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SPECIFICATION FOR TESTING GAS DISCHARGE LIGHT SOURCE SUBSYSTEM

2007-10-08
CURRENT
USCAR27
This specification is a general level subsystem light source specification that establishes test requirements of a Gas Discharge Light Source (GDLS) subsystem for use on passenger vehicles. The completed test data to this test specification is intended to be provided to the OEM by the Tier one lamp set maker as part of the lamp assembly PPAP. Re-testing shall be required if any portion of the approved GDLS experiences a design, manufacturing or component change. This document shall be applied to systems that meet the requirements for design, performance and validation established by government standards. The subsystem is defined as the ballast, igniter and light source and shall be tested as a subsystem and considered one test sample for the entire test sequence. A failure of any component in the test sample shall constitute a failure of the entire sample. Substitution or replacement of only the light source shall be allowed during testing.
Standard

PERFORMANCE SPECIFICATION FOR AUTOMOTIVE UNIVERSAL SERIAL BUS (USB) CONNECTION SYSTEM

2006-11-10
CURRENT
USCAR30
Procedures included within this specification are intended to cover performance testing at all phases of development, production, and field analysis of any USB cable assemblies and associated connections that constitute the electrical connection systems between the consumer peripheral interface and the USB computer source in road vehicle applications. These procedures are only applicable to the USB connector and the cable. Unless otherwise specified, all of the tests listed in this specification are for both consumer and nonconsumer interface connectors.
Standard

STANDARD FOR IN-TANK ELECTRIC FUEL PUMPS

1999-08-15
CURRENT
USCAR13
This standard covers the operational characteristics, environment, durability procedures, and test procedures for in-tank electric fuel pumps for automotive gasoline applications. Specific performance and test criteria used in conjunction with this procedure are specified on the pump drawing. Particular sections of this document may be required for all applications. This standard 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.
Standard

Specification for Testing Automotive Halogen Light Sources

2006-01-01
CURRENT
USCAR14-2
The procedures contained in this specification cover the laboratory testing of replaceable halogen incandescent bulbs for use in automotive road illumination. The following tests are intended to be run under the following conditions. New bulb design Design or process change made to an existing bulb, which could affect the outcome of the test The completion of one calendar year, accept as noted in the following Test Schedule Table. Test Title Yearly Physical Dimensions X Mean Spherical Candela (MSCD) X External Visual Examination X Color X Leak/Sealability Through Terminals and Seals X Deflection X Fluid Compatibility Terminal Retention X Resonant Frequencies Aged Resonant Frequency Salt Spray Outgassing Temperatures Requirement Laboratory Life at 14.0 VDC X Luminous Intensity Maintenance X Vibration Durability Shock Aged Vibration Durability Terminal Requirements DRL (SAE J2087)
Standard

HIGH VOLTAGE CONNECTOR PERFORMANCE SUPPLEMENT TO SAE/USCAR-2

2008-08-27
CURRENT
USCAR37
Procedures included within this specification supplement are, when used in conjunction with SAE/USCAR 2, intended to cover performance testing at all phases of development, production, and field analysis of electrical terminals, connectors, and components that constitute the electrical connection systems in high voltage (60~600V) road vehicle applications. These procedures are applicable to terminals used for In-Line, Header, and Device Connector systems with and without Shorting Bars. This supplement applies to both sealed and unsealed connection systems.
Standard

Performance Specification for Automotive Electrical Connector Systems

2013-02-01
CURRENT
USCAR2-6
Procedures included within this specification are intended to cover performance testing at all phases of development, production, and field analysis of electrical terminals, connectors, and components that constitute the electrical connection systems in low voltage (0 – 20 VDC) road vehicle applications. These procedures are only applicable to terminals used for In-Line, Header, and Device Connector systems. They are not applicable to Edge Board connector systems, twist lock connector systems, > 20 VAC or DC, or to eyelet-type terminals. No electrical connector, terminal, or related component may be represented as having met USCAR/EWCAP specifications unless conformance to all applicable requirements of this specification have been verified and documented. All required verification and documentation must be done by the supplier of the part or parts.
Standard

