Engineering Specification

PART NAME PART NUMBER

SPECIFICATION-THROTTLE BODY CAST HOUSING VE3L3U-9E927-AA
LET A B C D
FR 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
LET
FR
LET FR REVISIONS DR CK REFERENCE
INITIAL RELEASE ∇ES2S6U-9F991-AA
010907 DF00 E 11268597 000 JR RD PREPARED/APPROVED BY
8 REVISED THREADED HOLE REQUIREMENTS
12 ADDED EXCEPTION NOTE CHECKED BY DETAILED BY
12 ADDED SECTION 7 J.R. J.R.
020415 A DF00 E 11268597 004 CONCURRENCE/APPROVAL
11 REVISED TOWER DAMAGE CRITERIA SIGNATURES
050121 B DF00 E 50000382 091 Air Metering Sr. Design Engr.
C 2,4, Jim Rauch
ADDED SECTION 8
15 Air Metering Design Supervisor
4 ADDED IP FREQUENCY NOTE Mike Chabon
8 REVISED CHART, ADDED EXCEPTION Die Cast Engineering Supervisor
9 ADDED THREADED HOLE PHOTOS Bryan McKeough
11 ADDED COVERAGE OF SECTION 6 Rawsonville Air/Fuel PD Resident
060616 DFNC E 50019548 042 JR EB Scott Langley
D 7 CORRECTED VALUE IN FLOW CHART Raws. Quality Specialist
10 REVISED/CLARIFIED PHOTOS Pete Mariotti
11 REVISED FLOW CHART Raws. Mfg Engr. Supervisor
070521 DFNC E 50019548 082 JR JR Dan Tigner
Raws. Area D Manager
Andy Karve

FRAME 1 OF 18 REV D

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TABLE OF CONTENTS
I. GENERAL

II. SUMMARY OF PRODUCTION VALIDATION AND IN-PROCESS TESTS

III. TEST PROCEDURES

1. General Defects

2. Shaft Holes / Bearing Pockets

3. Throttle Bore Area

4. Threaded Holes

5. Tower Damage

6. Machined Flanges

7. Gasket Grooves (Manifold Mounting and Venturi)

8. Other Machined Surfaces

IV. REVALIDATION REQUIREMENTS

V. INSTRUCTION AND NOTES

VI. COMPILATION OF REFERENCE DOCUMENTS

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I. GENERAL

The machined throttle body housing is typically an aluminum component that houses throttle body
sub-components such as throttle shaft bearings and shafts. The housing also provides anchoring
points for other components such as throttle position sensors, electronic actuator motors, and, idle
adjust screws. The machined throttle body housing is the core component that allows for all sub-
components to function together as a system.

This Engineering Specification is a supplement to the released drawing on the above part, and all
requirements herein must be met in addition to all other requirements of the part drawing.

The Engineering Specification is intended to evaluate specific characteristics as a supplement to

normal material inspections, dimensional checking, and in-process controls, and should in no way
adversely influence other inspection operations.

Preparation and submission of an acceptable Control Plan are the responsibility of the
manufacturing source. The manufacturing source will retain the original Control Plan and any later
revisions per ISO/TS 16949:1999 and provide a copy to the design responsible Product Engineering
activity.

II. SUMMARY OF PRODUCTION VALIDATION AND IN-PROCESS TESTS

Production Validation (PV) tests are used to obtain an initial estimate of the process potential to
produce parts that conform to engineering requirements, and to identify causal or predictive
relationships between significant design and process characteristics (to be used for process control).
These tests must be completed satisfactorily using initial parts from production tooling and
processes before Part Submission Warrant (PSW) approval and authorization of production parts
can be issued. Sampling plans for PV testing must be included in the Control Plan.

In-Process (IP) tests are used to further understand the relationship between significant design and
process characteristics and to establish a basis for continuing improvement. Tests must be
completed with production parts on an ongoing basis. Sampling plans for both IP testing and
evaluation of the significant process characteristics must be included in the Control Plan. When the
process is found to be out of control or the test acceptance criteria are not met, the reaction plan
approved in the Control Plan shall be invoked.

