Doc. No. MS.

90089
COATINGS PERFORMANCE
REQUIREMENTS FOR PAINTED FCA Italy Class: CMD
UNDER HOOD AND CHASSIS FCA US Doc. Type: MS
COMPONENTS
Date: 16-DEC-2024

HARMONIZED DOCUMENT

CARRYOVER/FROZEN
change level: D

This standard is being phased out and shall be used on carryover parts/programs only.

If there is a new document to refer to, that document number is:

MS.90551

DO NOT USE THIS STANDARD ON NEW PARTS/PROGRAMS or add this standard as a change to any
model. This standard may be retained on CATIA/NX models revisions, if it was included at the beginning
of the program. Contact the originating department identified with this standard for the proper
replacement standard.

Comments from author:

New document in use MS.90551

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 FCA Italy S.p.A. and FCA US LLC.
IN CASE OF DISPUTE, THE ONLY VALID REFERENCE IS THE ENGLISH EDITION
 MS.90089
COATINGS PERFORMANCE
Material Specification
REQUIREMENTS FOR PAINTED UNDER
HOOD AND CHASSIS COMPONENTS
Page: 1/34

Date: 11-OCT-2023

GLOBALLLY HARMONIZED DCOUMENT

Author / Region email Department

Kim Tress / North America [Link]@[Link] Materials Engineering
Co-Author / Region email Department
Paolo Faussone / Europe [Link]@[Link] Materials Engineering

Regional specific requirements apply for:

NORTH AMERICA SOUTH AMERICA ENLARGED EUROPE MIDDLE EAST & CHINA INDIA AND ASIA
AFRICA PACIFIC

© 2022 STELLANTIS
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 STELLANTIS
COMPANY. IN CASE OF DISPUTE, THE ONLY VALID REFERENCE IS THE ENGLISH EDITION
 Page: 2/34
MS.90089
Change Level: C

COATINGS PERFORMANCE REQUIREMENTS FOR PAINTED UNDER

HOOD AND CHASSIS COMPONENTS

TABLE OF CONTENTS

1 GENERAL ................................................................................................................................................. 3
1.1 Purpose .................................................................................................................................................. 3
1.2 Coverage of this Standard ..................................................................................................................... 3
1.3 Limitations on Usage.............................................................................................................................. 7
2 REFERENCES.......................................................................................................................................... 7
3 DEFINITIONS/ABBREVIATIONS/ACRONYMS/SYMBOLS ..................................................................... 9
4 CORRELATION TO OTHER STANDARDS ........................................................................................... 10
5 REGULATED SUBSTANCES & RECYCLABILITY ................................................................................ 10
6 MATERIAL CHARACTERISTICS ........................................................................................................... 10
7 CHEMICAL COMPOSITION ................................................................................................................... 11
8 PERFORMANCE REQUIREMENTS OF THE MATERIAL..................................................................... 11
8.1 Engineering Development (ED) Performance Requirements ............................................................... 11
8.2 Design Verification (Materials Engineering Level) DVm Performance Requirements.......................... 11
8.3 Design Verification (Product Engineering) DVe Performance Requirements....................................... 19
8.4 Production Validation/Production Part Approval Process (PV/PPAP) Requirements .......................... 24
8.5 Continuous Conformance (CC) Requirements ..................................................................................... 24
8.6 Forever Requirements FR..................................................................................................................... 28
8.7 Initial Film Build Capability, Part Coverage, and Adhesion................................................................... 28
8.8 Cyclic Chipping Scab Corrosion Test .................................................................................................. 29
9 QUALITY ................................................................................................................................................. 30
10 SPECIAL REQUIREMENTS ................................................................................................................. 30
11 APPROVED SOURCE LIST ................................................................................................................. 30
12 ADDITIONAL CONTACTS.................................................................................................................... 30
13 RELEASE AND REVISIONS ................................................................................................................ 31
Annex A....................................................................................................................................................... 32
 Page: 3/34
MS.90089
Change Level: C

1 GENERAL

1.1 Purpose

This standard defines the global FCA organic coating performance requirements for underhood and
chassis components. The performance requirements are divided into the phases of the FCA Product
Creation Process. These phases are:
Engineering Development (ED)
Design Verification (DV)
o Materials Engineering level (DVm)
o Product Engineering Level (DVe)
Production Validation/Production Part Approval Process (PV/PPAP)
Continuous Conformance (CC)
The coating systems validated according to this process and specification will provide acceptable
durability, cosmetic appearance, and color match/harmony. The requirements for each phase are
outlined in Section 8 - Performance Requirements of the Material.

Samples for PV shall meet statistical capabilities for machine and manufacturing processes. This
specification shall be used on all FCA programs and supersedes MS.90089, and 9.55842.

1.2 Coverage of this Standard

This standard covers the performance requirement of the organic coatings applied to the under hood
and/or chassis purchased finished parts which are the integral design of aesthetic, corrosion resistant,
and durable finishes that are defined in the Table 3. Materials Engineering and Product Engineering will
develop the appropriate class level.

This standard does not cover the Engineering Approved Source List, this information can be obtained by
referring to the individual specifications as described in the Tables 3 and 4.

EXAMPLE OF SPECIFICATION IN ENGINEERING DOCUMENTS: MS.90089 Level D1A

Table 1 - Part Classification

Class
Description Examples
Level
Parts that are painted for aesthetic reasons and exposed Parts visible through the
A to indirect sunlight that do not require corrosion protection, grill, radiator, interior seat
based on the position on the vehicle. rails, brake pedal
Parts that are exposed to corrosion, not exposed to
B sunlight, based on the position on the vehicle (often Drive shaft, engine blocks
higher in the engine compartment)
Engine supports, shock
Parts that are highly exposed to corrosion and/or stone absorbers, exposed
C impingement, not exposed to sunlight, based on the brackets, Tow hooks (not
position on the vehicle visible part), brake rotors,
drive shafts, half shafts
Suspension cradles,
Critical parts that are exposed to corrosion not exposed to crossmembers, fuel tank
D1A sunlight, based on the position on the vehicle. Parts are straps, suspension
typically zinc-coated (galvanized). components with galvanized
coating
 Page: 4/34
MS.90089
Change Level: C

Table 1 - Part Classification

Class
Description Examples
Level
Trailer hitch, Side steps
Critical parts with special aesthetic importance that are
Tow hooks, Rock rails
D1B exposed to corrosion and sunlight, based on position on
(external surface), brake
the vehicle
calipers
Very critical parts that are not zinc-coated (e.g.
galvanized) that are exposed to corrosion, high stone Cradles, suspension arms,
D1C
impingement, and abrasion resistance but not exposed to rear suspension axle
sunlight, based on the position on the vehicle.
Stainless steel, aluminum or coated via electrolysis, that Mufflers, exhaust
E
are painted for aesthetic reasons components
Plastic parts that are painted for aesthetic reasons not
F Plastic Engine Covers, etc.
exposed to sunlight, based on the position on the vehicle

Table 2 indicates the types of organic coatings and the relative minimum thicknesses required. Where
they are not indicated, these values must be agreed and shared with Materials Engineering department.
Any deviation from these general provisions must be agreed and authorized by Materials Engineering
department.

Table 2 - Available Finishes

Coating Description A B C D1A D1B D1C E F

Water or solvent based

epoxy bicomponent
Epoxy primer (interior box
Primer paint
Yes Yes - - - - - -
sectionsand complex
geometries cannot be
protected)
Not recommended
as a final finish for
parts that come in
contact with direct
sunlight.

Electro Thickness ≥ 20 µm
deposition Not recommended as a
final finish forparts that
("E-coat") come in contact with - - Yes - - - - -
Cathodic epoxy direct sunlight.
electrocoats used
for allmetallic Thickness ≥ 25 µm
substrates Not recommended as a
including steel, final finish forparts that
-
zinc- coated come in contact with - - Yes - - -
substrates, zinc -
direct sunlight.
die cast alloys,
aluminum, and Thickness ≥ 35 µm
magnesium.
Not recommended
as a final finish for
parts that come in - - - - - Yes - -
contact with direct
sunlight.
 Page: 5/34
MS.90089
Change Level: C

Table 2 - Available Finishes

Coating Description A B C D1A D1B D1C E F

Powder Coating thickness:

≥ 50 µm
coating
(Magnesium sub.:
≥ 75 µm)
Epoxy-based
and hybrid - Yes Yes Yes - Yes - -
Good flexibility and
coatings used high film builds provide
for all metallic superior chip and
substrates abrasion resistance.
including steel,
zinc-coated Not recommended
substrates, zinc as a final finish for
die cast alloys, parts that come in
aluminum, and contact with direct
magnesium sunlight.

