CS.

00034
Installation dimension of coolant hoses and
CHARACTERISTIC STANDARD
fittings
Design directives
Page: 1/18

Date: 08-NOV-2022

HARMONIZED DOCUMENT

Change level Date Description of change

- 21-JUL-2014 Initial release
A 03-JUN-2015 Added interference 0.8 for NAFTA market
B 08-MAR-2016 Update table of fitting, new sketch and reference of table and spec.
C 31-JUL-20 Updated references for Tab. Clamp, and added tolerance on incision.
D 20-APR_2022 Updated Table 3
E 08–NOV-2022 Updated Figure 15

For APAC, LATAM and Maserati contacts, please consult SD.00130

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CONFIDENTIAL
THIS DOCUMENT MUST NOT BE REPRODUCED OR CIRCULATED TO THE THIRD PARTIES WITHOUT PRIOR WRITTEN CONSENT BY FCA ITALY S.P.A. IN CASE OF
DISPUTE THE ONLY VALID REFERENCE IS THE ITALIAN EDITION.
IF THE ITALIAN EDITION IS NOT AVAILABLE OR NOT UPDATED, THE ENGLISH EDITION IS THE VALID REFERENCE
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INSTALLATION DIMENSION OF COOLANT HOSES AND FITTINGS.

DESIGN DIRECTIVES

TABLE OF CONTENTS

1.1 Purpose.................................................................................................................................... 3
1.2 Coverage of this Standard ........................................................................................................ 3
1.3 Limitations on Usage ................................................................................................................ 3
2 REFERENCES ......................................................................................................................... 4
3 DEFINITIONS/ABBREVIATIONS/ACRONYMS/SYMBOLS ....................................................... 4
4 REGULATED SUBSTANCES & RECYCLABILITY.................................................................... 4
5 REQUIREMENTS/CONDITIONS .............................................................................................. 5
5.1 Connections dimensions and tolerances between fittings and hoses/coupling ........................... 5
5.2 Configuration and dimension of bead ........................................................................................ 8
5.2.1 Solution A – Metallic Pipe only ........................................................................................... 8
5.2.2 Solution B .......................................................................................................................... 9
5.2.3 Solution C ........................................................................................................................ 10
5.3 Hose/coupling depth of engagement on fitting ......................................................................... 11
5.3.1 Locating notch/arrow............................................................................................................... 12
5.4 Test equipment....................................................................................................................... 13
5.5 Prescriptions and allowed solutions for coolant hoses. ............................................................ 14
5.5.1 Cut at each end of the hose must be with 2 mm perpendicular to the centerline of the hose .... 14
5.5.2 Except without notch/arrow solution, is allowed a smooth 5x30° for effort force performance
according requirement of harmonized functional specification. ................................................ 14
5.6 Hose clamp and position prescriptions. ................................................................................... 15
5.6.1 Circumferential band (Examples of locating circumferential band for clamp installation............ 15
5.6.2 Hose clamp types ................................................................................................................... 17
6 APPROVED SOURCE LIST ................................................................................................... 18
Annex A 18
End of Annex A ..................................................................................................................................... 18

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1 GENERAL
1.1 Purpose
This Standard provides general design directives for specifying installation dimensions of fittings and
hoses used on motor vehicle engine cooling and occupant compartment heating systems.
Also provided are design constraints for parts which interact in coupling a flexible connecting member
(hose) with a rigid element (radiator, water pump, heater, etc.). As a result, the installation fits shall be
part of a single design project to include said coupled items thus affording the necessary uniformity and
standardization that will prevent hose/fitting assemblies having different diameters at respective ends.

1.2 Coverage of this Standard

Requirements covered herein are applicable to end fittings either of metal - cut from tube, cast or
machined - or plastic material.

1.3 Limitations on Usage

- Longitudinal slits are not allowed.
- Die/mold burr/flash or parting line over 0.1 mm are not allowed (see Fig. 1)
- Max. die offset allowed is 0.1 mm (see Fig. 1)
- In cases where offset and burr/flash errors overlap specified tolerance is 0.1 mm max. (see Fig. 1)

Figure 1: Fitting cross section example

 Alternative with burr only and no die offset.

Alternative with die offset only.
Alternative with die offset + burr.
Is highly recommended to keep the same diameter for both ends of fitting hose.

