GMW14906Feb2012 PDF

WORLDWIDE
ENGINEERING
STANDARDS
General Specification
GMW14906
Lamp Development and Validation Test Procedures

Table of Contents
Section #
Section Name
Section #
Introduction
4.6.1
Dimension
Reference
4.6.2
Aim
2.1
External Standards
4.6.3
Seal Leak Test Pressure (LTP)
2.2
GM Standards/Specification
4.6.4
Light Output
2.3
Additional References
4.6.5
Appearance
Test Preparation and Evaluation
4.6.6
Function
3.1
Resources
3.2
Preparation
3.3
Conditions
3.4
Section Name
4.7
Requirements and Procedures (cont)
Electrical Components and Electronic

Interfaces
4.7.1
Electrical Connectors and Power

Interface
Instructions
4.7.1.1
Electrical Connectors
3.5
Data
4.7.1.2
3.6
Safety
Electrical Wiring and Lamp

Harness Cables
3.7
Documentation
4.7.2
Headlamp Bulb and Connector

Temperature Cycle
Requirements and Procedures
4.7.3
Solenoids
4.1
Development
4.7.4
Bulb and Socket Removal Force
4.2
Highly Accelerated Life Test (HALT)
4.8
Accelerated Corrosion
4.3
Pre-test Requirements
4.9
Weatherability
4.3.1
Dimension
4.10
Internal and External Heat
4.3.2
Aim
4.10.1
Internal Heat
4.3.3
Seal
4.10.2
External Heat
4.3.4
Light Output
4.10.3
4.3.5
Appearance
External Heat Test for Headlamp

Bulb Connector Terminals
4.3.6
Function
4.11
Light Up
4.4
SAE J575e August 1970 Vibration
4.12
Weld Joint and Snap Attach Stress
4.5
Temperature and Vibration
4.13
LED Light Source Requirements
4.5.1
Temperature Cycling
4.13.1
LED Lamp Actuation Cycle
4.5.2
Vibration.
4.13.2
LED Continuous Activation
4.6
Post-Test Requirements
Copyright 2012 General Motors Company All Rights Reserved
February 2012
Originating Department: North American Engineering Standards
Page 1 of 59
GM WORLDWIDE ENGINEERING STANDARDS
GMW14906
Table of Contents continued

Section #
4
Section Name
Requirements and Procedures (cont.)
4.14
Condensation for Lamps with

Oleophobic Membranes
4.15
High Humidity Environments
4.16
High Pressure Water
4.17
Leak Check for Production

Processing Determination
4.18
HID Component Ignition Reliability
4.19
Adaptive Forward Lighting and

Dynamic Headlamp Leveling
System
4.20
Solar Load Test
4.21
Submersion Test
4.22
Free Fall
4.23
Storage
4.24
Thermal Shock
4.25
Headlamp Aim Adjustment Retainer

and Fixed Pivot Pull Force
4.26
Solar Irradiance for Lamps with

Condensing Lenses
Provisions for Shipping
Notes Glossary/Acronyms
Additional Paragraphs
7.1
Restricted and Reportable

Substances for Parts
Coding System
Release and Revisions
Appendix
A
Data Sheets
Appendix
B
Test Setup Photos and Illustrations
February 2012
Page 2 of 59
WORLDWIDE
ENGINEERING
STANDARDS
General Specification
GMW14906
Lamp Development and Validation Test Procedures

1 Introduction
Note: Nothing in this standard supercedes
applicable laws and regulations.
Note: In the event of conflict between the English
and domestic language, the English language shall
take precedence.
1.1 Scope. This document defines the mechanical,
electrical,
and
environmental
performance
requirements, test conditions, and procedures for
lamps and reflective devices used for functional
and durability tests.
1.2 Mission/Theme. This procedure applies to all
original equipment and replacement exterior
lighting devices for passenger cars, Multipurpose
Passenger Vehicles (MPV), and trucks.
1.3 Classification. Not applicable.
2 References
Note: Only the latest approved standards are
applicable unless otherwise specified.
2.1 External Standards/Specifications.
ASTM C150
ASTM E927-10
FMVSS 108
IEC 60068-2-27 Ea
ISO 4892-1/2
ISO 16750-3
ISO 16750-4
ISO/IEC 17025
SAE J564
SAE J575e (AUG 1970)
SAE J577
SAE J1889
SAE J2527
2.2 GM Standards/Specifications.
GMW3059
GMW3172
GMW3191
GMW8287
GMW14264
GMW14444
GMW14528
GMW14570
GMW14571
GMW14572
GMW14650
GMW14651
GMW14668
GMW14669
GMW14729
GMW14872
GMW15272
GMW15308
GMW15626
GMW15760
2.3 Additional References.

GM1829 Analysis Development Validation Plan
and Report
USCAR 15 - Bulb Insertion/Removal Force
3 Test Preparation and Evaluation

3.1 Resources. If not otherwise stated, resources
are indicated in the test methods.
3.1.1 Calibration. The test facilities and equipment
shall be in good working order and shall have a
valid calibration label. Exception to this is if the
information is otherwise preserved in the test
facility records.
3.1.2 Alternatives. Alternative test facilities and
equipment may also be used. However, all
measuring variables as specified in this standard
shall be determined correctly with respect to their
physical definition.
3.1.3 Facilities. Any specific facility requirements
are listed in each individual test procedure. The
test facilities shall be accredited to ISO/IEC 17025
or by the International Laboratory Accreditation
Cooperation.
3.1.4 Equipment. The test equipment needed for
each test is listed in each individual test procedure.
3.1.5 Test Vehicle/Test Piece. The test samples
shall be production intent design and materials for
design validation (DV) or production intent design
and materials manufactured with production
processes (homeline) for product validation (PV).
Any changes to the components or material, e.g.,
design,
fit,
form,
function,
properties,
manufacturing process, and/or location of
manufacture, require revalidation. GM shall
approve validation methods for product/process
changes before the supplier is committed to the
change.
3.1.6 Test Time. The total estimated time for DV
and PV testing is shown below.
Calendar time:
154 days (22 weeks)
Test hours:
3700 hours
Coordination hours:
100 hours
February 2012
Originating Department: North American Engineering Standards
Page 3 of 59

3.1.7 Test Required Information. See individual
procedures.
3.1.8 Personnel/Skills. The test facility shall have
sufficient personnel having the necessary
education, training, technical knowledge, and
experience for performing the required tests.
3.2 Preparation.
3.2.1 Fixtures. Unless otherwise specified, mount
the test sample on a fixture of welded construction
designed to place the test sample in its vehicle
orientation. Photometric measurement fixtures may
be of alternate construction and do not need to
meet the requirements of 4.5.2.4.
3.2.2 Wire Harnesses. All testing that requires a
vehicle interface harness shall have a terminal and
wire inserted into each connector cavity per the
production intent design.
3.2.3 Test Samples. All test samples shall be
design intent and meet all functional and
dimensional pre-test requirements, as defined by
this document. Lamp assembly designs with
secondary components such as cameras, handles,
sensors, washer nozzles, etc., shall have those
secondary components installed in test samples
during test. Reuse of secondary components for
multiple tests is allowed where function of the
secondary part is not critical to lamp testing. The
GM Validation Engineer and GM Designing
Engineer (DE) shall approve any exceptions prior
to the start of testing.
3.3 Conditions. All test conditions shall be
adjusted to specified values and remain within
given () tolerances. Target test values shall not be
adjusted within tolerances unless the target value
cannot be maintained. If such an adjustment is
made, it shall be approved by the applicable GM
engineer prior to the start of any testing.
Unless otherwise specified perform the tests in the
as received condition without any special
preconditioning.
3.3.1 Environmental Conditions. See individual
procedures in Section 4.
3.3.2 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. Such deviations shall be approved by the GM
Validation Engineer and specified on the GM1829
Analysis Development and Validation Plan and
Report and test reports.
Voltage for photometric testing pre-test and
post-test use the voltage specified by the
regulation in the countries where the lamp will be
sold. For lamps sold in both Economic Commission
GMW14906
for Europe (ECE) and SAE International regulated

regions select one test method.
If the vehicle provides a Pulse Width Modulation
(PWM) voltage to the lamp, activate the specified
function at the specified PWM - rms voltage
+0.25 V. In all other tests that require a test voltage
input, use 13.9 V 0.2 V.
3.4 Instructions. See the specific procedures in
Section 4.
3.5 Data. Record on the data sheets in
Appendix A.
3.6 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.
3.7 Documentation. Samples of components or
material released to this standard shall be tested
for conformity with the requirements of this
standard and approved by the responsible GM
department prior to the start of delivery of
production level components or materials. Any
change to the component or material, e.g., design,
function, properties, manufacturing process and/or
location of manufacture requires a new release of
the product. It is the sole responsibility of the
supplier to provide the customer, unsolicited, with
documentation of any change or modification to the
product/process, and to apply for a new release.
If not otherwise agreed to, the entire verification
test shall be repeated and documented by the
supplier prior to start of delivery of the modified or
changed product. In some cases, a shorter test
can be agreed to between the responsible GM
department and the supplier.
Document the test results in a test report. Test
reports shall include all of the following: test
equipment serial numbers, calibration information,
test Data Sheets A1 through A17, description of
test material (including design revision, lot or
batch, options, etc.) test specification date,
pertinent setup information, and photographs.
3.7.1 Test Results. Record on the data sheets in
Appendix A.
4 Requirements and Procedure

4.1 Development. This section of the test
specification outlines the development tests for
lamps and reflective devices for which there are no
defined acceptance criteria. Review the results
February 2012
Page 4 of 59

with GM to determine if corrective action is
necessary.
4.2 Highly Accelerated Life Test (HALT).
Reference GMW3172 and GMW8287. See Data
Sheet A1.
4.2.1 Purpose. To quickly determine the
weaknesses of the product when subjected to
environmental and vibration stresses. The supplier
shall perform this test prior to all other subsystem
level testing as soon as representative samples
are available.
Only complex lamp assemblies shall be tested.
Examples of lamps to be tested are:
Headlamps
Front fog lamps
Lamps with electronic or electro-mechanical

components
Lamps with
components
Lamps using any non-traditional fastening

techniques
Lamps with multi-color lenses
complex
or
many
internal
Lamps using non-traditional vehicle mounting

Examples of lamps not to be tested include:
Simple lamps consisting of a lens and housing

mounted in a traditional manner
Simple signal lamps mounted in a fascia or to

sheet metal
Simple tail lamps

The GM Validation Engineer and GM Designing
Engineer shall approve any lamp type that is not
tested.
With the approval of the GM Validation Engineer
and GM Designing Engineer the supplier may test
non-dimensionally correct or non-representative
samples if the time to obtain dimensionally correct
or representative samples is prohibitive.
The supplier engineer shall be present during
testing, and a GM representative should be
present during the testing.
The supplier and GM engineer shall analyze each
test incident to determine its likelihood of occurring
in the field. Quick and simple tests may be used
when applicable to verify the potential incident (i.e.,
a heat test). Not all incidents require corrective
action based on the above analysis.
Engineer, along with Engineering Group Manager,
and the Validation Technical Integration Engineer
(TIE) shall determine which incidents require
corrective action and verification through an
GMW14906
additional HALT test. Incidents occurring above the

temperature limits of materials, for example, do not
require corrective action if the material is suitable
for the particular application.
4.2.2 Equipment. Environmental chamber with the
following specifications.
4.2.2.1 Thermal capability of -100 C to +200 C
with a ramp rate of at least 40 C per minute.
4.2.2.2 Omni-axial (six degrees of freedom)
repetitive shock system with 50Grms capability
between 2 Hz and 2000 Hz frequency bandwidth.
4.2.3 Sample Size. Three (3) samples per part
number (excluding color) or two pair. For example,
Center High Mounted Stop Lamps (CHMSL) would
require three parts. High Intensity Discharge (HID)
and halogen headlamps would require a total of
four parts. Test all test samples regardless of the
results of previous tests.
4.2.4 Setup.
4.2.4.1 Specifics of the test setup parameters are
the responsibility of the GM Validation Engineer
and GM Designing Engineer. Parameters which
need to be defined are:
4.2.4.1.1 Fundamental part operating limits.
Temperature limits are the following.
4.2.4.1.1.1 Headlamps, front fog lamps, and
interior CHMSLs: -100 C to +120 C.
4.2.4.1.1.2 Remaining lamps: -100 C to +85 C.
4.2.4.1.2 Activate all functions during the test
including non-lighted system components such as
dynamic headlamp leveling (DHL) motors and
adaptive forward lighting (AFL) system motors.
4.2.4.1.3 Mount the sample(s) to a rigid, lightweight
test fixture of welded construction that represents
the vehicle mounting orientation and installation
and uses production fasteners or equivalent. Note
requirements for the functional response of the test
part mounted to the test fixture, included below. If
possible, lamp locating features and body
interfaces must be represented in the fixture
design. Position the fixture retention points to the
test base such that the fixture can be removed
without removing the lamp.
4.2.4.1.4 The collection of product response data
from temperature and vibration is required to
provide credible response that temperature and
vibration stress was applied to the product.
Reference GMW8287 for thermocouple and
accelerometer specifications.
February 2012
Page 5 of 59
GMW14906
4.2.4.1.5 Functional test goals are to achieve