Powder Coating thickness: ≥

coating 50 µm (Magnesium e-coat
substrates: ≥ 75 µm) (Thickness
Powder coatings ≥25 µm)
used for all Good flexibility and high +
metallic film builds provide - - - - powder - - -
substrates superior chip and coating
including steel, abrasion resistance.
zinc-coated
substrates, zinc In addition, powder
die cast alloys, coatings can be provided
aluminum, and in a multitude of colors
magnesium and appearances (e.g.
gloss, texture,etc.).
May be used as a
final finish for parts
that come in contact
with direct sunlight
Water reducible
Water system for cosmetic
reducible andenhanced Yes - - - - - -
coatings for -
corrosion resistance
castings or suitable for castings
engines and components that
are affected by high
cure temperatures
High Siliconic Liquid
temperature coating systems
- - - - - - Yes -
resistance for developed for very
engine high temperature
components stability for
Refer to applications such as
MS-PF-7-1 exhaustcomponents
 Page: 6/34
MS.90089
Change Level: C

Table 2 - Available Finishes

Coating Description A B C D1A D1B D1C E F
Bakingenamel Water-based or 2K Yes Yes Yes - - - - -
system requiring a
thermal cure process.
Air dry enamel Water reducible
forchassis system for cosmetic -
Yes Yes - - - - -
andenhanced
corrosion resistance
suitable for castings
and components that
are affected by high
cure temperatures
Poly- urethane,
Polyurea, orPVC High durability
coatings for critical - - - - Yes - - Yes
chip,scratch and
corrosion resistance.

The pretreatment used prior to paint application shall meet the performance requirements based on the
substrate being painted. Table 3 provides the list of appropriate surface treatments for each substrate.

Table 3 - Surface Treatment Requirements For Various Substrates

Substrate Surface Treatment Prior Painting

Steel Zinc phosphate per PS-508 (Note 1)

Steel / Stainless Steel

applications with service temperature Iron phosphate / sandblasting
above 260 °C (500 °F)
Zinc (e.g. galvanneal, galvanize,
Zinc phosphate per PS-508 (Note 1)
zamak)
Aluminum, or zinc + aluminum
MS.90112 or PS-508 (Note 1)
assemblies

Magnesium PS-10449 (Note 1)

Unless otherwise specified, thermoplastic parts shall be

thoroughly cleaned utilizing solvent or cleaners that are not
detrimental to the base plastic immediately prior to painting.
Thermoplastics: ABS, PC/ABS, For polypropylene: after cleaning, flame treatment and
Reinforced Nylon, Pulp Preform adhesion promoter are mandatory. For NAFTA, flame
Molded Board. treatment is optional but adhesion promoter is required.
FCA Materials Engineering plastic paintability approval is
required.
For fluid test refer to LP-463PB-31-01
Refer to Norm MS.90053
NOTE 1: EMEA, LATAM, APAC Regions may use alternative pre-treatments products for local
market vehicles that meet the performance requirements.
 Page: 7/34
MS.90089
Change Level: C

Table 4 provides the standards for many of the common finishes. Unless otherwise indicated on the print,
the coating thickness shall be defined in the standards listed below. Please refer to the appropriate
standard for the list of approved materials.

(NOTE 1)
Table 4 - Material Standards For Specific Finishes
Standard Document Title
MS-PG-13-1 PAINT – BAKING ENAMEL – FOR PARTS
MS-PB-57-1 PAINT - CATHODIC ACRYLIC ELECTROCOAT
MS-PG-20-1 PAINT – CHASSIS ENAMEL – WATER REDUCIBLE
MS-PF-7-1 PAINT - HIGH TEMPERATURE RESISTANT
MS.90168 PAINT – POWDER COATING – MISCELLANEOUS PARTS
MS.90124 PAINT – PRIMER - CATHODIC EPOXY ELECTROCOAT – COMPONENTS
MS-PF-2-14 PAINT - WRINKLE FINISH - BAKING TYPE
MS-PE-20-1 PAINT COATING FOR HIGH TENSILE COIL SPRINGS
PAINT - IMPROVED CORROSION PROTECTION WATER REDUCIBLE COATING-
MS-PF-1-25
FOR CASTING OR ENGINES
MS.90019 PERMANENT VINYL BASED RESIN PROTECTANTS
MS.90116 POLYURETHANE OR POLYUREA SPRAYABLE PROTECTIVE COATING
MS-A0024 HOT STAMPING/PAD PRINTING/SILK SCREENING INKS
NOTE 1: EMEA, LATAM, APAC Regions may use alternative products for local market vehicles.

1.3 Limitations on Usage

NOTE: Pad printing with inks is not recommended for underhood components.

2 REFERENCES

Table 5 - References
downloadab
Shield/Desi le for
Document Number gnator (if Document Title suppliers
applicable) from
beSTandard

50184 ENVIRONMENTAL TESTS FOR PAINTS (HUMIDITY, THERMAL CYCLE) Y

50470 WATER RESISTANCE TEST FOR PAINTS, ENAMELS, ETC. Y
REQUIREMENTS FOR NON-METAL ENVIRONMENTAL TESTS FOR Y
50493/04
PAINTS, ENAMELS, ADHESIVES, DOPES
9.01102 QUALITY OF SUPPLIES Y
9.01103 PRODUCT QUALITY AND CONFORMITY CERTIFICATE Y
9.55842 VARIOUS METALLIC PART PAINTING Y
COATINGS PERFORMANCE REQUIREMENTS FOR PAINTED UNDER Y
MS.90089
HOOD AND CHASSIS COMPONENTS
A COLOR AND GLOSS REQUIREMENTS FOR INTERIOR, EXTERIOR Y
AS.00001
TRIM, UNDERHOOD, AND FUNCTIONAL COMPONENTS
AS-10119 A GENERAL REQUIREMENTS FOR DESIGNATED APPEARANCE ITEMS Y
A SURFACE APPEARANCE REQUIREMENTS FOR FASCIAS AND Y
AS-10169
EXTERIOR COMPONENTS
STANDARD PRACTICE FOR OPERATING SALT SPRAY (FOG) N
ASTM B117
APPARATUS
 Page: 8/34
MS.90089
Change Level: C

Table 5 - References
downloadab
Shield/Desi le for
Document Number gnator (if Document Title suppliers
applicable) from
beSTandard

STANDARD PRACTICE FOR TESTING WATER RESISTANCE OF N

ASTM D1735
COATINGS USING WATER FOG APPARATUS
STANDARD TEST METHOD FOR IMPACT RESISTANCE OF FLAT,
ASTM D5420 RIGID PLASTIC SPECIMEN BY MEANS OF A STRIKER IMPACTED BY A N
FALLING WEIGHT (GARDNER IMPACT)
ASTM G85 STANDARD PRACTICE FOR MODIFIED SALT SPRAY (FOG) TESTING N
TEST METHOD FOR COPPER-ACCELERATED ACETIC ACID-SALT N
ASTM B368
SPRAY (FOG) TESTING (CASS TEST)
TEST METHOD FOR MEASUREMENT OF METAL AND OXIDE
ASTM B487 COATING THICKNESS BY MICROSCOPICAL EXAMINATION OF N
CROSS SECTION
ASTM D3359 TEST METHODS FOR RATING ADHESION BY TAPE TEST N
ASTM D3363 TEST METHOD FOR FILM HARDNESS BY PENCIL TEST N
STANDARD TEST METHODS FOR MANDREL BEND TEST OF N
ASTM D522
ATTACHED ORGANIC COATINGS
STANDARD TEST METHODS FOR MANDREL BEND TEST OF N
ASTM D870
ATTACHED ORGANIC COATINGS
CS-9003 REGULATED SUBSTANCES AND RECYCLABILITY Y
APPLICATION OF THIS STANDARD, THE SUBSCRIPTION SERVICE, Y
CS-9800
AND APPROVED SOURCES
CORROSION REQUIREMENTS - VEHICLE SYSTEMS AND Y
CS.00081
COMPONENTS
ISO 2409 PAINT ADHESION TEST METHOD N
PAINTS AND VARNISHES - RAPID-DEFORMATION (IMPACT
ISO 6272-2 RESISTANCE) TESTS - PART 2: FALLING-WEIGHT TEST, SMALL-AREA N
INDENTER
QUALITY MANAGEMENT SYSTEMS — PARTICULAR REQUIREMENTS
ISO/TS 16949 FOR THE APPLICATION OF ISO 9001:2008 FOR AUTOMOTIVE N
PRODUCTION AND RELEVANT SERVICE PART ORGANIZATIONS
LP-463PB-31-01 RESISTANCE TO VARIOUS FLUIDS Y
LP-463PB-54-01 CROCK MAR RESISTANCE Y
LP-463PB-44-01 PAINT - FLEXIBILITY TESTING Y
MS.90112 CHEMICAL SURFACE TREATMENT - PRIOR TO PAINTING ALUMINUM Y
MS.90116 POLYURETHANE OR POLYUREA SPRAYABLE PROTECTIVE COATING Y
PAINT – PRIMER - CATHODIC EPOXY ELECTROCOAT – Y
MS.90124
COMPONENTS
COATINGS PERFORMANCE REQUIREMENTS FOR PAINTED Y
MS.90053
INTERIOR PARTS
COATINGS PERFORMANCE REQUIREMENTS FOR PAINTED UNDER Y
MS.90089
HOOD AND CHASSIS COMPONENTS
MS-PB-57-1 PAINT - CATHODIC ACRYLIC ELECTROCOAT Y
MS.90168 PAINT – POWDER COATING – MISCELLANEOUS PARTS Y
MS-PE-20-1 PAINT COATING FOR HIGH TENSILE COIL SPRINGS Y
PAINT-IMPROVED CORROSION PROTECTION WATER REDUCIBLE Y
MS-PF-1-25
COATING-FOR CASTING OR ENGINES
MS-PF-2-14 PAINT - WRINKLE FINISH - BAKING TYPE Y
MS-PF-7-1 PAINT - HIGH TEMPERATURE RESISTANT Y
MS-PG-13-1 PAINT – BAKING ENAMEL– FOR PARTS Y
MS-PG-20-1 PAINT – CHASSIS ENAMEL – WATER REDUCIBLE Y
MS-A0024 HOT STAMPING/PAD PRINTING/SILK SCREENING INKS Y
NON-CHROME PRETREATMENT OF MAGNESIUM PRIOR TO Y
PS-10449
PAINTING
 Page: 9/34
MS.90089
Change Level: C

