WORLDWIDE

ENGINEERING
STANDARDS
Test Procedure
Materials
GMW16037


Test Method to Quantify Cleanliness of Powertrain Components


Copyright 2009 General Motors Corporation All Rights Reserved
July 2009
Originating Department: North American Engineering Standards
Page 1 of 4

1 Scope
Note: Nothing in this standard supersedes
applicable laws and regulations.
Note: In the event of conflict between the English
and domestic language, the English language shall
take precedence.
1.1 Purpose. This document outlines a method for
determining the weight (and size, if specified) of
foreign material (residual dirt) retained in or on any
component after final washing and just prior to
engine or transmission assembly.
1.2 Foreword. This method may be used to
quantify foreign material present in components,
sub-assemblies and assemblies; and may be used
after pre-machining operations prior to shipment to
the final machining location.
1.3 Applicability. The method involves washing
engine and transmission components deemed
necessary with a specified wash fluid, collecting
the rinse wash fluid, filtering solid materials from it
and determining the weight (and size, if specified)
of solids present.
2 References
Note: Only the latest approved standards are
applicable unless otherwise specified.
2.1 External Standards/Specifications.
None
2.2 GM Standards/Specifications.
None
3 Resources
3.1 Facilities. While no specific facility
requirements are defined herein, it is preferred that
the test procedure is carried out in an enclosed
room or laboratory separate from the plant
environment. This will protect the equipment and
minimize the possibility of introducing foreign
material to the components.
3.2 Equipment. A list of equipment and materials
which may be necessary and useful in evaluating
components for sediment levels is shown in
Appendix A.
3.2.1 Nylon filter membranes, 10 micron
(maximum), shall be used except where local test
procedures require the use of 44 micron
(maximum) and 10 micron (maximum) nylon filters
in series.
3.2.2 Paper filter elements may also be used at
those locations where this procedure is used to
monitor grease content of plant wash system
coolant.
3.2.3 A 5 micron filter (or equivalent) shall be used
for filtering wash fluid that is recycled to a
reservoir.
3.2.4 Acceptable wash fluids are listed in
Appendix A.
3.3 Test Vehicle/Test Piece. Components,
subassemblies and assemblies shall be obtained
from the production process at the point of their
inclusion into the assembly (if washed at the plant)
or as shipped from a supplier (if shipped directly to
the assembly line). Components may also be
obtained from the production line at the final
washer exit in order to monitor and control washer
effectiveness.
3.4 Test Time. Not applicable.
3.5 Test Required Information. Not applicable.
3.6 Personnel/Skills. Per local requirements.
4 Procedure
4.1 Preparation. Prior to sediment evaluation, test
samples must not be rinsed, wiped, or cleaned in
any way other than what is typical for the
production process. Lot numbers or other pertinent
shipment information should be recorded for
samples to be tested. Protect samples from
airborne debris during transport to the sediment
test equipment and avoid rough handling.
4.2 Conditions.
4.2.1 Environmental Conditions.
4.2.1.1 When evaluating transmission assemblies,
torque converters shall be checked separately,
exterior surfaces shall not be rinsed as part of the
procedure. Local procedures shall dictate whether
or not to remove valves from bores.
GMW16037 GM WORLDWIDE ENGINEERING STANDARDS

Copyright 2009 General Motors Corporation All Rights Reserved
Page 2 of 4 July 2009

