1993 CHEVROLET PLYMOUTH ACCLAIM Solenoid

AUTOMATIC AIR LOAD LEVELING SYSTEM INDEX
page page
Compressor Performance Test .............. 61
Compressor Relay ........................ 72
Control Module .......................... 72
General Information ....................... 59
Major Components ....................... 59 Rear Leveling Diagnostic Procedures
......... 65
Right Shock Absorber (With Height Sensor) .... 72
Service Procedures ....................... 62
System Operation ........................ 61
GENERAL INFORMATION
The automatic air load leveling system includes
the following (Fig. 1).:
² Compressor Assembly
² Control Module Wiring Harness
² Air Lines
² Compressor Relay
² Air Shock Absorbers
² Air Dryer
This system is used to supplement standard sus-
pension systems on vehicles so equipped.
MAJOR COMPONENTS
COMPRESSOR ASSEMBLY
The compressor assembly is driven by an electric
motor and supplies air pressure between 1172 to
1516 kPa (170 to 220 psi) (Fig. 2). A solenoid oper-
ated exhaust valve, located in the compressor head
assembly, releases air when energized.
CONTROL MODULE
The Control Module (CM) is a device that controls
the ground circuits for the compressor relay and the
exhaust valve solenoid. A microprocessor within the
module limits the compressor pump operation time to
140 to 160 seconds. To prevent damage to the com-
pressor motor.
Fig. 1 Automatic Air Load Leveling System
Ä SUSPENSION AND DRIVESHAFTS 2 - 59

