Chrysler Group LLC Document Number: PS-4401

Process Standard Date Published: 2013-04-02

Category Code: P-3 Change Level: AG
EASL Requirement: No
Restricted: No

STATIC WATER TESTING FOR EVALUATION OF SEALING SYSTEMS ON FINISHED CAR AND
TRUCK BODIES***

1.0 GENERAL

1.1 Purpose of the Standard

This standard defines a practical method for evaluating the effectiveness of vehicle sealing systems in
preventing openings that would admit water, dust, air, and unwanted noise into a finished vehicle body. It
is intended to ensure vehicle sealing capability by Sealing Engineering, Plant Assembly Process and
Customer Satisfaction and Corporate Audit groups.

1.2 Purpose of the Process

This process provides a uniform, controlled means of performing a static water test on all corporate
vehicle lines at the respective assembly plants or other locations.

1.3 Coverage of this Standard

This standard covers equipment, set up, testing, leak definition and reporting methods required to insure
vehicle sealing integrity.

2.0 SPECIAL TEST EQUIPMENT

2.1 Test Facility

The static water test booths will be composed of the halo design.

2.1.1 Halo Rack Design

2.1.1.1 Halos

The halo is an arch-like header that has overhead nozzles, upper quarter nozzles, and side nozzles
symmetrically located throughout the arch.

The nozzle angle and distance from the vehicle must be reviewed to ensure an overlapping coverage of
the spray patterns. The objective is to cover the entire vehicle with a sheet of water without gaps in spray
coverage. Please refer to the picture in Appendix A.

Each halo is spaced 304.8mm (12) apart, with the total number of halos used dependent on the vehicle
line being tested. Longer vehicles will have more halos and shorter vehicles will have fewer halos. The
entire length of the vehicle must be covered with halos including a minimum of one halo forward and
rearward of the vehicle.

If the vehicle is taller than 1915mm (75.4) then the height and width of the halo structure must be
modified to ensure overlap of the spray. Please refer to the picture in Appendix A which refers to design
study DPM001893571.

PS-4401, Change AG, 2013-04-02, Page 1

Copyright Chrysler Group LLC

2.1.1.2 Underbody

The underbody portion consists of two nozzles per halo spaced at 12 inches. They are to be aligned
along the entire length of the water booth.

2.2 Water Pressure

The pressure in the water test facility shall be regulated to thirty (30) plus or minus five (5) PSI at nozzles,
measured at a nozzle location closest to the supply header and at a nozzle furthest away within each
major branched section. Water filters in system must be changed regularly to ensure specified pressure.
The maintenance schedule will vary from plant to plant dependent on system cleanliness. Monitor the
water pressure to determine filter change schedule or other required maintenance. Please refer to
Appendix B for the nozzle specification.

2.3 Water Quality

The water used in testing must be clean and unadulterated with substances such as soaps that can affect
its surface tension. The water must be changed once a week and the recirculation pit must be deep
cleaned twice a year. Deviations require the approval of the Plant Quality Manager and the respective
Vehicle Platform Sealing Engineer.

Sheeting agents and algaecides may only be used with Dry Car Engineering Lead and Plant Safety Office
approval.

Fluorescent dyes may be used to detect water leaks, but may not affect the surface tension of the water.

2.4 Spray Nozzles

2.4.1 Nozzle Maintenance

2.4.1.1 Clogged Nozzles

Spray nozzles must be free from foreign particles that prevent nozzles from operating properly.
All nozzles are to be operational at all times. Any nozzle found to be inoperable is to be corrected within
three (3) working days.

2.4.1.2 Missing Nozzles

All missing nozzles must be replaced immediately after discovery. Inspection for nozzle presence must
be performed prior to beginning of each shift.

2.4.2 Halo-Style Nozzles

Spray nozzles on the halo style booth are intended to be mounted normal to the vehicle body surfaces
and adjustment is not normally required. Impact points of nozzles that are not normal to body from the
halo must to be identified as shown in APPENDIX C.