4.2.5.3 Vibration Step Stress. Cycle sample(s) in
100% of thermal and vibration inputs. Functional
vibration
steps
at
ambient
to
50Grms.
response, of the test part mounted to the test
Recommended vibration steps are 5Grms with a
fixture, from vibration, shall be 70% or greater than
minimum dwell of 10 minutes.
the vibration input.
4.2.5.4 Combined Environment. While subjecting
the sample(s) to the Rapid Thermal Transition in
Engineer shall approve the design.
4.2.5.2, vibrate the sample(s) in steps per the
Vibration Step Stress procedure in 4.2.5.3. If no
4.2.5 Procedure. Cycle the samples through the
incidents occur, continue testing at the maximum
HALT test procedure in the order listed. Samples
vibration level with Rapid Thermal Transitions until
shall be leak tested as described in 4.3.3 at the
an incident does occur.
start and after each test segment. If possible,
4.2.6 Report. An interim test report shall be
continue testing until three distinct failure modes
are observed. Activate all light sources and motors,
provided per 3.5 including which cycle the incident
where applicable, continuously during the high
occurred, and GM/supplier participants of the test.
temperature portions of the test sequence and any
4.3 Pre-test Requirements for all Remaining
transitions to a high temperature. For example,
Tests.
activate stop lamps, turn signal lamps, and DHL
4.3.1
Dimension.
Measure
all assembly
motors continuously. High temperature is defined
checkpoints on one lamp or pair of handed lamps
as temperatures above ambient.
and record on the test log sheet. All measured
4.2.5.1 Thermal Step Stress. Cycle sample(s) in
assemblies shall be dimensionally within twice the
temperature steps to the fundamental temperature
drawing tolerance for development and design
limits. First test the upper limits, then the lower
validation (DV) testing. Measure and record one
limits. Recommended temperature steps are 20 C
lamp or pair of handed lamps used in product
with a minimum dwell of 10 minutes until 20 C
validation (PV) testing. The GM Validation
from the expected upper temperature limit is
Engineer and GM Designing Engineer must review
reached. Then step 10 C with a minimum dwell of
the dimensional data prior to start of test.
10 minutes.
4.3.2 Aim.
4.2.5.2 Rapid Thermal Transition. Cycle
4.3.2.1 Aim Position. All aimable lamps shall be
sample(s) between the operational temperature
aimed. Lamps with DHL or AFL shall be centered
limits. At least five cycles are recommended
to design nominal position.
utilizing transitions greater than 40 C per minute.
Allow for thermal stabilization between transitions
with a recommended minimum dwell of
10 minutes.
Table 1: Seal Test Method
Lamp Description
Test Method
Small lamp with no lighted function; no tooled openings in housing (i.e., reflex reflector)
Vacuum Chamber
per 4.3.3.1
Small lamp with lighted function; no socket; lamp side connector is sealed (i.e., light
emitting diode (LED) CHMSL with internal potted lamp side connector)
Vacuum Chamber
per 4.3.3.1
Small lamp with lighted function; with sealed socket (i.e., license lamp with bulb and
socket)
Submersion per
4.3.3.2
Small lamp with lighted function; with no socket; lamp side connector is not sealed (i.e.,
LED CHMSL with vented lamp side connector body connector contains seal)
Pressurization per
4.3.3.3
Body sealed lamp
Pressurization per
4.3.3.3
(Note: A rigid fixture that represents the lamp mating sealing surface and attachment is required.)
Other lamp with lighted function(s)
Pressurization per
4.3.3.3
February 2012
Page 6 of 59
4.3.3 Seal. Leak test each lamp per the test

method described in Table 1. Data shall be
recorded for all lamps subject to Seal Test
Methods (Table 1), including data for those lamps
that may not meet pre-test requirements. Indicate
in test incident notes, on the data sheets, if lamp
quantities greater than the minimum sample size
were required to collect test ready lamps.
4.3.3.1 Vacuum Chamber Method. Lamp shall be
tested at room temperature. Allow lamp to stabilize
at 23 C 3 C temperature for a minimum 1 h.
Submerse the lamp in 23 C 3 C water, inside of
the vacuum chamber (mount lamp to a simple
fixture using production mounting points, if
required). Let stand for 5 minutes. Observe the
lamp for leakage. A leak is defined as any bubbles
originating from a single point on the lamp. If no
leakage is noted; evacuate the chamber with
submersed lamp inside to reduce the pressure to
21.0 kPa for 15 s. Lamps shall show no bubbles
during test.
Caution: Safety precautions shall be taken to
protect test engineer. Monitor pressure to prevent
water from boiling at low pressures.
4.3.3.2 Submersion Method. Energize lamp for
30 minutes at ambient. Continue to supply voltage
and submerse to a depth 10 mm under water at
2 C 2 C for 5 minutes. With the lamp under
water, turn off supply voltage to the lamp and let
stand for 5 minutes. Remove the lamp from the
water and inspect for water ingress. Repeat this
instruction three times per lamp assembly. There
shall be no cracking, ingress of water or evidence
of internal condensation.
4.3.3.3 Pressurization Method. Pressurize each
lamp completely under 2.5 cm of water at 7.0 kPa
for 5 minutes using the pressurization guidelines
in 4.17. All aimable lamps shall be cycled through
their total travel while pressurized. If the leak test
pressure
(LTP)
was
determined
using
procedure 4.17, this pressure shall be used.
Lamps shall show no bubbles as defined in
4.17.4.5.
4.3.4 Light Output. The purpose of this
measurement is to compare the light output before
and after the tests described in this document.
Measurements are not an indication of compliance
to regulations and are for pre-test and post-test
comparison only.
Measure and record the luminous flux photometric
output of one lamp or pair of handed lamps. Low
beam, high beam and fog lamp functions shall be
measured by positioning the test lamp on a
goniometer per guidelines in the applicable
GMW14906
regulatory requirements and measured over a

matrix that spans the horizontal and vertical beam
pattern extents defined in the applicable regulatory
requirements at an increment of 0.2 degrees.
Other lamp functions shall be measured at an
increment of 1.0 degree. License lamps and reflex
reflectors are not required to follow this
measurement method; but measurement data to
evaluate pre-test requirements shall be provided,
as noted below. This data shall be provided
electronically to GM upon request.
Headlamps shall be aimed properly and the
gradient recorded if applicable. Light emitting
diodes (LED) shall be tested per SAE J1889 or
ECE regulations for the specific lamp stabilization
time. Lamp functions that are required to operate
with vehicle "Start/Stop" conditions shall also be
measured for light output at 12.8 V at
horizontal-vertical (H-V). This data shall be
provided electronically to GM upon request.
Reflex and license lamps shall be measured to the
regulatory requirements instead of a matrix;
non-functional reflex does not need to be
measured, and electronic data need not be
provided.
If the photometric regulatory requirements require
an accurate rated light source, measure and record
the device photometric output using an accurate
rated source activated at the proper current. Then
use a standard light source for testing.
If the photometric regulatory requirements do not
require an accurate rated light source or the
sample uses non-replaceable light sources,
measure and record the photometric output of the
device using a standard source energized at
12.8 V unless otherwise specified by the device. If
a standard replaceable source is used for the
photometric measurements, another standard
source shall then be used for testing other than
photometry. Use the same standard light source
for the initial and final photometry.
4.3.5 Appearance. All lamps shall be visibly free of
warps, cracks, crazing, blistering, chalking,
condensation, delamination, out-gassing, or any
other visible change without magnification.
4.3.6 Function. Assure all functions are
operational, i.e., aimable lamps can be adjusted
through full travel, aimable lamps will not incur
damage or loss of function if adjusted past their
effective adjustment range, all vehicle headlamp
aiming devices (VHAD) function and read correctly,
replaceable bulbs can be removed from their
sockets, etc., and all joints are tight with all
fasteners engaged.
February 2012
Page 7 of 59

Note: To verify aim adjustment, cycle the lamp full
down, then full up, then back to nominal position
evaluating breakaway and prevailing torque using
a performance console to record and chart values.
Attach charts to the existing data sheets. During
this evaluation, also verify the number of turns to
adjust aim one degree and record.
4.3.7 Squeak and Rattle. Perform a subjective
evaluation for squeak and rattle by holding a
complete lamp assembly in hand and twisting in
multiple directions. With the same lamp assembly
in hand, gently shake the assembly in all
directions. Evaluations during each condition shall
be evaluated per GMW14264 in a room with no
ambient noise.
4.4 SAE J575e August 1970 Vibration.
Note: Operators are to use the SAE J575e August
1970 version which aligns with a prior standard
referenced in Federal Motor Vehicle Safety
Standards (FMVSS) documents. Although this test
is not for compliance, only this version is to be
used. Operators are not to use the latest/current
version of SAE J575e for GMW14906.
4.4.1 Equipment. Vibration test equipment
described in SAE J577.
4.4.2 Sample Size. Two (2) pair or three samples.
4.4.3 Procedure. Test samples to the vibration
procedure described in SAE J577 for 60 minutes.
Inspect the parts for the acceptance criteria listed
in FMVSS 108 without removing from the fixture, If
the sample(s) passes, continue testing for an
additional 30 minutes. Remove from the fixture and
repeat the part inspection. See Data Sheet A2.
4.5 Temperature and Vibration. Conduct the
tests in this section in the order presented with the
same samples through the entire sequence of
pre-test measurements, temperature, vibration,
and post-test requirements. In addition, inspect all
sample(s) after each test section using the
procedure specified. See Data Sheet A3.
Note: Optional HID or Adaptive Forward Lighting
(AFL) System (AFL headlamps are examples
requiring separate vibration validation. Slight
variations of lamp options (up-level vs. base, lens
color changes, flashed over sockets for corner
lamps, multiple cavities for the same part, multiple
assembly lines, etc.) shall be intermixed in the
assemblies according to GMW15760. The GM
GMW14906
Validation Engineer and GM Designing Engineer

shall approve any combination assumptions.
4.5.1 Temperature Cycling.
4.5.1.1 Purpose. To verify the lamp assembly can
withstand temperature extremes and precondition
the lamp assembly for vibration testing.
4.5.1.2 Equipment. Environmental chamber
capable of -40 C to +120 C with either random air
circulation or circulating air with a predominant air
flow direction. The chamber shall be capable of
3 C 1 C per minute.
4.5.1.3 Sample Size. Seven (7) pair or
14 samples.
4.5.1.4 Temperature Procedure. Perform the
temperature cycle in Figure 1 two times with lamp
assemblies positioned in vehicle orientation.
4.5.2 Vibration.
4.5.2.1 Purpose. To determine if the lamp will
withstand severe vibration input.
4.5.2.2 Equipment. Random vibration equipment
described
in
ISO 16750-3,
SAE J575,
or
equivalent.
4.5.2.3 Sample Size. The same seven pair or
14 samples used in 4.5.1 Temperature Cycling.
4.5.2.4 Test Fixture Rigidity. Mount all test
samples to the vibration equipment using a test
fixture that duplicates the production vehicle
mounting interfaces, fasteners, and vehicle
orientation. Measure the first resonant frequency of
one sample of each assembly in each axis and
record. The procedure shall include the
measurement of the vibration input and the fixture
response from 10 Hz to 1000 Hz. This fixture,
when coupled with the test sample or equivalent
mass and center of gravity, shall not have a
resonant frequency between 10 Hz and 250 Hz in
any axis and no vibration responses greater than
two times the input signal in this frequency range.
In addition, the test fixture acceleration amplitude
frequency responses at the individual mounting
points, when the entire fixture is subjected to
constant excitation, shall only differ from each
other within the frequency range to be tested by
3 dB maximum (between 250 Hz and 1000 Hz by
10 dB maximum). The fore-aft and lateral
resonances shall be at least 10 dB below the
signal in the test direction. The test fixture
performance shall be approved by the GM
Validation Engineer and GM Designing Engineer.
February 2012
Page 8 of 59
GMW14906
Temperature Cycling for Interior CHMSL's, and all Other Lamps

120
100
Temperature (C)
80
60
40
20
0
-20
-40
0
10
12
14
16
18
20
22
24
Time (hours)
Interior CHMSL Cycling
1 hour
4 hours
2 hours
16 hours
1 hour
Other Lamp Cycling
Cooling to -40 C
At -40 C
Heating to +80 C (110 C for Interior CHMSLs)
At +80 C (110 C for Interior CHMSLs)
Cooling to +23 C 5 C
Figure 1: Temperature Cycling
4.5.2.5 Lamp Assembly Resonance. Measure

the lamp assemblys first resonant frequency prior
to testing. In addition, measure the first resonant
frequency of lamp components retained through an
aim mechanism using optical aids such as a laser.
Record the specific procedure used and measured
data on Data Sheet A3.
4.5.2.6 Accelerometer Locations. Test all
component lamps in random vibration. Mount
redundant vibration control accelerometers on the
fixture. Mount one at the base and one as far as
practical from the base to reduce the test fixture
influence on the lamp. The test shall be limited by
the higher of the two values. Record the locations
in the test report.
4.5.2.7 Lamp Activation During Vibration.
During vibration testing, activate all light sources
according to the Lamp Activation Profile in
Figure 2. Using this profile, activate the lamp
functions for 3 h as described in Figure 4, of each
8 h vibration test on each axis. If a dedicated
Daytime Running Light (DRL) is contained in
another lamp assembly, activate the DRL for the
first 5 h, then low beam/high beam as indicated for
3 h.
4.5.2.8 AFL and DHL Activation During
Vibration. If a headlamp assembly contains an
Adaptive Forward Lighting System (AFL), activate
the angular mechanism during random vibration as

directed in Figure 3 while simultaneously activating
the lamp functions as directed in Figure 2.
If the headlamp contains Dynamic Headlamp
Leveling (DHL), activate during random vibration
as directed in Table 7 when the high and low beam
lamp functions are activated in Figure 2.
Note: AFL/DHL systems shall not be reinitialized
prior to post-test measurements. If an electronic
control module is used to control the AFL/DHL
system during test, any calibration used to
automatically zero the lamp position shall be
deactivated.
4.5.2.9 Vibration Duration.
4.5.2.9.1 All Lamps Except Pickups. Vibrate
samples for the duration specified in Table 2 using
the temperature profile outlined in Figure 4 and the
Power Spectral Density in Figure 5.
Table 2: Vibration Duration by Axis
Vertical
8 hours
Fore/aft
8 hours
Lateral
8 hours
February 2012
Page 9 of 59

4.5.2.9.2 Pickups. For lamps on pickups, vibrate
lamps for the duration specified in Table 3 using
the temperature profile outlined in Figure 4 and the
Power Spectral Density in Figure 5.
4.5.2.9.3 Vibration Axis Sequence. The axis of
vibration sequence need not be the same for each
sample tested, but must be noted in test log data.
The lamp orientation during testing is always to be
as in the vehicle.
GMW14906
Table 3: Vibration Duration for Pickups

Vertical
8 hours
Fore/aft
8 hours
Lateral
8 hours
5
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95
100
105
110
115
120
125
130
135
140
145
150
155
160
165
170
175
180
Lamp Activation Profile for Light-Up and Vibration (min)

Lamp functions
High Beam - 4 Bulb Burn
Duration
on
30 on / 60 off
off
Low Beam; on
off
180 on
(incl. AFS/DHL)
High Beam - 2 Bulb Burn on

& Bi-Funtion Projector off
40 off / 20 on /
70 off
Low Beam; on
off
40 on / 20 off /
70 off
(incl. AFS/DHL)
Dedicated DRL on
(tested separately) off
Front Fog
180 on
on
90 on / 90 off
off
on
Turn Signal / Hazard/
Side Repeater off
120 on flashing
/ 60 off
on
Static bending/ Cornering
Stop / CHMSL
Rear Fog
Backup
Taillamps/License Lamps
180 on / 3s
cycle @50% on
time
off
on
off
30 on, then 15
off / 15 on
on
60 on / 30 off /
60 on
off
on
10 on / 50 off
off
on
180 on
off
Side Marker / Park / on

Position/Clearance/ID off
180 on
Switched lamps: Cargo, on

Spot, etc. off
30 on / 60 off
Unswitched lamps: on
puddle, assist step off
1 on / 1 off
Note: Lamp assemblies with multiple lamp functions shall have all functions on/off according to the activation profiles
above. Use the specific vehicle mechanization to determine activation behavior (for example, Scandanavian countries
may require mechanization of park function on with DRL on).
Figure 2: Lamp Activation Profile During Vibration and Light-up Tests
February 2012
Page 10 of 59
GMW14906
Figure 3: Adaptive Forward Lighting System Cycle
1 hour
Cooling from 23 C 5 C to -40 C
1 hour
at -40 C
2 hour
Heating to 50 C
2 hours
At 50 C (with lamp activated as described in Figure 2; begin at time = 0)
1 hour
Cooling to 23 C 5 C (with lamp activated as described in Figure 2; begin at

time = 120)
1 hour
at 23 C
Figure 4: Temperature Curve for Vertical Random Vibration Test Only
February 2012
Page 11 of 59
Vertical Axis - All Lamps

Except Pickups
( )
Frequency range:
Horizontal Axis - All

Lamps Except Pickups
(---)
Vertical and Horizontal

Axes - Pickups Only
( -- -- -- )
10 Hz to 1000 Hz
2
0.201 G /Hz at 10 Hz
2
0.00666 G /Hz at 300 Hz