No surface flaws allowed on the hose/coupling inner surface within matching length l1 such as would be
prejudicial to required sealing under normal service conditions.

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2 REFERENCES
Table 1: References
Document Number Document Title
Quality of supplies 1/20 06/01/2007 Forbidden/limited substances or
9.01108
substances to be monitored (Annex CK)
PF.90080 Coolant hoses and plumbing assemblies.
SP.10035 Tightening clamps with worm screw Nemo Bes type
SP.10034 Double ratchet lock elastic clamp (VISA E)
SP.10027 Snap-coupled elastic clamp for fastening hoses (CLIC E)
SP.10028 Snap-on hose band clamp (CLIC R)
SP.10026 Double ratchet clamps (VISA Standard)
SP.10024 Spring clamps
Supplier requirements for vehicle and service parts: material content
CS-9003
reporting, marking, and recyclability

3 DEFINITIONS/ABBREVIATIONS/ACRONYMS/SYMBOLS
Table 2: Definitions/Abbreviations/Acronyms/Symbols
NIST National Institute of Standards and Technology
NDA Nominal diameter Assembly
EMEA Europa, Medio Oriente e Africa Markets
NAFTA North American Free Trade Agreement Markets

4 REGULATED SUBSTANCES & RECYCLABILITY

Products and processes used to manufacture the products listed in this standard must conform to the
employee and consumer health, employee safety, regulated substances, recycling and environmental
reporting requirements, according to 9.01108 for EMEA Plants / CS-9003 for other plants.

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5 REQUIREMENTS/CONDITIONS
5.1 Connections dimensions and tolerances between fittings and hoses/coupling

Figure 2: Connection sketch

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Table 3: Dimensions and tolerances of connections

HOSES/COUPLINGS 6
FITTINGS

LL s2 4 l1
d x f D t
3
Min.
Std. Intermediate min.
Tol. 7 Nom Tol. min.
value range

8
8 ±0.20 24 0.20 31 1.00 3.5 ±0.35 0.30 31
≥ 6 ≤ 14
12 ±0.20 24 0.20 31 1.00 3.5 ±0.35 0.30 31

16 > 14 ≤ 18 ±0.25 24 0.25 31 1.50 3.5 ±0.35 0.35 31

20 > 18 ≤ 22.5 ±0.25 27 0.25 34 1.50 3.5 ±0.35 0.35 34

25 ±0.25 27 0.25 34 1.50 4.0 ±0.40 0.35 34

0
> 22.5 ≤ 32.5
30 ±0.25 27 0.25 34 1.50 - 0.60 4.0 ±0.40 0.35 34

35 ±0.30 27 0.30 34 1.50 4.0 ±0.40 0.40 34

> 32.5 ≤ 42.5
40 ±0.30 27 0.30 34 1.50 4.0 ±0.40 0.40 34

45 ±0.30 27 0.30 34 1.50 4.0 ±0.40 0.40 34

> 42.5 ≤ 50
50 ±0.30 27 0.30 34 1.50 4.0 ±0.40 0.40 34

Note: Nominal hose Ø must be chosen by subtracting the nominal interference of the specific field of application from the
chosen d Ø of the filler.
1 The bead shall be on 360°
2 Hose/coupling useful engagement length , subject to total run out and surface roughness tolerance restrictions
3 Hose/coupling and length subject to tolerance restrictions on "D", "t" and "s".
4 Recommended thickness. For any other thickness, tolerances hall be within ± 10%. Far styles A3-0, B3-0 and B4 the
tolerance on thickness, shall be specified by drawing. (In the case of particular geometric configurations, it is possible to
deviate from these values provided agreement between Customer and Supplier with max. deviation of ± 0.5.
5 Surface roughness : Ra = 0.8 to 8m.
6 Dimensional deviations, shown in above table, refer to rubber hoses/couplings with or without reinforcement according to
9.02136/01 or its harmonized spec.
7 For NAFTA market 0,8 is allowed
8 6 mm dimension only for metallic spigot

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Table 3b: Dimensions and tolerances of connections for C and D classes from PF.90080 (*)