2.4.3 Inoperable Nozzles

All nozzles on the halo style racks are to be operational at all times, however, discrepancies may be
allowed provided that maintenance and repair procedures are in place and implemented within five (5)
calendar days of a reported incident of non-compliance:

A maintenance schedule must be designed by each facility for prevention of clogged or inoperable
nozzles.

PS-4401, Change AG, 2013-04-02, Page 2

Copyright Chrysler Group LLC

3.0 PROCESS

3.1 General Guidelines

3.1.1 Extent of Build

3.1.1.1 Pre-Launch Phases (VP Phase)

For New vehicle (Major) Launches, 100% of the build must be tested in the static water booth for five (5)
minutes. Exceptions are to be defined by Dry Car Lead, Body Sealing Manager, and Quality Center
Manager of affected facility. These exceptions are usually, but not limited to, impact vehicles, bucks, etc.

This static water test procedure must be followed for major launches regardless if the assembly plant has
in line water test facilities or not. For in-line water both please refer to PS-9300.

3.1.1.2 Launch Phases through Volume Production (PS and V1 Phase)

For New vehicle (Major) Launches, 100% of the build must be tested in the static water booth for five (5)
minutes until 95% FTC is achieved for five (5) consecutive days. Afterwards, refer to the sampling
schedule defined under Manufacturing Quality Government Regulatory 06 (MQGR 06). Temporary test
booths should be used if the assembly plant does not have the capacity to test 100% of the build until the
FTC target has been reached.

This static water test procedure must be followed for major launches regardless if the assembly plant has
in line water test facilities or not. For in-line water both please refer to PS-9300.

For Model Year (Minor) Launches, 100% of the build must be tested, until build volume exceeds test
volume capability. Afterwards, refer to the sampling schedule defined under Manufacturing Quality
Government Regulatory 06 (MQGR 06).

All exceptions to this test schedule must be approved by the Plant Quality Center Manager and/or Plant
Manager, the respective Vehicle Platform Program Manager, Dry Car Lead and the Body Sealing
Manager.

3.1.2 Engine/Climate Control Settings

The vehicle must be tested with the fresh air door in the open position and the fan in the OFF or on the
lowest speed setting if OFF does not exist. Automatic climate control systems must be placed in the
manual mode and adjusted to the above settings. The static water test may be performed with the engine
running.

3.1.3 Wiper Settings

The vehicle must be tested with all wipers OFF and in the park position.

3.1.4 Modular Assemblies

Modular assemblies such as sunroofs, modular rear door fixed glass, flipper windows, quarter windows,
sliding backlights and flush glass assemblies must not leak per PF-10737<S>.

PS-4401, Change AG, 2013-04-02, Page 3

Copyright Chrysler Group LLC

3.1.5 Vendor Installed Options

All sunroofs, T-bar roofs, roof vents, limousines, cargo doors, specialty vehicles, etc. will be tested in a
manner similar to the static water test procedure agreed to by Sealing Design Engineer and the Supplier.

3.1.6 Door and Glass Fitting

All door fitting and glass adjustments must be made prior to water testing. No refit or readjustment is
permitted without retest to ensure a dry vehicle.

3.2 Test Setup

3.2.1 Vehicle Preparation

During the early launch phases it is recommended that Sealing Validation vehicles be built with a
minimum of the trim for complete vehicle testing. This must be coordinated with the Product Sealing
Engineer, Supervisor, and Program Management.

Full de-trimming prior to the water test is the most desirable condition for leak detection, root cause and
reprocess. The Sealing and Dry car Team recognizes that the de-trimming operation is destructive to the
vehicle and its part integrity. Therefore, it is agreed that the Dry Car Teams for each assembly plant can
specify a minimum de-trimming on an as needed basis for production vehicle testing. Minimum de-
trimming should allow for inspection of all four corners of the vehicle including top and bottom. The Dry
Car Team at each assembly plant must have identified and documented what de-trimming is required for
that particular vehicle line at that plant. The de-trim level must be approved by the Quality Engineer
and/or Plant Vehicle Engineer, Dry Car Engineer and the respective Platform Sealing Engineer.