2
Power spectral density:
GMW14906
0.0006158 G /Hz at
1000 Hz
0.1006 G /Hz at 10 Hz
0.08184 G /Hz at 10 Hz
0.08184 G /Hz at 40 Hz
0.00339 G /Hz at 300 Hz
0.000308 G /Hz at
1000 Hz
0.01364 G /Hz at 250 Hz

2
0.0001364 G /Hz at
500 Hz
2
0.0001364 G /Hz at
1000 Hz
Total G:
2.84Grms
2.0Grms
3.04Grms
Figure 5: Frequency Range and Power Spectral Density Graph

February 2012
Page 12 of 59

4.5.2.10 Temperature Curve for Vertical Test
Direction. The vibration test in the vertical
direction only uses a superimposed temperature as
shown in Figure 4 and described below, as well as
the lamp activation profile according to Figure 2.
Perform testing in the fore/aft and lateral directions
at 23 C 5 C.
4.5.2.11 After random vibration is complete on all
three axes, re-measure the first resonant
frequency of the specimen tested in 4.5.2.5 and
record on Data Sheet A3.
4.5.2.12 Record All Results per 3.5.
4.5.3 Temperature and Vibration Acceptance
Criteria.
4.5.3.1 The first natural frequency post-test shall
not have degraded >15% compared with the
pre-test value; however, it shall be >35 Hz in every
case.
4.5.3.2 Lamps shall pass all of the post-test
requirements in 4.6 after completing the entire 4.5
test sequence.
4.5.3.3 Replaceable light source filament failures
are acceptable. If filament failures occur, replace
the light source immediately and continue the test
so that the light sources are activated as intended
for the entire test duration. Record each incident
on the test log sheets and retain the bulbs to
review with the GM Validation Engineer and GM
Designing Engineer.
4.6 Post-Test Requirements.
4.6.1 Dimension. The measured sample shall be
dimensionally correct within twice the drawing
tolerance.
4.6.2 Aim. Measure the change in all aimable
lamps. The aim shall not have changed more than
0.2 degree for vertical or 1.0 degree for
horizontal. This criteria applies to all aimable lamps
including lamps that are part of an AFL system.
Record the amount of aim change.
4.6.3 Seal Leak Test Pressure (LTP). Leak test
and evaluate each lamp per the test method
described in Table 1.
4.6.4 Light Output. Measure and record the
photometric output of the original test sample(s)
over the same matrix extents at an increment of
0.2 degree for forward lighting and 1.0 degree for
rear and side lighting using the original light
source. Test LED per SAE J1889 or the ECE
regulation for the specific lamp. Headlamps shall
be aimed properly and the gradient recorded if
applicable. This data need not be provided
electronically to GM.
GMW14906
Reflex shall be measured to the regulatory

requirements instead of a matrix, non-functional
reflex does not need to be measured, and
electronic data need not be provided.
If the photometric regulatory requirements require
an accurate rated light source; measure and record
the photometric output of the device using an
accurate rated source activated at the proper
current. A standard source shall then be used for
the test.
If the photometric regulatory requirements do not
require an accurate rated light source or the
sample uses non-replaceable light sources,
measure and record the photometric output of the
device using a standard source energized at
12.8 V unless otherwise specified by the device. If
a standard replaceable source is used for the
photometric measurements, another standard
source shall then be used for testing other than
photometry. The standard source originally used
for the initial photometry shall be used for final
photometry.
LED functions that are required to operate with
vehicle "Start/Stop" conditions shall also be
measured for light output at 6V, 8V and 10V at
H-V. Functions required to operate with vehicle
"Start/Stop"
functionality
shall
meet
the
requirements of applicable technical specifications
and Figure 6, as required.
If any test point measurements change >25% and
the change cannot be attributed to slight
mis-position, or total lumen output changed >20%,
determine and record the root cause of the change
and ensure that the root cause does not violate
any other acceptance criteria. Ensure that the
repeatability and reproducibility of the photometric
test setup is not a major contributor.
4.6.5 Appearance. All external lamp surfaces and
all internal surfaces visible through the lens or
during normal service procedures shall be visibly
free of fractures or mechanical damage, warps,
cracks,
crazing,
blistering,
condensation,
delamination, discoloration, or deterioration of any
component, without magnification.
Some chalking (also called powdering or dusting)
and outgassing is acceptable, but must be
approved by the GM Validation Engineer and GM
Designing Engineer. Test reports shall detail the
region(s) of the lamp affected with photographs
and when during the test the onset of chalking
occurred.
February 2012
Page 13 of 59
Function
GMW14906
Light Output from LED Functions

[v-100 = 100% light output @ 12.8 V at H-V]
>75% of v-100 at 10 V
>50% of v-100 at 8 V
>25% of v-100 at 6 V
>50% of v-100 at 10 V
>25% of v-100 at 8 V
>0% of v-100 at 6 V
Control Module
2 LED in Series
3 LED in Series
Minimum Required
NOT ALLOWED
NOT ALLOWED
Stop
Allowed
Minimum Required
NOT ALLOWED
Rear Fog
Allowed
Minimum Required
NOT ALLOWED
Cornering light
(AFL)
Allowed
Minimum Required
NOT ALLOWED
Front Position/Park
Allowed
Minimum Required
NOT ALLOWED
DRL
Allowed
Minimum Required
NOT ALLOWED
High Beam
Allowed
Minimum Required
NOT ALLOWED
Tail/Rear Position
Allowed
Minimum Required
NOT ALLOWED
Backup lamp
Allowed
Allowed
Minimum Required
Front Fog
Allowed
Allowed
Minimum Required
Side Repeater
Allowed
Allowed
Minimum Required
Front/Rear Side
Marker (US)
Allowed
Allowed
Minimum Required
License Plate
Allowed
Allowed
Minimum Required
Turn Signal
Allowed
Allowed
Minimum Required
CHMSL
Allowed
Allowed
Minimum Required
Required Output
Conditions
Typical Execution
Low Beam
>90% of v-100 at 6 V
Figure 6: Exterior Lamp Functions Start/Stop Minimum Requirements

4.6.6 Function.
4.6.6.1 All illumination functions are operational. If
multi-source function, each discrete light source
must remain illuminated.
4.6.6.2 Aimable lamps are adjustable through full
travel, including Adaptive Forward Lighting (AFL)
System and Dynamic Headlamp Leveling (DHL).
Adjusters shall meet the following requirements:
a. Headlamp Adjuster
1. Dynamic Breakaway Torque: 3.5 Nm
2. Dynamic Prevailing Torque: 2.0 Nm
3. Adjuster Gear Ratio shall provide:

2 to 4 turns per degree of lamp movement
b. Fog Lamp Adjuster
1. Dynamic Breakaway Torque: 3.5 Nm
2. Dynamic Prevailing Torque: 2.0 Nm
3. Adjuster Gear Ratio shall provide:
2 to 4 turns per degree of lamp movement
4.6.6.3 All VHADs function and read correctly.
4.6.6.4 Replaceable bulbs are removable from
their sockets.
4.6.6.5 All joints are tight with all fasteners
engaged.
February 2012
Page 14 of 59

4.6.6.6 The lamp is removable without loss of
function to fasteners.
4.6.6.7 Bulb filament fractures are not necessarily
test failures. Record filament fractures on the test
log sheets.
4.6.6.8 Bulbs and bulb sockets shall not show any
evidence of arcing, deformation, or melting.
Gaskets shall not deform or result in loss of sealing
capability. Some discoloration of bulbs, sockets
and socket gaskets is acceptable, but must be
approved by the GM Validation Engineer and GM
Designing Engineer. All sockets and bulbs shall be
removed from the lamp post-test in order to
perform the inspection. Test reports shall detail
specific sockets, bulbs and gaskets affected with
photographs.
4.6.7 Squeak and Rattle. Perform a subjective
evaluation for squeak and rattle by holding a
complete lamp assembly in hand and twisting in
multiple directions. With the same lamp assembly
in hand, gently shake the assembly in all
directions. Evaluations during each condition shall
be evaluated per GMW14264 in a room with no
ambient noise. The subsystem shall have a
subjective rating of at least nine (9) when
evaluated to GMW14264 Subjective Rating Scale
for Squeaks and Rattles.
4.6.8 Record All Results per 3.5.
4.7 Electrical Components and Electronic
Interfaces.
4.7.1 Electrical Connectors and Power
Interface.
4.7.1.1
Electrical
Connectors.
Electrical
connections shall meet GMW3191 for the following
environments:
Temperature: Class 2 for headlamps and Class 1
for all other lamps.
Vibration: Class 1.
Sealing: Class 2 for headlamps, fog lamps, and
side repeater lamps; Class 1 for all other lamps.
Connector Mating Force: Use appropriate
classification based on physical size.
4.7.1.2 Electrical Wiring and Lamp Harness
Cables. Lamp wiring and lamp harness cables
shall meet GMW15626 for the following
environment:
Temperature: Class C for external headlamp
cables and other external lamp cables exposed to
the engine compartment. Class A for all other
external lamp cables. Internal cable classifications
shall be determined per results of lamp thermal
analysis.
GMW14906
4.7.2
Headlamp
Bulb
and
Connector
Temperature Cycle.
4.7.2.1 Rigidly mount ten production intent
headlamp bulbs (representative of the intended
bulb type, bulb variant (long life, standard life, etc.),
bulb orientation, bulb terminal material (nickel
plated stainless, etc.), and bulb supplier) inside a
thermal chamber capable of -40 C to 140 C.
Chamber shall be capable of maintaining the
specified temperature with the ten bulbs energized.
4.7.2.2 Mount thermocouples to each terminal of
each connector as close as possible to the bulb
terminal interface. Thermocouples shall be
permanently
attached.
Ensure
that
the
thermocouple mounting will not disturb the
performance of the connection system and that all
the connection system components (connector
body, terminal position assurance (TPA), etc.) are
installed properly.
4.7.2.3 Cycle thermal chamber while energizing
bulbs at 14.5 V following the schedule below.
During entire test, measure and record the
temperature of each connector ground terminal
every 5 minutes.
4.7.2.3.1 Set thermal chamber to 140 C with a
minimum transition of 2 C/minute while energizing
bulbs at 14.5 V. Transition and hold 140 C for
240 minutes total.
4.7.2.3.2 Set thermal chamber to -40 C with a
minimum transition of 2 C/minute with all bulbs off.
Transition and hold -40 C for 120 minutes total.
4.7.2.3.3 Repeat cycle above for 2500 h. Replace
any bulb which burns out during test and continue
test. Record each bulb replacement and verify that
the bulb filament has failed. Connectors shall not
be disconnected other than to replace bulbs due to
burnout.
4.7.2.4 Acceptance Criteria.
4.7.2.4.1 If more than 10 samples are tested, all
samples shall comply with the acceptance criteria.
4.7.2.4.2 All samples tested shall continue to
power the bulb throughout the test.
4.7.2.4.3 All measured terminal temperatures shall
not increase from the maximum temperature
measured within the first 48 h by more than 20 C
throughout the test. All temperature shall be
graphed and provided to GM. In addition, the
temperature of the terminals shall not increase
above the heat deflection temperature of the
connector body materials.
4.7.2.4.4 All samples shall show no heat distortion
of any component after the test. Any discoloration
of any components shall be reviewed with GM for
approval.
February 2012
Page 15 of 59

4.7.2.4.5 Measured terminal temperatures shall be
recorded and shall be less than or equal to the
specified maximum rated temperature for the
terminal substrate and plating materials.
4.7.3 Solenoids.
4.7.3.1
Solenoids
shall
meet
durability
requirements per methods defined in SAE J564.
Test shall be performed using the projector
assembly or partial lamp assembly to which the
solenoid is mounted.
4.7.3.2 Verify that the mechanical connection of
the solenoid to lamp shield and solenoid to its
mounting surface is made. Power the solenoid and
cycle to 200 000 cycles or four (4) lives
(1 life = 50 000 cycles).
4.7.3.3 Evaluate for proper operation (full open to
full close) every 50 000 cycles and record results
on the data sheet.
4.7.3.4 Continue to cycle solenoid to failure or
300 000 cycles and record results on the data
sheet.
4.7.3.5 Acceptance Criteria. Solenoid shall
remain functional at the end of 200 000 cycles.
4.7.4 Bulb and Socket Removal Force.
4.7.4.1 The cold removal force shall be determined
on ten (10) actual bulb/socket samples intended for
the application using the procedure outlined in
USCAR 15, titled Bulb Insertion/Removal Force.
Lamp assemblies may be reused.
4.7.4.2 The hot removal force shall then be
determined using the same USCAR 15 method.
Energize all the filaments in same bulb/socket
samples as in 4.7.4.1, at 14.1 V for 30 minutes in
the lamp assembly at ambient temperature. If the
lamp assembly is not yet available, utilize a
surrogate lamp with a similar cavity volume as the
intended lamp assembly. GM shall approve the
lamp chosen prior to testing. With the bulb still
energized, remove the socket and measure the
removal force of the bulb within 30 seconds of
removal. Only one (1) pull force measurement is
required (instead of the five (5) required in the
USCAR 15 procedure).
4.7.4.3 The cold removal force of the same
bulb/socket combination shall then be re-measured
using the same USCAR 15 procedure.
4.7.4.4 Acceptance Criteria. Bulb removal force
shall not degrade more than 10% or degrade
below the minimum removal force requirements
contained in SAE/USCAR 15, when measured cold
versus hot after being energized for 30 minutes in
the lamp assembly, and then measured cold again.
4.8 Accelerated Corrosion. Lamps completely
located inside the passenger compartment such as
GMW14906
CHMSLs with no external exposure are excluded

from this procedure.
4.8.1 Purpose. To primarily determine the
corrosion and humidity resistance of lamp
assemblies and to secondarily determine stress
levels are acceptable in welded assemblies and in
lamps with snap fit attachments.
4.8.2 Sample Size. The sample size for all
corrosion testing is three pair or six samples
through each test.
4.8.3 Procedure.
4.8.3.1 Perform pre-test requirements 4.3.3, 4.3.5,
and 4.3.6.
4.8.3.2 For lamps with snap fit attachments, test
attached to the mating component or a
representation of it. For other attachments to the
body, represent the fastener, torque, and interface
as close as possible.
4.8.3.3 Cyclic Corrosion Testing GMW14872.
See Data Sheet A4. Test all parts as assemblies in
cyclic corrosion per GMW14872 for validation.
4.8.3.3.1 For coatings and substrates test as
assemblies in cyclic corrosion per GMW14872.
4.8.3.3.2 For headlamps, side repeaters, front fog
lamps and under hood (UH) areas.
4.8.3.3.2.1 UH, All, Method 1/2, Exposure B + D.
4.8.3.3.3 For all other lamps.
4.8.3.3.3.1 Exterior (EXT) Applications, All, Method
1/2/3, Exposure C + D.
Note: After exposure B and C, all metal surfaces
shall fulfill cosmetic requirements as defined in
GMW15272. After exposure D, there shall be no
loss of function.
4.8.3.4 Painted metal external parts on lamps must
perform to GMW14669, Type A2.
4.8.3.5 Painted metal internal parts on lamps must
perform to GMW14669, Type B2.
4.8.3.6 Chrome plated external plastic components
must perform to GMW14668 (48 h) plus four
thermal cycles per GMW14668.
4.8.4 Perform post-test requirements 4.6.3, 4.6.5,
and 4.6.6 as noted above.
4.8.5 Acceptance Criteria.
4.8.5.1 Headlamps, Side Repeaters, and Front
Fog Lamps. After exposure B all metal surfaces
shall fulfill cosmetic requirements as defined in
Table A1, Cosmetic Corrosion Resistance
Requirements, of GMW15272. Samples shall pass
post-test requirements in 4.6.3, 4.6.5, and 4.6.6.
No cracks near attachments or interfaces of
welded components are permissible.
February 2012
Page 16 of 59