In addition, there is an air regeneration cycle that
is controlled by the Control Module (CM). If the
height sensor signal is in the neutral or high posi-
tion. When the ignition switch is turned to the ON
position, after a 22 to 28 second delay, the compres-
sor will run from 2 to 6 seconds. To prevent excessive cycling between the compres-
sor and the exhaust solenoid circuits during normal
ride conditions. A 12 to 18 second delay is incorpo-
rated in the microprocessor.
HEIGHT SENSOR
A magnetic switch type sensor, located in the right
air shock absorber, monitors rear vehicle height. The
sensor sends signals to the (CM) relating to vehicle
rear suspension status (low, trim, high).
AIR LINES AND FITTINGS
To release an air supply line from a rear shock ab-
sorber assembly. Push in (toward shock absorber) on
the plastic ring of the shock absorber air line fitting.
Then while holding in the plastic ring on shock ab-
sorber fitting pull the air supply line strait out of fit-
ting (Fig. 3). The fitting has a unique push-in feature. A brass
type collet locks the air line in place. One rubber
O-ring seals the air line to prevent air leakage. To
attach air line, push into fitting (Fig. 4).
COMPRESSOR RELAY
The relay is mounted to a bracket on the Control
Module (CM). When the relay is energized, it allows
the compressor to operate. This unit is controlled by
the CM.
AIR ADJUSTABLE SHOCK ABSORBERS
Air shock absorbers are essentially hydraulic shock
absorbers with a neoprene bladder sealing upper and
lower sections together. This creates an air cylinder
inside of the shock absorber.
AIR DRYER
The air dryer is attached to the compressor. This
component serves two purposes; it absorbs moisture
from the atmosphere before it enters the system. And
with the internal valves maintains a residual system
pressure of 69 to 152 kPa (10 to 22 psi).
AIR CHECK, RESIDUAL (FIG. 5).
The air dryer has a valves arrangement that main-
tains 69 to 152 kPa (10 to 22 psi) in the air shocks.
This is to improve the ride characteristics of the ve-
hicle under light load conditions. To test this func-
tion, perform the following procedure: (1) Remove the air line from the dryer and right
shock absorber. Attach a piece of bulk nylon tubing
to one side of a Pressure Gauge (0-300 psi), and to
the right shock absorber (Fig. 5). (2) Attach another piece of nylon tubing from the
dryer (compressor) to other side of the pressure
gauge.
Fig. 2 Compressor AssemblyFig. 3 Release Air Line from Fitting
Fig. 4 Push Air Line into Fitting
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A compression ball sleeve nut and sleeve for 3/16
inch tubing with ball sleeve connector and an inter-
nal pipe T-fitting. Can be used to attach the tubing
to the pressure gauge. (3) Cycle ignition from OFF to ON.
(4) Apply a load to the rear of the vehicle (two as-
sistants or approximately 300-325 lbs.) to run com-
pressor and raise the vehicle. (5) Remove the load applied in Step 4. Allow the
system to exhaust and lower the vehicle. (6) When no more air can be exhausted, the gauge
should indicate 69 to 152 kPa (10 to 22 psi). (7) Remove the pressure gauge and nylon tubing.
Attach the air line between the dryer and shock ab-
sorber. Repeat Steps 3, 4, and 5 to ensure system air
pressure is in the shocks.
LEAK CHECKS
(1) Repeat Residual Air Check Steps 1, 2, 3, and 4.
Allow the system to fill until gauge reads 483 to 621
kPa (70 to 90 psi). If compressor is permitted to run until it reaches
its maximum output pressure, the vent solenoid
valve will function as a relief valve. The resulting
leak down, when compressor shuts off, will indicate a
false air leak. (2) With load still applied, disconnect wire harness
connector from the control module, then remove ap-
plied load. Vehicle should rise. Cycle ignition switch
to OFF. (3) Observe if pressure leaks down or holds steady
(wait approximately 15 minutes). (A) If system will not inflate beyond 345 kPa (50
psi). A severe leak may be indicated. Check for a
pinched pressure line between compressor and
shocks. (B) The standard soap solution check procedure is
acceptable. (C) If pressure holds steady, perform the diagnosis
procedures.
SYSTEM OPERATION
RAISING VEHICLE HEIGHT
When weight is added to the rear suspension. The
body of the vehicle is lowered, moving the height
sensor down. This action will activate the internal time delay
circuit. After a time delay of 12 to 18 seconds. The
control module (CM) activates the ground circuit to
the compressor relay. With the relay energized, the compressor motor
runs and air is sent through the system. As the
shock absorbers inflate, the body moves upward to a
corrected position. When the body reaches the correct
height, the control module (CM) stops the compressor
operation.
LOWERING VEHICLE HEIGHT
When the weight is removed from the vehicle. The
body moves upward, which allows the height sensor
to move upward and activate the internal time delay
circuit. After a time delay of 12 to 18 seconds. The (CM)
activates the exhaust solenoid circuit. Air is ex-
hausted from the shock absorbers through the air
dryer and exhaust solenoid to the atmosphere. As the body lowers, the height sensor is lowered to-
ward its original position. When the body reaches the
original vehicle height, the (CM) opens the exhaust
solenoid valve circuit.
COMPRESSOR PERFORMANCE TEST
This test can be performed on the vehicle. It is
used to evaluate compressor current draw, pressure
output, and leak down. (1) Disconnect the compressor motor wiring har-
ness connector. (2) Disconnect air line between dryer and right
shock absorber. (3) Connect an air pressure gauge into the system
(Fig. 5). (4) Connect an ammeter in series between the red
wire terminal on compressor connector and a 12 volt
power source. Also, connect a ground wire from the
black wire terminal on the compressor connector to a
good ground on the frame (Fig. 6). (5) If the current draw to the compressor motor ex-
ceeds 21 amperes, replace the compressor assembly. (6) When the air pressure stabilizes at 827 kPa
(120 psi), disconnect the (+) wire lead from the con-
nector. Replace the compressor assembly if any of the
following conditions exists:
Fig. 5 Pressure Gauge Installed in System
Ä SUSPENSION AND DRIVESHAFTS 2 - 61