The table that follows summarizes the various DV, PV, and IP tests and the acceptance parameters
for each. They form the basis on which to develop a complete Control Plan for these and their
related significant process characteristics. The Control Plan will include frequencies, sample sizes
and reaction plans; see Ford Quality System Requirements, ISO/TS 16949:1999.

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Summary of ES Test and Acceptance Parameters

Preliminary
Control Plan
I P Lower Upper Minimum Parameters
Test Test P V Tolerance Target Tolerance Conformance
# Characteristic Limit Value Limit To Tolerance IP PV Min.
Sample
Freq. Size

1.0 GENERAL DEFECTS X X SEE SECTION 1 NO REJECTS # 5

2.0 SHAFT HOLES/ BEARING POCKETS X X SEE SECTION 2 NO REJECTS # 5

3.0 THROTTLE BORE AREA X X SEE SECTION 3 NO REJECTS # 5

4.0 THREADED HOLES X X SEE SECTION 4 NO REJECTS # 5

5.0 TOWER DAMAGE X X SEE SECTION 5 NO REJECTS # 5

6.0 MACHINED FLANGES X X SEE SECTION 6 NO REJECTS # 5

7.0 GASKET GROOVES X X SEE SECTION 7 NO REJECTS # 5

8.0 OTHER MACHINED SURFACES X X SEE SECTION 8 NO REJECTS # 5

# Casting supplier is responsible for determining IP frequency to ensure conformance to this

specification

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III. TEST PROCEDURES

1. General Defects

Defect Location on Part Description

Cracks Anywhere on Part No cracks are acceptable
Missing Metal (Poor Fill) Anywhere on Part No more than 0.25mm deep
No more than 0.25mm in
length
Missing Metal (Shrink) Anywhere on Part No shrinkage allowed
Any Hole No more than 0.75mm deep
No more than 1.25 in length
Missing Metal (Ejector pin marks) At ejector pin locations No more than 0.40mm deep
Excess Metal (Ejector pin marks) At ejector pin locations No more than 1mm raised
Missing Metal (Steel protruding from
cast die) Anywhere on part No more than 0.75mm deep
No more than 0.75mm
square
Anywhere on part except
Excess Metal (Steel broken out of on the top of the throttle No more than 0.75mm
cast die) bore raised
No more than 0.75 square
Nothing acceptable within
the first 19mm down from
the top of the throttle bore

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2. Shaft Holes / Bearing Pockets

No more than four (4) porosity holes per shaft hole per the following conditions
a) Porosity holes no more than 4mm wide and 2mm deep.
b) Porosity holes must be at least 6mm apart.
c) Small, scattered porosity (less than 1 mm) is acceptable

Yes Are there more than 4 distinct holes

per shaft hole? (Scattered porosity
is acceptable)

No
Yes If there is porosity in a shaft hole, is
the porosity larger than 4mm wide?

Scrap Castings No
Yes
Are holes greater than 2 mm deep?

No

Yes Are the porosity holes within 6mm

of each other?

No

Castings Are Acceptable

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3. Throttle Bore Area

No porosity holes larger than 0.5mm in width or depth and no more than 10 such holes are
allowed in the red shaded area shown in the picture below. All holes must be at least 5mm from any
other hole. The red area is 14mm in thickness and is centered on the throttle shaft centerline.

The areas of the throttle bore not shaded in red are allowed porosity holes not larger than 1mm wide
and 1mm deep and must be 7mm from any other hole.

Are there holes larger than 0.5 mm

in the red area of the throttle bore.
Yes
No
Are there 10 or more holes smaller
than .5mm in the red area of the
Yes throttle bore?
No
No

Scrap Castings Are holes closer than 5 mm?