4.8.5.2 All Other Lamps: After exposure C, all
visible metal surfaces shall fulfill cosmetic
requirements as defined in Table A1, Cosmetic
Corrosion
Resistance
Requirements,
of
GMW15272. Surfaces visible when hoods,
decklids, liftgates, etc., are in the open position are
classified as visible surfaces. Samples shall pass
post-test requirements of 4.6.5. No cracks near
attachments or interfaces of welded components
are permissible.
4.8.5.3 Functional. After Exposure D there shall
be no loss of function per GMW15272 (Reference
section titled: Functional Corrosion Resistance).
The samples shall pass post-test requirements of
4.6.3 and 4.6.6.
4.9 Weatherability. This test is required on all
lamps with externally visible multi-color and overlay
interfaces, adhesive bonded lens to housing joints,
and externally visible unpainted and uncoated
plastics. See Data Sheet A5.
4.9.1 Purpose. To determine if molded lighting
subsystems will incur damage when subjected to
simulated sunlight, heat, and moisture.
4.9.2 Sample Size. Samples are to be
plaque-sized sections cut from production
representative or production lamps containing the
interface to be tested. One sample of each
condition outlined in 4.9.
4.9.3 Procedure. For exterior mounted lamps test
to
GMW14650
(Reference
section
titled:
Weather-Ometer
Resistance)
Class 3
2
2
(>2500 kJ/m to SAE J2527 or >3000 kJ/m to
ISO 4892-1/2. For interior CHMSLs and other
interior mounted lamps, test to GMW14651 and
exposure requirements per GMW14444. Interior
painted plastic shrouds shall also be tested to
GMW14444. Inspect samples biweekly.
4.9.4 Acceptance Criteria. Samples shall pass
post-test requirements in 4.6.5.
4.10 Internal and External Heat. See Data
Sheet A6.
4.10.1 Internal Heat.
4.10.1.1 Purpose. To determine the effect of
extreme heat with light sources activated. This
procedure applies to all lamps.
4.10.1.2 Equipment.
4.10.1.2.1
Thermal
chamber
capable
of
maintaining +100 C without air circulation.
4.10.1.2.2 Power supply capable 9 V to 16 V and
be able to maintain a constant supply of power at
16 V to all lamps.
GMW14906
4.10.1.3 Sample Size. Three (3) pair of

headlamps. Two (2) pair or three samples of all
other lamps.
4.10.1.4 Test Procedure.
4.10.1.4.1 Perform and pass all pre-test
requirements in 4.3.
4.10.1.4.2 For headlamps and front fog lamps,
uniformly apply by brush or spray to the lamp lens
surface normally exposed to road dirt a mixture of
fine powdered cement and water in accordance
with ASTM C150 or equivalent composition and
particle size. For all rear lighting do not apply this
mixture to the lens. Reduce the photometric output
at the horizontal-vertical (H-V) test point of the
upper beam, the 0.5D-1.5R test point of the lower
beam, the H-2D point of the fog lamp, to
25% 2% of the clean lens photometric output
(equal to a 75% 2% reduction). Determine the
reduction under the same conditions as the original
measurement. AFL headlamps shall be tested with
the movable beam contributor in the nominal
position, only.
4.10.1.4.3 Mount lamps in the chamber in vehicle
orientation.
4.10.1.4.4 Set temperature to 39 C 1.0 C with
air circulation. Place the lamp in the chamber in
vehicle orientation and maintain the temperature
for 60 minutes allowing the lamp to stabilize.
4.10.1.4.5 Shut off air circulation and seal off
chamber. Ensure that the lamp does not raise the
oven temperature more than 5 C. Note decrease
or increase in chamber temperature on the data
sheet.
4.10.1.4.6 Activate the lamp functions that draw
the highest wattage. Additionally, test to the
conditions in 4.10.1.4.6.1 through 4.10.1.4.6.5, as
applicable.
4.10.1.4.6.1 If a turn signal is part of the lamp
assembly, activate it at 90 flashes/minute with a
50% 2% current on time.
4.10.1.4.6.2 If a headlamp option includes both a
halogen and high intensity discharge (HID) light
source, test the halogen light source only.
4.10.1.4.6.3 If a headlamp system consists of a
four-bulb upper and lower beam, perform the test
with the low or dipped beam source first, then the
high beam source per the vehicle mechanization.
4.10.1.4.6.4 If a lamp assembly contains other
lighting functions, including a dedicated DRL,
activate the other lighting functions at the
maximum wattage possible per the vehicles
mechanization. Visually inspect the lamp. Then
continue test with the DRL activated continuously
for an additional 90 minutes.
February 2012
Page 17 of 59

4.10.1.4.6.5 For rear combination lamps, activate
the stop, backup and other functions that can be
energized with the stop and backup according to
the first hour in the Lamp Activation Profile (LAP) in
Figure 2.
4.10.1.4.7 Maintain set temperature plus tolerance
for 60 minutes while lamps are being cycled. If the
lamp contains a dedicated DRL, dwell for
90 minutes while the lamps are being cycled.
4.10.1.4.8 Remove the samples to ambient and
clean the lens.
4.10.1.4.9 Perform post-test requirements in Data
Sheet A6.
4.10.1.4.10 Re-test steps 4.10.1.4.1 through
4.10.1.4.9 on a new set of lamps with the
temperature in 4.10.1.4.4 set at 50 C instead of
39 C. If three samples are being tested, test the
second and third samples at 50 C.
4.10.2 External Heat Test.
4.10.2.1 Purpose. To determine the effect of
extreme heat with light sources activated; including
the effects of elevated ambient temperatures at the
front of lamp and back side of lamp, exposed to
engine compartment temperatures. This procedure
applies to all headlamps, fog lamps, and other
lamps mounted to the front of the vehicle and
extending into the engine compartment.
4.10.2.2 Equipment.
4.10.2.2.1 Thermal chamber with baffle capable of
maintaining +100 C with air circulation on the
back side of lamp and +50 C with air circulation
on the front side of lamp.
Note: The thermal chamber equipment specified in
the internal heat test is for a thermal chamber
without air circulation.
4.10.2.2.2 Power supply capable 9 V to 16 V and
be able to maintain a constant supply of power at
16 V to all lamps.
4.10.2.3 Sample Size. One additional pair of
lamps with clean lens.
4.10.2.4.1 Secure the lamp in vehicle orientation in
the chamber. Construct a baffle of insulating
material around the periphery of the assembly and
use tape to seal off air flow at the housing to lens
interface. This setup must expose the lens to
ambient air temperature at 50 C and the housing
to ambient air temperature at 100 C. Tool access
to housing mounted sockets shall be considered,
as noted in the procedure below. Reference
Figure B1 for a simple test setup alternative to
using a dual chamber.
GMW14906
4.10.2.4.2 Set the front side chamber temperature

to 50 C and the back side chamber temperature to
100 C and allow the chamber temperatures to
stabilize.
If the lamp contains an independent DRL, fog

lamp or, both; test to sections 4.10.2.4.3
daytime mode activation and then 4.10.2.4.4
nighttime mode activation.
If the lamp is a dedicated DRL, fog lamp or,

combination DRL/fog lamp using the same
light source; test to section 4.10.2.4.3 daytime
mode activation.
For all other lamp types, test to section

4.10.2.4.4 nighttime mode activation.
Note: The same set of lamps is to be used for
daytime and nighttime testing, if both test modes
are required.
4.10.2.4.3 Daytime Mode Activation. Activate the
function(s) allowed by the vehicles mechanization
in daytime mode (i.e., for dedicated DRL activate
the DRL; for dedicated fog lamp activate fog; for
combination DRL/fog lamp activate DRL). Allow
lamp to dwell for 4 h with chamber temperatures
maintained at 50 C and 100 C as specified
above.
4.10.2.4.3.1 For lamp types noted in 4.10.2.4.2 that
contain a socket or heat sink that directly connects
to the housing and holds an active light source in
daytime mode, perform the following:
4.10.2.4.3.1.1 At 100 C, with the lamp in the
chamber, apply a 10 N load normal to the socket or
external heat sink (if exposed) of the active light
source for 20 s. See Figure B2 for a sample photo
displaying load direction and load tip.
4.10.2.4.3.1.2 After loading, remove the lamp from
the chamber, cool to ambient temperature, and
evaluate according to 4.10.4.
4.10.2.4.3.2 For all lamp types noted in 4.10.2.4.2
that do not contain a socket or heat sink that
directly connects to the housing, remove the lamp
from the chamber and evaluate according to
4.10.4.
4.10.2.4.4 Nighttime Mode Activation. Activate
the highest wattage light source(s) allowed by the
vehicles mechanization in nighttime mode. Allow
lamp to dwell for 4 h with chamber temperatures
maintained at 50 C and 100 C as specified
above.
4.10.2.4.4.1 For lamp types noted in 4.10.2.4.2 that
contain a socket or heat sink that directly connects
to the housing and holds an active light source in
daytime mode, perform the following:
February 2012
Page 18 of 59

4.10.2.4.4.1.1 At 100 C, with the lamp in the
chamber, apply a 10 N load normal to the socket or
external heat sink (if exposed) of the active light
source for 20 s. See Figure B2 for a sample photo
displaying load direction and load tip.
4.10.2.4.4.1.2 After loading, remove the lamp from
the chamber, cool to ambient temperature, and
evaluate according to 4.10.4.
4.10.2.4.4.2 For all lamp types noted in 4.10.2.4.3
that do not contain a socket or heat sink that
directly connects to the housing, remove the lamp
from the chamber and evaluate according to
4.10.4.
4.10.3 External Heat Test for Headlamp Bulb
Connector Terminals.
4.10.3.1 Purpose. To verify that heat generated by
the lamp subsystem does not exceed thermal
properties of the headlamp bulb connector(s). This
procedure applies to all headlamps.
4.10.3.2 Equipment. Reference equipment noted
in the External Heat Test of this section.
4.10.3.3 Sample Size. One sample that has
completed the Internal Heat Test of this test
section.
4.10.3.4.1
Instrument
test
sample
bulb
connector(s) as instructed in the Headlamp Bulb
and Connector Temperature Cycle Test.
4.10.3.4.2 Perform the External Heat Test in
Nighttime Mode Activation. During entire test,
measure and record the temperature of each
connector terminal at a minimum of every
30 minutes.
4.10.3.4.3 Record maximum rated terminal
temperature as defined by the manufacturer.
4.10.3.4.4 Remove the lamp from the chamber and
evaluate according to 4.10.4
4.10.4.1 Lamps tested at 39 C shall pass all
post-test requirements in 4.6.
4.10.4.2 Lamps tested at 50 C shall pass all of the
post-test requirements in 4.6 except that lens
deformation up to 1.0 mm is acceptable. Review
any lamp with slight deformation with the GM
4.10.4.3 Lamps tested at 50 C front side and
100 C back side shall pass all of the post-test
requirements in 4.6 except that outer lens
deformation up to 1.0 mm is acceptable. Review
any lamp with slight deformation with the GM
4.10.4.4 Measured temperatures shall not exceed
the maximum rated temperature for terminal
GMW14906
substrate and plating materials as provided by the

terminal supplier.
4.11 Light Up. See Data Sheet A7.
4.11.1 Purpose. To determine the effects of long
term lamp activation on lamp components.
4.11.2 Equipment.
4.11.2.1 An area where three pair or six samples
can be positioned in vehicle position spaced
>300 mm apart horizontally and vertically edge to
edge (to minimize heating affects) with minimal
airflow less than 3 km/h at an ambient temperature
of 23 C 5 C.
4.11.2.2 Direct Current (DC) power supply capable
of supplying 9 V to 16 V DC.
4.11.2.3 Controller capable of energizing all lamp
functions contained in the sample following the
cycles specified in the LAP in Figure 2.
4.11.3 Sample Size. Three (3) pair or six samples.
4.11.4 Procedure.
4.11.4.1 Perform and pass pre-test requirements in
4.3.3, 4.3.5, and 4.3.6.
4.11.4.2 Mount lamps in vehicle orientation.
4.11.4.3 Unless otherwise specified, activate the
highest wattage light source(s) as electrically
mechanized by the vehicle and for the durations
shown in Figure 2.
4.11.4.4 Lamp Assemblies Without Dedicated
DRL. Activate all light sources according to
Figure 2,
repeating
the
180 minute
cycle
continuously for 12 days. During the last hour of
each 24 h, turn off all lamp functions to completely
cool the lamp. Begin the next cycle at the
beginning of the LAP. Reduced Intensity Low
Beam (RILB) DRL is not evaluated in this test.
Note: Lamp assemblies with an independent DRL
source as an integral part of the assembly shall
also be tested to section 4.11.4.8, for the DRL
function only. The DRL function is not active during
Section 4.11.4.4.
4.11.4.5 Signal Functions. Activate signal
functions at 90 flashes 30 flashes per minute with
50% 20% current on-time. Do not flash a red
signal function when combined with the stop
function or an amber signal when used as a DRL.
4.11.4.6 Fog Lamps. Activate front fog lamp
functions as indicated in Figure 2 unless the
function is contained within the headlamp. In that
case, activate the front fog lamp with the low beam
only. For fog lamps combined with DRL activate
each function as independent functions.
February 2012
Page 19 of 59

4.11.4.7 Unswitched Lamps. If a lamp function
does not have a switching mechanism that allows
the function to be on continuously such as puddle
lamps, assist step lamps, etc., then activate the
function on and off at the vehicle time out duration
at a cycle of 1 h activated and 1 h off. If the vehicle
time out duration is not provided, activate the
function for 1 minute on and 1 minute off.
4.11.4.8 Dedicated DRL and Stand Alone DRL.
Separately test lamp assemblies containing a
dedicated DRL (including H15 bulb or other two
filament executions) with three pair of unique
samples for 23 h on and 1 h off with the DRL
activated for 28 days. LED dedicated DRL stand
alone lamps are not required to complete this test
and shall fulfill the LED Light Source
Requirements.
4.11.4.9 Inspections. A visual inspection is
required after the first 4 h and then once after
every 24 h cycle until complete. Inspect the lamp
with functions activated and off. Monitoring can be
suspended for a period of up to 72 h to account for
weekends. Document the onset of visual
incidences, contact the GM Validation Engineer
and GM Designing Engineer, and continue the test
the full 12 or 28 days.
4.11.4.10 Perform post-test requirements 4.6.3,
4.6.5, and 4.6.6.
4.11.4.11 Acceptance Criteria. Lamps shall pass
post-test requirements specified. No outgassing on
dedicated DRLs is permissible.
4.12 Weld Joint and Snap Attach Stress. See
Data Sheet A8.
4.12.1 Purpose. To determine if the stress levels
within a welded lamp assembly, multi-color lens
assembly, and over-molded lens assembly are
within acceptable levels. Alternately, to determine if
the stress levels within snap attachment features
are within acceptable limits when tested in a
nominal deflected state.
4.12.2 Equipment.
4.12.2.1 Ethanol.
4.12.2.2 Methanol.
4.12.2.3 Ethyl Acetate.
4.12.2.4 Isopropanol.
4.12.2.5 Reagent Grade Ethanol (>97%).
4.12.3 Sample Size. Two (2) pair of lamps or three
samples for each specific test. When testing snap
attachment features, two pair of samples or three
samples from each tool cavity shall be tested.
4.12.4 Procedure.
GMW14906
4.12.4.1 Lamps require production representative

molding stress levels of the bonded materials and
production representative bonding between the
joints to be tested. Snap features shall be tested in
their installed design nominal position and
orientation, requiring a mounting plate or fixture.
Annealing shall also be representative of the
production process with the time and temperature
noted in the test report.
4.12.4.2 Solution Preparation. Prepare solutions
as follows:
Solution Number 1, 34% ethyl acetate in

methanol
Solution Number 2, 50% ethanol in water
Solution Number 3, 50% methanol in water
Solution Number 4, 50% isopropanol in water
Solution Number 5, reagent grade ethanol

