same temperature, send an internal automatic pressure of 3 bar keeping it for
5 min.

Acceptance Criteria
No leakage, loss, burst or beginning of tearing allowed on the external surface.

7.3 Resistance to vacuum in temperature

Procedure
A. Mount hose or assembly simulating the mounting on vehicle (with clamps and tightening torque as
per design).
B. Measure and report external diameter of rubber hoses only, then mark zone involved in the
measurement
C. Put the hoses into the environmental chamber at a temperature of 100 °C ± 2°C (212 °F ± 3,6 °F) for
type C, 120 °C ± 2°C (248 °F ± 3,6 °F) for type D and 150 °C ± 2°C (302 °F ± 3,6 °F) for types A, B,
B-0, E, G and F for a period of 4 h and send a vacuum of 0,03 bar (if not otherwise required by
design) into the hoses.
D. Measure and report external diameter value again in marked zone.
E. Calculate percentage variation by comparing it with prescriptions.

Acceptance Criteria
External Diameter value: < 10 %.

7.4 Burst test

Procedure
A. Mount in following conditions:
1. interface pipe unions required by design;
2. clamps required by design; in case use is made of clamps with cutting-head screw, close at
maximum speed required by design.
In case of components consisting of several elements (plastic, metal or rubber pipes, fast couplings, etc.),
test must be carried out on the supply assembly.
B. Connect hoses to a bench that can send to the tested pipe a pneumatic (or hydraulic) pressure with
increase of 2 bar/min.
C. On the bench pressure gauge measure the bursting or withdrawing pressure of the rubber pipe from
the interface pipe unions.
D. Repeat the test on after aging for 70 h at the foreseen continuative working temperature (according to
characteristic table 1).

Acceptance Criteria
Burst or pull off > 7bar.

7.5 Insertion Effort test

Test fixture shall be set up using production design hose and tube fittings.
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Procedure
A. Lubricate the ID of the hose with lubricant from MS-3881“Fluid – Rubber Assembly – Wetting Agent in
Water” or 2.00102/06 unless otherwise specified by the release engineer.
B. Immediately push onto the fitting until the hose touches the stop bead.
C. Record the peak push-on force for each test sample.

Acceptance Criteria
The maximum force shall be ≤ 75 N.

7.6 Virtual Analysis

Shall be done only if there is a rigid part in the assembly
7.6.1 FEM analysis (structural analysis)

Acceptance Criteria
According SSTS Requirements.

7.6.2 CFD analysis (Pressure Lost)

Acceptance Criteria
According SSTS Requirements.

7.6.3 Welding areas analysis

Acceptance Criteria
According to perform all test Requirements.

7.6.4 Mold cavity filling (injection or BM or other technologies)

Acceptance Criteria
To guarantee a 100% component fulfill geometry to respect all performance test Requirements.

7.7 Pressure Leak Test only for Continuing Conformance

(ANNEX A1)
Only if charge air hose assembly include rigid pipe with welding or/and crimping areas.

Procedure
A. Seal all openings without dimensionally changing the part and maintain an internal air pressure of 70
kPa (± 0,5 kPa) gage for 8 s.
B. The room ambient temperature cannot change by more than ± 1˚C (1,8 °F) during the testing.

Acceptance Criteria
Any leakage from the welding joint, crimping or fill neck weld joint is considered a failure.
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7.8 Diameter expansion

Procedure
A. Mount charge air hose on a special equipment simulating mounting on vehicle (with clamps and
tightening torque as per design).
B. Measure external diameter, then mark the zone involved in measurement.
C. Submit charge air hose to peak pressure indicated in characteristic table 2.
D. With peak pressure, to measure again the external diameter value in previous marked zone.
E. Calculate percentage variation.

Acceptance Criteria
Expansion: ≤ 10%.

F. Repeat test as per points A-E after charge air hoses conditioned in environmental chamber at
required continuative working temperature (indicated in characteristic table 2) for 4 h.

Acceptance Criteria
Expansion: ≤ 15%
.
8 SAFETY AND REGULATORY REQUIREMENTS

Supplier shall ensure compliance to all applicable regulatory requirements for the charge air hoses and
plumbing [Link] the markets where the vehicles are sold.

9 RELIABILITY / DURABILITY REQUIREMENTS

Reliability/durability test procedures are required to demonstrate at engineering level (with a given
probability and level of confidence) that a system or component will perform its intended functions over
the expected useful life, under all anticipated operating conditions and environments as specified in
preceding sections. The tests must ensure that expected design and process variations are covered,
resulting in adequate product robustness. Test to Failure (TTF) is the preferred test methodology.