Table 5 - References
downloadab
Shield/Desi le for
Document Number gnator (if Document Title suppliers
applicable) from
beSTandard

A DISTRIBUTION OF MASTER SPECIMENS FOR DESIGNATED Y

PS-4559
APPEARANCE ITEMS
CHEMICAL SURFACE TREATMENT OF AUTOMOTIVE PARTS IN Y
PS-508
GENERAL INDUSTRY
OUTSIDE DESIGNED AND DEVELOPED ITEMS - FCA US LLC AND Y
PS-7000
SUPPLIER RESPONSIBILITIES
SAE J1976 OUTDOOR WEATHERING OF EXTERIOR MATERIALS N
SAE J2334 LABORATORY CYCLIC CORROSION TEST N
SAE J2527 ACCELERATED WEATHERING – XENON ARC/BORO-BORO FILTERS N
SAE J400 TEST FOR CHIP RESISTANCE OF SURFACE COATINGS N

3 DEFINITIONS/ABBREVIATIONS/ACRONYMS/SYMBOLS
AAR: Appearance Approval Report
ABS: Acrylonitrile butadiene styrene
APAC: Asia and Pacific markets
AQP: Advanced Quality Planning
AS: Appearance Standard
ASTM: American Society for Testing and Materials
CC: Continuous Conformance
CS: Characteristic Standard
DV: Design Verification
DVe: Design Verification for Engineering and Applications
DVm: Design Verification for Coating Materials
DVP&R: Design Verification Plan & Report
ED: Engineering Development
EMEA: European, Middle Eastern, and African markets
ISO: International Organization for Standardization
ISO/TS: ISO/Technical Specification
kJ: Kilo joules (unit of energy)
LATAM: Latin American markets
LP: Laboratory Standard
MS: Material Standard
NA: Not Applicable
OEM: Original Equipment Manufacturer
PC/ABS: Polycarbonate Acrylonitrile Butadiene Styrene
PA66: Polyamide 66, also Nylon 66
PF: Performance Standard
PPAP: Production Parts Approval Process
PS: Process Standard
PSO: Process Sign Off
PV: Production Validation
SAE: Society of Automotive Engineers
SQ: Supplier Quality
°C: Degrees Celsius (unit of temperature)
Stellantis Document that merges xFCA & xPSA Know How (K.H.)
 Page: 10/34
MS.90089
Change Level: C

Harmonized
Regional document
(xFCA Document created and adopted by a single region
applicabality)
Globally Document that has been approved by representatives of all Regions (EMEA,
Harmonized NORTH AMERICA, APAC, LATAM, MASERATI). All the contents are common and
(xFCA applicability) valid at a Global level.

4 CORRELATION TO OTHER STANDARDS

Refer to section 1.2.

5 REGULATED SUBSTANCES & RECYCLABILITY

Coatings must comply with CS-9003 SUPPLIER REQUIREMENTS FOR VEHICLE AND SERVICE
PARTS: RESTRICTED AND PROHIBITED.

6 MATERIAL CHARACTERISTICS
The coatings requiring materials engineering approval shall meet the performance requirement as stated
in Tables 6 through 8, along with the additional requirements defined in the appropriate material standard
from Table 3.

ED development of coatings shall require the formulating target, range of resins, pigments, additives,
solvents, and the key characteristics be disclosed in a design matrix. Upon approval of a product the
design matrix must be signed off by the appropriate engineers in either FCA US or EMEA Materials
Engineering. Due to proprietary information, the design matrix is retained by the supplier but available for
review upon request.

All panels to be tested shall receive a minimum of 24 hours post-cure dwell time. All parts to be tested
shall receive the full 72 hours post-cure dwell time unless otherwise indicated.

Materials or finishes submitted shall meet the performance requirements according to the Tables 6
through 8 of this standard in conjunction with appropriate material standards listed in Table 3 and Table 4.

The paint supplier shall submit a defined bake window (time and temperature), defined film build
tolerances (minimum, maximum, and target), and technical data sheets for each individual coating layer.
Reprocess parameters may be provided if appropriate.

All reprocess conditions shall perform to the extent that the part meets the performance requirements in
Tables 6 through 8 without negatively affecting the substrate or final performance of the component.

The paint suppliers should follow Table 2, 3, and 4 for the paint layering system film builds and surface
treatment of the applicable substrates.

If there is a change in any part of the layering system, i.e. pretreatment or enamel, the complete paint
system shall be re-evaluated as per Table 7. Contact FCA Materials Engineering for possible deviations.
 Page: 11/34
MS.90089
Change Level: C

7 CHEMICAL COMPOSITION
Not Applicable.

8 PERFORMANCE REQUIREMENTS OF THE MATERIAL

The supplier of the OEM component must insure that the coating on the part meets all of the performance
requirements listed in Tables 6, 7, and 8.

The paint supplier shall have a defined bake window (time and temperature) and defined film build
tolerances (minimum, maximum and target) as validated and approved by FCA in the ED/DV testing.
Total film build must be measured for each tested sample/part and recorded along with the results in the
test report. The paint supplier’s Technical Data Sheet requirements for film build and cure MUST be
consistent with the values signed off in the test report.

Reprocess layers shall be limited to two, unless agreed upon with SQ and ME. Maximum film builds are
a function of the layering system.

Photographic records of pre- and post- conditions shall be included in the test report as noted in Section
8.1.

For parts that require a specified FCA-defined appearance (color and/or texture code), parts and
submissions must follow AS-10119<A> “GENERAL REQUIREMENTS FOR DESIGNATED
APPEARANCE ITEMS” and PS-4559<A> “DISTRIBUTION OF MASTER SPECIMENS FOR
DESIGNATED APPEARANCE ITEMS”. These are the key documents that the tier supplier must follow for
the FCA Product Design Office.

8.1 Engineering Development (ED) Performance Requirements

The ED phase pure technology validation is managed by Materials Engineering and is done primarily at
the plaque level. This stage of the development cycle is the longest and therefore is performed
“decoupled” from the vehicle plan/programs. ED approval must be met for all coating materials/suppliers
in the “stack-up” for the part. Once all coating material/suppliers in the proposed “stack -up” have FCA-ED
approval, the finish may be coupled to a program and the Design Verification (DV) may begin.
Technologies for the color layer are ED validated by testing a set of colors that “box” the color layer
formulation practices. The ED requirements listed herein are f or the full “stack-up”. See the individual
Materials Standard for each material layer for requirements beyond the full “stack -up”.

8.2 Design Verification (Materials Engineering Level) DVm Performance Requirements

The DVm phase is primarily used for aesthetic finishes and is the validation of the color and “stack -up”
including substrate by Materials Engineering, primarily at plaque level. This phase validates the color
execution within a set of ED approved layers (e.g. - primer/basecoat/clearcoat or primer/monocoat). The
compatibility of the individual layers and substrate is also verified. The timing is shorter 2 – 6 months,
and therefore amenable to program timing. These approvals are documented in the Master Tracking
System (MTS) using the Source Approval Status Form (SASF).

Table 6 - ED / DVm - Phase Performance Requirements

Test
Test Specification Duration Requirement
Number
 Page: 12/34
MS.90089
Change Level: C

Table 6 - ED / DVm - Phase Performance Requirements

Test
Test Specification Duration Requirement
Number
LP-463PB-54-01
Gloss retention >70% (60°)
1 Mar Resistance using 9 micron 10 double rubs
without polish
paper
Complete PDO Review to
Appearance (Color AS-10119<A>, and
2 Not applicable verify match to master at
Match, Gloss) AS.00001<A>
SASF and ATAR phases.