FITTINGS HOSES/COUPLINGS

LL
d x f D s2 t l1

Min.
Intermediate min.
Std. value Tol. Nom Tol. min.
range

16 > 14 ≤ 18,5 ±0.25 24 0.25 31 1.50 3.8 ±0.38 0.35 31

25 > 20 ≤ 28.5 ±0.25 27 0.25 34 1.50 4.5 ±0.45 0.35 34

(*) For both tables: Notch references to be updated with next release

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5.2 Configuration and dimension of bead

5.2.1 Solution A – Metallic Pipe only

Figure 3: Sketch

Table 4: Dimensions and tolerances

s R
TYPE d h α°
Nom. Tolerance (± 0,3)
+ 0.10
A ≥ 8 ≤ 14 0.50 0.5 8
0
7 + 0.15
A/1 > 14 ≤ 32,5 0.75 0.75 11
0
+ 0.20
A/2 > 32,5 ≤ 50 1.00 1.3 13
0

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5.2.2 Solution B

Figure 4: Sketch

Table 5: Dimensions and tolerances

s1
d h s R1 R2 R3 β°
min.
TYPE ▲ ■
▲ ■ nom. Tolerance (± 0,3) (± 0,5) ▲ ■
(± 0,5) (± 0,3)
+0.10
B ≥ 8 ≤ 14 2.0 1.25 0.50 1.0 1.6 1.6 0.75 20 15
0
+0.15
B/1 > 14 ≤ 32,5 7 2.5 1.50 0.75 1.2 1.8 1.8 0.75 25 20
0
+0.20
B/2 > 32,5 ≤ 50 3.0 2.50 1.00 1.4 2.0 2.0 1.50 30 25
0
For metal sheet thickness see specifications on drawing.
Applicable to both plastic and metal components.
▲ Values for plastic fittings, including any metal reinforcement bushing.
■ Values for to metal fittings.

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5.2.3 Solution C

Figure 5: Sketch

Table 6: Dimensions and tolerance

s1
d h s R1 R2 R3 R4 K
TYPE min.
Nom. Tol. Nom. Tol. Nom. Tol. (± 0,3) (± 0,3) (± 0,3) (± 0,3) Nom. Tol.

C + 0.20 0
> 18 ≤ 32.5 ±0.3 2.5 ±0.25 0.7 0.7 0.9 0.6 0.5 5.0
- 0.05 - 0.1

C/1 + 0.5 + 0.15 0

> 32,5 ≤ 42,5 7 ±0.3 3.0 1.0 0.7 0.9 0.6 0.5 5.0
0 - 0.10 - 0.1

C/2 + 0.5 + 0.20 0

> 42,5 ≤ 50 ±0.3 3.0 1.0 0.7 0.9 0.6 0.5 5.0
0 0 - 0.1

Applicable to both plastic and metal components.

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5.3 Hose/coupling depth of engagement on fitting

Figure 6: Depth of engagement sketch

Shoulder: Provided the above mandatory requirements are met, any design ensuring correct
positioning of hose/coupling fitting is allowed.

Table 7: Dimensions
d q min
8 ≤14 3.5
>14≤18 3.5
>18≤22.5 3.5
All types
>22.5≤32.5 4.0
>32.5≤42.5 4.0
>42.5≤50 4.0

f = Fitting length to shoulder.

For preformed hoses/couplings which must be installed in a specific position, length “f” shall be increased
by 3 mm to take into account the depth of locating notch (see examples below). In such cases, one of the
two ends shall be marked in indelible paint with the name of the element on which it is installed in order to
prevent reversed coupling.

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5.3.1 Locating notch/arrow

Figure 7: Solution 1 (plant mounting assemblies)

Figure 8: Solution 2 (plant mounting assemblies)

Figure 9: Alternative solution 3 only if not possible to use 1 or 2 for

plant mounting assemblies or for supplier assemblies

◄ For fittings obtained from tube a shoulder ring shall be provided at 180° from locating lug, as shown on drawing
■ In case of preformed hose with constrained assembly position required , independently of solution locating notch, the name of
the part on which it fitted must be indicated on one of the two ends using permanent paint.

The reference notch on hose/coupling may depart from its original position by ±3° and tolerance dimension incision

The notch provided on fitting shall always be in a location visible upon assembly.
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5.4 Test equipment

The dimensional accuracy of end formed tubing shall be verified by trained personnel using the
appropriate inspection equipment, such as a shadow graph, micrometers or calipers. Measurement
instrumentation must be calibrated to a standard traceable to NIST (National Institute of Standards and
Technology) or European Institute for Reference Materials and Measurements ISO/TS 16949 approved.
Instrumentation shall be calibrated immediately following an accidental impact, such as being dropped.
Otherwise, all instrumentation shall be calibrated at a minimum of once annually or at a greater frequency
in order to insure measurement accuracy.