3.2.2 Position of Vehicle in Booth

In order to obtain proper spray coverage of the vehicle body, the vehicle must be positioned accurately,
both laterally, and fore and aft in the spray booth. Refer to APPENDIX A

3.2.3 Test Duration

3.2.3.1 Duration

The duration of the water leak test will be five (5) minutes, plus or minus ten (10) seconds. Any
deviations from this must be reported on a report form. Plant Quality Center Manager and Dry Car Lead
shall also be informed of these deviations.

3.2.3.2 Retest Duration

Severe leakage, which would cause damage to a vehicle interior, must be reprocessed immediately.
After the leak is root caused for location, corrected, and documented; a minimum retest of five (5)
minutes, plus or minus ten (10) seconds is required to complete test requirements. A minimum retest of
five (5) minutes is required for all repaired vehicles. Retest to be performed after vehicle and repair
material has been thoroughly dried.

3.2.4 Test Procedure

A. Check that all doors, windows, and sunroof are fully closed.

B. Set climate control and wipers per Section 3.1.2 and 3.1.3.

PS-4401, Change AG, 2013-04-02, Page 4

Copyright Chrysler Group LLC

C. Prep vehicle per 3.2.1.

D. Select correct nozzle configuration/test duration for the vehicle being tested (if applicable).

E. Drive vehicle into the test booth and center vehicle left to right, pull forward until front tires contact
wheel stops per Section 3.2.2.

F. Start water test.

G. Using a portable light, continuously inspect for leakage in the vehicle interior throughout the test
cycle. If any severe leakage is discovered, end test immediately. See Section 3.2.3.2.

H. At end of water test cycle, drive vehicle out of water test booth.

I. Open all doors and liftgate / trunk to inspect for any water in vehicle. This includes spare tire
compartment, front floor, upper corners and Ram Box if applicable.

J. Record findings per Section 3.3.4.

K. Pass vehicle or send for reprocess.

3.3 Sealing Evaluation and Reporting

3.3.1 Vehicle Standard Evaluation System

All leaks for a particular vehicle tested will be noted and the results reported on PFS (Performance
Feedback System), if available, and the Dry Car Matrix Report (work sheet).

3.3.2 Definition of Leaks

Even one drop over the five (5) minute test constitutes a failure. The following definitions for Minor Leak
and Major Leak are for leak magnitude description only.

3.3.2.1 Minor Leak

Anything less than 10 drops or a puddle less than 75mm (3) in diameter witnessed during the entire five
(5) minute test procedure.

3.3.2.2 Major Leak

Anything 10 drops or a puddle greater than 75mm (3) in diameter witnessed during the entire five (5)
minute test procedure.

3.3.3 Leak Sourcing

It may sometimes be convenient to use a water hose and a stream of water to pinpoint the exact location
of suspected leaks. When using a hose, a 4-6 inch horizontal drop in the stream of water from a half (1/2)
inch diameter hose permits a reasonable amount of water to be used without forcing or creating a leak
with too much pressure. Apply the water starting low and working up for proper identification of leak
source.

Another method to determine leak sources would be to spray area with soap and water and watch for
bubbles when air is added from the inside of the cavity.

PS-4401, Change AG, 2013-04-02, Page 5

Copyright Chrysler Group LLC

3.3.4 Reporting Procedures

This section pertains to the recording of water leaks on the work sheets for a tested vehicle.

If a number of distinct leaks can be seen on a surface and the point of origin is known, but hidden from
view, each leak and known source is to be recorded.

If the point of origin of a leak can be seen, even though the leak splits as it travels, only the original leak is
recorded.

3.3.4.1 Recording Procedure

For those plants that have PFS available, leaks should be entered into the QU48 query screens. This
way each failure mode is tied directly to each vehicle, and the information can then be catalogued in the
vehicle water leak database. During new launches all water leaks must be entered in the Dry Car Matrix
during VP and PS phases.

For those plants without PFS, this procedure must be done manually in the established paper recording
system.

