Procedures

AR32.22-P-2001-02GZ Repairing AIRmatic pressure line connection
- with CODE (489) All-round level control system

Special Tools:

Repair Materials:

Component Identification:

In the event of damage to the compressed-air connection (1a) and the pressure line (4) a pressure line connector (3) or a repair screwed connection (1) has to be mounted.

The lines should be replaced completely if pressure lines are damaged at the front components.

A pressure line connector (3) should be used if pressure lines are damaged at the rear components (of the air suspension).

1 Undo pressure line connection (1a) from relevant component (e.g. air suspension strut) and cut pressure line (4) to suitable length using knife.

Special care must be taken to ensure that the cuts are exactly at right angles to the lines.

2 Insert the cutoff pressure line (4) up to the stop or 19.5 mm into the pressure line connector (3).
3 Cut the repair line (2) so as to obtain the original length and shape (straight end or 90 degrees arc) of the line.

Do not buckle line. When cutting the repair line (2) to length, note the insertion depths in the threaded repair fitting (1) and pressure line connector (3).

Repair line (2) with 90 degrees arc for: Rear axle elements, compressor, valve unit, central reservoir. Repair lines (2) supplied by the parts service, with one straight and one bent end for each repair line (2).

4 Insert the repair line (2) up to the stop or to a depth of 19.5 mm in the pressure line connector (3).
5 Screw the repair bolted connection (1) into the component in question.
6 Pull plastic guard (1c) out of repair connection (1).
7 Insert the repair line (2) into the repair bolted connection (1) up to the stop or to a depth of 19.5 mm.

If necessary mark the repair line (2) at 19.5 mm with a felt-tip pen beforehand.

After inserting, the pressure lines should be pulled back slightly so that the retaining edges around the inside of the clamping ring (1b) engage in the outer surface of the line.

When pulling in or routing the line it should be ensured that, after fastening, the lines cannot be twisted anymore. Secure pressure line connectors (3) to a suitable point on the vehicle using tie straps to prevent the pressure lines from chafing and to prevent rattling noises.

If bubbles form at the repair point after a leak test with leak detector spray, check that the pressure lines are inserted as far as the stop. If bubbles continue to form nevertheless, then the pressure line connector (3) may be defective and a new pressure line connector (3) or a new repair bolted connection (1) should be used.