No
Are there holes larger than 1.0 mm
located outside of the red area?
Yes
No
Are the holes outside the red area
Yes closer than 7 mm apart?

No

Castings Are Acceptable

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4. Threaded Holes
No porosity holes are allowed in the first 3 threads or 3mm. See the area shaded in red
below.

No more than 3 porosity holes per the following specs: See the area shaded in yellow
below.
• Porosity holes no larger than Y mm wide (measured at widest point) by 2 mm deep
(see Table 1 below).
• Porosity holes must be 3 mm apart.
• At least 80% of the threads must be visible in each hole
Please note that porosity levels of this magnitude may cause tapped holes to shift in location. Although the
porosity levels are approved for screw function, location of the tapped holes must be verified to be within print
if high levels of porosity exist.
Section castings as needed to quantify threaded hole porosity.

Table 1
Tapped Value Y Value Y
Hole (0.7 times Exception
Size hole size) (see below)
(mm) (mm) (mm)
4 2.8 3.2
5 3.5 N/A
6 4.2 N/A
8 5.6 N/A
10 7.0 N/A

Threaded Holes Threaded Holes

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4. Threaded Holes (continued)

Table 1 Exception

The Table 1 exception applies for ETB gearbox cover and position sensor M4 tapped holes only.
Please see below for limit examples.

3.2 maximum width

measured at widest point
3.2 maximum width
measured at widest point
Are there any porosity holes in the
Yes first 3 threads?

No
Beyond the first 3 threads, are there
any porosity holes larger than 2mm
Yes deep & Y wide by chart dimension?

Scrap Castings No
Beyond the first 3 threads, are there
more than 3 porosity holes?
Yes
No
Are at least 80% of the threads in
each hole visible?
No
Yes
Castings Are Acceptable
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5. Tower Damage

During the shot blast process in the Die Cast Department, minor damage may occur to the tops or
towers of the throttle bodies.

Minor damage to the towers is acceptable, and parts with minor damage can be shipped to our
customers since the zip tube seals on the outside diameter of the housing. A housing shall be
considered unacceptable if it has a flaw that meets ALL of the following criteria:
1) span the width of the tower
2) deeper than 1.3 mm from the top of the housing wall
3) greater than 3.6 mm wide

Acceptable since flaw is not Acceptable since flaw does

wider than 3.6 not span width of tower

Unacceptable since flaw is wider than

Acceptable since flaw is not 3.6, deeper than 1.3 AND spans width
deeper than 1.3 of tower

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5. Tower Damage (continued)

Yes
Does the flaw span the width of
the tower?

No
Scrap Yes
Is the flaw wider than 3.6mm?
Casting
No
Yes
Is the flaw deeper than 1.3mm?

No

Casting is Acceptable

6. Machined Flanges
Machined flanges include manifold mounting flanges, gearbox cover mounting flanges, position
sensor mounting flanges, and intermediate gear boss faces.

Porosity hole size must be no greater than 0.5mm deep by 0.5mm wide.
Porosity holes must not be closer than 5mm apart.
Maximum number of permitted defects on each machined surface is 10.

Machined Gearbox Machined Intermediate Position Sensor Machined Manifold

Flange Gear Boss Mounting Flange Mounting Flange

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6. Machined Flanges (continued)

Yes Are the porosity holes greater than
0.5mm deep?

No
Yes Are the porosity holes greater than
0.5mm wide?

Scrap Castings No
Yes
Are the holes closer than 5mm apart?

No

Yes Are there more than 10 porosity holes

on any one machined surface?

No

Castings Are Acceptable

Exception to 6: Where an integrated Gasket Groove is incorporated into the Casting (refer to 7.), the
criterion for 6 is not applicable but cosmetic acceptability is still a factor.

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7. Cast or Machined Gasket Grooves (Manifold Mounting and Venturi)

Porosity hole size must be no greater than 1mm deep by 1mm wide. May be modified dependent on
gasket width of specific new programs, to ensure satisfactory sealing land.
Porosity holes must not be closer than 5mm apart.
Maximum number of permitted defects on each surface is 10.