3.4 Changes or Revisions

Any proposed changes to this standard or process must be approved by the Dry Car Lead, Quality Center
Manager of Facility, and Body Sealing Manager for the appropriate platform and the Sealing Systems
Core Team prior to implementation.

4.0 QUALITY

Refer to CS-9801 for general quality requirements.

5.0 DEFINITIONS/ABBREVIATIONS/ACRONYMS

Not applicable.

6.0 GENERAL INFORMATION

Three asterisks *** after the section/paragraph header denotes single or multiple technical changes to
the section/paragraph. Specific technical changes within a section, subsection, table, or figure may be
highlighted in yellow.

Certain important information relative to this standard has been included in separate standards. To
assure the processes submitted meet all of Chrysler requirements, it is mandatory that the requirements
in the following standards be met.

CS-9800 - Application of this standard, the subscription service, and approved sources
CS-9003 - Regulated substances and recyclability

Within Engineering Standards, the Regulatory (Government-mandated) requirements are designated by

<S> and <E> which correspond to Safety and Emission Shields respectively. When applicable, the
Chrysler mandated requirements are designated by <D> which correspond to the Diamond symbol and
by <A> for Appearance related objectives, respectively.

For specific information on this document, please refer to the contact person shown in the "Publication

PS-4401, Change AG, 2013-04-02, Page 6

Copyright Chrysler Group LLC

Information" Section of this document. For general information on obtaining Engineering Standards and
Laboratory Procedures, see CS-9800 or contact the Engineering Standards Department at
engstds@chrysler.com.

7.0 REFERENCES

Chrysler ASTM ISO SAE Federal

Standards Standards Standards Standards Standards
CS-9003
CS-9800
CS-9801
PF-10737<S>
PS-9300
PS-7300<D>
Quality and Reliability Documents

Other Documents
Manufacturing Quality Government Regulatory (MQGR-06)
- Available from the contact of this spec.

8.0 ENGINEERING APPROVED SOURCE LIST

Not applicable.

9.0 PUBLICATION INFORMATION

Contact/Phone Number: Bidhi N. Singh, 248 944 0252

Alternate Contact/Phone Number: Brad Mondora, 248 576 4387
Department Name & Department Number/Tech Club/Organization: Body Sealing Engineering
Department 1610
Date Standard Originally Published: 1965-02-23
Date Published: 2013-04-02
Change Notice:
Description of Change:
- Reformatted document.

#####

PS-4401, Change AG, 2013-04-02, Page 7

Copyright Chrysler Group LLC

 APPENDIX A: WATER COVERAGE OF VEHICLE

FIGURE A-1: FORE AFT VIEW

NOTE: Full vehicle must be covered by the water shield. Refer to study DPM0011893571 length will
vary based on vehicle length. Hallows are 304.8mm (12 inches) apart. The entire length of the
vehicle must be covered with halos including a minimum of one halo forward and rearward of
the vehicle.

FIGURE A-2: ISOMETRIC VIEW

PS-4401, Change AG, 2013-04-02, Page 8

APPENDIX A
Copyright Chrysler Group LLC
 APPENDIX B: NOZZLE SPECIFICATION

NOTE: Nozzles required are from Spraying Systems Corporation here in Michigan (Spray.com).
We use the ProMax Quick Release - Full Cone spray nozzle <QPHA6.5>. This nozzle flows at
1.1gpm at 30psi and clamps to a 1 PVC or steel line. Pressure requirement is thirty (30) plus or
minus five (5) PSI at nozzles.

FIGURE B-1: REQUIRED NOZZLE

PS-4401, Change AG, 2013-04-02, Page 9

APPENDIX B
Copyright Chrysler Group LLC
 APPENDIX C: NOZZLE LAYOUT

NOTE: Outer dimensions may vary. The dimensions between the nozzles are critical.

FIGURE C-1: BASIC NOZZLE DISTANCES

PS-4401, Change AG, 2013-04-02, Page 10

APPENDIX C
Copyright Chrysler Group LLC