A. Vehicle Design or Service Life Requirements: 10 years / 150 000 miles

B. Minimum Reliability and Confidence demonstration: R90 / C90

9.1 System and Vehicle Level Requirement

FCA Engineering shall perform system and vehicle level tests on program phase vehicles (such as,
System bench tests, Plywood Buck, Hardware in Loop, Corrosion, PG Driving, BSR, Hot/Cold Trips, etc.)
during program development. Examples of Chrysler Proving Grounds include HMSR, SXV, PT-7, L4S,
etc. or reliability validation on 336 vehicle fleets to verify system interface and customer usage
applications during different stages of program development (Examples: FDV, VP, PS and Job 1).

Any degradation to functional and/ or performance requirement involving component reliability/ durability
issues shall be promptly addressed by component Supplier. Corrective actions shall focus on issue
prevention and may involve changes to design including any component validation testing.
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9.2 Design Failure Modes and Effects Analysis (DFMEA)

The DFMEA must address and correlate to all of the functions which are specified in this Performance
Standard. All potential Failure Modes, as described, must be evaluated and taken into account in the
DFMEA risk analysis. FMEA analysis shall be included in timing plan shared and agreed with supplier at
project start. A complete DFMEA is normally property of suppliers and available for examination at their
site. Supplier will be responsible for DFMEA execution and content accuracy; FCA component or system
specialist shall analyze and approve supplier’s analysis.

9.3 Pressure Cycling Test

If heavy duty usage is specified in the SSTS, then 9.3.1 - 9.3.2 and 9.3.3 must be run. For standard duty
usage, only 9.3.3 applies.

9.3.1 Heavy duty Requirements

Procedure:
A. Assembly hose with production intent clamp onto production intent tube fitting using the lubricant from
MS-3881 unless otherwise specified by the Chrysler release engineer. Clamp shall be installed in the
production intent position. Hose shall be pushed until end of hose contacts the stop bead.

B. The samples are to be placed in a chamber that is capable of vary the vibrating and capable of
holding the internal pressure of the samples of up to 280 kPa-g (41 psig).

C. The peak air temperature is to be heated for the entire test as described in Figure 2.

D. Vibration Cycle: With one end fixed, shake duct assembly in the approx. direction of engine roll +/-
19.05mm (¾”) at 2.4 Hz for 2,000,000 cycles (Approximate test duration is 10 days of continuous
testing).

E. Pressure Cycle: Once the test begins, start the pressure impulses in the hose. Hold the pressure at
PMAx (as defined in Figure 3) for 15 seconds. After 15 seconds, the pressure will be dropped briefly
to 35 kPa-g (5 psig) and then raised back to P MAx. This change drop and rise in pressure should take
place over 5 seconds. This pressure cycle (shown in Figure 4) must be repeated 3 times per minute.
These pressure impulses must be performed for the entire length of the test.

Figure 2 - Peak air temperature for each usage

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Figure 3 - Maximum internal pressure

Figure 4 - Pressure cycling

Acceptance Criteria: At end of test (after 2,000,000 vibration cycles), the CAC assembly shall be then
subjected to the air leakage test outlined in 9.3.2 for any signs of performance degradation.

9.3.2 Air leakage test

Test Set-up: Assemble hose with production intent clamp onto production intent tube fitting using the
lubricant from MS-3881 unless otherwise specified by Chrysler release engineer. Clamp shall be installed
in the production intent position. Hose shall be pushed until end of hose contacts the stop bead.
Submerge the hose assembly under water. Pressurize the assembly with air to 300 kPa-g (43.5 psig) and
hold for 60 seconds at RT (22 +/ - 5 0C). Disregard leakage for first 30 seconds of pressurization to allow
air trapped to escape from between tube and cover of hose and between clamp and end of hose.
Acceptance Criteria: Maintain pressure for at least three minutes without continuous leakage (six bubbles
or more of any size per minute) from CAC Plumbing Assembly during the Air Leakage Test.

9.3.3 Standard Duty Requirements

Procedure:

A. Mark and record value for 3 different diameter section areas of component under test

B. Mount air hoses in following conditions:

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1. As for fast-coupling pipelines, (plastic and/or metal) pipes, test shall be performed on the
production intent assembly to evaluate all connections/interfaces;
2. Interface pipe unions required by design;
3. Clamps required by design; in case use is made of clamps with cutting-head screw, close at
maximum speed required by design;
4. Hoses shall be mounted in test fixtures representing in-vehicle position without adding any
additional stresses on the hoses.