4.12.4.3 Apply the applicable solution from Table 4
to the lamp welded joint and/or snap features with
a cotton ball, cotton swab, or cheesecloth.
Thoroughly saturate the housing, housing and lens
joint, entire lens surface, and snap features. Allow
to evaporate.
Note: Use a well ventilated area and personal
protective equipment to apply solvent in all 4.12
tests.
4.12.5 Acceptance Criteria. Inspect weld joint
and/or snap feature for stress cracks on the lens
and housing and snap features usually shown in
the form of white cracks perpendicular to the weld
joint or other feature line. No cracks may form on
either the lens or housing within 10 minutes of
application.
4.13 LED Light Source Requirements. See Data
Sheet A9.
4.13.1 LED Lamp Actuation Cycle.
4.13.1.1 Purpose. To verify the LED lamp
assembly meets long-term requirements.
4.13.1.2 Sample Size. Three (3) pair or six
samples.
4.13.1.3 Procedure.
4.13.1.3.1 Perform pre-test requirements 4.3.3,
4.3.4, 4.3.5, and 4.3.6.
4.13.1.3.2
Activate
lamps
at
90 flashes 30 flashes per minute with 50%
current on-time for 1 500 000 on activations
(approximately 12 days duration).
4.13.1.3.3 Lamps designed to function with dual
current shall be tested with 20% of activations at
high current, and 80% at low current values.
February 2012
Page 20 of 59

Table 4: Weld Joint Stress Test Solutions by
Lamp Material
Housing
Substrate
PC
Lens/Frame
Substrate
Stress Solution
PC (Lens or Frame) Solution #1
Cracking
substrate
PC
PC
ABS+PC (Frame)
Solutions 2, 3, and 4
ABS+PC
PC
ABS (Frame)
ABS
PC
ASA (Frame)
PC
ASA+PC (Frame)
PC
ABS+PC
PMMA (Lens)
Solution #3
PC (Lens or Frame) Solutions 2, 3, and 4
ASA
ASA+PC
PMMA
ABS+PC
ABS+PC
ABS+PC (Frame)
ABS+PC
ABS+PC
ABS (Frame)
ABS
ABS+PC
ASA (Frame)
ASA
ABS+PC
ASA+PC (Frame)
ABS+PC
ABS+PC
PMMA (Lens)
PMMA
ABS
ABS
ABS
ABS+PC (Frame)
ABS
ABS
ABS (Frame)
ABS
ABS
ASA (Frame)
ABS
ABS
ASA+PC (Frame)
ABS
ABS
PMMA (Lens)
ABS
ASA
ASA
ASA
ABS+PC (Frame)
ASA
ASA
ABS (Frame)
ABS
ASA
ASA (Frame)
ASA
ASA
ASA+PC (Frame)
ASA
ASA
PMMA (Lens)
PMMA
ASA+PC
PC (Lens or Frame) Solution #3
ASA+PC
ASA+PC
ABS+PC (Frame)
ABS+PC
ASA+PC
ABS (Frame)
ABS
ASA+PC
ASA (Frame)
ASA+PC
ASA+PC (Frame)
ASA+PC
PMMA (Lens)
Solution #3
ASA
ASA+PC
PMMA

4.13.1.4.1 Lamps shall pass post-test requirements
4.6.3, 4.6.4, 4.6.5, and 4.6.6.
4.13.1.4.2 All circuitry shall function; all LEDs shall
function with no more than 25% change in
photometric output.
4.13.1.4.3 Record All Results per 3.5.
4.13.2 LED Continuous Activation.
4.13.2.1 Purpose. To determine the photometric
degradation of the lamp system after long-term
continuous activation conditions.
4.13.2.2 Sample Size. Three (3) pair or six lamp
samples.
GMW14906
4.13.2.3 Procedure.
4.13.2.3.1 Perform pre-test photometric testing
4.3.4.
4.13.2.3.2
Set
ambient
temperature
to
23 C 5 C.
4.13.2.3.3 Activate light source and circuit
assembly.
4.13.2.3.4 Activate for 2000 h continuously without
interruption.
4.13.2.3.5 Perform post-test photometric testing
per 4.6.4.
4.13.2.4 Acceptance criteria. All circuitry shall
function; all LEDs shall function with no more than
25% change in photometric output.
4.14 Condensation for Lamps with Oleophobic
Membranes. See Data Sheet A10.
4.14.1 Purpose. To determine if condensation will
form inside a lamp after exposure to high humidity
and temperature change conditions with water
spray. This procedure is applicable to lamps with
and without anti-fog coating applied to the interior
surface of the lens. Lamps with anti-fog coating
shall be tested with and without the coating
applied.
4.14.2 Equipment.
4.14.2.1
DC
power
supply
capable
of
12 V to 16 V DC.
4.14.2.2 Forty eight (48) h timer.
4.14.2.3 Dual water spray and thermal chamber(s)
capable of temperatures from 20 C to 85 C with
circulating air and humidity levels of 50% to 100%
relative humidity (RH) on one half of the chamber.
4.14.2.4 Water spray capability from simple shower
manifold to deliver a solid conical spray at
approximately 18 L/minute at 3 bar and capable of
temperatures from 15 C to 25 C.
4.14.2.5 Baffle to separate front and rear
environments of the lamp.
4.14.3 Sample Size. Two (2) pair or three (3)
samples. If initial samples include anti-fog coating
an additional two (2) pair or three (3) samples
without anti-fog coating are required.
4.14.4 Procedure.
4.14.4.1 Pre-condition the test lamp at
80 C 2 C and <10% RH with all bulbs and bulb
access covers removed from the lamp for at least
24 h.
February 2012
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4.14.4.2 Cool to ambient temperature, re-install
bulbs and bulb access covers and mount the lamp
in the thermal chamber in vehicle position;
pre-conditioned
at
20 C 4 C
and
70% 10% RH on the back side of lamp. The front
side environment shall be at 20 C 4 C and
75% 25% RH. Install a baffle around the lamp to
separate the front and rear of lamp. Pre-condition
the lamp for at least 24 h.
4.14.4.3 For headlamps, fog lamps, and other
lamps mounted to the front of the vehicle only:
Increase ambient temperature of the back chamber
at > 2 C per minute to 80 C 2 C and
10% 5% RH until the ambient temperature
reaches 80 C. Activate all functions mechanized
with low beam and begin continuous spray of the
lamp lens, uniformly across the lens surface.
4.14.4.4 For rear lamps, side lamps, and other
lamps not mounted to the front of the vehicle:
Increase ambient temperature of the back chamber
at > 2 C per minute to 50 C 2 C and
10% 5% RH until the ambient temperature
reaches 50 C. Activate the lamp functions that
draw the highest wattage per the vehicles
mechanization. Activation shall be approved by the
responsible GM Engineer. If a turn signal is part of
the lamp assembly, activate it 90 flashes/minute
with a 50% 2% current on time. Begin continuous
spray of the lamp lens, uniformly across the lens
surface.
4.14.4.5 Continuously monitor the lamp for the
formation of condensation.
4.14.4.6 Record the time duration to form
condensation from the start of water spray. Record
ambient conditions on the front and back side of
lamp.
4.14.4.7 After 60 minutes, shut off water supply
and turn off lamp functions. With an indelible
marker, mark the areas where condensation is
visible on the lens or interior surfaces of the lamp,
if condensation is present. Photograph the marked
areas. Attach labeled photographs to the test data
sheet for each sample.
4.14.5.1 Lamps shall pass post-test requirements
4.6.3, 4.6.5, and 4.6.6.
4.14.5.2 The time to form visible condensation
shall be greater than 20 minutes. If the production
intent design includes anti-fog coating and the test
sample is tested without the anti-fog coating, the
time to form visible condensation shall be greater
than 15 minutes.
GMW14906
4.15 High Humidity Environments. See Data

Sheet A11.
4.15.1 Purpose. To determine if the lamp is
resistant to extended humidity exposure.
samples.
4.15.3 Equipment. Thermal chamber capable of
temperatures from 20 C to 50 C with circulating
air and humidity levels of 50% to 97% RH.
4.15.4 Procedure.
4.3.3, 4.3.5, and 4.3.6.
4.15.4.2 Test to GMW14729, 97% 3% RH
exposure at 40 C for 240 h with all bulbs and bulb
access covers removed. After the test, install all
service gaskets and covers, and store the samples
for 24 h at +70 C 3 C, 10% 5% RH.
4.15.5.1 Lamps shall pass post-test requirements
4.6.3, 4.6.5, and 4.6.6.
4.15.5.2 No test samples shall show any dripping
moisture or any degradation of aluminized
components.
4.16 High Pressure Water. See Data Sheet A12.
4.16.1 Purpose. To verify the seal integrity of
externally mounted lamps whose rear components
extend into the interior of the vehicle.
samples.
4.16.3 Procedure.
4.16.3.1 Perform and pass pre-test requirements
4.3.3, 4.3.5, and 4.3.6.
4.16.3.2 Test body-sealed lamps to the
requirements of GMW3172 IPX9K installed in
vehicle orientation with a test distance of
300 mm. Lamps shall be mounted to a fixture
which represents a nominal body sealing condition.
4.16.4 Acceptance Criteria. No ingress of water
into the body cavity or lamp assembly is permitted.
Lamps shall pass post-test requirements 4.6.3,
4.6.5, and 4.6.6.
4.17 Leak Check for Production Processing
Determination. See Data Sheet A13.
4.17.1 Purpose. To determine the LTP and
Pressure Decay Rate (PDR) parameters for the
production samples during the production process.
4.17.2 Equipment.
4.17.2.1 Pressure system capable of delivering air
pressure from 0 kPa to 70 kPa in 1.75 kPa
increments.
February 2012
Page 22 of 59

4.17.2.2 Mass Flow equipment capable of
measuring a decay rate accurate to 1 Standard
Cubic Centimeter per Minute (SCCM) at the above
pressures.
4.17.3 Sample Size. Fourteen (14) samples are
required for LTP determination and 30 samples for
the PDR.
Note: Forty four (44) unique samples are required.
Do not reuse samples.
4.17.4 Procedure.
4.17.4.1 Determine minimum pressure failure limit
for each lamp. All samples shall be fully production
representative and include all boots, sockets,
sealing grommets, etc., with all adhesives cured.
Body sealed lamps shall be mounted to a rigid
fixture using production mounting features and
fasteners, only. The lamp seal to fixture interface
shall represent the nominal seal surface. The
fixture shall be sealed at all joints and surfaces
where the body sealed lamp does not mount and
also allow for lamp pressurization through a sealed
port.
4.17.4.2 Install all mating electrical connectors and
pressurize the lamp the same way the production
facility will test it.
4.17.4.3
Guidelines
for
Pressurization
Techniques.
4.17.4.3.1 Use the vent opening to pressurize the
lamp.
4.17.4.3.2 If the lamp has multiple vents, use one
of the vents for pressurization and plug the other
openings.
4.17.4.3.3 If the lamp has no vents, remove the
bulb socket or connector and pressurize through
that opening.
4.17.4.4 Submerse the lamp completely under
2.5 cm of water and pressurize in 1.75 kPa
increments
below
10.5 kPa
and
3.5 kPa
increments above 10.5 kPa. Dwell for a minimum
of 1 minute at each increment until a leak is
detected.
4.17.4.5 Leak Definition. A leak is any visible
bubble under water or trail of bubbles emanating
from the lamp assembly. Bubbles emanating from
a wire harness lead at the connector shall not be
considered a leak if the connection is made inside
the vehicle.
4.17.4.6 Record the pressure failure limit and leak
locations for each lamp.
4.17.4.7 Statistically determine using normal
distribution analysis the 3 (three standard
deviations) pressure leak Lower Control Limit
(LCL). Statistically, this is the maximum lamp
GMW14906
pressure that will not exceed its pressure failure

limit.
4.17.4.8 The LTP is 80% of the LCL calculated
above. The LTP shall be at least 7.0 kPa. Any
pressure above 28.0 kPa shall be tested at
28.0 kPa.
4.17.5
Pressure
Decay
Rate
(PDR)
Determination.
4.17.5.1 Measure all decay rates in Standard
Cubic Centimeters per Minute (SCCM) using a
Mass Flow Decay system with a minimum
stabilization time of 10 s.
4.17.5.2 During a production representative run of
the lamp, measure the PDR of each lamp at the
LTP determined in 4.17.4.7.
4.17.5.3 After the run, verify each lamps seal
using the 2.5 cm test specified in 4.3.3. If the
adhesive is not totally cured during the production
process, also measure the PDR of each lamp at
the LTP determined in 4.17.4 with the adhesive
fully cured.
4.17.5.4 Statistically determine using normal
distribution analysis the 3 (three standard
deviations) maximum PDR Upper Control Limit
(UCL) which can occur without the lamp leaking.
This PDR shall be used during the production
process.
4.17.5.5 Also, calculate the minimum PDR LCL for
the same lamps. If during production, the mean of
accepted parts drops below the calculated PDR
LCL, recalibration of the PDR is required. In all
cases the PDR shall be < 35 SCCM at 7.0 kPa.
4.17.6 LTP and PDR. The LTP from 4.17.4.7 and
the PDR from 4.17.5.4 are the parameters that
shall be used to set up the production leak test
equipment. The Supplier shall determine the
specific fill time, stabilization time, and test time
based on repeatedly being able to measure a
lamp's leak rate.
Note: The adhesive may not be totally cured when
leak tested in the production process. If a lower
LTP than determined in 4.17.4.7 is necessary,
demonstrate there is correlation between the
uncured LTP and PDR to the LTP determined in
4.17.4.7 and the PDR determined in 4.17.5.4. The
Engineer and supplier quality engineer shall
approve this correlation.
4.18 HID Component Ignition Reliability. See
Data Sheet A14.
4.18.1 Purpose. This test verifies high intensity
gas discharge igniter assemblies reliability under
extreme temperatures.
February 2012
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4.18.2 Sample Size. Seven (7) pair or 14 HID
igniter assemblies.
4.18.3 Procedure.
4.18.3.1 HID High Temperature Test. Pre-soak
igniter assemblies at 100 C 3 C for 2 h.
Activate as in Table 5, eight times sequentially for
a total of 16 h at 100 C 3 C, monitoring for
correct ignition throughout.
4.18.3.2 HID Low Temperature Test. Pre-soak
the same igniter assemblies at -40 C 3 C for
2 h. Activate as in Table 5, eight times sequentially
for a total of 16 h at -40 C 3 C, monitoring for
correct ignition throughout.
4.18.4 Acceptance Criteria. Lamps shall pass
post-test requirements 4.6.6.
Table 5: HID Ignition Cycling Activation Times
On time
(seconds)
Off time
(seconds)
1200
12
480
300
300
180
180
180
120
180
60
180
30
180
18
18
1200
282
1200
900
4.19 Adaptive Forward Lighting and Dynamic

