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Diagnostic Manual, Body and Accessories,
Volume 1.1

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LOCATION:

3.5 Models 129, 140, 170 > Pneumatic System Equipment (PSE) > 32 Pneumatic Test Program - Test (CL)

Pneumatic Test Program - Test (CL)

Preparation for Test:
1. Review section 0,
2. Review C/1,

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:
1. Provide access to PSE control module (A37) and disconnect pneumatic line with socket from PSE control module.
2. Connect tester to disconnected pneumatic line using with connector
129 805 03 44.

If an actuator does not operate correctly and no leakage is found, check the respective lines for kinks or blockages.

Parts Required for Test:
1 Connector 202 805 03 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 Connector FT on PSE.
Yellow connector
on tester. Apply 600 mbar pressure to entire system. Pressure loss
30 mbar in
1 minute.
32 PSE/CL 11.0,
32 PSE/CL 13.0

2.0 Complete system evacuated Connector FT on PSE.
Black connector
on tester.
Apply 300 mbar vacuum to entire system. Vacuum loss
30 mbar in
1 minute.
32 PSE/CL 12.0
32 PSE/CL 14.0

3.0 Complete system pressurized Connector BFT or BFT/FOND on PSE.
Yellow connector
on tester. Apply 600 mbar pressure to entire system. Pressure loss
30 mbar in
1 minute.
32 PSE/CL 9.0

4.0 Complete system evacuated Connector BFT or BFT/FOND on PSE.
Black connector
on tester.
Apply 300 mbar vacuum to entire system. Vacuum loss
30 mbar in
1 minute.
32 PSE/CL 10.0

5.0 Complete system pressurized Connector HD or HECK on PSE.
Yellow connector
on tester.
Apply 600 mbar pressure to entire system. Vacuum loss
30 mbar in
1 minute.
32 PSE/CL 9.0

6.0 Complete system evacuated Connector HD or HECK on PSE.
Yellow connector
on tester.
Apply 300 mbar vacuum to entire system. Vacuum loss
30 mbar in
1 minute.
32 PSE/CL 10.0

7.0 Complete system pressurized Connector TK or Tank on PSE.
Yellow connector
on tester.
Apply 600 mbar pressure to entire system. Vacuum loss
30 mbar in
1 minute.
32 PSE/CL 9.0

8.0 Complete system evacuated Connector TK or Tank on PSE.
Black connector
on tester.
Apply 300 mbar vacuum to entire system. Vacuum loss
30 mbar in
1 minute.
32 PSE/CL 10.0

Preparation for Test:
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

1. If an actuator does not operate correctly and no leakage is found, check the respective lines for kinks or blockages.
2. Disconnected pneumatic lines are to be reconnected to the distributor with connector 007 997 61 82.

Parts Required for Test:
1 Pneumatic hose, 50 mm long 007 997 61 82

Parts Required for Repair:
1 Pneumatic hose, (as needed) 007 997 61 82

Test scope Test connection Test condition Nominal value Possible cause/Remedy

9.0 Line and actuator pressurized Yellow connector
on tester. Apply 600 mbar pressure to line and actuator. Pressure drop
25 mbar in
1 minute.
32 PSE/CL 11.0
32 PSE/CL 13.0

10.0 Line and actuator evacuated Black connector
on tester. Apply 300 mbar vacuum to line and actuator. Vacuum loss
25 mbar in
1 minute.
32 PSE/CL 12.0
32 PSE/CL 14.0

Preparation for Test:
1. Remove non functioning actuator.
2. Connect vacuum/pressure tester to pneumatic connection of actuator.

Parts Required for Test:
1 Pneumatic line 129 800 95 15
1 Pneumatic line, 1 m long 000 158 14 35
1 Pneumatic hose, 50 mm long 007 997 61 62
1 Connector 202 805 03 44

Test scope Test connection Test condition Nominal value Possible cause/Remedy

11.0 Actuator holds pressure Yellow connector
on tester. Apply 600 mbar pressure
to actuator. Pressure drop
25 mbar in
1 minute.
Actuator leaks. Replace actuator.

12.0 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 11 45
1 Pneumatic hose, 50 mm long 007 997 61 82

Test scope Test connection Test condition Nominal value Possible cause/Remedy

13.0 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.

14.0 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.