Note: In the case of total supply system is present a rigid pipe made of plastic material, formed by 2 or
more elements welded together (excluding mounting brackets) must be performed am additional on the
total supply system the execution of 5 cycles thermal each of which so' consists of:

5. 8 h continuous operating temperature of the relevant class (see table 1)

6. 16 h at -40° C (-104 °F). Switching from 1 environment to another must be made within 60 s.

C. Fill the air hose with used engine oil up to 50% of internal volume and plug both ends.
D. Put the parts into the environmental chamber at the continuative working temperature relevant to the
Type (see table 1; excluding Types B / B-0 and G for which the temperature must be 180 ± 2°C – 356
°F ± 3,6) for 24 h.
E. Empty oil from the parts without dismounting pipe unions and clamps, then put them into the
environmental chamber again, positioning them as in service, at the working temperature (see table
1) for 1h.
F. Submit the hose to a pulsing pneumatic pressure with the cycle required in Figure 5 below.

Figure 5 - Pressure Diagram

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G. Carry out a total of 150 000 cycles in 4 different steps with pressures and temperatures indicated in
Figure 6 below.

Figure 6 - Cycles Diagram

H. With pressure and temperature of test, measure again the external diameter value in previous
marked zone.

I. Calculate percentage of diameter variation.

Acceptance Criteria
Cycles: > 150,000 (unless otherwise indicated on drawing) without burst, leakages, spalling or
tearing of the coating, break of stiffener. During the test no sliding of the connection toward the
bead is allowed.
During and after test, visual check according to § 6.2.4.
Are not admitted detachment, tearing on inner liners for oil protection
Diameter deformations (even if localized) ≤ 20%.
NOTE: Any no conformity detected during the test on the connections out of the supply purpose must be signaled in test report .

J. At the end of Pressure Cycling Test perform the resistance to pressure test according § 7.2 from point
A to B and use the peak pressure indicated in characteristic table 2 w

Acceptance criteria
No leakage, loss, burst or beginning of tearing allowed on the surfaces including all component interfaces
and during Tier 2 test validations.
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10 PRODUCT ASSURANCE
The manufacturing facility for a particular component or system shall develop an appropriate product
assurance plan, in accordance with the Chrysler Group LLC's "Process Sign-Off" manual (for Chrysler) or
“Qualification of production parts new components” (PPAP) - 07740 (for FCA) to order to assure the part
meets the quality, durability, and reliability targets throughout the manufacturing process.

10.1 Approved Best Practices

Only approved materials and technical solutions may be used. New materials and technical solutions
may only be proposed after thorough validation.

11 WARRANTY RETURNED PARTS TEST AND ANALYSIS PROCEDURES

The product design, development and manufacturing entities shall comply with Chrysler standards (PS-
11346, Warranty Returned Parts and Analysis Procedures) and FGA 71085 standards.

Annex A
(Normative)
Design Verification & Production Validation Summary

Table A-1 - Design Verification & Product Validation

Sample Size Acceptance Criteria (NOTE 3)
Section (Note 1) Comments &
Function
# Responsibility
DV PV DV PV
ENVIRONMENTAL 5

Corrosion Testing 5.1.1 22 22 R90C90 R90C90 Supplier

APPEARANCE / PHYSICAL / MECHANICAL / ELECTRICAL REQUIREMENTS 6.3

Material Meet Meet
6.2.1 1 1 Acceptance Acceptance Supplier
Requirements Criteria Criteria
Meet Meet
Dimensional
6.2.2 3 3 Acceptance Acceptance Supplier
Requirements Criteria Criteria

Weight Meet Meet

6.2.3 1 3 Acceptance Acceptance Supplier
Requirements Criteria Criteria
Meet Meet
Visual Inspection 6.2.4 1 3 Acceptance Acceptance Supplier
Criteria Criteria
Impurities
6.3.1 15 15 P99C90 P99C90 Supplier
measurements
Meet Meet
Part Identification
6.3.2 1 3 Acceptance Acceptance Supplier
and Marking Criteria Criteria
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Table A-1 - Design Verification & Product Validation

Sample Size Acceptance Criteria (NOTE 3)
Section (Note 1) Comments &
Function
# Responsibility
DV PV DV PV
FUNCTIONAL 7
Expulsion test 7.1 15 15 P99C90 P99C90 Supplier
Resistance to
7.2 15 15 P99C90 P99C90 Supplier
pressure
Resistance to
vacuum in 7.3 15 15 P99C90 P99C90 Supplier
temperature
Burst test 7.4 15 15 P99C90 P99C90 Supplier

