STN - GMP Powertrain/Carbody Adaptation Interface Assembled Exhaust Line

PSA PEUGEOT - CITROËN
Normative Technical Specification

B22 3120
STN (Normative technical Specification) – GMP (POWERTRAIN)

POWERTRAIN/CARBODY ADAPTATION INTERFACE
ASSEMBLED EXHAUST LINE
Page 1/42
No use restriction
FOREWORD
As experimental Norm, this applicable document is submitted to observations for 6 months
If no observation is received before 17/09/2009 to the address: normesExp@mpsa.com, the content of this
document will be confirmed.
This Normative Technical Specification (STN) is a document drawn up in compliance with the principles of the
Engineering of the Automotive Systems (ISA) that capitalizes, for the given system of the arborescence of the
products development, all the generic requirements aligned with all the parties involved.
The STN allows the Project team to draw up the corresponding Technical Specification (ST) while adapting the
content of the STN to the project scope. The RETEX (experience feedback) of the projects as well as the
innovation and the external requirements are the elements that allow the STN to evolve.
Writer Checking person Assenting person
Caroline GASQ Xavier PRADERE Gautier DEKERLE

DRD/DCTC/IACT/TRM//A2RM DRD/DCTC/IACT/TRM//A2RM DRD/DCTC/IACT/TRM/CPEE
Date Signature Date Signature Date Signature
12/02/2009 12/02/2009 12/02/2009
OR : 01/09/1980 B : 17/02/2009 INTERNAL USE

STN GMP (Powertrain-Normative Technical Specification)– EXHAUST LINE B22 3120 2/42
RECORDS
Index Date Type of modification
OR 01/09/1980 CREATION OF THE NORM
A 04/11/1997 REWORKED IN “IDEM”
COMPLETE REVISION OF THE NORM (SUPERSEDES THE STE

B 17/02/2009
96 536 292 99)
INTERVENING PEOPLE
The people below took part in the drawing up and checking of this norm:
DRD/DCTC/IACT/TRM//A2RM Xavier PRADERE, Gildas MIOSSEC

DRD/DCTC/IACT/TRM/CPEE Gautier DEKERLE, Patrick GAILLARD, Pierre VERWAERDE
DRD/DCTC/CSCT/ASFP/SDFA Nicolas LAURENT
DRD/DAPF/RHN/ENV/HPE Adeline GUINY
OR : 01/09/1980 B : 17/02/2009 INTERNAL USE

CONTENT
1. OBJECT 4
2. APPLICATION SCOPE 4
2.1. DEVELOPMENT CONTEXT OF THE SYSTEM 4
2.2. GENERAL DESCRIPTION OF THE SYSTEM 5
3. DOCUMENTS MENTIONED 6
3.1. DOCUMENTS OF REFERENCE 6
3.2. APPLICABLE DOCUMENTS 6
3.2.1. Norms 6
3.2.2. regulations 7
3.2.3. Other documents 7
4. TERMINOLOGY 9
4.1. GLOSSARY 9
4.2. SIGLES AND ACRONYMS 9
5. REQUIREMENTS 10
5.1. FUNCTIONAL REQUIREMENT 10
5.1.1. sealing 10
5.1.2. engine performance 10
5.1.3. Acoustic services 11
5.1.4. emission control 19
5.2. PERFORMANCE REQUIREMENTS 20
5.2.1. Durability 20
5.2.2. resistance to thermal shock (water projections) 21
5.2.3. Resistance to gritting / shot-blasting 21
5.2.4. Thermal propagation 22
5.2.5. Resistance to corrosion 24
5.2.6. Resistance to inflammability of the insulation elements 24
5.3. REQUIREMENTS FOR EXTERNAL INTERFACES 25
5.3.1. Interfaces 25
5.3.2. lay-out 28
5.4. OPERATIONAL REQUIREMENTS 28
5.4.1. mission profile 28
5.4.2. Lifespan 28
5.4.3. Ergonomiy AND HUMAN FACTORS 29
5.4.4. FUNCTIONAL SAFETY 29
5.4.5. product quality 30
5.4.6. Protection against malevolence 30
5.4.7. system resources 31
5.4.8. requirements for documentation 31
5.5. CONSTRAINST REQUIREMENTS 32
5.5.1. regulation and consumerism 32
5.5.2. Weith and other physical characteristics 32
5.5.3. design and manufacture 33
5.5.4. Cost 34
5.5.5. lead time 34
5.5.6. Style 34
5.5.7. Traceability and configuration management 34
5.5.8. Transportability, storage and conditioning 34
5.5.9. Flexibility and extension 35
5.5.10. service removal 35
5.5.11. environmental conditions 35
5.6. INTEGRATION AND VALIDATION REQUIREMENTS 35
5.6.1. validation and integration drawing 35
APPENDIX 1 PROCEDURE MEASURES EMISSIVITY 36
APPENDIX 2 MEASUREMENT AND CALCULATION OF THE ACOUSTIC POWER 38
APPENDIX 3 DEFINITION OF SPRINKLING CRITERIA 39
APPENDIX 4 ENDURANCE PROCESS SHEET (CYCLE HB1) 41
APPENDIX 5 LIST OF THE EXHAUST LINE « ER » (ER LE) 42
OR : 01/09/1980 B : 17/02/2009 INTERNAL USE

1.OBJECT
The aim of this Normative Technical Specification (STN) is to define the requirements to which the exhaust line
must comply, it means the components located downstream the manifold for atmospheric power plants or
downstream the turbine for supercharged engines.
The exhaust line is located in the arborescence of the development of the product as follows:
VEHICLE
POWER TRAIN
POWER TRAIN /CARBODY INTERFACE
EXHAUST LINE
2.APPLICATION SCOPE
2.1.DEVELOPMENT CONTEXT OF THE SYSTEM
Remark: The STN (Normative Technical Specification) is based on the functional analysis (reference of document:
AGCC_TRM07_0505).
Life situation : Use (driving and accident)
FS1 Service function 1 To remove the exhaust gas from the manifold outlet at the RR part of
the vehicle.
FS2 Service function 2 To treat the acoustic emissions of the engine and turbo.
FS3 Service function 3 To treat the polluting emissions of the engine.
FC1 Constraint function 1 To follow / to resist the environment.

FC2 Constraint function 2 To follow the outer environmental requirements.
FC3 Constraint function 3 To follow / to resist / to link up with the environment under car body and
car body.
FC4 Constraint function 4 To guarantee the permeability required for the correct running of the
engine.
FC5 Constraint function 5 To resist / to link up with the engine.
FC6 Constraint function 6 To respect the passengers and pedestrians.
FC7 Constraint function 7 To limit the contribution of the vehicle to fuel consumption.
FC8 Constraint function 8 To respect the style.
FC9 Constraint function 9 To resist the exhaust gas and condensates.
FC10 Constraint function 10 To follow the regulations and norms in force.
FC11 Constraint function 11 To follow the impact requirements and constraints.
Life situation : Transport
FC12 Constraint function 12 To adapt oneself/to resist transport and packaging means.
OR : 01/09/1980 B : 17/02/2009 INTERNAL USE

Life situation : Storage and handling
FC13 Constraint function 13 To adapt to the operator / to resist the operator,

To adapt / to resist storage, packaging and handling means.
Situation de vie : Montage
FC14 Constraint function 14 To adapt / to resist the operator

To adapt /to resist the assembly means.
Life situation : Aftersales / maintenance
FC15 Constraint function 15 To adapt to the operator.

To adapt to the tools, to repair.
Life situation : End of life / recycling
FC16 Constraint function 16 To adapt to disassembler, to extraction tools to valorization.