ISO 2409,
Initial Adhesion with ISO 2409 Classification = 0
3 Tape 3M 898 or NA
Cross Hatch (0% coating removal)
Tape Tesa 4657

As defined on chemical
Thickness (metal
4 ASTM B-487 NA supplier’s Technical Data
substrates)
Sheet

Report dry film thickness

Report film
for each layer. The paint
thickness
thickness at DVm defines
specification in
the minimum dry film paint
Micrographic or the technical data
Thickness (plastic thickness required on the
5 Erichsen PIG sheet as part of
substrates)
instrument actual part. The film build
Materials
at DVm level shall match
Engineering
the Technical Data Sheet
certification
of the material.
package.
10 double rubs
LP-463PB-31-01 No change in
Method J Demonstrate that appearance, paint
6 Cure Check MIBK, or solvent under cure or removal, loss of gloss,
recommended by under crosslinked nor softening of the
paint manufacturer coatings fail. coatings.
Submit bake chart

50452/02 or ASTM
7 Pencil Hardness NA Report results
D3363

8 Conical Mandrel ASTM D-522 1/8” Mandrel No cracking

24 hr @ 60 C
50470 or LP-
(48 Hr @ 40 C for
463PB-31-01
classes D1A, D1B,
Method L ISO 2409 Classification = 1
DI Water Immersion D1C)
9 or better (not greater than
+ Adhesion
+ ISO 2409, 5% detachment)
Solvent borne
Tape: 3M 898 or
coatings:
Tesa 4657
Cross hatch
adhesion test after
 Page: 13/34
MS.90089
Change Level: C

Table 6 - ED / DVm - Phase Performance Requirements

Test
Test Specification Duration Requirement
Number
2 hour recovery
,
Water borne
coatings:
Cross hatch
adhesion test after
6 hour recovery
500 hours

Solvent borne
coatings:
Adhesion test
ISO 2409 Classification = 1
performed between
or better (not greater than
ASTM D1735 or 1 and 2 hours after
5% detachment)
Humidity Adhesion 50184, removal from
cabinet.
10 No blistering, change in
(Plastic and metal + ISO 2409,
appearance, or other
substrates) Tape: 3M 898 or Water borne
detrimental failures when
Tesa 4657 coatings:
compared with original
Adhesion test
sample.
performed within 6
hours after removal
from humidity
cabinet

Testing shall be performed

with minimum 2 panels
(additional panels may be
tested).

Test one panel up to 2500kJ,

record data at 900kJ, 1240kJ
and 2500kJ. After 1240kJ,
Artificial Weather
perform adhesion test after
Resistance
one hour recovery.
Only for
Continue second panel up to
components that are
ED - 2500kJ 4500kJ, record data at
directly exposed to SAE J2527
Review Panels at 1800kJ 2500 kJ, and 4500kJ.
sunlight, including Boro/Boro Filters
11 600kJ, 1240kJ, After 4500kJ perform
Side steps, adhesion test after one hour
1800kJ,2500kJ
Exposed trailer + ISO 2409. recovery.
and 4500 kJ
hitch
Exposed tow Color Change
hooks Evaluation
Record data for color
shift ΔL, Δa, Δb and
Delta E
There shall be no
discoloration, chalking,
cracking, peeling or
other detrimental effects
on the coating.
Delta E < 2.5 at 1240kJ
 Page: 14/34
MS.90089
Change Level: C

Table 6 - ED / DVm - Phase Performance Requirements

Test
Test Specification Duration Requirement
Number
Delta E < 3.0 at 2500kJ
Adhesion after 1240KJ
and 2500kJ: 0-1 as per
ISO 2409.
Gloss Retention: 90%
Testing shall be performed
with minimum 2 panels.

Test panels up to 1240kJ,

Artificial Weather record data at 300kJ, 600kJ,
Resistance 900kJ and 1240kJ. After
1240kJ, perform adhesion
Only for test after one hour recovery.
components that are
indirectly exposed to Color Change
sunlight, including: SAE J2527 Evaluation
ED - 1240kJ Record data for color
Brake calipers Boro/Boro Filters
12 Review Panels at
Wheel springs shift ΔL, Δa, Δb and
600kJ and 1240kJ
shocks, and struts + ISO 2409. Delta E
that are colors There shall be no
other than black discoloration, chalking,
Components cracking, peeling or
visible through the other detrimental effects
grill on the coating.
Delta E < 2.5 at 1240kJ
Adhesion after
exposure: 0-1 as per
ISO 2409.
Gloss Retention: 90%
Natural Weathering
Resistance

(Only for 1 Year: 90% Gloss

components that are retention, polished and
directly exposed to unpolished, no cosmetic
SAE J1976
13 sunlight. 1 year and 2 year corrosion
South Florida
Required for Class 2 Year: 85% Gloss
Level A, B, and C) retention, unpolished

(Not required for

DVm phase)
Natural Weathering South Florida per
Resistance SAE J1976
2 years outdoor
exposure
(Only for + ASTM D1735 or Adhesion Rating: 0 to1 per
followed by 240
components that are 50184, ISO 2409
hours humidity
14 directly exposed to
followed by 3 pints
sunlight. + ISO 2409 Gravel Rating: <49 chips at 1
of gravel, ambient
Tape: 3M 898 or to 3 mm size
temperature, 45
Required for Class Tesa 4657
degree angle
Level D, E and F
applications + SAE J400
 Page: 15/34
MS.90089
Change Level: C

Table 6 - ED / DVm - Phase Performance Requirements

Test
Test Specification Duration Requirement
Number

(Not required for

DVm phase)

Natural Weathering
Resistance

(Only for South Florida per

No functional failures for ,
components that are SAE J1976 3 years, 4 years,
15 cracking, adhesion,
directly exposed to and 5 years
blistering, delamination, etc.
sunlight + ISO 2409

(Not required for

DVm phase)
NAFTA: South NAFTA: 12 Scribe creep ≤ 4 mm for
Outdoor Corrosion Florida black box months, spray zinc coated substrates
or twice per week and aluminum, ≤12 mm
16
(Not required for EMEA: Genoa test, for CRS (total scribe
DVm phase) natural exposure EMEA: 12 months width, average of 5
near the sea readings/scribe)
1 pint (0.5 kg) @
Gravel Resistance
70 psi (4,5 Bar)
Rating of 7B
45 and 90 degree
17 (Not required for SAE J400
angles
Class Level A and
Temperature of 23
F)
°C
1 pint (0.5 kg) @
Gravel Resistance
70 psi (4.5 Bar)
with Humidity
45 and 90 degree
Exposure
SAE J400 angles Rating of 7B or better before
+ ASTM D1735 Temperature of 23 and after humidity exposure
18 (Not required for
°C (ED, DV, PV,
Class Level A and
or 50184 and CC) and -30
F)
°C (ED, DVm only)
500 hours humidity
exposure
Less than 5% loss of paint in
Cyclic Chipping
the tested surface area.
+
NAFTA: SAE J2334 Section 8.9 Less than 2 mm creep per
Scab Corrosion
+ SAE J400 scribe for aluminum,
19
Total test duration: magnesium, and zinc coated
(Not required for
EMEA: 50493/04 60 days steel substrates.
Class Level A and
Less than 4 mm per side for
F)
CRS.
Less than 5% loss of paint in
Cyclic Chipping with NAFTA: SAE J2334 the tested surface area.
Section 8.9
Scab Corrosion + SAE J400 Less than 2 mm creep per
scribe for aluminum,
20 Total test duration:
(Not required for EMEA: 50493/04 magnesium, and zinc coated
30 days
Class Levels A, B steel substrates.
and F) (Section 8.8) Less than 4 mm per side for
CRS.
 Page: 16/34
MS.90089
Change Level: C