Headlamp Leveling System.
If a headlamp is so equipped, requirements and
methods of GMW14570, GMW14571, and
GMW14572 apply. Complete tests in this section in
the order defined. See Data Sheet A15.
4.19.1 Mechanical Fatigue Test Procedure.
4.19.1.1
High
Temperature
Degradation.
Conduct this test on an Adaptive Forward Lighting
(AFL) and/or Dynamic Headlamp Leveling (DHL)
lamp module, bracket and motor system according
to test methods of GMW3172 and the
environmental codes defined in the respective
specification document. The test period is 2000 h
at the maximum operating temperature of the
headlamp. During and after the test, functional
status classification A is required. AFL and DHL
GMW14906
operation shall be from the full inboard to full

outboard positions for a total number of
movements equal to 10% of total movements
required during the Component Reliability Test
defined in 4.19.3.
4.19.2 AFL/DHL Component Mechanical Shock.
Conduct this test according to test methods of
IEC 60068-2-27 Ea or as included in GMW3172.
Use samples tested to High Temperature
Degradation, only. With the mechanism securely
mounted in vehicle orientation, apply successive
shocks in each direction of the three principle
perpendicular axes for six directions total. See
Table 6.
Table 6: Mechanical Shock Parameters
Description
Acceleration
Nominal shock duration
Nominal shock shape
Total number of shocks
Test
25G
10 ms
Half sine
400 6 = 2400
4.19.3 Component Reliability Requirements and

Test Procedure. The reliability requirement is
R97/C50 (97% reliability with 50% confidence).
Test seven pair or 14 lamp assembly samples to
two
lives
(8 000 000
movements/life
or
approximately 14.7 weeks/life) for success-based
testing. Use Figure 3 for the required swivel range
or the respective part drawing. A 0.5 s dwell
follows each movement. Repeat the 40 s cycle
continuously. If the operating angle extremes are
different than shown in Figure 3, use a
proportionally similar 40 s cycle approved by the
Engineer.
4.19.3.1
AFS/DHL
Combined
Movement
Requirements.
4.19.3.1.1 All lamp illumination functions are off
during this test.
4.19.3.1.2 Test 10% at 100 C; 10% at -30 C;
80% at 25 C.
4.19.3.1.3 Test 25% of AFS movements with
maximum DHL movements, 25% of AFS
movements with two-thirds () maximum DHL
movements, 25% of AFS movements with
one-third () maximum DHL movements, and 25%
of movements with no DHL movement. See
Table 7. Test complete table, then repeat, if time
allows.
February 2012
Page 24 of 59

4.19.3.1.4 Measure accuracy in degrees to the
nominal (photometric) position and response time
every 1.0 million cycles. Systems designed to
interface with vehicle Local Interconnect Network
(LIN) shall also be tested and monitored for
functionality using the corresponding AFS/DHL
electronic control module. LIN communication shall
be replicated in the test setup and used to control
movements and diagnose potential incidents.
4.19.3.1.5 Calculate reliability at 8.0 million
movements with Weibull analysis of failure data.
4.19.3.1.6 Test to failure or stop when schedule
requires. At least one life is required. Two (2) lives
are preferred. If no failures, use degradation
analysis to predict when accuracy or response time
would have reached an unacceptable value. Apply
Weibull analysis to the predicted degradation to
estimate reliability at 8.0 million movements.
4.19.3.2
DHL
(no AFS)
Movement
Requirements.
4.19.3.2.1 All lamp illumination functions are off
during this test.
4.19.3.2.2 Test 10% at 100 C; 10% at -30 C;
80% at 25 C. See Table 7, DHL System Only
cycles. Test complete table, then repeat, if time
allows.
4.19.3.2.3 Measure accuracy in degrees to the
nominal (photometric) position and response time
every 1.0 million cycles. Systems designed to
interface with vehicle LIN shall also be tested and
monitored for functionality using the corresponding
AFS/DHL
electronic
control
module.
LIN
communication shall be replicated in the test setup
and used to control movements and diagnose
potential incidents.
4.19.3.2.4 Calculate reliability at 8 million
movements with Weibull analysis of degradation
data.
4.19.3.3.1 No loss of function.
4.19.3.3.2 Accuracy greater than 0.2 degree
vertical and 1 degree horizontal from nominal.
4.19.3.3.3 Response time degradation < 10%.
4.19.3.3.4 No perceptible degradation of operation
smoothness.
4.20 Solar Load Test.
4.20.1 Purpose. To determine if a lamp meets
specified requirements when exposed to solar
load. The GM Validation Engineer and GM
Designing Engineer shall approve lamps selected
for test. Lamp assemblies meeting any of the
following criteria shall also be subject to this test.
GMW14906
4.20.1.1 Linear distance of the exposed class A

lens surface is more than 450 mm and lamp is
mounted above the rear or front bumper/fascia.
Examples would include cross-car CHMSL,
appliqu or, vertically oriented tail lamps; such as
shown in Figure B3 of Appendix B.
4.20.1.2 Any part of the lens surface extends to an
adjacent interfacing panel providing exposure of a
horizontal surface to the sun. Examples are shown
in Figure B3 of Appendix B.
4.20.2 Equipment.
4.20.2.1 Radiant heat source using a bank of
250 W infrared heat lamps.
4.20.2.2 Shielded test fixture base.
4.20.2.3 Black painted 10 10 cm (4 in 4 in)
sheet aluminum panels. Black to be 5% to 10%
gloss
4.20.3 Sample Size. Three (3) samples or two (2)
pair of handed samples.
4.20.4 Procedure.
4.3.3 and 4.3.5. See Data Sheet A16.
4.20.4.2 Fixture sample in car position to test
fixture base. Test fixture base shall be shielded
such that its temperature is not affected by the
solar lamps.
4.20.4.3 Place the sample and the radiant heat
source in the environmental chamber such that the
light from the radiant heat source is uniformly
distributed over the test sample. If the lamp has
surface that extends to the horizontal surface of
the vehicle per production design, the radiant heat
source shall be placed above the samples. For
appliqus, rear quarter mount and other rear facing
lamps mounted above the fascia, the radiant heat
source shall be placed in a forward facing position
to the rear surface of the lamp.
4.20.4.4 Place three (3) black test panels evenly
distributed on each test sample. One panel shall
be on the centerline of the lamp. The remaining
test panels shall be placed the distance from the
test sample centerline to edge of sample or 30 cm,
whichever is greater. See Figure 7.
4.20.4.5 Correlate the radiant heat source by
adjusting the distance to the test samples such that
when the environment is stabilized at 23 C, the
black test panel temperatures are maintained at
85 C 5 C. If the radiant heat source is placed
above the sample according to 4.20.4.3, then the
black panel temperatures are to be maintained at
95 C 5 C.
Reference
GMW15308
for
illustrations that define vehicle temperature zone
requirements in the proximity of exterior lamps.
February 2012
Page 25 of 59
GMW14906
At DHL Angle
1 degrees ( Max.)
At DHL Angle
2 degrees ( Max.)
At DHL Angle
3.5 degrees (Max.)
Play Road Lighting

Movements (x1000)
Town Lighting Movements

(x1000)
Country Lighting
Movements (x1000)
6.7
20
43.3
21.7
23.3
16.7
34
30.7
12.4
DHL Movements (x1000)
Nominal Position
35
-8
(Max.)
DHL System Only
DHL Angle (% of Total

Movements)
At DHL Angle
1.5 degrees ( Max.)
1 680
Adverse Weather
Movements (x1000)
At DHL Angle
3 degrees ( Max.)
21
Motorway Movements
(x1000)
At DHL Angle
5 degrees (Max.)
AFL Advanced Lighting Modes
Movements @ Swivel
Angle (x1000)
DHL Movements (x1000)

When Combined with AFL
AFL Swivel Angle

(% of Total Movements)
AFL Swivel Angle

(degrees)
AFL (Swivel Only)
Note 1
DHL Angle (degrees) [Max.

= maximum]
Table 7: Movement Requirements for AFS/DHL Combined
-5
2.9
(Max.)
21
420
80
-3
-3
320
35
6.7
20
43.3
21.7
23.3
16.7
6.5
5.9
2.4
0.5
0.6
(2/3 Max.)
-1.5
-1
12
960
35
6.7
20
43.3
21.7
23.3
16.7
19.4
17.6
7.1
1.1
1.7
(1/3 Max.)
12
240
26
2 080
35
6.7
20
43.3
21.7
23.3
16.7
42.1
38
15.3
2.3
3.6
0
1
26
520
13
1 040
35
6.7
20
43.3
21.7
23.3
16.7
21.1
19
7.7
1.2
1.8
(1/3 Max.)
13
260
14
280
10
200
2
3
400
35
6.7
20
43.3
21.7
23.3
16.7
8.1
7.4
0.5
0.7
(2/3 Max.)
3.5
5
240
35
6.7
20
43.3
21.7
23.3
16.7
4.9
4.4
2.4
0.5
80
35
6.7
20
43.3
21.7
23.3
16.7
1.7
1.5
1.8
0.2
160
35
6.7
20
43.3
21.7
23.3
16.7
3.3
7.1
0.3
11
80
35
6.7
20
43.3
21.7
23.3
16.7
1.7
1.5
0.2
13
15
160
35
6.7
20
43.3
21.7
23.3
16.7
3.3
0.3
(Max.)
10
800
35
6.7
20
43.3
21.7
23.3
16.7
16.2
14.7
1.4
% of Total Advanced Lighting Movements:

8 Million Movements
2 Million Movements
42.0% 37.9% 15.2%
1.4%
388,000 Movements
(Max.)
3.5%
2 Million Movements
Note 1: Max. denotes Maximum in Table 7.
4.20.4.6 Remove the black panels.

4.20.4.7 Expose the samples to the correlated
radiant heat source for 3 hours. Record
observations every half hour. The lamps are not to
be activated.
4.20.4.8 Perform post-test requirements 4.6.3 and
4.6.5 and record all results.
4.20.5.1 Lamps shall pass post-test requirements.
4.20.5.2 If a defect is detected, it is only

considered a failure if it is perceivable from greater
than 30 cm (1 ft) away. Record all defects on the
data sheet, including those visible from closer than
30 cm (1 ft) away.
4.21 Submersion Test. (Applicable to lamps with
glass lenses only.)
4.21.1 Purpose. To determine if a lamp with glass
lens is resistant to stress induced from thermal
shock events.
February 2012
Page 26 of 59
GMW14906
4.21.2 Sample Size. Two (2) pair or three

samples.
Figure 7: Solar Test Setup

4.21.3 Equipment. Thermal chamber capable of
temperatures from ambient to 85 C.
4.21.4 Procedure.
4.3.3 and 4.3.5. See Data Sheet A17.
4.21.4.2 Test to ISO 16750-4 (reference section
titled: Submersion).
4.21.4.2.1 The exposure temperature Tmax shall be
specified by the temperature code selection for
GMW3172 tests as defined in the Subsystem
Technical Specification (SSTS) or respective
specification.
4.21.4.2.2 The holding time th shall be equal to

30 minutes.
4.21.4.2.3
Transition
duration
shall
be
<10 seconds.
post-test requirements 4.6.3 and 4.6.5.
4.22 Free Fall Test for All Lamps. Reference
GMW3172.
4.22.1 Purpose. This test is applicable to all lamp
types and shall verify lamp function and breakage
caused by free fall.
4.22.2 Sample Size. Two pair or three lamps.
February 2012
Page 27 of 59

4.22.3 Equipment. Concrete surface or steel plate.
4.22.4 Procedure.
4.3.3, 4.3.5 and 4.3.6.
4.22.4.2 Suspend lamp from 1 m above the
concrete surface or steel plate.
4.22.4.3 Position the lamp in an orientation that
may create the worst case for impact.
4.22.4.4 Release the lamp and inspect for damage
and/or loss of function after impact.
4.22.4.5 Repeat 4.22.4.2 through 4.22.4.4 with the
same lamp oriented in the same dimensional axis
but on the opposite side of the housing.
4.22.4.6 Repeat the procedure for remaining
samples. Record all results on Data Sheet A18.
4.22.5 Acceptance Criteria. Lamps shall be
evaluated to post-test requirements 4.6.3, 4.6.5
and 4.6.6 after each free fall. If no visible damage
is noted after impact, the lamp shall meet post-test
requirements. The lamp shall be disassembled for
inspection of internal components. No hidden
damage is accepted. Visible damage is
acceptable. If visible damage without disassembly
of the lamp is noted, results meet acceptance
criteria.
4.23 Storage Test.
4.23.1 Purpose. To determine if a lamp meets
specified requirements when exposed to storage
conditions and in the orientation as shipped in the
production container.
4.23.3 Equipment.
4.23.3.1 Thermal chamber capable of maintaining
+90 C to -40 C with air circulation.
4.23.3.2 Production container or simulated
container environment.
4.23.4 Procedure.
4.3.1 and 4.3.5.
4.23.4.2 Place test sample in the environmental
chamber in its shipping position at ambient.
4.23.4.3 Increase the chamber temperature at a
rate of 1 C per minute and expose the test sample
to Cycle 1, per Table 8.
GMW14906
Table 8: Storage Test Temperature Profile
Cycle
1
Temperature
Duration
80 C 3 C
48 h
Ambient
(23 C 5 C)
15 minutes
-40 C 3 C
24 h
Ambient
(23 C 5 C)
15 minutes
Lamps shall be unlit during test.