4.2.1.2 Test frequency and sample size should be
determined by local plant procedures. Sample size
must be sufficient to allow for statistical control of
production processes and establishment of control
limits. Reduced sampling is possible based on
statistical data showing process capability.
4.2.1.3 Reintroduction of test samples into the
production process must occur before the final
wash.
4.2.2 Test Conditions. Deviations from the
requirements of this standard shall have been
agreed upon. Such requirements shall be specified
on component drawings, test certificates, reports,
etc.
4.3 Instructions.
4.3.1 Prepare Test Equipment and Materials.
4.3.1.1 Oven dry the required number of filters for
30 to 35 minutes at 50 to 55C. Allow filters to cool
for 15 to 20 minutes in a desiccator prior to use.
Times and temperatures may be adjusted to meet
current plant practices and production schedules.
4.3.1.2 Ascertain the weight of filters to four
decimal places by means of an analytical balance
and record the value in milligrams (mg).
4.3.1.3 Rinse collection sink/tray before and after
each test with a sufficient quantity of wash fluid to
purge the system of any foreign material. Collect
the fluid in a beaker and visually examine the
sediment for unusual particles or amounts.
Equipment and materials should be protected from
environmental contamination when not in use.
4.3.1.4 Monthly wash fluid cleanliness check (for
sites that recycle fluid). Collect at least 1 L of wash
fluid in a clean beaker and note the volume used.
Filter the fluid with vacuum assist through a
pre-dried and pre-weighed 10 micron (maximum)
filter. Remove filter from the funnel and expose to
drying cycle (4.3.5.1). Determine amount of
residue collected by subtracting original filter
weight from weight of filter plus (+) residue. If
amount of residue exceeds 0.50 mg/L, wash fluid
must be replaced with new. Wash fluid must be
replaced annually regardless of test results.
4.3.2 Measurement of Test Sample. Prepare the
required number of filters per 4.3.1.1 and 4.3.1.2.
4.3.2.1 Place component to be evaluated in the
clean collection tray/washing cabinet and rinse
surfaces of interest with wash fluid. Rinse device
should be a handheld spray gun with 70 kPa
(0.7 bar) minimum nozzle pressure. Appendix A
lists equipment part numbers currently in use at
some plants. Other equipment may be acceptable
as long as a nozzle pressure of 70 kPa (0.7 bar) is
maintained throughout the rinsing operation. Effort
should be made to ensure that all foreign material
and loose debris is removed from the component
and the collection tray/washing cabinet by flushing
the tray with excess fluid and wiping it with a
non-metallic squeegee. Collect all sediment from
the tray in a beaker and mark the beaker for
identification.
4.3.2.2 Engine components with internal oil and/or
coolant passages (i.e., engine blocks) shall be
rinsed according to work instructions such that
sediment levels are established for each type of
passage. Water passages must be rinsed first.
4.3.2.2.1 To ensure all sediment is removed from
internal passageways of components such as
cylinder blocks and heads, pressurized air shall be
used. Pressure shall be 210 kPa (2.1 bar) and
orifice size shall be 2.0 mm (0.080 in).
4.3.2.3 Burrs resulting from machining operations,
casting processes, etc., which remain firmly
attached after rinsing and air blowout shall be
noted but shall not be included in the total
sediment weight. Appropriate equipment (mirrors,
lights, bore scopes) shall be used to inspect
internal passageways for loose chips not removed
by the rinse or air blowout. In such cases, proper
actions shall be taken to improve the cleanliness
process.
4.3.2.4 Any plant specific procedures regarding
rinsing sequence, burr reporting, etc., must be the
same site-to-site for similar components.
4.3.3 Place dried and weighed filters in the filtration
funnel.
4.3.4 Pour the collected wash fluid through the
filter plus (+) funnel using a vacuum assist. Rinse
the collection chamber/beaker thoroughly and
transfer the wash fluid to the funnel for filtering.
4.3.5 Carefully remove the filter from funnel and
expose to the following drying cycle.
4.3.5.1 Filters must be dried 30 to 35 minutes at 50
to 55 C. Times and temperatures may be adjusted
to meet current plant practices and production
schedules as long as there is evidence that filter
weight has stabilized for that cycle.
4.3.6 After drying, the filters shall be placed in a
desiccator to cool for 15 to 20 minutes. Debris
samples must be properly identified.
4.3.7 Weigh dried filter plus (+) sediment and
record weight.
4.3.8 Return washed parts to departments from
which they were taken unless surface condition
has been degraded or component has been
disassembled during sediment testing.
Transmission seals and clutch plates must be
scrapped.
GM WORLDWIDE ENGINEERING STANDARDS GMW16037

Copyright 2009 General Motors Corporation All Rights Reserved
July 2009 Page 3 of 4