Table 6 - ED / DVm - Phase Performance Requirements

Test
Test Specification Duration Requirement
Number
High Performance 3 pints (1.5 kg) @
Gravel Resistance 70 psi, 90 degree
with Humidity SAE J400 angle
Exposure Temperature Rating of 7B or better before
21
+ ASTM D1735 or -30 °C and after humidity exposure
(Required for Level 50184
D) 500 hours humidity
exposure
Evaluate and perform
adhesion on the samples 1
and 2 hours after complete
test. Compare the results.
LP.7M070, Method 15 Cycles Complete recovery after 2
Thermal Cycle For 4 (Automatic and hrs. at ambient temperature.
22
Metal Substrates Manual Cycles
+ ISO 2409 acceptable) Adhesion 0-1 per ISO 2409
No blistering, cracking,
change in appearance or
other failure when compared
with original sample.
No detrimental effects such
Fluid Resistance per
as swelling, discoloration,
LP-463PB-31-01 Defined in LP-
23 LP-463PB-31-01 cracking, coating
Underhood 463PB-31-01
delamination or appreciable
Requirements
softening.
23a Fluid Resistance - No detrimental effects such
Armor All Cleaner as swelling, discoloration,
LP-463PB-31-01
or 24 hours at 23 °C cracking, coating
Method B
Arexons Shampoo delamination or appreciable
4432 softening.
No detrimental effects such
Fluid Resistance –
as swelling, discoloration,
Methanol Fuel LP-463PB-31-01
23b 24 hours at 23 °C cracking, coating
For APAC and Method B
delamination or appreciable
LATAM markets
softening.
Heat soak at
maximum
3 cycles with Adhesion rating of 0 to 1
temperature (See
Thermal Shock / forced air dry No other cracking, blistering
Table 10) for 15
Water Quench between each or loss of adhesion. Slight
24 minutes, followed by
cycle. Perform discoloration or dulling is
water quench at 23
adhesion test after acceptable. Report test
°C for 1 minute and
final cycle. temperature with results.
adhesion test per
ISO 2409
Heat soak at
maximum part
Maximum creep from scribe
temperature
line in 0.8 mm per side, 1.6
(See table 10), 24 hour heat soak,
mm total.
25 Heat Resistance X-Scribe adhesion 24 hours humidity,
Slight dulling or discoloration
test, Humidity test
is acceptable for
per ASTM D1735 or
temperatures over 150 °C
50184, X-Scribe
adhesion test
 Page: 17/34
MS.90089
Change Level: C

Table 6 - ED / DVm - Phase Performance Requirements

Test
Test Specification Duration Requirement
Number
No corrosion, loss of
adhesion, or blistering.
Maximum scribe creep 2 mm
Per Class Level in
from line, 4 mm total scribe
Corrosion Testing 50180 B1 or Table 8
26 width, and 2 mm from the
Ferrous Substrates Scribe + Salt Spray
components sharp edges
per ASTM B117
and corners.
(Average of 5 readings per
scribe) (NOTE 3)
No corrosion, loss of
adhesion, or blistering.
Maximum scribe creep 4 mm
50493/04
Per Class Level in from line, 8 mm total scribe
without immersion,
Table 9 width) and 4mm from the
with stone chipping
components sharp edges
Cyclic Corrosion upon request
(NOTE 1) and corners.
Testing -
(Average of 5 readings
27 (Zinc, Galvanized,
/scribe) (NOTE 3)
Galvanneal, etc
No corrosion, loss of
substrates)
adhesion, or blistering
Line Scribe, Max creep from scribe: 2
SAE J2334 30 cycles mm from line, 4 mm total
(NOTE 2) scribe width, and 2 mm from
the components sharp edges
and corners
Sheet or extrusions:
No corrosion, loss of
adhesion, or blistering.
Max creep from scribe: 2 mm
from line, 4 mm total scribe
Line Scribe, width, and 2 mm from the
ASTM G85 components sharp edges
15 weeks
Annex 2 and corners
(NOTE 2)

Cast aluminum:
Cyclic Corrosion Max creep from scribe: 4 mm
Testing – from line, 8 mm total scribe
28 Aluminum width, and 4 mm from the
Substrates components sharp edges
No corrosion allowed, loss of
adhesion or
Blistering of the support
50493/04 material. Maximum
without immersion, Per Class Level in scribe creep 4 mm from line,
with stone chipping Table 9 8 mm total scribe
upon request width) and 4mm from the
(NOTE 1)
components sharp edges
and corners.
(Average of 5 readings per
scribe) (NOTE 3)
 Page: 18/34
MS.90089
Change Level: C

Table 6 - ED / DVm - Phase Performance Requirements

Test
Test Specification Duration Requirement
Number
No corrosion allowed, loss of
adhesion or blistering.
Corrosion Testing –
Maximum scribe creep 2 mm
Aluminum Line Scribe, 168 hours
from line, 4 mm total scribe
Substrates ASTM B368
29 width, and 2mm from the
(CASS test) Aluminum Castings
components sharp edges
(Not required for ISO 2409 only: 48 hours
and corners.
Class Level A)
(Average of 5 readings per
scribe) (NOTE 3)
No corrosion allowed, loss of
adhesion or blistering.
Corrosion Testing – Maximum scribe creep 2 mm
Aluminum Line Scribe, from line, 4 mm total scribe
30 Substrates, ASTM B117, 48 hours width, and 2mm from the
ISO 2409 components sharp edges
(Only Class Level A) and corners.
(Average of 5 readings per
scribe) (NOTE 3)
Cyclic Corrosion Max creep from scribe: 4 mm
Testing – ASTM G85 from line, 8 mm total scribe
31 6 weeks
Magnesium Annex 2 width, and 4 mm from the
Substrates components sharp edges

Flexibility Mandrel diameter 1

50453/01or No cracking, delamination or
32 (TPO, TPU, RIM to 1.3 cm
LP-463PB-44-01 other detrimental effects.
substrates only) @ (-18 °C)

ISO 6272-2
no loss of adhesion to
initial, aged 10
the substrate when
Nominal sphere days @ 70 °C (158
Impact Resistance impacted direct and
33 diameter: °F),
(Steel substrates) indirect at 2.26N.m (20
Ecoat: 12.7 mm and frozen 4 hours
in-lbs) increments up to
Powder coat: 15.9 @ -30 °C (-20 °F)
13.6 N.m (120 in-lbs)
mm
Compare the coated panels
ASTM D5420 3 painted
or part vs. uncoated panels
Striker Diameter plaques for
or part. There shall be no
Impact Resistance – GB 15.86 each color, 1
34 changes in the types of
(Plastic substrates) Impact Mass - uncoated
cracks, brittleness, ductility
9.N.M panels to be
between coated and
80 inch pounds tested.
uncoated panels
DOE’s include variations in
As applicable to
Test to Failure Per DOE (Design bake, film build and process
35 specific application
FMEA/DOE of Experiments) for all layers. Reprocess
and technology
should also be assessed.
NOTE 1: Not mandatory for North American region.
NOTE 2: Mandatory for components of vehicles for North America market.
NOTE 3: For box-type components: at the end of the test it is necessary to verify the internal corrosion
propagation by sectioning the components itself.
Limits: Inside boxes: 2 corrosion points 3 mm every 5 cm2 of the inner surface (at least 2 cm
apart) are allowed. In the contact and welding areas: sub-film propagation 4 mm from the contact
point.
 Page: 19/34
MS.90089
Change Level: C

8.3 Design Verification (Product Engineering) DVe Performance Requirements

The DVe phase applies to all finishes and validates the finish on surrogate or actual parts as close to
production conditions as possible. Product Engineering executes this phase as part of the DVP&R. It is
critical in this phase to validate design and production specific elements. Examples include: actual
substrate (not generic), processing fluids (mold release, mill oils, drawing compounds/dry films, cleaners,
etc), design of part (parting lines, gates, sharp edges, tight radii, hard to coat geometries, etc), general
process considerations (lag times, pretreatments, cure method, etc), reprocess, shipping, and other
conditions. Should any relevant conditions change, then appropriate testing must be redone and
documented as part of the DVe plan. DVe starts when the component is sourced to a production supplier
(Tier 1) and SASF is approved by materials engineering at step 2. The DVe requirements listed below are
the recommendations of Materials Engineering and are subject to agreement of Product Engineering.

Table 7 - DVe Phase Performance Requirements (Product Engineering)

Number Test Specification Duration Requirement

Complete PDO Review to
Appearance (Color AS-10119<A>, and
1 Not applicable verify match to master at
Match, Gloss) AS.00001<A>
SASF and ATAR phases.