To fit into valorization networks.
2.2.GENERAL DESCRIPTION OF THE SYSTEM

This Normative Technical Specification (STN) concerns all exhaust systems equipping the vehicles of the Peugeot
Citroën range. Its scope includes:
• The exhaust downpipe and its various components (catalyst, FAP (particulate filter), heat shields fitted on
the emission control elements),
• The assembled exhaust line under car body and its various components (crank, muffler, catalyst, FAP,
swan neck, flexible, suspending systems, hooks on the exhaust line side…),
Heat shields under car body and the RTE system (Exhaust Thermal Recirculation) are not treated in this STN
(Normative Technical Specification).
Preliminary remarks :
The decoupling system, suspending systems, impregnated ceramics, catalyst and FAP are in addition submitted to
specific norms:
B22 3250 : Exhaust flexible.
B22 3240 : Exhaust suspending systems.
B22 3215 : Catalytic element for the treatment of exhaust gases.
B22 3210 : Catalysts and FAP assembled (technical characteristics)
Furthermore the FAP is treated in the Book of Specifications CGMP/CMOD 020.00 (technical characteristics), and
in the norm B32 3130 (visual controls).
The requirements concerning the integration of these various components in the exhaust line are treated in this
STN (Normative Technical Specification).
Since the system is made up of several sub-assemblies, this STN (Normative Technical Specification) concerns
the system assembled as well as the various sub-assemblies.
OR : 01/09/1980 B : 17/02/2009 INTERNAL USE

3.DOCUMENTS MENTIONED
3.1.DOCUMENTS OF REFERENCE
Reference Title
A10 0310 Normative Technical Specification (STN) – Technical Specification (ST) – Standard
drawing and wording guide.
3.2.APPLICABLE DOCUMENTS
3.2.1.NORMS
References Titles
A12 5500 VHU (Out-of-Use Vehicle)– Data concerning the composition of masses, materials and
substance of the parts.
A12 5510 VHU – Vehicle aptitude to emission control.
A12 5550 VHU – Prohibition management of the four heavy metals (lead, hexavalent chrome,
mercury, cadmium).
A31 2200 Technical drawing – welding representation.
A31 2205 Technical drawing – nomenclature of welding processes.
A33 3510 Help to tolerance of the elementary functions.
B11 3110 Iso metric threading for general uses.
B12 2819 Tube end-pieces for fuel systems: « petrol – diesel »
B13 1220 Spot welding by resistance welding of steel sheets – definition of the assemblies.
B13 1226 Spot welding by resistance welding of steel sheets – quality of the assemblies.
B13 1530 ARC welding– MAG welding of steels, MIG braze welding of steels, MIG welding of
aluminium sheets – definition of assemblies.
B13 1540 ARC processes – MAG welding of steels, MIG braze welding of steels, MIG welding of
aluminium sheets – acceptance criteria of a bead.
B18 3515 Brazing and braze welding – Definition of assemblies.
B20 0110 Supplies of products – general prescriptions.
B20 0200 VHU – Prescriptions for recycling purposes.
B21 7120 Environmental specifications of electric and electronic equipments – mechanical

characteristics.
B22 3130 Aftersales clamp Norm.
B22 3210 Assembled catalyst– Assembled FAP (particulate filter)
OR : 01/09/1980 B : 17/02/2009 INTERNAL USE

B22 3215 Catalytic elements of the treatment of exhaust gases.
B22 3240 STN concerning Exhaust suspending systems..
B22 3241 Exhaust Line Material Norm
B22 3250 STN concerning Exhaust flexible
B32 0730 Fatigue validation test procedure of the metallic parts (Locati Staircase)
B32 3110 Measurement procedure of the loss of power and of the CPE of one exhaust line.
B32 3120 Norm concerning the rate of leak at the periphery of the internal catalytic element.
B32 3130 Diesel FAP – visual controls.
B32 3140 Measurement norm of the BBE (Exhaust Mouth Noise).
B32 3200 Test procedure of the characterization of the removal of condensates.
B22 3211 STN concerning Biconical connection (STE 96 552 239 99)
D14 1428 Anti chip products – Plastics / Rubbers – Resistance to shot blasting.
D15 5279 Heat shields – Thermal efficiency.
D15 5521 Measurement of thermal conductivity of materials.
D15 5522 Measurement of thermal emissivity of materials.
D45 1333 Inner materials of car interior – horizontal combustibility.
D45 5038 Sound proofing materials / acoustic insulation.
D45 5254 Materials submitted to heat source - combustion by radiation.
D45 5430 Acoustic absorption factor – measurement with impedance tube.
R12 2002 Regulation norm for the elements linked to engine: exhaust, manifold, supercharging,
catalyst, FAP (Particulate Filter).
3.2.2.REGULATIONS
Reference Title
CE 97/69 Directive 97/69.CE of the commission of December 5th, 1997 concerning the 23th
adaptation to the technical progress of the directive 67/548/CEE of the council concerning
the rapprochement of the legislative, regulatory and administrative clauses concerning the
classification, packaging and labeling of dangerous substances.
3.2.3.OTHER DOCUMENTS
Reference Title
OR : 01/09/1980 B : 17/02/2009 INTERNAL USE

AGCC_TRM07_0505 Functional analysis of exhaust line.
DTAT/DVHL/PHV/ACV/EPA/99648/PRUJ Evaluation chart of the exhaust specialist evaluation protocol (21-12-

99).
CGMP/CMOD 020.00 Book of specifications regrouping the technical characteristics of the

FAP.
DITV_ATAT07_0010 APOQUA sheet« Exhaust line ».
DITV_ATAT07_0168 APOQUA sheet« Connection of FAP pressure delta rigid pipes ».
DITV_ATAT07_0224 APOQUA sheet« Front tube reinforcement T square ».
STE 9656225999 Sealing norm.
DMOV_MON06_2147 Generic requirements to ensure the assembly of exhaust system on

the PSA vehicles.
Generic book of specifications concerning exhaust shock – cold
AGCC_ADTR06_1063
section.
AGCC_ADTR07_0088 Calculation protocol of shocks on Powertrain RR exhaust system.
AGCC_ADTR07_0114 Consultation inlet data sheet of exhaust line (generic).
IAMT_CGOA05_0089 Meshing book of specifications for shocks simulation.
IAMT_CGOA05_0040 RR exhaust shock test protocol.
IAMT_CGOA06_0045 RR exhaust test additional sheet.
AGCC_ADTR06_1055 Book of specifications of generic pre-catalyst shock.
IAMT_CGOA06_0041 Hot section meshing procedure.
AGCC_ADTR06_1104 Characterisation test protocol of the shocks on hot section.
OR : 01/09/1980 B : 17/02/2009 INTERNAL USE

4.TERMINOLOGY
4.1.GLOSSARY
For the needs of this norm, the following terms are defined:
Hot part All the emission control elements (it means. Pre-catalyst, catalyst and particulate filter (FAP),
even when they are located under car body).
Hot part All the elements downstream emission control elements.
Canning Operation concerning the “canning” procedure of the catalytic elements for the treatment of
exhausts. By extension refer to the envelope of catalytic converter..
Exhaust Part of exhaust line interdependent of engine.
downpipe
Line under car Part of exhaust line interdependent of car body.
body
Loss of power Difference of pressure between 2 points measured on a jig in laboratory on a flux bench. This
involves that the air flux going through the element is at “ambient” temperature.
Counter-pressure Difference of pressure measured in real conditions of use, it means on engine bench.
(CPE)
4.2.SIGLES AND ACRONYMS

For the needs of the present norm, the following initials and acronyms are defined:
APOQUA Global improvement of the Quality function (PSA procedure).