Venturi Gasket
Groove Manifold Gasket
Groove

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7. Gasket Grooves (Manifold Mounting and Venturi) Continued

Yes Are the porosity holes greater than

1mm deep?

No
Yes
Are the porosity holes greater than
1mm wide?

Scrap Castings No
Yes
Are the holes closer than 5mm apart?

No

Yes Are there more than 10 porosity holes

on any one machined surface?

No

Castings Are Acceptable

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8. Other Machined Surfaces

Other machined surfaces include faces of clamping lugs that are machined off, surfaces machined
for clearance reasons, slots or grooves cut for spring legs, inside diameters of drilled holes (i.e.
intake flange mounting holes or intermediate shaft holes), and boss faces not used for clamping (i.e.
cup plug boss face).

• No more than 3 porosity holes larger than 1 mm

• No single porosity hole shall exceed 3mm wide or 3mm deep

Note: Limits above are for protection of throttle body function. Additional porosity requirements may
be required if under hood appearance is a concern. In this event additional requirements including
limit samples should be determined as required to ensure acceptable appearance.

Acceptable

Unacceptable
if width or
depth > 3mm

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8. Other Machined Surfaces (continued)

Yes Are more than 3 porosity holes present

that are greater than 1mm wide?

No

Yes Are any porosity holes greater than

3mm wide?

Scrap Castings No
Are any porosity holes greater than
Yes
3mm deep?

No
Has engine Is porosity a
No plant approved Yes potential underhood
porosity appearance
specification? concern?

Yes No

Castings Are Acceptable

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IV.REVALIDATION REQUIREMENTS

The manufacturing source and the Product Engineering Office will jointly determine which potential
changes to the process, materials, or material sources would have significant impact on the product's
function, performance, durability or appearance. The supplier will describe these conditions in the
Control Plan, along with either (1) The revalidation plan that would be followed in each case, or
(2) a provision to submit an amended Control Plan for approval if any of those process changes are
planned.

The Control Plan also must include a provision that for any significant change in processing, Product
Engineering Office and the manufacturing location (internal or supplier) shall jointly determine if PV re-
testing is required, and if so, to what degree, i.e. a full or partial PVP&R.

No change in processing may be allowed without the prior engineering approval of the process
changes and the attendant Control Plan changes.

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V. INSTRUCTIONS AND NOTES

Control Plans address all significant design and process characteristics, which include all ES tests
and Control Item characteristics. They describe the process potential studies that will be performed for
Product Validation (including PV tests) and the ongoing product and process evaluation for continuing
improvement (including IP tests). They include acceptance criteria, sample sizes, frequencies, data
analysis, methods and reaction plans.

The Control Plan is developed, and updated as necessary, by the manufacturing source in conjunction
with the Product Engineering Office, and other appropriate functions such as STA. The Control Plan
defines the management of the upstream production process and part variables (significant process
characteristics) that affect the outcome of the ES tests or other significant design characteristics. The
Control Plan also identifies the specific ES tests, with their sample sizes and frequencies, that will be
performed in order to:

• Confirm whether the process is being managed effectively.

• Further identify significant process characteristics.
• Evaluate performance of marginal processes.
• Better anticipate the customer effect of proposed process improvements.

For any part on which ES tests have been specified, the manufacturing source must present the
Control Plan and any revisions to Product Engineering & Manufacturing Operations and STA for
approval. Product Engineering & Manufacturing Operations has flexibility to honor business
relationships with suppliers having proprietary processes.

Examples of formats for Control Plans are shown in Quality System Standard ISO/TS 16949:1999.

VI. COMPILATION OF REFERENCE DOCUMENTS

Rawsonville Plant porosity specifications RDC 1007 and RDC 1012.

PD
May 92 3947a2e (Previous editions may be used)