4.23.4.4 At the completion of Cycle 1, allow the
lamp to stabilize, then expose to Cycle 2, per
Table 8.
4.23.4.5 Remove the lamp from the chamber and
record all observations on Data Sheet A19.
post-test requirements 4.6.1 and 4.6.5 at the end
of Cycle 2.
4.24 Thermal Shock. Reference GMW3172.
4.24.1 Purpose. To verify that the lamp is immune
to thermal fatigue that is caused by temperature
changes and possible miss-matching of the
coefficient of thermal expansion (CTE) of
materials.
4.24.3 Equipment. Environmental chamber, with
circulating air, capable of maintaining the test part
at TMIN and TMAX as defined by the Electrical/
Electronic Environmental code in the relevant
specification. The chamber shall be capable of the
temperature transition rate as shown in Figure 8.
4.24.4 Procedure.
4.3.2, 4.3.3, 4.3.4, 4.3.5 and 4.3.6. Record on Data
Sheet A20.
4.24.4.2 Place the test part in the environmental
chamber at room temperature.
4.24.4.3 With test lamp unlit, lower the chamber
temperature to TMIN at the rate defined by Figure 8
and then dwell for 120 minutes.
4.24.4.4 Transition the chamber temperature to
TMAX within a time period 20 seconds. Dwell for
120 minutes.
4.24.4.5 Lower the chamber temperature to
ambient temperature at the rate defined by
Figure 9. Immediately, repeat the temperature
shock profile for a total of five (5) consecutive
cycles.
February 2012
Page 28 of 59
GMW14906
Figure 8: Lamp Thermal Shock Profile

4.24.4.6 After cycling, allow the test lamp to
stabilize at ambient temperature.
post-test requirements 4.6.2, 4.6.3, 4.6.4, 4.6.5
and 4.6.6 at the completion of repetitive shocks.
4.25 Headlamp Adjustment Retainer and Fixed
Pivot Pull Force.
4.25.1 Purpose. To determine if the pull out forces
associated with the headlamp adjustment retainers
and mounting fixed pivots meet axial loading
requirements correlated to vehicle loading
conditions experienced during maximum pot hole
and rough road events.
4.25.2 Sample Size. Seven samples, Dry As
Molded. Multiple cavity tools shall test seven (7)
samples of each adjuster stud and adjuster
retainer combination.
Note: Shipping plastic components may skew test
results due to moisture absorption of some
plastics. It is recommended that this test be
performed in the manufacturing facility where
adjustment mechanisms are produced.
4.25.3 Equipment. Tensile test apparatus capable
of measuring 500 N load, force gage if required
and holding fixture as specified in the procedure.
4.25.4 Procedure.
4.25.4.1 Secure adjuster retainer holding fixture,
with a retainer used for setup, to the tensile test
apparatus.
4.25.4.2 Mount an adjuster stud into the tensile test
apparatus, or force gage if required, as shown in
Figure 9.
4.25.4.2.1 Align adjuster stud to retainer and set

the downward travel on the tensile test apparatus
to properly engage the adjuster stud into the
retainer, as specified on component drawings.
Note: Do not allow over travel of the headlamp
stud in the direction of engagement as this may
damage the test fixture or test parts.
4.25.4.2.2 After alignment, proper engagement of
the adjuster components and tensile tester
apparatus setup, replace the adjuster retainer and
adjuster stud with new test samples.
Figure 9: Retainer Pull Test Setup
February 2012
Page 29 of 59

4.25.4.2.3 Using the tensile tester, insert the
adjuster stud into the retainer at a speed of
127 mm/minute 1 mm/minute. No measurement
required.
4.25.4.2.4 Reset any required measurement gages
and equipment.
4.25.4.2.5 Pull out the adjuster stud from the
adjuster
receiver
at
a
speed
of
127 mm/minute 1 mm/minute. Measure the peak
force. Record all data on Data Sheet A21.
4.25.5 Acceptance Criteria. Pull out force of dry
as molded adjuster components, if applicable, shall
be 440 N.
4.26 Solar Irradiance for Lamps with
Condensing Lenses.
4.26.1 Purpose. To determine if a condensing lens
in a lamp assembly will focus sunlight and damage
other internal components of the lamp.
Note: This test is applicable to lamp assemblies
containing
condensing
lenses.
If
internal
components adjacent to the lenses are 100%
bright metalized, this test may be waived by the
responsible GM Validation Engineer.
4.26.2 Sample Size. One sample.
4.26.3 Equipment.
4.26.3.1 Steady state solar simulator capable of
2
producing irradiance 1000 W/m and classified to
Class A for spectral match, spatial non-uniformity
and temporal instability of irradiance per
ASTM E927-10. Irradiance shall be independent of
distance to the test piece.
Note: Solar simulation equipment is capable of
producing collimated light and is not to be replaced
by standard laboratory heat lamps or other artificial
light sources.
4.26.3.2 Lamp holding frame or fixture, capable of
automatically or manually rotating the lamp through
90 degrees of travel in each axis, in order to
expose condensing lenses to the simulator light
source.
4.26.4 Procedure.
4.3.5 and record on Data Sheet A22.
4.26.4.2 Secure lamp in holding frame or fixture
and position lamp in a nominal start of test
position.
4.26.4.3 Activate the simulation light source so that
the source directs light into the projector
2
condensing lens at an irradiance of 1000 W/m or
greater, and at the determined nominal start
position. Figure 10 shows a typical simple test
setup.
GMW14906
Figure 10: Solar Irradiance Sample Test Setup

4.26.4.4 Slowly rotate the lamp (or light source)
through 90 degrees of travel in each X-Y-Z axis
and at compound angles attempting to focus the
light exiting the condensing lens, as shown in
Figures 11 and 12.
Note: Focused light will be evident on adjacent
components or surfaces of adjacent internal lamp
parts (for example, on a bezel surface).
Figure 11: Collimated and Focused Light

through a Condensing Lens
February 2012
Page 30 of 59
Figure 12: Collimated and Focused Light

through a Condensing Lens on Bezel
4.26.4.5 Repeat lamp rotations several times
attempting to focus light collimated to the lens.
Record the positions at which light will focus on
Data Sheet A22 and attach photos.
4.26.4.6 For each position recorded on the data
sheet, expose the test part for 10 minutes and
record observations on Data Sheet A22. Attach
photos. Note location of focused light.
4.26.5 Acceptance Criteria. Lamps shall meet
4.6.5 post-test requirements and shall not exhibit
any defect from collimated light focused through a
condensing lens at any position.
5 Provisions for Shipping

Not applicable.
6 Notes
6.1 Glossary.
Activate: Applying the voltage specified to a lamp
light source(s) or other device.
Cycle: Time duration that a lamp light source is
activated and deactivated during a test sequence.
A cycle repeats until the test is complete, unless
otherwise specified.
High Beam Four Bulb Burn: A headlamp lighting
system that meets high or driving beam
requirements by energizing two beam contributors
on each side of the vehicle.
High Beam Two Bulb Burn: A headlamp lighting
system that meets low beam requirements by
energizing one beam contributor on each side of
the vehicle.
Low Beam Four Bulb Burn: A headlamp lighting
system that meets low or dipped beam
requirements by energizing two beam contributors
GMW14906
Low Beam Two Bulb Burn: A headlamp lighting

system that meets low or dipped beam
requirements by energizing one beam contributor
Socket: Any mechanism to retain and provide
power to a replaceable bulb. Examples are quarter
turn sockets, circuit plates, or bulbs with which
contain electrical connectors.
Vehicle Voltage (High): Voltage at activated
function when ambient temperature is 40 C, the
battery state of charge is < 80% and the electrical
loads are minimal. Voltage to signal functions that
are activated with headlamps shall be determined
with headlamps activated.
Two (2) filaments or other light sources in a bulb
shall be treated as two light sources and shall both
be activated if the light sources can be activated
simultaneously in the vehicle, excluding flash to
pass.
Vehicle Voltage (Low): Voltage at the activated
function when the battery is at 12.8 V. If the power
provided by the vehicle to the lamp is controlled
through wave shaping like Pulse Width Modulation
(PWM), then the voltage applied during test shall
duplicate this wave shaping, preferably using the
same control module that is intended for the
vehicle.
6.2 Acronyms, Abbreviations, and Symbols.
ABS
Acrylonitrile Butadiene Styrene
AFL
Adaptive Forward Lighting System
(may be used interchangeably with
AFS)
AFS
Adaptive Front Lighting System (may
be used interchangeably with AFL)
ASA
Acrylonitrile Styrene Acrylate
CHMSL
Center High Mounted Stop Lamp
CTE
Coefficient of Thermal Expansion
DC
Direct Current
dB
decibel
DE
Designing Engineer
DHL
Dynamic Headlamp Leveling
DRL
Daytime Running Light
DV
Design Validation
ECE
Economic Commission for Europe
EXT
Exterior
FMVSS
Federal Motor Vehicle Safety Standard
G
Gravity
Grms
Gravity root mean square
HALT
Highly Accelerated Life Test
HID
High Intensity Discharge
February 2012
Page 31 of 59

H-V
LAP
LCL
LED
LIN
LTP
MPV
PC
PDR
PMMA
PV
PWM
RH
RILB
RMS
SAE
SCCM
SSTS
TIE
TPA
UCL
UH
VHAD
Horizontal-Vertical
Lamp Activation Profile
Lower Control Limit
Light Emitting Diode
Local Interconnect Network
Leak Test Pressure
Multipurpose Passenger Vehicle
Polycarbonate
Pressure Decay Rate
Polymethylmethacrylate
Product Validation
Pulse Width Modulation
Relative Humidity
Reduced Intensity Low Beam
Root Mean Square
SAE International
Standard Cubic Centimeter per Minute
Subsystem Technical Specification
Technical Integration Engineer
Terminal Position Assurance
Upper Control Limit
Under Hood
Vehicle Headlamp Aiming Device
7 Additional Paragraphs
GMW14906
Issue
Publication
Date
Description
(Organization)
AUG 2007
Initial publication.
MAR 2009
Revised 4.5 Temperature

and Vibration, Figure 2
LAP, Figure 4 Power
Spectral Density, Table 4,
4.8 Corrosion, 4.10 Internal
Heat, 4.12 Weld Joint
Stress, Table 3 added, 4.14
Condensation, 4.16 High
Pressure Water. Table 5
updated to GMW3172 Aug
2008. Data sheet for salt
spray removed. Separate
Light Up Data Sheet
removed and combined
with
Figure
2.
Anticondensation
coating
testing and data sheet
removed.
Water
spray
removed. Combined water
spray and dust exposure
removed. References to
GMW3172 Code Letters
removed. (Exterior Lighting
GSSLT)
NOV 2010
Added Seal test methods

for pre-post test verification.
General comments added
for
clarity.
Corrected
misprint in Vibration PSD
table. Modified truck profile
to match vehicle data.
Added DHL only durability
requirements. Added AFL
durability requirements for
systems with increased
environmental functionality.
Updated Data Sheet A10
Condensation for Lamps
with
Oleophobic
Membranes.
Added
additional
terms
in
Glossary. Added Headlamp
bulb and connector testing.
Added
solenoid
requirements and testing.
(Exterior Lighting GSSLT)
7.1 All parts or systems supplied to this standard

must comply with the requirements of GMW3059,
Restricted and Reportable Substances for
Parts.
8 Coding System
This standard shall be referenced in other
documents, drawings, etc., as follows:
GMW14906
9 Release and Revisions

This standard was originated in December 2005. It
was first approved by the Exterior Lighting GSSLT
in August 2007. It was first published in
August 2007.
February 2012
Page 32 of 59
Issue
Publication
Date
Description
(Organization)
AUG 2011
Added
Solar
Test,
Submersion Test for glass
lens lamps. Revised Light
Up Test for Dedicated
Stand Alone DRL, External
Heat test, Condensation
test.
(Exterior
Lighting
GSSLT)
FEB 2012
Added Free Fall, Storage,

Thermal Shock, Adjuster
Pull Force and Solar
Irradiation testing. Added
Start/Stop, Post-Test Rattle,
Aim
Screw,
Headlamp
Connector Thermal and
Dual Function LED Light up
Requirements. Clarified and
detailed multiple sections.
Harmonize with reorganized
SSTS. (Exterior Lighting
GSSLT)
GMW14906
February 2012
Page 33 of 59
GMW14906
Appendix A: Test Data Sheets

Data Sheet A1: Highly Accelerated Life Test (HALT)
Part Name:
Part Number:
Program Name:
Test Location:
Test Date:
Test Voltage:
4.2.5.4 Combined Environment
4.2.5.3 Vibration Step Stress
4.2.5.2 Rapid Thermal Transition
4.2.5.1 Thermal Step Stress
4.3.6 Function
4.3.6 Squeak and Rattle
Post-Test
4.3.5 Appearance
4.3.4 Light Output
4.3.3 Seal
4.3.2 Aim
4.3.1 Dimension
Right Hand
Left Hand
Sample Number
Pre-Test
Test Incident Notes
Enter data or observations in the appropriate box.
Comments:
Instrument Calibration Record
Instrument
Number
Calibration Date
Recorded by:
Calibration Due Date
Date:
(Signature)
February 2012
Page 34 of 59
GMW14906
Data Sheet A2: SAE J575 Vibration 90 Minute

Part Name:
Part Number:
Program
Name:
Test Date:
Test Location:
Test Voltage:
60-Minute
Observations
90-Minute
Observations
No observed
rotation,
displacement,
cracking,
looseness, or
rupture of parts
of the device
(except bulb
filaments or
headlamp light
source
filaments).
No observed
rotation,
displacement,
cracking,
looseness, or
rupture of parts
of the device
(except bulb
filaments or
headlamp light
source
filaments).
4.6.6 Function
4.6.5 Appearance
4.6.3 Seal (LTP)
Post-Test
4.6.2 Aim
4.3.6 Function
4.3.5 Appearance
4.3.3 Seal
4.3.2 Aim
Right Hand
Left Hand
Sample Number
Pre-Test
Comments:

Instrument
Number
Calibration Date
Recorded by:
Date:
(Signature)
February 2012
Page 35 of 59
Instrument
Recorded
by:
February 2012

Number
Calibration Date
Test Location:
Test Date:
Test Voltage:
Program Name:
4.6.6 Function
Part Number:
4.6.5 Appearance
Part Name:
4.6.4 Light Output
4.6.3 Seal (LTP)
Pre-Test
4.6.2 Aim
4.6.1 Dimension
Lamp First Natural

Frequency (vertical)
Lamp First Natural
Frequency (lateral)
Lamp First Natural
Frequency (longitudinal)
4.3.6 Function
4.3.5 Appearance
4.3.4 Light Output
4.3.3 Seal
4.3.2 Aim
4.3.1 Dimension
Resonant Frequency of
Aiming Mechanism
Headlamp Reflector Natural
Frequency
Lamp First Natural

Frequency (longitudinal)
Lamp First Natural

Frequency (vertical)
Lamp First Natural
Frequency (lateral)
Right Hand
Left Hand
Sample Number

GMW14906
Data Sheet A3: Temperature Cycling Vibration
Post-Test

Test Incident Notes
10
11
12
13
14
Comments:
Date:
(Signature)
Page 36 of 59
GMW14906
Data Sheet A4: Accelerated Corrosion - Cyclic

Part Name:
Part Number:
Program Name:
Test Location:
Test Date:
4.6.6 Function
4.6.5 Appearance
4.6.4 Light Output
4.6.3 Seal (LTP)
4.6.2 Aim
4.6.1 Dimension
4.3.6 Function
Post-Test
4.3.5. Appearance
4.3.4 Light Output
4.3.3 Seal
4.3.2 Aim
4.3.1 Dimension
Right Hand
Left Hand
Sample Number
Pre-Test
Test Incident Notes
1
2
3
4
5
6
Comments:
Instrument
Number
Calibration Date
Recorded by:
Date:
(Signature)
February 2012
Page 37 of 59
GMW14906
Data Sheet A5: Weatherability
Pre-Test
Observation
1
Observation
2
Observation
3
Observation
4
Observation
5
Post-Test
4.6.5 Appearance
4.6.5 Appearance
4.6.5 Appearance
4.6.5 Appearance
4.6.5 Appearance
4.6.5 Appearance
Part Number:
Test Location:
4.3.5 Appearance
Right Hand
Left Hand
Sample Number
Part Name:
Program Name:
Test Date:
Test
Incident
Notes
6
Comments:
Instrument
Number
Recorded by:
Calibration Date
Calibration
Due Date
Date:
(Signature)
February 2012
Page 38 of 59
GMW14906
Data Sheet A6 (Part 1): Internal and External Heat