Insertion effort test 7.5 15 15 P99C90 P99C90 Supplier

Virtual analysis 7.6

According
FEM (structural) 7.6.1 1 - SSTS - Supplier
requirements
According
CFD (pressure lost) 7.6.2 1 - SSTS - Supplier
Requirement
Meet
Welding areas 7.6.3 1 - Acceptance - Supplier
Criteria
Meet
Mold cavity filling (all
7.6.4 1 - Acceptance - Supplier
technologies) Criteria

Diameter expansion 7.8 15 15 P99C90 P99C90 Supplier

RELIABILITY/ 9
DURABILITY

Pressure Cycle Test 9.3 22 22 R90/C90 R90/C90 Supplier

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Table A-1 - Design Verification & Product Validation

Sample Size Acceptance Criteria (NOTE 3)
Section (Note 1) Comments &
Function
# Responsibility
DV PV DV PV

NOTE 1: If provided, the sample size shown is the FCA recommended samples per QR.00001, which in
conjunction with the analysis method indicated best demonstrates the Acceptance Criteria has
been met. The supplier is responsible for meeting the Acceptance Criteria specified and may
use other valid sample sizes and analysis methods approved by FCA.

NOTE 2: Applicable tests, sample sizes and acceptance criteria shall be per requirements specified in
each of these sections. If not specified, Release Engineering & Supplier shall define those in
the DVP&R.

NOTE 3: Engineer shall specify objective or subjective acceptance criteria (R90C90, No failure or
functional degradation, no physical degradation, etc.) in the DVP&R document.

CONTINUING CONFORMANCE:
Table A-2 - Continuing Conformance
Section Sample
Function (1) Acceptance Criteria Frequency
# Size
Leakage Test 7.7 1 All must pass 100%
NOTE 1: Above tests are in addition to all the in-process functional verifications identified in the Control Plans to prevent potential
Design & Process failures.

End of Annex A

Annex B
(Informative)
Examples of FCA and International Specifications
Table B-1 - Example of Related Specifications per different requirements
Document
Item Document Title
Number
Environmental CS.00081 CORROSION REQUIREMENTS - VEHICLE SYSTEMS AND COMPONENTS
Environmental 50180 CORROSION TESTS
Environmental MS.90089 VARIOUS METALLIC SPECIFICATION PART PAINTING
Environmental MS.50075 HOSE - TURBO CHARGER APPLICATIONS - SILICONE COVER/ FLUROCARBON LINED -
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Table B-1 - Example of Related Specifications per different requirements

Document
Item Document Title
Number
META ARAMID REINFORCEMENT
CS-
Functional ROUTING REQUIREMENTS - TUBING, HOSE AND CABLES
ROUTING
Functional DS-158 ERGONOMICS PROCESS DRIVEN DESIGN STANDARD
Functional 9.01111 General ergonomics requirements
Hazardous
SUPPLIER REQUIREMENTS FOR PRODUCTION AND SERVICE PARTS: MATERIAL
Material CS-9003
CONTENT REPORTING, MARKING, AND RECYCLABILITY
Control
Mechanical DS-107 BSR DESIGN GUIDELINES
Mechanical 7.N0007 FINISH COMPONENTS VEHICLE INTERNAL/EXTERNAL PROTECTIONS
Mechanical CS.11000 TRADEMARK IDENTIFICATION ON PARTS
Mechanical PS-4480 IDENTIFICATION OF PARTS
Mechanical MS-PM-3-1 PAINT – IDENTIFICATION COATING
Mechanical PS-8800 BAR CODING OF PARTS
PS- IDENTIFICATION NUMBER STAMPINGS - BODY, CHASSIS, ENGINE,
Mechanical
11961<S> TRANSMISSION,TRANSAXLE
Reliability QR.00001 PRODUCT ASSURANCE TESTING (PAT)
Reliability CS.00133 INTERNAL AND EXTERNAL PROJECT F.M.E.A.
Safety FMVSS FEDERAL MOTOR VEHICLE SAFETY STANDARDS
Safety CMVSS CANADIAN MOTOR VEHICLE SAFETY STANDARDS
Safety ECE ECONOMIC COMMISION FOR EUROPE
Test Planning QR-10021 DVP&R Template
Warranty PS-11346 WARRANTY RETURNED PARTS TESTING AND ANALYSIS PROCEDURES
OPERATIVE PROCEDURE FOR
Warranty 71085
CHARGEBACK
Product
07740 Qualification of production parts new components (buy)
Assurance
Product "Process
Chrysler Group LLC's manual
Assurance Sign-Off"

End of Annex B