Checking For Leaks
Preliminary operation:
Check pneumatic function of the supply pump, Testing and Inspection
Data (mbar)
Permissible leak rate of the entire system at 600 mbar pressure and 300 mbar vacuum in 1 minute: <=30
Permissible leak rate of the elements with lines and 600 mbar pressure and 300 mbar vacuum in 1 minute: <=25
Permissible leak rate of the distributor plug at 600 mbar pressure in 1 minute: 0
Special tools
Commercially available tool
Digital multimeter e.g. Sun, DMM-5
Parts for the test
Sealing piece 124 805 02 44
Connecting piece 007 997 61 82
Sealing cap 000 987 11 45
A. Control of the switchover valves - venting of the central locking of driver's door Y65/1 and passenger door Y65/2 (vehicles up to 12/93)
Prerequisites for testing
Battery voltage 11 - 14V.
Preparing test
1. Remove electrical cable harness (c) on the supply pump
2. Connect digital multimeter to the connector on the electrical cable harness.
Test:
B. Checking entire system for leaks
NOTE: The pneumatic distribution plugs on the supply pump have been eliminated as of the production breakpoint for pneumatic lines using the stamping production method (09/95).
Preparing test
1 Remove distributor plug (b) and electric cable harness (c) on supply pump
2 Bridge sockets 6 and 12 on electrical connection which has been removed (vehicles up to 12/93 only).
3 Connect tester to the bottom of the distributor plug (identification ZV) (vehicles up to 08/95) or to the disconnected yellow pneumatic line (vehicles as of 09/95).
Test:
C. Checking distributor plug for leaks
NOTE: The pneumatic distribution plugs on the supply pump have been eliminated as of the production breakpoint for pneumatic lines using the stamping production method (09/95).
Preparation for test
1 Lever off all pneumatic lines on the distributor plug with open-ended wrench (width between flats 7).
2 Seal off all connections on the upperside of the distributor plug with sealing pieces (Part No. 124 805 02 44).
3 Connect tester to the underside of the distributor plug (designation ZV).
Test:
D. Checking lines with elements for leaks
NOTE: As of the production breakpoint for pneumatic lines produced using the stamping method (09/95) one pneumatic line leads to a 6-way distributor. The individual pneumatic lines are connected here. In order to check the individual actuators and lines for leakage, it is necessary to cut off the corresponding pneumatic lines at the distributor and reconnect them to the distributor after testing using hose connectors. Letters on the distributor indicate the points to which the individual pneumatic lines lead.
A -> Left door
B -> Trunk lid
C -> Connection plugged
D -> Plugged
E -> Right door
F -> Tank flap
Preparing test
1 Connect tester with connecting piece (Part No. 007 997 61 82) to the pneumatic line for the driver's door.
NOTE: If the element does not work correctly, although no leaks have been established, check the relevant line for kinks and continuity.
Test, Part 1 of 3
Test, Part 2 of 3
Test, Part 3 of 3