APV After sales.
BBE Exhaust “Mouth” Noise
BEA Alternate force Bench
BVM Manual Gear Box
BVA Automatic Gear Box
CCP Dimensioning of Contacts and Proximities
CPE Exhaust Counter-Pressure
CRPP Particular Clauses and planning of the Results.
CSE Main Supervising Characteristic.
CTF Functional Technical Characteristics.
DSP Power Spectral Density.
EF Finished Elements.
ER Unwanted Event.
ERC Customer Unwanted Event.
ER LE Exhaust Line Unwanted Event.
FAP Particulate Filter.
FC Constraint Function (defined in the Functional Analysis).
FS Service Function (defined in the Functional Analysis)
IOD Coming from Final Tooling.
PC Full power.
PIV Integration Schedule and Validation
ST Technical Specification.
STN Normative Technical Specification.
VHU Out-of-Use Vehicle.
OR : 01/09/1980 B : 17/02/2009 INTERNAL USE

5.REQUIREMENTS
5.1.FUNCTIONAL REQUIREMENT
5.1.1.SEALING
Function Requirement Definition

FS1 Follow-up of the requirements of the STN « Sealing of exhaust lines ».
FS3
FC1 B223120-001 If 2 parts are making up the FAP, the sealing must meet the following requirements :
Sealing at new state < 100 l/h under 0,8 bar
Sealing after ageing < 100 l/h under 0,8 bar
Sealing after ageing and change of < 200 l/h under 0,8 bar
FAP (particulate filter) (After sales
intervention).
5.1.2.ENGINE PERFORMANCE
5.1.2.1.Loss of power of the exhaust line.
See definitions concerning the loss of powers and counter-pressure: § 4.1.
The static counter-pressure requirements (CPE) are stated in the following conditions:
• Upstream consultation scope
For the line under car body, the flexible will then be included in the measurement.
• To the working point(s) (flow and nominal temperature of exhaust gases) specified in the Project Technical
Specification.
The measurements concerning the loss of powers and the CPE (Exhaust Counter-Pressure) are performed in
compliance with the norm B32 3110.
For the measurements, the inner diameter of the tube upstream and downstream the system are specified in the
Project Technical Specification.
The supplier must specify the tolerances linked to the manufacturing dispersions of the mass production system.
Generic target value of dispersion:

+/- 3,5 % in equivalent section .

FS1 Follow-up of the nominal static CPE criterion to the specified working points.
FC4 B223120-002 Follow-up of the dispersion criteria.
OR : 01/09/1980 B : 17/02/2009 INTERNAL USE

5.1.2.2.Engine filling
For engine filling requirements, some engineering parameters can be imposed in order to control the acoustic
tunings favouring the draining of cylinders:
• The position and definition of the intermediate muffler of the line under car body.
• The diameter of the downpipe.

FS1 In compliance with Project Technical Specification.
FC4 B223120-003 Position and inner sketch concerning the intermediate muffler.
Diameter of downpipe.
5.1.3.ACOUSTIC SERVICES
5.1.3.1.Exhaust muffler noise (BBE)
The requirement of the mouth noise level is specified in the Project Technical Specification.
The BBE measurements on the vehicle are performed in compliance with the norm B32 3140.
5.1.3.1.1.Idling speed noise

FS2 Idling speed noise (main harmonic and harmonic attenuation)
FC6 The acoustic pressure at 10*10 from the exhaust mouth is measured in Pa.
-5
FC10 B223120-004 The criteria are given in dB(B) : reference 2.10 , weighting B.
They must be checked during idling speed :
• To dead centre for Manual Gear Box,
• To parking, neutral, drive and reverse gear positions for Automatic gear box.
Generic book of specifications for the 4 cylinders

When in idling speed with harmonic 2, the exhaust mouth noise (BBE) must be below 80 dB(B).
The other harmonics of the engine must follow the harmonic attenuation:
OR : 01/09/1980 B : 17/02/2009 INTERNAL USE

Generic Book of Specifications for the 3 cylinders
The level of the harmonic 3 must remain below 80 dB(B).

The other harmonics must follow the following harmonic attenuation:
5.1.3.1.2. Buzzing noise

FS2 Level of the main harmonic in acceleration and deceleration.
FC6 B223120-005
The criteria are measured in dB(B) : reference 2.10-5, weighting B.
5.1.3.1.3.Medium

FS2 The levels of secondary harmonics in acceleration and deceleration are
FC6 B223120-006 characterized by a notion of harmonic attenuation.
FC10
By default, the harmonic attenuation to be implemented is:

• 6 dB per octave, for the multiple harmonics of the main harmonic.
• 6 dB per octave to which 10 dB is subtracted, for the other harmonics.
OR : 01/09/1980 B : 17/02/2009 INTERNAL USE

For the 4 cylinders:
For some projects with particular coloration requests, a sound synthesis work involves a specific requirement on
the harmonic staging’s (example 3 cylinders)..
5.1.3.1.4.Blow noise
Function requirement Definition

FS2 Blow noise (level)
FC6 B223120-007
The criteria are given in dB(A), filtered 30 Hz - 20kHz : reference 2.10-5, weighting A.
When shifting down, the levels must be below the full acceleration levels.
FS2 Blow noise (coloration): Level of noise in 1/3 octave to be followed in full power at
FC6 B223120-008 4000 r.p.m or with a decrease in full power between 3800 r.p.m. and 4200 r.p.m.
FC10
The acoustic pressure at 10*10 from the exhaust mouth is measured in Pa.
The criteria are given in dB(A) : reference 2.10-5, weighting A.
Pa in dB(A)
95
dB Slope : -4Db/octave
400 Hz 1 kHz 20 kHz

Hz
OR : 01/09/1980 B : 17/02/2009 INTERNAL USE

5.1.3.1.5.Subjective listening

FS2 Subjective listening
FC6 A listening of exhaust systems must be performed outside the vehicle, near the
FC10 B223120-009 mouth, within idling speed, acceleration and deceleration conditions (gas impulse).
Any noise liable to give an impression of non-quality is to be proscribed (noise of the
cup, propagation of the line when in idling speed, whistle, swallowing, blow noise,
leaks, puffing noises, put-putting, splashing…).
Unless otherwise stipulated in the Project Technical Specifications, the level of
service required corresponds to a dimension of 8 in the
DTAT/DVHL/PHV/ACV/EPA/99648/PRUJ estimation chart of 21-12-99.
Remark:
In order to improve the quality of the noise perceived outside the vehicle, when starting, during parking operation
and to control the global noise, a predisposition to the fitting of an absorbing fiber (silencing system on the
outlet pipe of the RR muffler) must be performed for each exhaust line.
5.1.3.2. Limit the vibrating propagations (blocking efforts).
5.1.3.2.1.Idling speed

FS2 The modes of exhaust line must not be in coincidence with the frequencies of the first
FC6 B223120-010 harmonics of the engine idling speed.
FC10
5.1.3.2.2.Buzzing noise / medium

FS2 Efforts transmitted to car body by each connection between the line and the structure
FC6 B223120-011 in 3rd gear PC (full power) and when shifting down (main harmonic and harmonic
FC10 attenuation).
The levels of efforts are given in Npeak.
For a 4-cylinder,
By default, the harmonic attenuation to be implemented is:

• 6 dB per octave, for the multiple harmonics of the main harmonic.
• 6 dB per octave to which 10 dB is subtracted, for the other harmonics.
OR : 01/09/1980 B : 17/02/2009 INTERNAL USE

5.1.3.2.3.Hook mode
In order to limit the vibration propagation, the hooks must be designed in order to obtain a first Eigen mode above
the frequency stipulated in the Project Technical Specification f hook)). The justification must be performed:
1- In vehicle configuration, it means while taking into consideration the « flexibilities » (tube, envelope) of the
welding.
10 cm on both side of the tube are taken into consideration.
2- .In embedding condition on welding, it means exhaust system considered .extremely rigid.
Unless otherwise stipulated in the Project Technical Specification, the suspending system is modelized for a mass
of 50g, applied in the centre of its attachment on the hook.
.
The details of the calculation procedure are mentioned in the document below:
http://normes.inetpsa.com/normes/bv/bv00207/fr/Specif_calcul_Analyse_modale.zip

st
FS2 B223120-012 1 mode particular to each hook of the exhaust line > fhook
FC6
FC10
The supplier must mention the hook associated dynamic stiffness – line side, to the application point of the
suspension system effort. This stiffness must be at least 10 times above the associated filtering element.
5.1.3.3.Limit the acoustic propagation (emissivity)
5.1.3.3.1.Emissivity of the components
The level of propagation of the various components making up the exhaust line (flexible, catalyst, catacoustics,
resonator, muffler and tube) must be in compliance with the requirements below:

FS2 Propagation to 300 mm during a 1500 rpm stability (maximal engine power).
FC6 B223120-013
FC10 The acoustic pressure at 300mm on Y and Z is measured in Pa in compliance with
the procedure shown in appendix 1.
OR : 01/09/1980 B : 17/02/2009 INTERNAL USE

Standard Book of Specifications

FS2 Propagation to 300 mm during r.p.m. increase [1000 rpm – maximal speed] : global A
FC6 B223120-014 according to the r.p.m.
FC10
The acoustic pressure at 300mm on Y and Z is measured on Pa, in compliance with
the procedure shown in appendix 1.
CDC standard
OR : 01/09/1980 B : 17/02/2009 INTERNAL USE

5.1.3.3.2.First Eigen mode of some components

st
FS2 Le 1 Eigen mode of some components (input and output cones of the catalyst, of
FC6 B223120-015 the FAP (particulate filter) or of the FAPcata, cups of muffler, envelope…) must be
above 400 Hz in hot condition (4-cylinder criterion).
FC10 The environment of the components and the thermal condition are to be taken into
consideration in the modal calculation.
5.1.3.3.3.Contribution of the emission control elements to the acoustic propagation of the engine.