ISO 2409,
Initial Adhesion with ISO 2409 Classification = 0
2 Tape 3M 898 or NA
Cross Hatch (0% coating removal)
Tape Tesa 4657

As defined on chemical
Thickness (metal
3 ASTM B-487 NA supplier’s Technical Data
substrates)
Sheet

Report film
thickness
specification in the
Micrographic or technical data As defined during DVm and
Thickness (plastic
4 Erichsen PIG sheet as part of chemical supplier’s Technical
substrates)
instrument Materials Data Sheet.
Engineering
certification
package.
LP-463PB-31-01
Method J No change in appearance,
5 Cure Check MIBK, or solvent 10 double rubs paint removal, loss of gloss,
recommended by nor softening of the coatings.
paint manufacturer
24 hr @ 60 C

(48 Hr @ 40 C for
50470 or LP-
classes D1A, D1B,
463PB-31-01
D1C)
Method L ISO 2409 Classification = 1
DI Water Immersion
6 or better (not greater than
+ Adhesion Solvent borne
+ ISO 2409, 5% detachment)
coatings:
Tape: 3M 898 or
Cross hatch
Tesa 4657
adhesion test after
2 hour recovery
,
 Page: 20/34
MS.90089
Change Level: C

Table 7 - DVe Phase Performance Requirements (Product Engineering)

Number Test Specification Duration Requirement

Water borne
coatings:
Cross hatch
adhesion test after
6 hour recovery
500 hours

Solvent borne
coatings:
Adhesion test ISO 2409 Classification = 1
performed between or better (not greater than
ASTM D1735 or
1 and 2 hours after 5% detachment)
Humidity Adhesion 50184,
removal from
7 cabinet. No blistering, change in
(Plastic and metal + ISO 2409,
appearance, or other
substrates) Tape: 3M 898 or
Water borne detrimental failures when
Tesa 4657
coatings: compared with original
Adhesion test sample.
performed within 6
hours after removal
from humidity
cabinet
1 pint (0.5 kg) @
Gravel Resistance
70 psi (4,5 Bar)
Rating of 7B
SAE J400 45 and 90 degree
8 (Not required for
angles
Class Level A and
Temperature of 23
F)
°C
1 pint (0.5 kg) @
Gravel Resistance
70 psi (4.5 Bar)
with Humidity
45 and 90 degree
Exposure
SAE J400 angles
Rating of 7B or better before
Temperature of 23
Required For Multi- and after humidity exposure
9 + ASTM D1735 °C (ED, DV, PV,
layer Systems
and CC) and -30
or 50184 °C (ED, DVm only)
(Not required for
Class Level A and
500 hours humidity
F)
exposure
Gravel (3 pints)
Cyclic Chipping Corrosion test 2
+ weeks Less than 5% loss of paint in
Scab Corrosion Section 8.8 Gravel 1 pint the tested surface area.
Corrosion 2 weeks Less than 2 mm creep per
Required For Multi- NAFTA: SAE J2334 (repeat 1 pint scribe for aluminum,
10
layer Systems + SAE J400 gravel and 2 weeks magnesium, and zinc coated
corrosion for full steel substrates.
(Not required for EMEA: 50493/04 test cycle) Less than 4 mm per side for
Class Level A and CRS.
F) Total test duration:
60 days
 Page: 21/34
MS.90089
Change Level: C

Table 7 - DVe Phase Performance Requirements (Product Engineering)

Number Test Specification Duration Requirement

Cyclic Chipping with
Less than 5% loss of paint in
Scab Corrosion
Section 8.8 the tested surface area.
Less than 2 mm creep per
Required For Multi- Total test duration:
NAFTA: SAE J2334 scribe for aluminum,
11 layer Systems 30 days
+ SAE J400 magnesium, and zinc coated
steel substrates.
(Not required for
EMEA: 50493/04 Less than 4 mm per side for
Class Levels A and
CRS.
B)
3 pints (1.5 kg) @
High Performance 70 psi, 90 degree
Gravel Resistance SAE J400 angle
with Humidity Temperature -30 Rating of 7B or better before
12
Exposure + ASTM D1735 or °C and after humidity exposure
(For Class Level D 50184
and if required) 500 hours humidity
exposure
Evaluate and perform
adhesion on the samples 1
and 2 hours after complete
LP-463PB-22-01,
test. Compare the results.
Method IV
15 Cycles Complete recovery after 2
Or
Thermal Cycle For (Automatic and hrs. at ambient temperature.
13 Fiat 50184
Metal Substrates Manual Cycles
Method D.
acceptable) Adhesion 0-1 per ISO 2409
No blistering, cracking,
+ ISO 2409
change in appearance or
other failure when compared
with original sample.
Fluid Resistance per
LP-463PB-31-01 No detrimental effects such
Underhood as swelling, discoloration,
Defined in LP-
14 Requirements LP-463PB-31-01 cracking, coating
463PB-31-01
delamination or appreciable
Based on position in softening.
vehicle
Fluid Resistance
based on vehicle
No detrimental effects such
position
as swelling, discoloration,
LP-463PB-31-01 5, 18, 24 hours at
15 cracking, coating
Armor All Cleaner Method B 23 °C
delamination or appreciable
or
softening.
Arexons Shampoo
4432
Fluid Resistance
based on vehicle No detrimental effects such
position and market as swelling, discoloration,
LP-463PB-31-01 5, 18, 24 hours at
16 cracking, coating
Method B 23 °C
Methanol Fuel delamination or appreciable
For APAC and softening.
LATAM markets
 Page: 22/34
MS.90089
Change Level: C

Table 7 - DVe Phase Performance Requirements (Product Engineering)

Number Test Specification Duration Requirement

Heat soak at
maximum
3 cycles with Adhesion rating of 0 to 1
temperature (See
Thermal Shock / forced air dry No other cracking, blistering
Table 10) for 15
Water Quench between each or loss of adhesion. Slight
17 minutes, followed by
cycle. Perform discoloration or dulling is
water quench at 23
adhesion test after acceptable. Report test
°C for 1 minute and
final cycle. temperature with results.
adhesion test per
ISO 2409
Heat soak at
maximum part See
Maximum creep from scribe
Table 10)
line in 0.8 mm per side, 1.6
temperature, X- 24 hour heat soak,
mm total.
18 Heat Resistance Scribe adhesion 24 hours humidity,
Slight dulling or discoloration
test, Humidity test
is acceptable for
per ASTM D1735 or
temperatures over 150 °C
50184, X-Scribe
adhesion test
No corrosion, loss of
adhesion, or blistering.
Maximum scribe creep 2 mm
Per Class Level in
from line, 4 mm total scribe
Corrosion Testing 50180 B1 or Table 9
19 width, and 2 mm from the
Ferrous Substrates Scribe + Salt Spray
components sharp edges
per ASTM B117
and corners.
(Average of 5 readings per
scribe) (NOTE 3)
No corrosion, loss of
adhesion, or blistering.
Maximum scribe creep 4 mm
50493/04
Per Class Level in from line, 8 mm total scribe
Cyclic Corrosion without immersion,
Table 9 width) and 4mm from the
Testing - with stone chipping
components sharp edges
20 (Zinc, Galvanized, upon request
(NOTE 1) and corners.
Galvanneal, etc (Average of 5 readings
substrates) /scribe) (NOTE 3)

SAE J2334 (NOTE 2) Per CS.00081 Per CS.00081

Cyclic Corrosion
Testing – Line Scribe,
21 Aluminum ASTM G85 - Annex Per CS.00081 Per CS.00081
Substrates 2 (NOTE 2)
 Page: 23/34
MS.90089
Change Level: C

Table 7 - DVe Phase Performance Requirements (Product Engineering)

Number Test Specification Duration Requirement

No corrosion allowed, loss of

adhesion or
Blistering of the support
material. Maximum
50493/04
Per Class Level in scribe creep 4 mm from line,
without immersion,
Table 9 8 mm total scribe
with stone chipping
width) and 4mm from the
upon request (NOTE 1)
components sharp edges
and corners.
(Average of 5 readings per
scribe) (NOTE 3)
No corrosion allowed, loss of
Corrosion Testing – adhesion or blistering.
Aluminum Maximum scribe creep 2 mm
Line Scribe, 168 hours
Substrates, from line, 4 mm total scribe
ASTM B368
22 width, and 2mm from the
(CASS test) For cast aluminum:
(Not required for components sharp edges
ISO 2409 48 hours
Class Level A and and corners.
F) (Average of 5 readings per
scribe) (NOTE 3)
No corrosion allowed, loss of
adhesion or blistering.
Corrosion Testing –
Maximum scribe creep 2 mm
Aluminum
Line Scribe, from line, 4 mm total scribe
Substrates,
23 ASTM B117, 48h width, and 2mm from the
ISO 2409 components sharp edges
(Only Class Level A
and corners.
and F)
(Average of 5 readings per
scribe) (NOTE 3)
Cyclic Corrosion Max creep from scribe: 4 mm
Testing – ASTM G85 from line, 8 mm total scribe
24 6 weeks
Magnesium Annex 2 width, and 4 mm from the
Substrates components sharp edges

Flexibility Mandrel diameter No cracking, delamination

50453/01or
25 (TPO, TPU, RIM 1 to 1.3 cm or other detrimental
LP-463PB-44-01
substrates only) @ (-18 °C) effects.
ISO 6272-2 initial, aged 10 no loss of adhesion to
days @ 70 °C the substrate when
Impact Resistance Nominal sphere (158 °F), impacted direct and
26 diameter:
(Steel substrates) and frozen 4 indirect at 2.26N.m (20
Ecoat: 12.7 mm
Powder coat: 15.9 hours @ -30 °C in-lbs) increments up to
mm (-20 °F) 13.6 N.m (120 in-lbs)
ASTM D5420 3 painted Compare the coated
Striker Diameter plaques for panels or part vs.
Impact Resistance
– GB 15.86 each color, 1 uncoated panels or part.
27 (Plastic
Impact Mass - uncoated There shall be no
substrates)
9.N.M panels to be changes in the types of
80 inch pounds tested. cracks, brittleness,
 Page: 24/34
MS.90089
Change Level: C

Table 7 - DVe Phase Performance Requirements (Product Engineering)

Number Test Specification Duration Requirement

ductility between coated
and
uncoated panels

8.4 Production Validation/Production Part Approval Process (PV/PPAP) Requirements

The PV phase essentially is to confirm that successful demonstration of all Performance Objectives
(ED/DV) will not be compromised by production process and variations to the DVe test parameters. It can
consist of 3 levels of testing – component, system and vehicle. At minimum, Product Validation at
component level (PPAP) must be completed prior to PS MRD. Parts must come from home line at
production rate preferably during PDR (Production demonstration run). The PPAP phase is to verify that
the conditions simulated during DVe are not changed at actual production process conditions. These
tests seek variation from the DV validation condition – this phase is not intended to simulate life testing.
Clearly stated – PV/PPAP testing does NOT in and of itself, demonstrate Performance Objectives are
met.