Figure 10: Measurements sketch

Sealing Bead Landing Length (Measurements in 3 locations)

The bead diameter and radii (see 5.2.3 Detail Z) The diameter of the fitting along the landing length
must be measured in four planes at 0º, 45º, 90º shall be measured at three different random
and 135º rotation. The observed dimensions of the distances from the end of the tube. At each
end formed tubes shall fall within the tabulated location, measurements shall be inspected in two
limits specified. Measured data shall be recorded planes: 0 degrees and 90 degrees rotation. The
and kept on file. observed dimensions of the end formed tubes shall
fall within the tabulated limits specified. Measured
data shall be recorded and kept on file.

Measurements taken at 0º, 45º, 90º & 135° Measurements taken at 0º & 90º

Figure 11 : Measurements sketch Figure 12 : Measurements Sketch

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5.5 Prescriptions and allowed solutions for coolant hoses.

5.5.1 Cut at each end of the hose must be with 2 mm perpendicular to the centerline of the hose

Figure 13: Profile tolerance prescription

5.5.2 Except without notch/arrow solution, is allowed a smooth 5x30° for effort force performance
according requirement of harmonized functional specification.

Figure 14 : End of hoses allowed solution

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5.6 Hose clamp and position prescriptions.

To ensure correct hose clamp positioning, ends of hoses/couplings shall be marked using paint or
equivalent means with a locating circumferential band indicating area on which clamp is to be installed.

5.6.1 Circumferential band (Examples of locating circumferential band for clamp installation
The bands shall be marked around the entire circumference of the hose if feasible. If a 360 degree band
is not feasible, then two diametrically opposite arcs of at least 120 degrees must be printed on hose. The
markings must be readily visible from the installed location of the hose.

Hose end without locating notch (≥ 6

mm ≤ 18 mm)

Figure 15 : Dimensions w/o local notch

Hose end with locating notch/arrow

(>18mm)

Figure 16 : Dimensions with local notch (arrow is

alternative solution according 5.3.1)

▰ Clamp positioning width

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Example of correct clamp positioning

Figure 17 : Clamp positioning sketch

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5.6.2 Hose clamp types

5.6.2.1 Standard solution for all Markets and Plants:
Clamp installed on coolant hoses has to be choose between shown in below table

Table 8: Coolant hoses clamps

Type Spec. Prescription details
For plastic filler necks: use only with glass fibres or with metallic
bushing reinforcement

SP.10035
DIMENSIONS:
Possible alternative to SP.10034 or SP.10026 for
different tools accessibility or in case of specific plant request
For plastic filler necks: use only with glass fibres or with metallic
bushing reinforcement

SP.10034
DIMENSIONS:
Use with Ø > 53mm.
Possible use for Ø ≤ 53mm. but suggest use SP.10026
For plastic filler necks: use only with glass fibres or with metallic
bushing reinforcement

SP.10026
DIMENSIONS:
Use with Ø > 25mm. ≤ 53mm.
Possible use for Ø ≤ 25 mm. but suggest use SP.10028 or SP.10027
DIMENSION:
Possible alternative to SP.10026 for
different tools accessibility
SP.10027

Possible use for Ø ≤ 25mm. but

suggest use SP.10028

DIMENSIONS:
SP.10028
Use for Ø ≤ 25mm.

The indicated Ø values in tab.6 are the Nominal of Diameter Assembly values.

NDA = Nominal diameter filler neck + 2 time coolant hose nominal thickness.

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5.6.2.2 Alternative solution possible to use for NAFTA plants only:

Clamp installed on coolant hoses has to be choose between shown in below table

Table 9: Coolant hoses clamps

Type Spec. Prescription details

Possible alternative to substitute standard solution SP.10034 or

SP.10024
SP.10026 or SP.10027 or SP.10028 in case of specific plant request

6 APPROVED SOURCE LIST

Only hose clamps from approved suppliers may be used. See table 1.

Annex A

Bead geometric
construction shape.pptx

End of Annex A

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