FS2 In every life situation, the on-board emission control elements must in no way
FC6 contribute to the engine acoustic propagation.
FC10
B223120-016 A measurement of the acoustic power must be performed in compliance with the
procedure described in appendix 2, on the following configurations:
• Configuration 1: measurement of the acoustic power (Pa1) of the engine exhaust

face equipped with a factice non emission element instead of the emission
control element (tube insulated with rockwool).
• Configuration 2: measurement of the acoustic power (Pa2) of the engine exhaust
face with the emission control element including its thermal insulation.
Criterion : Pa1 = Pa2
Measurement points :
• measurement at idling speed
• measurement from 1250 r.p.m. to 3500 r.p.m by range of de 250 r.p.m – full
engine power.
5.1.3.3.4. Acoustic characteristics of the thermo-acoustic shield (according to implementations).

FS2 Absorption acacoustic absorption
FC6 B223120-017 This measurement is performed with an impedance tube (PSA Norm: D45 5430) and
FC10 allows to determine the absorption curve in normal incidence of the material.
Standard Book of Specification

The absorption coefficient of the insulation element must be included between both templates (in blue) under the
following conditions:
:
• Temperature : 20 °C ± 2 °C
• Relative humidity : 65 % ± 5%
OR : 01/09/1980 B : 17/02/2009 INTERNAL USE


FS2 Acoustic transparency (attenuation index)
FC6 B223120-018 This measure must be performed in compliance with the Norm D45 5038
FC10 (measurement in small cab).
Standard Book of Specifications

The attenuation index must be above the template for the following conditions:
• Temperature : 20 °C ± 2 °C
• Relative humidity : 65 % ± 5%
OR : 01/09/1980 B : 17/02/2009 INTERNAL USE

5.1.4.EMISSION CONTROL
5.1.4.1.Leak at the periphery of the emission control elements
See requirement B223210-001 in the Norm B22 3210.
5.1.4.2.Thermo-management
In order to start the emission control elements at the earliest possible time, it is required to limit the thermal losses
upstream the emission control elements.

FS3 B223120-019 Maximal thermal losses upstream one emission control elements on various working
points (inlet date [flow, temperature], specified in the Project Technical Specification).
5.1.4.3.Sprinkling
The criteria are associated to the working points specified in the Project Technical Specifications (Temperature,
flow of exhaust gases and counter-pressure downstream).
The definition of the criteria is given in appendix 3.

B223120-020 Uniformity : γ ≥ 0,9
Detection of hot points [applicable for petrol engines]
B223120-021 Global criterion : A65 > 0,5

u max
Local criterion (intensity of the hot point) : < 1.4
um
Detection of non active zones
B223120-022 Global criterion : A35 > 0,9

FS3 Local criterion (backflow coefficient = intensity of non active zones) :
u min
Backflowindex = > 0,2
um
Homogeneity of the speeds
B223120-023 Mid 10 and Mid 20
Tangential speed [applicable for petrol engines]

B223120-024
For ceramics 900/2,5 : the maxi admissible speed is of 70m/s
For ceramics 600/4,3 : the maxi admissible speed is of 100m/s
OR : 01/09/1980 B : 17/02/2009 INTERNAL USE

5.2.PERFORMANCE REQUIREMENTS
5.2.1.DURABILITY
5.2.1.1.Mechanical behaviour of exhaust downpipe.

The complete exhaust downpipe (including manifold and turbo-compressor) must be designed in order to follow the
requirement below:

FC5 First f Eigen frequency in hot condition.
with rpmmax = maxi r.p.m. and n = quantity of

B223120-025 cylinders.
The flexible must be taken into consideration while applying ½ the mass of the latter
to the ¼ of its length.
The boss stiffness’s are specified in the Project Technical Specification (estimated
from the data calculated according to the method m-K-M or measured).
For a petrol ‘-cylinder (rpmmax = 6500 tr/min), f ≥ 270 Hz
For a diesel 4-cylinder (rpmmax = 5300 tr/min), f ≥ 220 Hz

FC5 If the modal criterion is not followed (presence of Eigen modes of the downpipe to <
B223120-026 ftarget frequencies), the following requirement must be checked :
Under the GMP (power train) excitation, all the assembled exhaust downpipe (cata,
manifold, turbo, heat shields and supports) must show no breaking after 2x107 cycles
on each of these Eigen modes.
FC5 The assembled exhaust downpipe must show neither breaking nor leak after the test
B223120-027 of resistance to vibrations described in the chapter 6.5 of the Norm
B21 7120 (resistance to a DSP (Power Spectral Density).
5.2.1.2.thermo-mechanical behaviour of the exhaust downpipe

FC5 The exhaust downpipe must be designed in order to follow the requirements below :
• Neither thermo-mechanical breaking nor plastic distortion under the differential
dilatation within maximal thermal conditions.
B223120-028
• Maximal force injected to engine < xx N
The thermal shock behaviour test will be performed on GMP bench by a succession of cycles starting from the
NTmaxi r.p.m. where the exhaust temperature is the most important in full power (PC) to the same r.p.m. – 500
r.p.m. no power (Nv).
OR : 01/09/1980 B : 17/02/2009 INTERNAL USE

Description of the cycle :
phase 1 2 3 4
speed Nv to Ntmax Ntmax Ntmax to Nv Nv
power 0 to PC PC PC to 0 0
duration (s) 15 225 15 225
The test is performed on 3000 cycles: 400 hours.
5.2.1.3.Resistance of the line under assembled car body.

FC5 B223120-029 The exhaust line must show neither breaking nor leak after validation on the
endurance bench (process sheet HB1 in appendix 4).
5.2.1.4.Resistance of the components

FC5 B223120-030 Behaviour of the components (including hooks).
The validation of the components must be performed on alternate force bench (BEA)
in compliance with the procedure B32 0730 and within the thermal conditions of use
on vehicle. .
FC5 Behaviour of the canning
B223120-031 The canning of the catalyst / FAP (particle filter) must be in compliance with the
requirements mentioned in the Norm B22 3210.
The isostatic resistance of the substrate is specified in the Project Technical

Specifications.
FC5 B223120-032 Behaviour of the flexibles
See Norm B22 3250
FC5 B223120-033 Behaviour of the suspending systems.
See Norm B22 3240
FC5 Mechanical resistance of the on-board heat shields (if these components are in the
B223120-034 supply of level 1).
See Norm B21 7120
5.2.2.RESISTANCE TO THERMAL SHOCK (WATER PROJECTIONS)
For the validation of the resistance of the canning to thermal shock: see Norm B22 3210.
5.2.3.RESISTANCE TO GRITTING / SHOT-BLASTING

FC1 In compliance with specifications (refer to. Project TS)
FC2 B223120-035 • Example of requirement for heat shield :
The system must resist shot blasting for 5 minutes.
Æ No perforation. Follow-up of the Norm D14 1428
OR : 01/09/1980 B : 17/02/2009 INTERNAL USE

5.2.4.THERMAL PROPAGATION
5.2.4.1.Performance requirements of on-board heat shields on emission control element or on exhaust

tube.
FC1 Within working conditions specified in the Project TS (gas T°, ambient T°, gas flow,
FC2 convective and propagation limit conditions…):
• Flux propagated < xx W/m² in all directions.
• Follow-up of the book of specifications concerning the thermal emissivity.
B223120-036
The temperature of the gases at the outlet of the emission control element must be
estimated.
The emissivity must be given for the new and used shields (D15 5522).
FC1 Thermal cover of the shield on exhaust system:
FC2 B223120-037 • Follow-up of the cover zones specified in the Project TS.
• A great care will be needed to treat the thermal sealing of the openings required
for the passage of probes, mounting pads and fastening lug of catalyst/Particle
Filter.
OR : 01/09/1980 B : 17/02/2009 INTERNAL USE