² Air pressure leaks down below 621 kPa (90 psi),
before it remains steady.
² Output pressure builds up to less than 758 kPa
(110 psi) when it stabilizes. If the compressor is allowed to run during this test
until it reaches its maximum output pressure of 1516
kPa (220 psi). The solenoid exhaust valve will act as a pressure relief valve. The resulting leak-down, af-
ter the compressor is shut off, will indicate a false
leak.
SERVICE PROCEDURES
COMPRESSOR ASSEMBLY
REMOVAL
(1) Disconnect negative battery cable.
(2) Raise vehicle, see Hoisting, Group 0.
(3) Remove cover from compressor assembly. Re-
move air hose and electrical connectors (Figs. 1 and
2). (4) Remove compressor assembly mounting bolts
and lower assembly from vehicle. (5) Remove mounting bracket bolts and slide
mounting bracket away from compressor.
INSTALLATION (1) Slide mounting bracket on compressor and in-
stall bolts and tighten to 8 N Im (70 in. lbs.) torque.
(2) Install compressor assembly to frame rail and
tighten bolts to 8 N Im (70 in. lbs.) torque.
(3) Connect air hose and electrical connector to
compressor assembly. (4) Install cover on compressor assembly and
tighten bolts to 8 N Im (70 in. lbs.) torque.
(5) Lower vehicle and connect negative battery ca-
ble. (6) Check operation of the system.
Fig. 6 Compressor Current Draw Test
2 - 62 SUSPENSION AND DRIVESHAFTS Ä

REAR LEVELING DIAGNOSTIC PROCEDURES
SELF-DIAGNOSTICS
A self-diagnostic procedure is available for the ser-
vice technician to use to detect system malfunctions.
BEFORE DIAGNOSTICS TEST
Check the 20 amp fuse (position W40) and the 30
amp circuit breaker (position W5) to be assured they
are functional components. Check all connectors that link the system into the
main body wiring harness. These include compressor,
height sensor, control module, (Fig. 7) and relay.
Also check the underbody to in trunk and leveling
harness to main body harness connectors. Also, check
all air lines, connectors, and other components for
correct installation.
TEST LAMP PIN OPERATION
The monitor lamp pin output will be activated (test
lamp on) if the detection of abnormal system opera-
tion is determined by the CM.
AFTER COMPLETION OF REPAIRS
To initiate diagnostics, disconnect the test ground
wire then reconnect for repair verification.
TERMINATION OF SELF-DIAGNOSTICS
The self-diagnostic operation is terminated when
any of the following takes place:
² Disconnecting the diagnostic input from the
ground circuit.
² Turn the ignition switch to the off position.
When the self-diagnostic operation is terminated.
The control module resumes normal operation unless
it ceases operation. Due to it detecting a system mal-
function.
TEST WEIGHT
Weight between 275-300 lbs. must be added to rear
of vehicle before diagnostic testing begins.
DIAGNOSTICS (TO START PROCESS)
(1) Remove protective connector cover from diag-
nostic connector. (2) Insert wire into diagnostic ground pin. Then at-
tach to compressor ground pin, or as an alternate, in-
sert wire into diagnostic ground pin. Then ground
other end of test wire to body structure or a control
module fastener.
IGNITION
The following self diagnostic operation is initiated
by connecting the diagnostic ground pin to ground af-
ter ignition switch is turned ON. A monitor lamp
must be connected between the Test Lamp Ground
Pin and the Test Lamp Feed Pin to display the con-
trol module diagnostics status. See (Fig. 8) for diag-
nostic test pin locations.
OPERATION
(1) The compressor relay output. From the control
module (CM), is activated until the vehicle is in the
high position. The maximum relay output operation
time is 150 610 seconds. If the expected position is
not obtained, the CM ceases self-diagnostics and any
further operation. (I.e. neither operates the compres-
sor relay or exhaust outputs). The monitor lamp out-
put is continuously activated until ignition is cycled
from OFF to ON or 60 61 minutes has elapsed after
ignition was turned off. See Diagnostics Chart 1. (2) The monitor lamp output should flash to indi-
cate the position of the height sensor. The sensor
should be in the high position. A continuously
lighted monitor lamp will indicate a system failure.
Such as the compressor relay output has operated for
150 610 seconds but the height sensor did not move
to the high position within the right shock absorber).
See Diagnostic Chart 1. (3) Next the exhaust solenoid output is activated
until the vehicle is in the low position. The maxi-
mum exhaust solenoid operation time is 120 610 sec-
onds. If the expected position is not obtained, the
module ceases self-diagnostics and any further oper-
ation. The monitor lamp output is lighted continu-
ously until ignition is cycled from OFF to ON or 60
6 1 minutes has elapsed after ignition is turned off.
See Diagnostic Chart 4. (4) The monitor lamp should flash to indicate the
height sensor is in the low position. A continuouslyFig. 7 Control Module Connector
Fig. 8 Diagnostic Test Pin Location
Ä SUSPENSION AND DRIVESHAFTS 2 - 65

