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Diagnostic Manual, Climate Control, Volume 1

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LOCATION:    3.3 Air Conditioning (A/C)    >   32 Pneumatic Test Program - Test


Pneumatic Test Program - Test

Preparation for Test

1. Disconnect all vacuum lines at vacuum distributor block (36).

2. Check gray vacuum line to intake manifold for leaks.

Note:
Permissible leakage of the elements with vacuum lines at 400 mbar vacuum per minute is 30 mbar.

Conventional tools, test equipment

Description Brand, model, etc.
Connector 129 805 04 44

A. Vacuum Distributor Block, Vacuum Reservoir, Switchover Valve Block (Y11/3) Test

Test scope Test connection Test condition Nominal value Possible cause/Remedy
1.0 Entire vacuum distributor block Connection "P" on vacuum tester. Evacuate system with
300 mbar vacuum
30 mbar pressure increase in
1 minute
Vacuum distributor block,
1.1
1.1 Vacuum distributor block,
check valve "a"
Connection "1" on vacuum tester. Evacuate system with
300 mbar vacuum
30 mbar pressure increase in
1 minute
Vacuum distributor block,
1.2
1.2 Vacuum distributor block,
check valve "b"
Connection "4" on vacuum tester. Evacuate system with
300 mbar vacuum
30 mbar pressure increase in
1 minute
Vacuum distributor block.
2.0 Vacuum reservoir with
vacuum line
Red/gray vacuum line (connection 4) on vacuum tester Evacuate system with
300 mbar vacuum
30 mbar pressure increase in
1 minute
Vacuum lines,
Vacuum reservoir.
3.0 Switchover valve
block (Y11/3)
Ignition: OFF
medium green line (connection 5) on vacuum tester
Evacuate system with
300 mbar vacuum
30 mbar pressure increase in
1 minute
Y11/3.

B. Vacuum system Test

Test scope Test connection Test condition Nominal value Possible cause/Remedy
1.0 Defroster flap vacuum element, long stroke (80%)   Press
Evacuate system with
300 mbar vacuum
30 mbar pressure increase in
1 minute
Vacuum line,
Defroster flap vacuum element.
2.0 Defroster flap vacuum element, short stroke (20%)1)   Press
Evacuate system with
300 mbar vacuum
30 mbar pressure increase in
1 minute
Vacuum line,
Defroster flap vacuum element.
3.0 Left and right center outlet tempering flap vacuum element   Press
Evacuate with
300 mbar vacuum
30 mbar pressure increase in
1 minute
Vacuum line,
Left and right center outlet tempering flap vacuum element.
4.0 Center outlet diverter flap vacuum element   Press
Evacuate system with
300 mbar vacuum
30 mbar pressure increase in
1 minute
Vacuum line,
Center outlet diverter flap vacuum element.
5.0 Fresh/recirculating air flap vacuum element, long stroke (80%)   Press
Evacuate system with
300 mbar vacuum
30 mbar pressure increase in
1 minute
Vacuum line,
Fresh/recirculating air flap vacuum element.
6.0 Fresh/recirculating air flap vacuum element, short stroke (20%) 1)   Press
Evacuate system with
300 mbar vacuum
30 mbar pressure increase in
1 minute
Vacuum line,
Fresh/recirculating air flap vacuum element.
7.0 Footwell flap vacuum element, long stroke (80%)   Press
Evacuate system with
300 mbar vacuum
30 mbar pressure increase in
1 minute
Vacuum line,
Footwell flap vacuum element.
8.0 Footwell flap vacuum element, short stroke (20%)1)   Press
Evacuate system with
300 mbar vacuum
30 mbar pressure increase in
1 minute
Vacuum line,
Footwell flap vacuum element.
1) Before activating the short stroke (20%), the long stroke (80%) must be activated.