Part Name:
Part Number:
Program Name:
Test Location:
Test Date:
Test Voltage:
4.6.6 Function
4.6.5 Appearance
4.6.4 Light Output
4.6.3 Seal (LTP)
4.6.2 Aim
4.6.1 Dimension
Post-Test 50 C
4.6.6 Function
4.6.5 Appearance
4.6.3 Seal (LTP)
4.6.2 Aim
4.6.1 Dimension
Dirty Candela
Initial Clean
Candela
4.3.6 Function
4.3.5 Appearance
4.3.4 Light Output
4.3.3 Seal
4.3.2 Aim
4.3.1 Dimension
Right Hand
Left Hand
Sample Number
4.6.4 Light Output
Post-Test 39 C
Pre-Test
Test Incidents

1
4.6.6 Function
4.6.5 Appearance
4.6.4 Light Output
4.6.3 Seal (LTP)
4.6.2 Aim
4.6.1 Dimension
4.6.6 Function
4.6.5 Appearance
4.6.4 Light Output
4.6.3 Seal (LTP)
4.6.2 Aim
4.6.1 Dimension
4.3.6 Function
4.3.5 Appearance
4.3.4 Light Output
4.3.3 Seal
4.3.2 Aim
4.3.1 Dimension
Right Hand
Left Hand
Sample Number
Post-Test 50 C/100 C
nighttime mode
Post-Test 50 C/100 C
daytime mode
Pre-Test
Test Incidents

5
Comments:
Instrument
Number

Calibration Date
Recorded by:
Date:
(Signature)
February 2012
Page 39 of 59
GMW14906
Data Sheet A6 (Part 2): External Heat for Headlamp Bulb Connector Terminals
Part Name:
Part Number
Program Name:
Test Location:
Test Date:
Test Voltage:
Maximum Rated
Temperature (C)
Temperature (C) at Time (minutes)

Terminal
Number
30
60
90
120
180
240
300
360
Terminal
Comments/Observations
Other
Meets Requirements (Yes/No)?_____

Additional Comments:
Instrument
Number

Calibration Date
Recorded by:
Date:
(Signature)
February 2012
Page 40 of 59
GMW14906
4.6.6 Function
4.6.5. Appearance
Post-Test
4.3.3 Seal
Day 12
4.6.5. Appearance
Day 11
Day 8
4.6.5. Appearance
4.6.5. Appearance
Day 7
4.6.5 Appearance
Day 10
Day 6
4.6.5 Appearance
4.6.5. Appearance
Day 5
4.6.5 Appearance
Day 9
Day 4
4.6.5 Appearance
Day 3
4.6.5 Appearance
4.3.6 Function
4.3.5 Appearance
4.3.3 Seal
Sample Number
Left Hand
Right Hand
Pre-Test
Day 2
Test:
Location:
Test Voltage:
4.6.5 Appearance
Program:
Name:
Test Date:
4 hour
Part Number:
4.6.5 Appearance
Part Name:
4.6.5. Appearance
Data Sheet A7: Light Up
Comments:
Instrument
Number
Calibration Date
Recorded by:
Date:
(Signature)
February 2012
Page 41 of 59
GMW14906
Data Sheet A8: Weld Joint Stress

Part Name:
Part Number:
Program Name:
Test Location:
Right Hand
Pre-Test
Left Hand
Sample Number
Test Date:
Lens/ Snap Material
Post-Test
Test Solution
Time to Cracking
Test Incident Notes
Comments:

Instrument
Number
Recorded by:
Calibration Date
Date:
(Signature)
February 2012
Page 42 of 59
GMW14906
Data Sheet A9: LED Light Source Requirements

Part Name:
Part Number:
Program Name:
Test Location:
Test Date:
Test Voltage:
Lamp Activation 1 500 000 Cycle Test
Pre-Test
LED 2000 h Steady Post-Test
Burn
LED 2000 h Steady Burn

Pre-Test
Post-Test
4.6.4 Light Output
(% reduction)
4.3.4 Light Output

(total candela
output)
4.6.6 Function
4.6.5 Appearance
4.6.4 Light Output
4.6.3 Seal (LTP)
4.3.6 Function
4.3.5 Appearance
4.6.4 Light Output
4.3.3 Seal
Right Hand
Left Hand
Sample Number
Pre-Test
Test Incident Notes
1
2
3
4
5
6
7
8
9
10
11
12
Comments:

Instrument
Number
Recorded by:
Calibration Date
Date:
(Signature)
February 2012
Page 43 of 59
GMW14906
Data Sheet A10: Condensation for Lamps with Oleophobic Membranes

Part Number:
Program Name:
Test Location:
Test Date:
Test Voltage:
Ambient
Temp (C)
Ambient Air,
Ambient Air,
Water Temp (C)
4.6.6 Function
4.6.5 Appearance
Place an X in the boxes below to

indicate requirements have been met.
Relative Humidity (%)
of Lamp
Ambient Air
Rear Side
of Lamp
Temp (C)
Front Side
Post-Test
4.6.3 Seal (LTP)
4.3.6 Function
4.3.5 Appearance
4.3.3 Seal
Right Hand
Left Hand
Sample Number
Pre-Test
Air Relative Humidity (%)
Part Name:
Test Incident Notes
1
2
3
4
Record results for additional samples without anti-fog coating, below (reference procedure)
1
2
3
4
Attach photos to final test report
Comments:

Instrument
Recorded
by:
Number
Calibration Date
Date:
(Signature)
February 2012
Page 44 of 59
GMW14906
Data Sheet A11: High Humidity Environments

Part Name:
Part Number:
Program Name:
Test Location:
`
T
est Post-Test
T
P
ostT
est
4.6.5 Appearance
4.3.6 Function
4.3.5 Appearance
Right Hand
L e f t Hand
Sample Number
Pre-Test
4.6.6 Function
Test Date:
Test Incident Notes
1
2
3
4
Comments:

Instrument
Number
Recorded by:
Calibration Date
Date:
(Signature)
February 2012
Page 45 of 59
GMW14906
Data Sheet A12: High Pressure Water

Part
Number:
Test
Location:
Part Name:
Program Name:
Test Date:
4.6.6 Function
4.6.5 Appearance
High Pressure
Water to GMW3172
IPX9K or
GMW14528
4.6.3 Seal (LTP)
Post-Test
4.3.6 Function
4.3.5 Appearance
4.3.3 Seal
Right Hand
Left Hand
Sample Number
Pre-Test
Test Incident Notes
4
Comments:
Instrument

Number
Calibration Date
Recorded by:
Date:
(Signature)
February 2012
Page 46 of 59
GMW14906
Data Sheet A13: Leak Test Pressure Decay Rate

Part Name:
Part Number:
Program Name:
Test Location:
Right Hand
Left Hand
Sample Number
Test Date:
4.17.5.2
Pressure
4.17.4.6
Production Decay Rate
Leak Test Average
Pressure Pressure Leak Test (measured 4.17.5.3 Production Pressure
Pressure Leak Test
Lower
Upper
Pressures
at
Seal
Pressure
Decay
Failure
Failure
Control
Control
(80% of
80% of
check per Decay Rate
Rate
Limit
Pressure Limit (LCL) Limit (UCL)
LCL)
LCL)
4.3.
UCL
LCL
Test Incident Notes

(include location of leaks)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
Comments:

Instrument
Number
Recorded by:
Calibration Date
Date:
(Signature)
February 2012
Page 47 of 59
GMW14906
Data Sheet A14: HID Ignition Reliability

Part Number:
Test Location:
Test Date:
Test Voltage:
Right Hand
Pre-Test
Left Hand
Sample Number
Part Name:
Program Name:
4.3.6 Function
HID High
Temperature
Test Function
HID Low
Temperature
Test Function
Post-Test
4.6.6 Function
Test Incident Notes
Comments:

Instrument
Number
Recorded by:
Calibration Date
Date:
(Signature)
February 2012
Page 48 of 59
GMW14906
February 2012
Page 49 of 59
GMW14906
Data Sheet A16 (Part 1): Solar Load

Part Name:
Part Number:
Program Name:
Test Location:
Test Date:
Test Voltage:
2
3
4.3.6 Function
4.3.5 Appearance
4.3.4 Light Output
4.3.3 Seal
4.3.2 Aim
4.3.1 Dimension
Right Hand
Test Incident Notes

Zero to 30 minutes
Left Hand
Sample Number
Pre-Test
4
Test Incident Notes
2
3
60 minutes
4
Test Incident Notes
2
3
90 minutes
4
Test Incident Notes
2
3
120 minutes
4
Note: Continue to record data on Data Sheet A16 (Part 2)
February 2012
Page 50 of 59
GMW14906
Right Hand
Left Hand
Sample Number
Data Sheet A16 (Part 2): Solar Load
Test Incident Notes
150 minutes
1
2
3
4
4.6.6 Function
4.6.5 Appearance
4.6.4 Light Output
4.6.3 Seal (LTP)
4.6.2 Aim
4.6.1 Dimension
Right Hand
Left Hand
Sample Number
Post-Test
Test Incident Notes
2
3
End of Test

Instrument
Number
Recorded by:
Calibration Date
Date:
(Signature)
February 2012
Page 51 of 59
GMW14906
Data Sheet A17: Submersion Test

Part Name:
Part Number:
Program Name:
Test Location:
Test Date:
Test Voltage:
4.3.6 Function
4.3.5 Appearance
4.3.4 Light Output
4.3.3 Seal
4.3.2 Aim
4.3.1 Dimension
Tmax (C)
Right Hand
Left Hand
Sample Number
Pre-Test
Test Incident Notes
1
2
3
4
4.6.6 Function
4.6.5 Appearance
4.6.4 Light Output
4.6.3 Seal (LTP)
4.6.2 Aim
4.6.1 Dimension
Right Hand
Left Hand
Sample Number
Post-Test
Test Incident Notes
2
3
End of Test

Instrument
Number
Recorded by:
Calibration Date
Date:
(Signature)
February 2012
Page 52 of 59
GMW14906
Data Sheet A18: Free Fall for All Lamps

Part Name:
Part Number:
Program Name:
Test Location:
Test Date:
Test Voltage:
4.6.6 Function
4.6.5 Appearance
4.3.3 Seal Leak
4.6.6 Function
4.6.5 Appearance
4.6.3 Seal Leak
Post-Test
4.3.6 Function
4.3.5 Appearance
4.3.3 Seal Leak
Tambient (C)
Right Hand
Left Hand
Sample Number
Pre-Test
Test Incident Notes
2
3
4

Instrument
Number
Recorded by:
Calibration Date
Date:
(Signature)
February 2012
Page 53 of 59
GMW14906
Data Sheet A19: Storage Test for All Lamps

Part Name:
Part Number:
Program Name:
Test Location:
Test Date:
Test Voltage:
4.6.5 Appearance
Post-Test
4.6.1 Dimension
4.3.5 Appearance
4.3.1 Dimension
Tambient (C)
Right Hand
Left Hand
Sample Number
Pre-Test
Test Incident Notes
1
2
3
4

Instrument
Number
Recorded by:
Calibration Date
Date:
(Signature)
February 2012
Page 54 of 59
GMW14906
Data Sheet A20: Thermal Shock

Part Name:
Part Number:
Program Name:
Test Location:
Test Date:
Test Voltage:
4.3.6 Function
4.3.5 Appearance
4.3.4 Light Output
4.3.3 Seal (LTP)
4.3.2 Aim
4.3.1 Dimension
Tmax (C)
Right Hand
Left Hand
Sample Number
Pre-Test
Test Incident Notes
1
2
3
4
4.6.6 Function
4.6.5 Appearance
4.6.4 Light Output
4.6.3 Seal (LTP)
4.6.2 Aim
4.6.1 Dimension
Right Hand
Left Hand
Sample Number
Post-Test
Test Incident Notes
2
3
End of Test

Instrument
Number
Recorded by:
Calibration Date
Date:
(Signature)
February 2012
Page 55 of 59
GMW14906
Data Sheet A21: Headlamp Adjustment Retainer and Fixed Pivot Pull Force
Adjuster Type/
Number
Pull Force
(N)
Test Incident Notes
Pull Force
(N)
Test Voltage:
Adjuster Type/
Number
Test Location:
Test Date:
Cavity Number
Program Name:
Cavity Number
Part Number:
Sample Number
Part Name:
Test Incident Notes
1
2
3
4
5
6
Sample Number
1
2
3
4
5
6
7

Instrument
Number
Recorded by:
Calibration Date
Date:
(Signature)
February 2012
Page 56 of 59
GMW14906
Data Sheet A22: Solar Irradiance for Lamps with Condensing Lenses
Pre-Test
Post-Test
4.3.5 Appearance
4.6.5 Appearance
Photo)
Test Voltage:
Position (Number and Attach
Test Location:
Test Date:
Right Hand
Program Name:
Left Hand
Part Number:
Sample Number
Part Name:
Test Incident Notes

Instrument
Number
Recorded by:
Calibration Date
Date:
(Signature)
February 2012
Page 57 of 59
GMW14906
Appendix B: Test Setup Photos and Illustrations

Note: Test photos and illustrations in this Appendix are provided for example only. Test equipment and
configurations may differ by location.
Figure B1: Partial External Heat Test Oven Bag Option for Back Side Temperature
Figure B2: External Heat Test - Load Adapter and Direction
February 2012
Page 58 of 59
GMW14906
Figure B3: Solar Load Test Lamp Selection Examples
February 2012
Page 59 of 59

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WORLDWIDE

Lamp Development and Validation Test Procedures

Seal Leak Test Pressure (LTP)

Test Preparation and Evaluation

Requirements and Procedures (cont)

Electrical Components and Electronic

Electrical Connectors and Power

Electrical Wiring and Lamp

Headlamp Bulb and Connector

Requirements and Procedures

Bulb and Socket Removal Force

Highly Accelerated Life Test (HALT)

Internal and External Heat

External Heat Test for Headlamp

SAE J575e August 1970 Vibration

Weld Joint and Snap Attach Stress

Temperature and Vibration

LED Light Source Requirements

LED Lamp Actuation Cycle

LED Continuous Activation

Originating Department: North American Engineering Standards

GM WORLDWIDE ENGINEERING STANDARDS

Table of Contents continued

Condensation for Lamps with

High Humidity Environments

High Pressure Water

Leak Check for Production

HID Component Ignition Reliability

Adaptive Forward Lighting and

Solar Load Test

Headlamp Aim Adjustment Retainer

Solar Irradiance for Lamps with

Provisions for Shipping

Restricted and Reportable

Release and Revisions

Test Setup Photos and Illustrations

Copyright 2012 General Motors Company All Rights Reserved

Lamp Development and Validation Test Procedures

2.3 Additional References.

3 Test Preparation and Evaluation

154 days (22 weeks)

Copyright 2012 General Motors Company All Rights Reserved

Originating Department: North American Engineering Standards

GM WORLDWIDE ENGINEERING STANDARDS

for Europe (ECE) and SAE International regulated

4 Requirements and Procedure

Copyright 2012 General Motors Company All Rights Reserved

GM WORLDWIDE ENGINEERING STANDARDS

Front fog lamps

Lamps with electronic or electro-mechanical

Lamps using any non-traditional fastening

Lamps with multi-color lenses

Lamps using non-traditional vehicle mounting

Simple lamps consisting of a lens and housing

Simple signal lamps mounted in a fascia or to

Simple tail lamps

additional HALT test. Incidents occurring above the

Copyright 2012 General Motors Company All Rights Reserved

GM WORLDWIDE ENGINEERING STANDARDS

4.2.4.1.5 Functional test goals are to achieve

Body sealed lamp

Other lamp with lighted function(s)