Preliminary work: PSE Control Module Test 32 PSE

Data (mbar)

Test procedure	Permissible deviation
Allowable system leakage at 600 mbar pressure or 300 mbar vacuum in 1 minute.	30 mbar
Allowable leakage of actuators with lines at 600 mbar pressure or 300 mbar vacuum in 1 minute.	25 mbar

Preparation for Test: Vehicles up to approx. 12/93: 1. Disconnect pneumatic multiple connector from PSE control module. 2. Connect tester to bottom side of pneumatic multiple connector at ZV (CL) using connector 129 805 04 44. Vehicles as of approx. 01/94: 1. Disconnect yellow pneumatic line with socket from PSE control module. 2. Connect tester to disconnected pneumatic line using with connector 129 805 04 44. Parts Required for Test: 1 Connector 129 805 04 44 2 Connection hose, 50 mm long 007 997 61 82 1 Pneumatic line, 1 m long 000 158 14 35 Note: The connections on the PSE control module and pneumatic multiple connector are marked with their German acronyms. In other words: ZV (German) = CL (English), SRU (German) = MVA (English), OSL (German) = OSB (English).

	Test scope	Test connection	Test condition	Nominal value	Possible cause/Remedy
1.0	Complete system pressurized	Yellow connector on tester. Connector ZV on bottom side of multiple connector.	Apply 600 mbar pressure to entire system.	Pressure loss 30 mbar in 1 minute.	33 PSE 1.0, 32 3.0
2.0	Complete system evacuated	Black connector on tester. Connector ZV on bottom side of multiple connector.	Apply 300 mbar vacuum to entire system.	Vacuum loss 30 mbar in 1 minute.	33 PSE 2.0, 32 4.0

Preparation for Test: Vehicles up to approx. 12/93: 1. Pry off yellow and black pneumatic lines at pneumatic multiple connector (using a 7 mm open end wrench). 2. Connect tester to each of the yellow or black CL pneumatic lines using connector 007 997 61 82. Vehicles as of approx. 01/94: 1. Disconnect pneumatic line leading to the non-operating pneumatic actuator at the pneumatic distributor. Letters on the distributor indicate to which of the CL actuators the pneumatic line leads. A Left front door D Right rear door B Right front door E Fuel tank filler flap C Left rear door F Trunk lid Note: 1. If an actuator does not operate correctly and no leakage is found, check the respective lines for kinks or blockages. 2. On vehicles as of approx. 06/94, the disconnected pneumatic lines are to be reconnected to the distributor with connector 007 997 61 82. Parts Required for Test: 1 Connector, 50 mm long 007 997 61 82

	Test scope	Test connection	Test condition	Nominal value	Possible cause/Remedy
3.0	Line and actuator pressurized	Yellow connector on tester.	Apply 600 mbar pressure to line and actuator.	Pressure drop 25 mbar in 1 minute.	32 5.0, 32 7.0
4.0	Line and actuator evacuated	Black connector on tester.	Apply 300 mbar vacuum to line and actuator.	Vacuum loss 25 mbar in 1 minute.	32 6.0, 32 8.0

Preparation for Test: 1. Remove actuator, see SMS, Repair Instructions, Job No.'s AR80.20-2160, AR80.20-2200, AR80.20-2300, AR80.20-2400. 2. Connect vacuum/pressure tester to pneumatic connection of actuator. Parts Required for Test: 1 Pneumatic line 129 800 09 15 1 Connector, 50 mm long 007 997 61 62 1 Connector 129 805 04 44

	Test scope	Test connection	Test condition	Nominal value	Possible cause/Remedy
5.0	Actuator holds pressure	Yellow connector on tester.	Apply 600 mbar pressure to actuator.	Pressure drop 25 mbar in 1 minute.	Actuator leaks. Replace actuator.
6.0	Actuator holds vacuum	Black connector on tester.	Apply 300 mbar vacuum to actuator.	Vacuum loss 25 mbar in 1 minute.	Actuator leaks. Replace actuator.

Preparation for Test: 1. Connect tester to one end of pneumatic line and plug other end with cap 000 987 29 45. Parts Required for Test: 1 Cap 000 987 29 45 1 Connection piece (30 mm long) 007 997 61 82

	Test scope	Test connection	Test condition	Nominal value	Possible cause/Remedy
7.0	Line holds pressure	Yellow connector on tester.	Apply 600 mbar pressure to lines.	Pressure drop 0 mbar in 1 minute.	Pneumatic line leaks. Repair/replace line.
8.0	Line holds vacuum	Black connector on tester.	Apply 300 mbar vacuum to lines.	Vacuum loss 0 mbar in 1 minute.	Pneumatic line leaks. Repair/replace line.