FC1 The « hot jerk » is a brutal stop of the engine after a situation requiring a stabilization
FC2 of the temperatures (ex. mountain towing). This involves the increase of the ambient
temperature under bonnet due to a fast restitution of the energy stored by the
emission control element during the stabilized driving phase.
Within working conditions corresponding to « hot jerk » and specified in the Project
TS (flow of gases = 0 kg/h, T° of gases, ambient T°, condition of natural convection) :
• Follow-up of the profile of the envelope temperature of the shield.
B223120-038
• Follow-up of the profile of the maxi Eigen flux radiated by the shields.
• Follow-up of the profile of temperature and of the maxi Eigen flux of the canning
envelope (non covered by its shield) in case of « hot jerk » ( in the hypotheses
where a zone of the emission control element would not be covered by the
shield).
OR : 01/09/1980 B : 17/02/2009 INTERNAL USE

In order to validate the technical performances of the shields, the following information and characteristics must be
specified:
• Precise denominations of all materials making up heat shields.
• Thickness of all materials making up heat shields.
• Maxi temperature of use defined in compliance with the Norm D45 5254
• Thermal efficiency in compliance with the Norm D15 5279, within surrounding conditions specified in the
Project TS.
• Thermal emissivity of inner face and outer face according to the temperature of material, in compliance with
the Norm D15 5522 (at new state and after ageing).
• Thermal conductivity of all the materials making up the thermal shields depending on the temperature of
material – in compliance with the Norm D15 5521
• Thermal conductivity of the complete shield according to the temperature of the material – in compliance with
the Norm D15 5521
• Specific heat, material density.
5.2.4.2. “Dry grass” (case of a cata or of a FAP under car body)

FC1 B223120-039 The envelope temperature tangent to the ground clearance of the cata-FAP must not
exceed 350°C. In the contrary case, a heat shield under this element must be
integrated to reach this aim.
5.2.5.RESISTANCE TO CORROSION
5.2.5.1.Corrosion
The materials of the exhaust line are to be defined for a 3-year guarantee period at 300 ppm, unlimited mileage
(defects exclusively corrosion). The aspect requirement (line with or without cosmetic) is specified in the Project
TS.
Refer to materials item 5.5.3.2
5.2.5.2.Removal of condensates
The components must include solutions that will allow removing condensates from exhaust line, more particularly
as regards RR muffler.
They must be characterized in compliance with the test procedure B32 3200.

FC9 B223120-040 Respect of the Norm B32 3200
5.2.6.RESISTANCE TO INFLAMMABILITY OF THE INSULATION ELEMENTS

FC6 B223120-041 It is possible that the vehicle has a non-automatic working mode. The temperatures
of exhaust gas and of the envelope of the components can then reach very high
temperatures (specified in the Project TS). During this phase, the shield must not be
catch fire.
To follow this requirement, the insulation layers must be of type A in compliance with
the Norm D45 1333 - and the Norm D45 5254 must be followed.
OR : 01/09/1980 B : 17/02/2009 INTERNAL USE

5.3.REQUIREMENTS FOR EXTERNAL INTERFACES

5.3.1.INTERFACES
The interfaces must be designed in compliance with the standards resulting from the APOQUA procedure, more
particularly as regards the choice of the screws and bolts elements and of the tightening torque. The main points
(references of the parts…) are mentioned below.
5.3.1.1. Exhaust interface on engine

5.3.1.1.1. Biconical interface
Follow the STN B22 3211 « Biconical Connection ».
5.3.1.1.2.Connection by flat flange

Use of nuts 96 121 449 80 (ECROU (NUT) KM HH EMB M8*125 AC8 CU4)
Torque and tightening process sheet: to be determined according to the assembly process.
The requirements concerning the surface condition of the flange (flatness, roughness) are indicated in the Project
TS.
5.3.1.1.3. Attachment of the exhaust downpipe on engine gearbox unit.

The attachments of the supports of the exhaust downpipe must be designed in compliance with the sheet
APOQUA « FRT tube Reinforcement T- square » DITV_ATAT07_0224.
All the attachment elements are fitted in the same direction.
Attachment Attachment on the supported part side

Coef 2
Ref 7903602024
Designation SCREW KP H EMB M8*125 L25 AC8 ZNIA3L
CC
Torque 20 N.m +/- 15%
5.3.1.2.Connections between components of the system

5.3.1.2.1. Biconical interface
Follow-up of the STN B22 3211 « Biconical Connection »
5.3.1.3.Attachments of the exhaust system on car body

The interfaces of the exhaust line on car body must be designed in compliance with the APOQUA sheet « Exhaust
Line» DITV_ATAT07_0010.
5.3.1.3.1. Design of hooks on the exhaust line side

The hooks must include beads. The shape of the beads must be designed for a tearing force of the hook in its
suspending system above or equal to 400N.
OR : 01/09/1980 B : 17/02/2009 INTERNAL USE

5.3.1.3.2. Design of the suspending systems

See STN B22 3240 « exhaust suspending system »
The suspending systems must arrive integrated to the exhaust line.
Adherized suspending systems are privileged.
5.3.1.3.3. Car body face interface

See sheet APOQUA DITV_ATAT07_0010
Suspending systems on car body :
Attachment Attachment on supported part Attachment on

side supporting (carrying)part side
Coef 2 2
Ref 9614106080 7903011385
Designation NUT K H EMB NETT M6*100 AC8 SCREW K CL SOUD ANN M6*100
ZNIA3L L25 AC8 CY
Torque 8 N.m +/- 25%
Suspentes à crochets :
Attachment Attachment on supported part Attachment on

side supporting (carrying) part side
Coef 2 2
Ref 7903301354 7903042051
Designation SCREW H RCL M6*100 L20 AC8 NUT K H SOUD M6*100 AC8
ZL VMGL OF
Torque 8 N.m +/- 25%
5.3.1.4. Probes and sensors

FS3 B223120-042 Follow the criteria concerning lay-out of the probes and of the characteristics of the
interface, shown in the following items.
5.3.1.4.1.Probe Lambda (probe O2)
Lay-out criterion
The lay-out must allow a tilting of the probe in comparison to the horizontal line above 10°.
The probe must never be in counter flux. The ideal positioning is a probe that would have an angle of 90° with the
flux of the exhaust gases. When such an angle is not possible, the probe must be positioned in order to be in co-
flux.
OR : 01/09/1980 B : 17/02/2009 INTERNAL USE

Drawing of the base

The functional dimension of the interface must be followed on the finished part (after welding).
General characteristics :
• Characteristics of threading: M18*1,5
• Flatness required: 0,2
• Tightening torque = 50N.m +/- 15%
5.3.1.4.2. Temperature probe
Base drawing
The functional dimension of the interface must be followed on the finished part (after welding).
Tightening torque : 30 N.m +/- 15%
5.3.1.4.3. Pressure connection piece
The pressure tubes are designed in order to be in compliance with the following criteria:
• No low point,
• Slope of the connection always positive,
• Follow the elements of the APOQUA sheet « rigid pipe connection - delta pressure FAP »
DITV_ATAT07_0168
OR : 01/09/1980 B : 17/02/2009 INTERNAL USE

Drawing of the base

The functional dimension of the interface must be observed on the finished part (after welding).
Definition of the end-piece of the rigid pipe

The end-piece of the rigid pipe must be of 8 mm diameter type (in compliance with the Norm B12 2819) :
• End piece of type 9 (with collar) for snap engagement.
• End piece of type 4 (with swelling) for elastic clamp.
The rigid pipe is secured with a H (HSP 19) recess to the following torque :
Tightening torque : 20 N.m +/-15%
The attachment of the support of rigid pipes is performed as follows :