Performance Specification for Automotive Electrical Connector Systems

2007-10-08
HISTORICAL
USCAR2-5
Procedures included within this specification are intended to cover performance testing at all phases of development, production, and field analysis of electrical terminals, connectors, and components that constitute the electrical connection systems in low voltage (0 - 20 VDC) road vehicle applications. These procedures are only applicable to terminals used for In-Line, Header, and Device Connector systems with and without Shorting Bars. They are not applicable to Edge Board connector systems, twist lock connector systems, > 20 VAC or DC, or to eyelet type terminals. Note: Some tests detailed in this document such as connector environmental or terminal electrical may be applicable to twist lock systems. For twist lock connector system ergonomic requirements refer to USCAR 25.
Standard

Performance Specification for Automotive Electrical Connector Systems

2004-05-25
HISTORICAL
USCAR2-4
Procedures included within this specification are intended to cover performance testing at all phases of development, production, and field analysis of electrical terminals, connectors, and components that constitute the electrical connection systems in low voltage (0 - 20 VDC) road vehicle applications. These procedures are only applicable to terminals used for In-Line, Header, and Device Connector systems with and without Shorting Bars. They are not applicable to Edge Board connector systems, > 20 VAC or DC, or to eyelet type terminals. IMPORTANT NOTICE: In any intended vehicle application, if the products covered by this specification are, or may be, subjected to conditions beyond those described in this document, they must pass special tests simulating the actual conditions to be encountered before they can be considered acceptable for actual vehicle application.
Standard

Performance Standard for Automotive Electrical Connection Systems

2001-04-01
HISTORICAL
USCAR2
Procedures included within this specification are intended to cover performance testing at all phases of development, production, and field analysis of electrical terminals, connectors, and components that constitute the electrical connection systems in low voltage (0 - 20 VDC) road vehicle applications. These procedures are only applicable to terminals used for In-Line, Header, and Device connector systems. They are not applicable to Edge Board connector systems, > 20 VAC or DC, or to eyelet type terminals.
Standard

LEAD-FREE SOLDER VALIDATION TEST PLAN

2011-04-01
HISTORICAL
USCAR40
This guideline is applicable to existing lead solder production products that will change to lead-free solder processes to meet the ELV Directive 2000/53/EC Annex II, exemption 8B requirements. This guideline is applicable to similar products used by multiple OEM's that have the same manufacturing processes / equipment. The intent is to streamline the supplier’s environmental testing via common qualification to reduce timing, quantities, and costs.
Standard

Lead-Free Solder Validation Test Plan

2015-04-22
CURRENT
USCAR40-1
This guideline is applicable to existing lead solder production products that will change to lead-free solder processes to meet the ELV Directive 2000/53/EC Annex II, exemption 8B requirements. This guideline is applicable to similar products used by multiple OEM's that have the same manufacturing processes / equipment. The intent is to streamline the supplier’s environmental testing via common qualification to reduce timing, quantities, and costs.
Standard

STANDARD FOR D.C. BRUSH MOTOR – HVAC BLOWERS

1999-02-01
CURRENT
USCAR6
This standard sets forth the performance and durability requirements for 12-volt, D.C. brush-type electric motors used for automobile Heating, Ventilation, and Air Conditioning (HVAC) blowers and outlines Production Validation and Continuing Conformance testing.
Standard

SPECIFICATION FOR TESTING AUTOMOTIVE LED MODULES

2013-02-19
CURRENT
USCAR33
This specification is a general level subsystem light source specification that establishes test requirements of Light Emitting Diode (LED) components and modules for use in automotive lighting systems. The completed test data to this test specification is intended to be provided to the OEM by the Tier I lamp set maker as part of the lamp assembly PPAP. Re-testing shall be required if any portion of the approved LED modules experiences a design, manufacturing or component change. This document shall be applied to systems that meet the requirements for design, performance and validation established by government standards. The LED module is defined as the LED devices and any electronics required to properly energize the LEDs using vehicle electrical power system along with any associated electrical wiring, connectors and thermal management system. Samples shall be tested as a subsystem and considered one test sample for the entire test sequence.
Standard