5 Data
5.1 Calculations. Determine total sediment weight
by subtracting filter weight (4.3.1.2) from weight of
filter plus (+) sediment (4.3.7). When two filters are
used (3.2.1), weights should be reported for each
filter size.
5.2 Interpretation of Results. If something
unusual is observed on the contaminated filters
(high weights, large particles, etc.), examination of
the filters under a light microscope is
recommended. Should part specifications include a
maximum allowable particle size, measure the
sediment particles using a calibrated grid. Note the
size (longest dimension in microns) of the largest
particle and record on datasheet.
5.3 Test Documentation.
5.3.1 Transfer engine data to Statistical Process
Control (SPC) charts and plot the data, where
applicable. Transmission data should be recorded
on suitable quality charts.
5.3.2 Notify Production Department Supervisor of
any out-of-control points or otherwise undesirable
conditions.
6 Safety
This standard may involve hazardous materials,
operations, and equipment. This standard does not
propose to address all the safety problems
associated with its use. It is the responsibility of the
user of this standard to establish appropriate safety
and health practices and determine the
applicability of regulatory limitations prior to use.
7 Notes
7.1 Glossary. Not applicable.
7.2 Acronyms, Abbreviations, and Symbols.
SPC Statistical Process Control
8 Coding System
This standard shall be referenced in other
documents, drawings, etc., as follows:
Test to GMW16037
9 Release and Revisions
9.1 Release. This standard originated in August
2008, replacing GMN6752. It was first approved by
GM Powertrain in June 2009. It was first published
in July 2009.
GMW16037 GM WORLDWIDE ENGINEERING STANDARDS

Copyright 2009 General Motors Corporation All Rights Reserved
Page 4 of 4 July 2009

Appendix A
A1 Laboratory Equipment
Some specific equipment that has proven useful in
testing is listed below. Other fluids and other
brands/models of equipment may be used as long
as the test procedure is not compromised.
A1.1 Drying oven with thermometer.
A1.2 Desiccator.
A1.3 Magnet.
A1.4 Analytical balance.
A1.5 Brushes.
A1.6 Vacuum pump, manifold, and trap.
A1.7 Squeegee.
A1.8 Drum pump.
A1.9 Stainless rinse collection sink (washable,
drainable).
A1.10 Side-arm flask, filter funnel, beakers, wash
bottles.
A1.11 Sediment wash cart.
A1.12 Air line and hose.
A1.13 Nalgene vacuum manifold Catalog No.
345-0001.
A1.14 Jabsco drum pump Model #16520-3350
(to be used with air pressure of 3500 kPa (50 psi)).
A1.15 Spraying Systems Co. GunJet Model #31-
39430 (source: Industrial Hose and Hydraulics,
Ltd., 905-688-1243).
A1.16 Vacuum pump Gast 0211 Series, oiless
(pump to be set at 381 mm (15 in) of Hg); or Piab,
Inc.
A1.17 Wash Fluids TechSolv 331 or 336;
Chemcentral SC142; Betz Permatreat 435 (4%
solution); Citrikleen 3SR166 (1:10 in water);
Odorless mineral spirits (Trans only); Naptha.
A1.18 Nylon filter membranes Great Lakes
Filters Part Number(as) 325-041-8000 (engines)
and
321-041-8000 (transmissions). Phone No.1-800-
521-8565.
A1.19 Stereomicroscope.
A2 Transmission Solvent Handling
System
A2.1 Sanborn paint tank and sprayer (#011-0798
(pressurized container).
A2.2 Whatman Gamma - 12 high performance
inline filter unit.
A2.3 Whatman filter tube 12-10 (VWR #28205-
349).
A2.4 Whatman filter tube 12-80 (VWR #28205-
280).
A2.5 Millipore 25 mm Filter-Jet solvent dispenser.
A3 Transmission Vacuum Filtration
System
A3.1 Kewaunee Scientific 1.22 m (4 ft) airflow
supreme hood.
A3.2 Gelman Sciences parabolic filter 4230.
A3.3 Funnel with Essig fitting.
A3.4 Gelman Sciences support screen 4235,
Serial No. 14770-00.
A3.5 Bottle, 18.9 L (5 gal).
A3.6 Hazardous waste collection drum.