Attachment Attachment on the supported part side
Coef 1
Ref 9630506380
Designation Screw K H RPL M6*100 L20 AC8 ZLVMGL
OF
Torque 3N.m +/-15%
5.3.1.4.4. Probe NOx
Specifications is being drawn up..
5.3.2.LAY-OUT

FC1 B223120-043 Observe the functional volume.
FC2 Observe the CCP (Dimensions Contacts and Proximities)
FC3 Æ See Project TS.
5.4.OPERATIONAL REQUIREMENTS
5.4.1.MISSION PROFILE
Without object – See Project TS
5.4.2.LIFESPAN
Without object – See Project TS
OR : 01/09/1980 B : 17/02/2009 INTERNAL USE

5.4.3.ERGONOMIY AND HUMAN FACTORS

5.4.3.1.Assembly / disassembly

FC14 It must be possible to disassemble the system with standard tools.
Observe the assembly requirements (more particularly the assembly and
B223120-044 disassembly forces) of the Project TS, while referring to the generic requirements
described in the document DMOV_MON06_2147.
Should the case arise, pre-holding systems, foolproofing systems would be specified
in the Project TS..
5.4.3.2.Absence of aggressive zone

FC14 The system must have no sharp, cutting or pointed edges that could involve injuries
B223120-045 to the operators or users, more particularly on the thermal insulations, hooks and
exhaust tube.
The system must involve no allergic risks to touch and to emanations.
5.4.4. FUNCTIONAL SAFETY

See the list of Unwanted event of the Exhaust (ER LE) in appendix 5.
5.4.4.1. Safety
Definition: Aptitude of one system to avoid events that could involve damages for people of materials.

toutes B223120-046 The system must be in compliance with the requirements of the Safety defined by the
manufacturer for each project (see requirements mentioned in the Project TS).
B223120-047 No simple failure must involve Unwanted Event of gravity 4 for the Customer.
5.4.4.2. Reliability
Definition: Aptitude of one system to achieve without failure a function required during a given time and within given
environmental and use conditions.

All B223120-048 The system must follow the Reliability requirements defined by the manufacturer for
each project (see requirements mentioned in the Project TS).
OR : 01/09/1980 B : 17/02/2009 INTERNAL USE

5.4.4.3. Maintainability
Definition: Aptitude of one system to be maintained (preventive maintenance) or restored (curative or corrective
maintenance) in normal working conditions within given environmental and use conditions while implementing the
required maintenance conditions.

All B223120-049 The system must follow the Maintainability requirements defined by the manufacturer
for each project (see requirements mentioned in the Project TS).
5.4.4.4. Availability
Definition: Aptitude of one system to achieve or to be in condition to achieve a required function at a given time.

All B223120-050 The system must follow the Availability requirements defined by the manufacturer for
each project (see requirements mentioned in the Project TS
5.4.5.PRODUCT QUALITY
5.4.5.1.Quality targets as new or after having been used

All B223120-051 The system must follow the quality targets of new or used products defined in the
Particular Clauses and Planning of Results (CPPR) by the manufacturer for each
project.
5.4.5.2. Quality Insurance
The Quality Insurance is implemented such as defined in the Particular Clauses and Planning of Results (CPPR).
5.4.5.3.CTF - CSE
List of the exhaust CTF described in the Project TS
The process must follow the capabilities below :

• CMK 1, 67 : short term capability, instantaneous dispersion of the means, on a minimum of 30 parts of the
same batch.
• CPK 1,33 : long term capability, global dispersion 5M (Method, Material, Machine, Environment, Manpower),
on 5 non consecutive batches of 12 parts.
5.4.5.4. Control of the parts supplied in VRS and PRS

In compliance with Project TS.
5.4.5.5. No residual welding

The system must show no residual welding or other object upstream the emission control elements and on the
functional zones (hooks, hoop, bicone, attachment support, etc…).
5.4.6.PROTECTION AGAINST MALEVOLENCE

Without object.
OR : 01/09/1980 B : 17/02/2009 INTERNAL USE

5.4.7.SYSTEM RESOURCES
Without object
5.4.8. REQUIREMENTS FOR DOCUMENTATION

5.4.8.1. Functional drawing
The functional drawing more particularly describes the functional volume of the system, the interfaces.
See Project TS.
5.4.8.2.Interface drawing
The interface drawing is validated and officialized by the pilots AGCC and AMMT at the JAI (interface milestone).
5.4.8.3. Supplier drawing

The drawings proposed to PSA for officialization must follow the data processing charter “CAO convention »
available on the B2B portal.
The supplier drawings must follow the indications stipulated in the document below :
http://normes.inetpsa.com/normes/bv/bv00207/fr/Guide_plans.zip
The drawings must also include a drawing sheet for Aftersales including:
• The line in XZ and YZ views.
• The separation zone.
• The references of the Aftersales parts.
• The sleeve to be used and the tightening torque.
5.4.8.4. Synthesis sheet

The supplier must provide the synthesis sheets of the systems (sketches, functional criteria…).
OR : 01/09/1980 B : 17/02/2009 INTERNAL USE

5.5. CONSTRAINST REQUIREMENTS

5.5.1. REGULATION AND CONSUMERISM
5.5.1.1.Homologation and regulation
The system is submitted to a declaration in the homologation files in compliance with the European Directives and
Regulations listed in the Norm R12 2002 "POWERTRAIN - INTERFACE - ADAPTATION OF EXHAUST LINE
POWERTRAIN/CAR BODY " This Norm also specifies the characteristics allowing to meet these
requirements.
For an evolution linked to the items mentioned in the Norm R, the system must be submitted to the DITV/RHN
homologation department in order to define the further actions. The references mentioned are the original
references; it is suitable to refer to the PSA internal use in the base:
REGLEM http://reglem.dtat.inetpsa.com/reglem/authentifier.do
5.5.1.2.Shock

FC11 B223120-052 The system must follow the shock requirements specified in the Project TS and
drawn up in collaboration with DTI/DPMO/ADTR/ARDC.
Shocks reference data base of the trade
Designation Reference
Generic book of specifications concerning the exhaust shock
AGCC_ADTR06_1063
on cold part.
Calculation protocol of shock GMP (powertrain) RR exhaust. AGCC_ADTR07_0088
Consultation inlet data sheet of exhaust line (generic). AGCC_ADTR07_0114

Line under car
body
Shock meshing. book of specifications IAMT_CGOA05_0089
RR exhaust shock test protocol. IAMT_CGOA05_0040
Additional sheet concerning RR exhaust test. IAMT_CGOA06_0045
Book of specifications of generic pre-catalyst shock. AGCC_ADTR06_1055

Exhaust down
Hot part meshing procedure. IAMT_CGOA06_0041
pipe
Hot part shock test protocol. AGCC_ADTR06_1104
5.5.2.WEITH AND OTHER PHYSICAL CHARACTERISTICS

FC10 B223120-053 The system must follow the mass targets specified in the Project TS. .
FC7
OR : 01/09/1980 B : 17/02/2009 INTERNAL USE

5.5.3.DESIGN AND MANUFACTURE

5.5.3.1.Studies and/or imposed solutions
FC10 The maintenance or thermal plates used for the design of catalyst of particle filters
B223120-054 must be of class 0 or not classified, in compliance with the European Directive
97/69/CE.
5.5.3.2.Materials
FC1 B223120-055 The choice of materials of the exhaust line must be in compliance with the Norm
FC9 B22 3241.
FC1 B223120-056 The system must be in compliance with the Norm A12 5550 « Management of the
prohibition of the use of the four heavy materials (lead, hexavalent chrome, mercury,
FC9 cadmium) ».
5.5.3.3. Manufacture
The system must follow the different PSA Norms concerning the process, tolerance application and technical
drawing:
A31 2200 Technical drawing – welding representations.
A31 2205 Technical drawing – nomenclature of the welding processes.
A33 3510 Help to tolerance application of the elementary functions.
B11 3110 Iso metric threading for general uses.
B13 1220 Resistance spot welding of steel sheets – definition of the assemblies.
B13 1226 Resistance spot welding of steel sheets – quality of the assemblies.
B13 1530 ARC welding–MAG welding of steels, MIG braze welding of steel, MIG welding of aluminium
sheets– definition of the assemblies.
B13 1540 ARC processes –MAG welding of steel sheets, MIG braze welding of steel sheets, MIG welding
of aluminium sheets, - acceptance criteria of one bead.
B18 3515 Brazing and braze welding – Definition of the assemblies.
5.5.3.4.Interchangeability
When the exhaust line is monoblock, for the replacement of muffler in the Aftersales operations, it is required to:
• Plan a cutting zone of the crank.
• Design a clamp to ensure the assembly of both parts during the muffler replacement.
The design must be in compliance with the Norm B22 3130.
5.5.3.5.Marking of the products