Material Engineering coating PPAP requirements are documented in PF-7051 and should be regarded as
the minimum component level coating PV/PPAP requirements. Additional PV testing may be required
according to additional Engineering PF’s called out and additional PV testing at the system and/or vehicle
level.

This design level also applies to PPAP/PSO and Forever Requirement paint testing driven by:

A: Significant Process Changes

B: New Part Supplier
C: New or Significant Change to Part/Design
D: New Substrate or Significant Change to Existing Substrate
E: Change in Paint Facility, Location or Process Line
F: New Paint Color, Technology, or Supplier
G: Change in Paint Material or Solvent Blend.
H: New Paint Supplier/Source

Refer to Table 8 for requirements.

8.5 Continuous Conformance (CC) Requirements

The Continuous Conformance phase is for continuous monitoring of process/materials after launch.
Refer to PF-7051 for Materials Engineering CC requirements for coatings. These should be regarded as
the minimum Continuous Conformance coating test requirements. The supplier control plan may be
supplemented by Product Engineering and/or Supplier Quality. Refer to Table 8 for requirements.
 Page: 25/34
MS.90089
Change Level: C

Table 8 - PV, PPAP and CC Phases Performance Requirements

Frequency
Phase Test Procedure Requirement
(For CC testing)
Paint Color Colorimeter (X-Rite) / Visual Visual match to One part per color
Verification and Inspection ATAR approved per day (minimum).
Appearance parts. Record
colorimeter data
(If applicable) (as per exterior
Craftsmanship
target). Parts
PV, PPAP, must meet the
CC appearance
requirements of
the appropriate
Appearance
Standard (AS)
AS-10119<A>,
and
AS.00001<A>
PV, PPAP, Appearance (Dirt Per AS-
AS-10169<A> Every lot
CC Management) 10169<A>
ISO 2409
Classification = One part per color
0 per shift minimum
ISO 2409, (0% coating (near start of shift).
PV, PPAP, Initial Adhesion with
Tape 3M 898 or Tape Tesa removal) Consecutive shift
CC Cross Hatch
4657 See Paragraph part inspection shall
8.7 for initial be at least 4 hours
PPAP apart.
procedure
Each layer shall One part per color
Generally Accepted Industry be measured. run per day
PV, PPAP, Coating Thickness PV – Per
Practice for the Substrate (minimum) at
CC (Dry Film Build) section 8.7 beginning and end of
CC – As agreed shift,
PV, PPAP, Cure Check - LP-463PB-31-01 Method J The coating One part per color
CC Solvent Wipe solvent per coating supplier shall not soften, per shift (minimum).
recommendations swell, or give
resistance to
wiping after 10
double rubs,
when tested
immediately
after cooling, at
the end of the
paint line. The
coating shall
return to
original color
and gloss after
30 minutes at
room
temperature.
 Page: 26/34
MS.90089
Change Level: C

Table 8 - PV, PPAP and CC Phases Performance Requirements

Frequency
Phase Test Procedure Requirement
(For CC testing)
PV, PPAP, Water Soak ASTM D870 or 50470, Check adhesion One part or
CC 40C(104F) 24 hours per ISO 2409 representative part
(or Humidity 96 hrs) (interior parts 2 hours) before and 2 section per shift
hours after (minimum) as
exposure. ISO agreed by FCA
2409 rating of 1 Engineering or SQ.
or better.
PV, PPAP, Humidity ASTM D1735 Check adhesion Must be run on parts
CC Per Class Level in Table 9 before and after at PPAP and every 3
exposure. ISO months thereafter
2409 adhesion and after significant
Rating of 1 or changes.
better.
PV, PPAP, For Steel Substrates ASTM B117 Creepback from Run monthly on
CC - Salt Spray Single line scribe – scribe not to representative
minimum 5 cm long exceed 2 mm in substrate(s) as
any direction at agreed by FCA
Per Class Level in Table 9 any point, no Engineering or SQ.
blistering or rust Must be run on parts
in unscribed at PPAP and every 6
areas per the months thereafter
boundary and after significant
sample changes.
established at
PPAP – (burr
removal at
edges and
holes may be
required)

PV, PPAP, For Galvanized or Single line scribe – Creepback from Run monthly on
CC Galvanneal minimum 5 cm long scribe not to representative
Substrates – Cyclic Per Class Level in Table 9 exceed 3 mm in substrate(s) as
Scab any direction at agreed by FCA
any point, no Engineering or SQ.
SAE- J2334 - 30 Cycles (15 blistering or rust Must be run on parts
cycles interior) in unscribed at PPAP and every 6
Or areas per the months thereafter
boundary and after significant
50493/04 Fiat Scab In door
sample changes.
– 6 days
established at
PPAP – (burr
removal at
edges and
holes may be
required)
 Page: 27/34
MS.90089
Change Level: C

Table 8 - PV, PPAP and CC Phases Performance Requirements

Frequency
Phase Test Procedure Requirement
(For CC testing)
PV, PPAP, For Aluminum ASTM B368 – 168 hours Creepback from Run monthly on
CC Substrates - CASS scribe not to representative
exceed 3 mm in substrate(s) as
Single line scribe – any direction, agreed by FCA
minimum 5 cm long no blistering or Engineering or SQ.
Per Class Level in Table 9 rust in Must be run on parts
Or 50493/04 Fiat Scab In unscribed areas at PPAP and every 6
door – 6 days (3 days per the months thereafter
interior) boundary and after significant
sample changes.
established at
PPAP – (burr
removal at
edges and
holes may be
required)
PV, PPAP, Gravel (optional for A rating of SAE Required - one part
CC cc, not required for 8C, or better. per color at
NAFTA(SAE J400)
interior parts) (see Paragraph PSO/PPAP.
- Flexible substrates: 2.2 for gravel
5 pints @ 45 deg., RT Optional for
chipping Continuous
- Rigid substrates: definition) Conformance as
2 pints @ 45 deg., RT directed by FCA
EMEA For EMEA Engineering or SQ.
procedure
1 pint (=0.5 kg)
rating must be
45 deg. Angle Fiat 7B or better
0C
PPAP, CC Initial Adhesion per ISO Must meet One part per color
2409 Initial Adhesion daily for every lot
requirements reprocessed (1X &
Reprocessed Parts (above). 2X reprocess)

Water Soak Check adhesion One part per shift for

ASTM D870 before and 2 every lot
hours after reprocessed (1X &
24 hours @40 °C (104 °F) exposure. 2X reprocess)

Humidity Resistance per No blistering, One part per color at

ASTM D1735 must pass PSO/PPAP only.
Per Class Level in Table 9 adhesion test (1X & 2X reprocess)
using X-scribe.

Gravel per NAFTA rating of One part per color at

NAFTA(SAE J400) SAE 8C or PSO/PPAP only.
better. (1X & 2X reprocess)
2 pints, room temperature,
45 degree angle
EMEA
1 pint (=0.5 kg) EMEA rating of
Fiat 7B or
 Page: 28/34
MS.90089
Change Level: C

Table 8 - PV, PPAP and CC Phases Performance Requirements

Frequency
Phase Test Procedure Requirement
(For CC testing)
45 deg. Angle better.
0C

Procedure for reprocessing See Salt Spray, One part at

parts sanded through to Cyclic Scab and PSO/PPAP only.
substrate must be verified Filiform (1X reprocess)
with Salt Spray/Cyclic requirements
Scab/Filiform testing defined in Table
depending on substrate. 9.

8.6 Forever Requirements FR

A supplier submits a Forever Requirements request when a change is made to process, materials,
manufacturing location, etc post PPAP approval. Product Engineering, Supplier Quality and Materials
Engineering shall review the nature of the change and determine a test plan for validation of the change.
This test plan may include elements from DVe, PV and CC testing.