SPECIFICATION FOR TESTING AUTOMOTIVE LIGHT BULB SOCKETS

2010-01-15
CURRENT
USCAR15-3
This specification establishes the requirements and test procedures for automotive miniature bulb retention devices, including wedge base sockets with integral connector, direct wire wedge base sockets, circuit plate assemblies, and associated interfaces. Tests shall follow the sequence shown in the flow charts in Appendix E whenever the following occurs: New design Design, material or process change made to an existing device, which could affect the outcome of the test. The test sequence shown in Appendix F shall be run annually. (NOTE: Production process control data collected at a shorter interval per an approved control plan, may be substituted if approved by customer’s responsible engineer and purchasing representative.)
Standard

Specification for Testing Automotive Miniature Bulb Socket/Circuit Plate Assemblies

2004-01-30
HISTORICAL
USCAR15
This specification establishes the requirements and test procedures for automotive miniature bulb retention devices, including wedge base sockets with integral connector, direct wire, widge base sockets, circuit plate assemblies, and associated interfaces. Tests shall follow the sequence shown in the flow charts in Appendix E whenever the following occurs: new design; and design, material or process change made to an existing device, which could affect the outcome of the test.
Standard

Specification for Testing Automotive Miniature Bulb Socket/Circuit Plate Assemblies

2004-12-10
HISTORICAL
USCAR15-1
This specification establishes the requirements and test procedures for automotive miniature bulb retention devices, including wedge base sockets with integral connector, direct wire wedge base sockets, circuit plate assemblies, and associated interfaces. Tests shall follow the sequence shown in the flow charts in Appendix E whenever the following occurs: New design Design, material or process change made to an existing device, which could affect the outcome of the test. The following test sequences shall be run annually: Production process control data collected at a shorter interval per an approved control plan, may be substituted if approved by customer's responsible engineer and purchasing representative. - Test Sequence #2 (Run only the tests listed below, in the following order.) o Bulb Insertion/Removal Force o Voltage Drop o Vibration o Bulb Insertion/Removal Force o Bulb Wobble - Test Sequence #8 - Test Sequence #9 - Test Sequence #10
Standard

Test Procedure for Electrical Ground Attachments

2003-09-18
CURRENT
USCAR26
This test procedure is intended to evaluate and/or validate electrical ground schemes for use on the body or chassis. There are two classes based on the expected environmental conditions. Exposed Grounds can be located anywhere in the vehicle (except on the powertrain) and is the class for which most schemes should be tested. Unexposed Grounds can only be used in the passenger compartment or trunk and as such are special cases. This procedure as written is not intended for testing powertrain grounds where high temperatures and vibration levels may be encountered. These situations may require modifications to this procedure and are left to the Responsible Engineer to determine. This specification does not specifically address validation of terminal to wire electrical crimps. Crimps are tested to SAE/USCAR-21
Standard

Performance Specification for Automotive Wire Harness Retainer Clips

2017-05-10
CURRENT
USCAR44
This specification describes a method and acceptance criteria for testing automotive wire harness retainer clips. Retainer clips are plastic parts that hold a wire harness or electrical connector in a specific position. Typical plastic retainers work by having a set of "branches" that can be inserted into a hole sized to be easy to install but provide acceptable retention. This specification tests retainer clips for mechanical retention when exposed to the mechanical and environmental stresses typically found in automotive applications over a 15-year service life. This specification has several test options to allow the test to match to the expected service conditions. The variability of applications typically arises a) from different ambient temperatures near the clip, different proximity to automotive fluids, different exposure to standing water or water spray and different thicknesses of the holes that the clip is inserted into.
Standard

Field Correlated Life Test Supplement to SAE/Uscar-2

2001-12-01
HISTORICAL
USCAR20
This life test for underhood/passenger/trunk connector systems may be used in place of Section 5.8.6 (Connector System Electrical Test Flow Chart) of SAE/USCAR-2. All other requirements of SAE/USCAR-2 remain applicable even when this test is used. Refer to SAE/USCAR-2 and Connector/Terminal Supplier for appropriate power rating and current cycle Testing.
Standard

FIELD CORRELATED LIFE TEST SUPPLEMENT TO SAE/USCAR-2

2004-06-23
CURRENT
USCAR20-1
This life test for underhood/passenger/trunk connector systems may be used in place of Section 5.9.6, Connection System Electrical Table of SAE/USCAR-2. All other requirements of SAE/USCAR-2 remain applicable even when this test is used. Refer to SAE/USCAR-2 and Connector/Terminal Supplier for appropriate power rating and current cycle Testing.
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