FC10 The marking of the system must be:
• visible without disassembly of the parts
B223120-057 • indelible
• in compliance with the Norm B20 0110.
For the emission control elements, see Norm B22 3210-004.
OR : 01/09/1980 B : 17/02/2009 INTERNAL USE

5.5.3.6. Suspicious smells

FC6 The system (ex. assembled catalyst, heat shield) must give off neither disagreeable
B223120-058 smokes or smells nor harmful chemical agents, more particularly during the first
hours of the engine running.
5.5.4.COST
To be specified in the Project TS.
5.5.5. LEAD TIME

To be specified in the Project TS.
5.5.6.STYLE
FC8 B223120-059 The system must follow the style requirements mentioned in the Project TS.
Ex amples :
• Requirements on the visible grooves and mouldings.
• Perception of heat shield in the sub-bonnet.
• …
5.5.7.TRACEABILITY AND CONFIGURATION MANAGEMENT

Without object.
5.5.8.TRANSPORTABILITY, STORAGE AND CONDITIONING

FC12 The packaging and re-packaging of the parts must allow:
FC13 • Guaranteeing the property of all the elements of the system.
FC14 • The absence of degradation for the aspect parts (scratches).
The parts must be protected (impacts, cleanliness); for storage and transport, no bulk
destocking of the parts. The products for which the packing has been deteriorated
B223120-060 must not be assembled on the vehicle (non guaranteed cleanliness, scratch risk on
the aspect parts).
It is more particularly necessary to make sure :

• Of the protection of flexible hoses thanks to a plastic shell.
• Of the fitting of the caps upstream the emissions control systems to prevent the
intrusion of foreign bodies in the line and on the probe bases. The disassembly
force of these caps must be below 30N.
• Of the protection of the exhaust tube mouldings.
In any case, the storage, packaging and transport of the parts must receive the
approval of the services concerned.
OR : 01/09/1980 B : 17/02/2009 INTERNAL USE

5.5.9.FLEXIBILITY AND EXTENSION

Without object.
5.5.10.SERVICE REMOVAL

FC10 B223120-061 The product must be in compliance with the Norms below relating to the VHU (out-of-
FC16 use vehicles) :
• B20 0200 « Prescriptions in view of recycling »
• A12 5510 « Aptitude to emission control of the vehicle»
FC10 B223120-062 For each references supplied, the supplier must indicate the mass decomposition
FC16 while completing the material sheets via the B2B portal – MACSI applications. These
elements are described in the Norm A12 5500 (« Data of the composition of the
masses, of material and substances of the parts »).
5.5.11.ENVIRONMENTAL CONDITIONS
The system must be designed for:

• All the conditions of use (climate from -30° to +45° and hygrometry from 0 to 100 %).
• All countries (except The United States).
5.5.11.1.Behaviour of heat shields to occasional contact of the fluids.
The heat shields must resist the contact with the fluids below:
• Water resistance: rain or snow.
• Corrosion resistance: disassembly of all the connections of the shield after 6 years .
• Oil resistance.
• Cooling liquid resistance.
• Fuel resistance.
• Window washer liquid resistance.
• Resistance to battery acid (sulfuric acid).
• Resistance to cleaning product.
• Resistance to solvents.
• Resistance to pressure water (KARCHER)
5.6.INTEGRATION AND VALIDATION REQUIREMENTS
5.6.1.VALIDATION AND INTEGRATION DRAWING

The supplier must follow and complete the Validation and Integration Drawings supplied by the Project TS.
OR : 01/09/1980 B : 17/02/2009 INTERNAL USE

APPENDIX 1
PROCEDURE MEASURES EMISSIVITY
Measurement procedure
The powertrain will have to be fitted on the vehicle frame with its connection wedges.
The exhaust line will have to be complying (geometry, mass, hooks, suspending systems, decoupling elements,
connection clamps) and the fitting conditions on vehicles will be followed.
The parts of the line upstream and downstream the part analyzed will be acoustically insulated together with the
engine. The background noise will be measured while insulating the element to be characterized. The difference
obtained between both measurements (with and without insulation) will be above 10db.
The measurement room will have to be characterized by its reverberation time (Maxi 0.3 second within the 400 –
20000 Hz range).
To decrease the test times, two microphones will be positioned at 300 mm according to the Y & Z axis in the center
of the elements to be tested. For the volumes, we will have to make sure that this recommendation is sufficient to
take all the acoustic problems into consideration (directivity of the source). On the other hand, it will be possible to
take the X axis into consideration for transversal volumes.
The engine and exhaust line will be stabilized in temperature before any the acoustic pressure measurement is
performed. The engine water temperature (90°C) and a thermocouple located on the tube upstream the catalyst
(constant envelope temperature at 3000 r.p.m.) will be used as indicators.
The results will have to be presented with a weighting (A).
The engine adjustment and the piloting of the bench will have to allow an engine speed increase (full power) of
1000 r.p.m. to a maximal engine speed (duration of 40 seconds for a 4-cylinder petrol engine). For a diesel engine,
the speed increase will have to be performed in 30 seconds.
Test conditions
2 types of tests are required:
• A test with acquisition of the data for 10 seconds on a engine speed stabilized at 1500 r.p.m.
• The second test will consist in performing acoustic pressure measurements during an engine speed
increase of 1000 r.p.m. to the maximal engine speed.
Both these tests are performed with a 100% engine power.
If emergences appear during engine speed increase, they will have to be submitted to a specific analysis of the
criticized engine speed (s).
OR : 01/09/1980 B : 17/02/2009 INTERNAL USE

Definition of the acquisition parameters
The adjustment of the parameters of the analyzer is:
Stabilized Speed increase

Sampling frequency 48 000 Hz 12 500 Hz
Window Hanning (energy) Hanning (energy)
Blocksize 2048 8192
Overlap O% 50 %
Analysis frequency 400 – 20 000 Hz 400-500 Hz
Qty of average 50
Speed resolution 30 r.p.m.
Frequential resolution 25 Hz 1.5 Hz
OR : 01/09/1980 B : 17/02/2009 INTERNAL USE

APPENDIX 2
MEASUREMENT AND CALCULATION OF THE ACOUSTIC POWER
1. Measurement and calculation of the acoustic power.
We consider that an engine face “radiates” through the face of a

cube aligned on the engine centre.
We take the surface in front of the distribution as a reference:

The distance of the calculation surface of the power “radiated” by
this face in the centre of the engine is therefore:
Its area is :
The power “radiated” by the distribution face will therefore be

obtained by the relation
2. Measurement condition and recommendations
The measurement can be considered as correct up to 8 KHz with a

spacer probe of 12 mm (Δr)
The minimal distance d of the probe to the acoustic sources = d ≥ 5

Δr it means 6 cm for a spacer of 12 mm.
The meshing pitch must be ≤ λ f max /2

Æ it means approximately 8 cm for fm ax = 8 KHz.
The scanning speed recommended is of 10 cm/s (maxi robot

speed).
OR : 01/09/1980 B : 17/02/2009 INTERNAL USE

APPENDIX 3
DEFINITION OF SPRINKLING CRITERIA
We consider the following notations:
• S totale the surface of the section
• U moy the average axial speed on the section
• S i the surface of the cell i of the section

• U i the axial speed in the cell i of the section
1. Uniformity criterion
The uniformity criterion γ is a criterion allowing estimating the dispersion of the profile of the speed in comparison
to the average speed of the gases.
This criterion is calculated separately on each flux.
∑ (U − U average ) ⋅ Si
n
1
γ = 1− i
2
2 ⋅ Stotale ⋅ U average i =1
The uniformity criteria γ to be considered is the worst γ obtained; the uniformity criterion on the average field is to
be avoided.
2. Homogeneity of the speeds