8.7 Initial Film Build Capability, Part Coverage, and Adhesion

The supplier shall check a minimum of 20 locations per square meter, or as required by FCA Engineering
and SQ, on a part for initial adhesion and film build thickness. For parts smaller than 100 dm 2 (4 in2), a
minimum of 2 locations shall be measured. This should include multiple color runs of each color to
establish capability and should be re-run when any changes are made to the paint application process.
These checks will ensure that all surfaces (tight radii, design recesses, and surfaces that contact adjacent
body sheet metal) meet the requirements. This requirement shall be completed and documented during
PSO/PPAP/FPSC/PV Testing. At a minimum (per ISO/TS 16949) quality performance records (e.g.
control charts, inspection and test results) shall be retained for one calendar year after the year in which
they were created. A minimum number of parts should be specified with the SQ Specialist or as required
by FCA Engineering and SQ. Once capability has been established the Supplier may return to a
minimum of five locations (as agreed with FCA SQ) across the part for CC Testing providing that the
selected points correlate/represent the Worst of Worst conditions and critical surfaces for appearance and
functional attributes.

Electrocoated parts shall be dissected at PPAP to certify coverage/film build in “boxed sections.” The
dissection certification shall be repeated annually for each part and whenever material, process, racking
or other changes are made.

Table 9 describes the corrosion duration testing required for each part based on the Class Level defined
on the print or PIP page.
 Page: 29/34
MS.90089
Change Level: C

Table 9 - Corrosion Duration

Salt Spray Test

Humidity Test Scab In Door Test
ASTM B117 or
Class Level (Table 1) ASTM D1735 or 50493/04
50180 B1 Fe
50184 (Zinc coated /
(Ferrous
Aluminum Substrates)
Substrates)
A 100 hours 48 hours 48 hours
B 150 hours 100 Hours 100 Hours
C 150 hours 300 Hours 300 Hours
D1A 300 hours 500 Hours 500 Hours
D1B 300 hours 500 Hours 500 Hours
D1C 500 hours 750 Hours 750 Hours
E 240 hours 240 Hours NA
F 500 hours NA NA
NOTE: For liquid coatings that are air dried (not thermally cured), follow Class Level C for corrosion
duration testing.

Table 10 describes the heat soak temperature required for validation of commonly used coatings.
Deviations to the temperature requirements may be specified on the print, process standard, or
performance standard.

Table 10 - Heat Soak Temperature (24 hours)

Metal
Components
Coating Plastic Components
(Steel, Zinc,
Aluminum, etc)
Ecoat 150 °C Not applicable
Powder coat 200 °C Not applicable
Ecoat + powder coat 200 °C Not applicable
Exhaust applications 500 °C Not applicable
100 °C for Nylon (PA66 and PA6) and
Polypropylene.
Other coatings 100 °C
Consult with FCA Materials Engineering for
other substrates

8.8 Cyclic Chipping Scab Corrosion Test

Procedure:
Step 1. X-Scribe the top half of the panel, verifying that the scribe is to the base metal. Confirm initial
adhesion per ASTM D3359 Method A.

Step 2. Gravel the bottom half of the panel per SAE J400, using 3 pints of gravel at ambient temperature
and a 90 degree angle.

Step 3. Expose to SAE J2334 for 15 cycles.

Step 4. After 15 cycles of SAE J2334 and prior to salt application, the bottom half of the test panels shall
be exposed to 1 pint of gravel at ambient temperature and a 90 degree angle. Wipe any dust and dirt
from the panel to avoid contaminating later test stages.
 Page: 30/34
MS.90089
Change Level: C

Step 5. Repeat Steps 3 and 4 four times, until a total of 60 cycles of SAE J2334 exposure has been
obtained.

Step 6. After the final corrosion cycle, shot blast the panels one final time.

Step 7. Wash with a warm water and mild laboratory detergent, dry.

Step 8. Apply the tape over the scribe and the entire shot blasted area to remove loose paint.

Step 9. Estimate and record the percent paint loss in the worst 8 cm x 8 cm (3.2 in x 3.2 in) portion of the
target area.

Step 10. Rate the creep back from the scribe in millimeters, recording both maximum and average
creepback.

9 QUALITY
For components that will be part of a vehicle designed in NAFTA and sold in all markets, conformance to
the material characteristics described by CS-9800 and PS-7000 must be met.

For components that will be part of a vehicle designed in EMEA and sold in all markets, the material
characteristics defined by 9.01102 and 9.01103 must be met.

10 SPECIAL REQUIREMENTS
The following documents must be provided for all materials following ED and DVm testing:

1. Compliance with CS-9003

2. Technology Approval with intended substrate(s).
3. Materials Engineering Certification with Technical Data Sheet co-signed by supplier and Materials
Engineering.
4. Application Process Parameters
5. Cure Window for systems requiring thermal cure

11 APPROVED SOURCE LIST

Refer to individual material standards as described in Tables 3 and 4.

12 ADDITIONAL CONTACTS
N/A
 Page: 31/34
MS.90089
Change Level: C

13 RELEASE AND REVISIONS

Change Date Description of change
level
- 8-APR-2015 Initial release. Chrysler MS-PZ-3-1 and Fiat 9.55842 were harmonized.
A 18-APR-2018 Reformat, define ED, DVe, DVm, PV, and CC level testing.
B 15-APR-2021 New template. Clarify Table 1 Part Classification and Table 8 Corrosion
Duration
C 11-OCT-2023 New template. Table 2 Available Finishes
Table 8: Class E : prescriptions aligned with MS-PF-7-1
 Page: 32/34
MS.90089
Change Level: C

Annex A
(Informative)
ED- Paint Materials Approval
Fiat Chrysler Automobiles
Organic Materials Engineering, Dept. 5840
800 Chrysler Drive
Auburn Hill, MI 48326-2757
E # ____________ SASF # ____________

PRODUCT INFORMATION

Supplier Technology Code.

Type of Technology (2K 1K, WB, SB High bake,

low bake )
Coating Chemistry ( Melamine, PU etc)

Type Of Material – CC, BC, Primer etc

.
Report Complete Layering System

FCA US or surrogate colors

Testing Performed Intended Substrates

Substrates CPN# and CP

Intended Application

Other

FCA Materials Engineer: ( Name)

Date:

Comments
 Page: 33/34
MS.90089
Change Level: C

PHYSICAL CONSTANTS / REQUIREMENTS:

% Weight Solids package (guaranteed minimum)

% Volume Solids Formula

Calculated
Package Viscosity #4 Ford Cup
Spray Viscosity #4 Ford Cup
Reducing Solvent
% Reduction
VOC Package
Applied
Film Build ( FB) Each Layer Minim Maximum Target =
um Mid-Point between
Min and Max DFT
Adhesion promoter / Primer
Basecoat (color)
(Minimum shall not be less than hiding film build)
Clearcoat.
Other (Ecoat etc.)

Supplier and FCA Initials Supplier FCA

Exterior - UV Transmissivity Requirements Report actual Transmissivity values.
Monocoat ( ED) – At 75% of target FB test one Attach graph with data values.
FCA color per each color family: White Straight.
shade, Red [Link] and a metallic.

For use over durable primer: Must be less than

0.1% between 290-360nm and less than 4% at
400nm.

( Note: BC and CC UV trans. validated at DV

level)
Primer – 75% of the Target FB must be less than
0.1% at 400nm.
REPORT TARGET DRY FILM BUILDS IN TECHNICAL DATA SHEET FOR EACH PAINT
LAYER
 Page: 34/34
MS.90089
Change Level: C

APPLICATION DATA ON ACTUAL SUBMISSION PANELS

Method of Application
Number of Coats
Flash Time Between Coats
Flash Time Before Bake
Bake Time and Temperature
- Submit Bake Charts, Run
DOE, including at minimum
Attach Report
film build and bake
( High FB/Low Bake, Low
FB/High Bake)
Actual Film builds Initials
Supplier FCA
Primer or Adhesion Promoter
Film build ( Attach a report)
See Note 1
Basecoat Film Build ( Attach
report) Note 1
Clearcoat Film build ( Attach
report ) Note 2
Report: For Plastics – Cross Section: For Metals – Step-off panel.

FLORIDA - Natural Weathering

Actual FCA US Colors Submitted

Surrogate Data ( Other OEM Specify) / Color
Codes
Years of Exposure

XENON – Artificial Weathering

Actual FCA US Colors

Surrogate Data ( Other OEM Specify) / Color
Codes
Kj / hours / Equipment

REPORT ACTUAL FILM BUILD ON THE FOLLOWING TEST PANELS

TEST FILM BUILD

Florida Panels
UV Transmissivity
Xenon
Gravel (All layers)

End of Annex A