The criteria Mid 10 and Mid 20 allow estimating the axial speed around the average axial speed observed.
« Mid 10 » represents the proportion of the section of the monolith on which the axial speed of the gas is
comprised in the interval [Average axial speed +/- 10%].
n
1
Mid10 = ⋅ ∑ Ai (U i − U max < 10% )
S totale i =1
« Mid 20 » represents the proportion of the section of the monolith on which the axial speed of the gas is
comprised in the interval [Average axial speed +/- 20%].
n
1
Mid 20 = ⋅ ∑ Ai (U i − U max < 20% )
S totale i =1
3. Detection criterion of hot points

Global criterion
The following criterion allows identifying in a global way a risk of hot points:
n
1
⋅ ∑ Ai ⎛⎜ i > 65% ⎞⎟
U
A65 =
S totale i =1 ⎝ U max ⎠
OR : 01/09/1980 B : 17/02/2009 INTERNAL USE

Local criterion (hotspot index)

This criterion, complementary to the global criterion, gives information on the most critical hot point.
This criterion compares the maximal speed of the gases to the average speed of the gases:
U max
Hotspot index = n
1
⋅ ∑ U i ⋅ Ai
S totale i =1
4. Detection criterion of the non active zones

Global criterion
This criterion allows identifying the catalyst zones that will be solicited to a lesser extend (dead zones).
n
1
⋅ ∑ Ai ⎛⎜ i > 35% ⎞⎟
U
A35 =
S totale i =1 ⎝ U max ⎠
Local criterion (back-flow coefficient)

This local criterion gives the indications on the zone that is the least solicited by gases:
U min
Backflow index = n
1
⋅ ∑ U i ⋅ Ai
S totale i =1
5. Criterion of the tangential speed

This criterion allows estimating the erosion risks of the FRT face of the catalyst and of the mat and depends on the
substrates used.
OR : 01/09/1980 B : 17/02/2009 INTERNAL USE

APPENDIX 4
ENDURANCE PROCESS SHEET (CYCLE HB1)
The validation of exhaust line is performed on endurance bench, in compliance with HB1 cycle. The endurance
process sheet is described below, it lasts for a minimum of 200 hours.
Principle sketch of the endurance bench :
Endurance process sheet :

* Excitation of the jacks: 1st flexion Eigen frequency:
• Amplitude 0,5 mm for suspending units on cradles,
• Amplitude 1,5 mm for the other suspending units.
* GMP tilting :
β°
α°
2 Sec
Values of the tilting angle: to be defined in the Project TS.

Engine running :
• h1 hours, engine stabilized to critical speed 1 (N1), to reproduce 2.107 cycles of the corresponding
mode,
• h2 hours, engine stabilized to critical speed 2 (N2), to reproduce 2.107 cycles of the corresponding
mode,,
• …
• 200 - (h1 + h2) hours of speed increase/decrease if required to complete the process sheets.
2 *10 7
N × 1.5 h=
X = 3600 * X
60
OR : 01/09/1980 B : 17/02/2009 INTERNAL USE

APPENDIX 5
LIST OF THE EXHAUST LINE « ER » (ER LE)
Gravity of the
ERC to which
ER N° Wording
contribute the
ER LE
ER LE 01 Loss of constituent of exhaust line. ER 4
ER LE 02 Leak localized on hot section and/or cold section – out of specification. ER 4
ER LE 03 Non follow-up of emission control specifications / Emission of harmful particles. ER 3
ER LE 04 Important and fast obturation of exhaust line. ER 4
ER LE 05 Suspicious smells given off by the exhaust line. ER 3
ER LE 06 Noises/ Vibrations generated by exhaust line. ER 3
ER LE 07 Non follow-up of acoustic specifications. ER 3
ER LE 08 Slow degradation of the counter-pressure. ER 2
ER LE 09 Partial obturation of the exhaust line. ER 3
ER LE 10 Non follow-up of the behaviour criteria of exhaust line to RR shock. ER 4
ER LE 11 Injury risk by physical contact with moulding or with the exhaust rod. ER 4
OR : 01/09/1980 B : 17/02/2009 INTERNAL USE

STN - GMP Powertrain/Carbody Adaptation Interface Assembled Exhaust Line

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PSA PEUGEOT - CITROËN

Normative Technical Specification

STN (Normative technical Specification) – GMP (POWERTRAIN)

Writer Checking person Assenting person

Caroline GASQ Xavier PRADERE Gautier DEKERLE

Date Signature Date Signature Date Signature

12/02/2009 12/02/2009 12/02/2009

OR : 01/09/1980 B : 17/02/2009 INTERNAL USE

Index Date Type of modification

OR 01/09/1980 CREATION OF THE NORM

A 04/11/1997 REWORKED IN “IDEM”

COMPLETE REVISION OF THE NORM (SUPERSEDES THE STE

DRD/DCTC/IACT/TRM//A2RM Xavier PRADERE, Gildas MIOSSEC

OR : 01/09/1980 B : 17/02/2009 INTERNAL USE

OR : 01/09/1980 B : 17/02/2009 INTERNAL USE

POWER TRAIN /CARBODY INTERFACE

FC1 Constraint function 1 To follow / to resist the environment.

Life situation : Transport

OR : 01/09/1980 B : 17/02/2009 INTERNAL USE

Life situation : Storage and handling

FC13 Constraint function 13 To adapt to the operator / to resist the operator,

Situation de vie : Montage

FC14 Constraint function 14 To adapt / to resist the operator

Life situation : Aftersales / maintenance

FC15 Constraint function 15 To adapt to the operator.

Life situation : End of life / recycling

FC16 Constraint function 16 To adapt to disassembler, to extraction tools to valorization.

2.2.GENERAL DESCRIPTION OF THE SYSTEM

OR : 01/09/1980 B : 17/02/2009 INTERNAL USE

A12 5510 VHU – Vehicle aptitude to emission control.

A31 2200 Technical drawing – welding representation.

A31 2205 Technical drawing – nomenclature of welding processes.

A33 3510 Help to tolerance of the elementary functions.

B11 3110 Iso metric threading for general uses.

B12 2819 Tube end-pieces for fuel systems: « petrol – diesel »

B18 3515 Brazing and braze welding – Definition of assemblies.

B20 0110 Supplies of products – general prescriptions.

B20 0200 VHU – Prescriptions for recycling purposes.

B21 7120 Environmental specifications of electric and electronic equipments – mechanical

B22 3130 Aftersales clamp Norm.

B22 3210 Assembled catalyst– Assembled FAP (particulate filter)

OR : 01/09/1980 B : 17/02/2009 INTERNAL USE

B22 3215 Catalytic elements of the treatment of exhaust gases.

B22 3240 STN concerning Exhaust suspending systems..

B22 3241 Exhaust Line Material Norm

B22 3250 STN concerning Exhaust flexible

B32 3130 Diesel FAP – visual controls.

B32 3140 Measurement norm of the BBE (Exhaust Mouth Noise).

B32 3200 Test procedure of the characterization of the removal of condensates.

D15 5279 Heat shields – Thermal efficiency.

D15 5521 Measurement of thermal conductivity of materials.

D15 5522 Measurement of thermal emissivity of materials.

D45 1333 Inner materials of car interior – horizontal combustibility.

D45 5038 Sound proofing materials / acoustic insulation.

D45 5254 Materials submitted to heat source - combustion by radiation.

D45 5430 Acoustic absorption factor – measurement with impedance tube.

OR : 01/09/1980 B : 17/02/2009 INTERNAL USE

AGCC_TRM07_0505 Functional analysis of exhaust line.

DTAT/DVHL/PHV/ACV/EPA/99648/PRUJ Evaluation chart of the exhaust specialist evaluation protocol (21-12-

CGMP/CMOD 020.00 Book of specifications regrouping the technical characteristics of the

DITV_ATAT07_0010 APOQUA sheet« Exhaust line ».

DITV_ATAT07_0168 APOQUA sheet« Connection of FAP pressure delta rigid pipes ».

DITV_ATAT07_0224 APOQUA sheet« Front tube reinforcement T square ».