lighted monitor lamp will indicate a system failure.
Such as the exhaust solenoid operated for 120 610
seconds but the height sensor did not move to the
low position. See Diagnostic Chart 4. (5) The compressor relay output is activated to re-
turn the vehicle to the neutral (leveled) position. The
maximum operation time of the relay output is 150
6 10 seconds. If the expected position is not obtained.
The control module ceases self-diagnostics and any
further operation. The monitor lamp is continuously
lighted until the ignition is cycled from OFF to ON
or 60 61 minutes has elapsed after ignition is turned
off. The sensor will move to the neutral position. If not,
a continuously lighted monitor lamp will indicate a system failure. Such as the compressor relay output
operated for 150 610 seconds but the sensor did not
move to or sense the neutral position. See Diagnostic
Chart 1. (6) Completion of diagnostics, is when self diagnostic
procedure is successfully completed and control module
resumes normal operation. The diagnostic test is now
complete. Throughout the testing the vehicle load must
be maintained at a specific level. No loads are allowed
to be added/removed to/from the vehicle once the self
diagnosis tests have been initiated. The Diagnostic connector cover must be in-
stalled after completion of the test.
2 - 66 SUSPENSION AND DRIVESHAFTS Ä

AUTOMATIC AIR SUSPENSION INDEX
page page
Air Lines ............................... 75
Air Springs Rear ......................... 87
Compressor Performance Test .............. 77
Diagnosis .............................. 78
General Information ....................... 73
Recharge Air Spring ...................... 87 Right Shock Absorber (With Height Sensor)
.... 88
Safety Concerns ......................... 78
Service Procedures ....................... 85
Shipping Mode .......................... 78
Solenoids (Struts and Air Springs) ............ 86
System Operation ........................ 78
GENERAL INFORMATION
This system provides automatic height control and
low spring rates to improve suspension characteristics
of the vehicle. And it will automatically level the front
and rear of the vehicle. It will also maintain the opti-
mum vehicle attitude from one passenger through full
vehicle load.
The automatic air suspension system includes the
following components:
² Compressor/air dryer assembly
² Compressor relay
² Front struts
² Rear springs
² Rear shocks
² Control module
² Air lines ²
Compressor
² Rear height sensor
² Wiring harness assembly
² Compressor cover
Front springs (and height sensors) are integral with
the shock absorber strut assemblies. While rear air
springs replace conventional steel units. Rear height is
controlled via a height sensor contained within the
right rear shock absorber. Solenoids (integral with each
air spring) control air volume/pressure requirements.
Pressurized air is distributed from the air compressor/
dryer assembly and routed to each air spring by four
separate air lines. The air lines start at the dryer and
terminate at the individual air springs. The system is
monitored and controlled by the Air Suspension Control
Module (ASCM) (Fig. 1).
Fig. 1 Automatic Air Suspension
Ä SUSPENSION AND DRIVESHAFTS 2 - 73

FRONT AND REAR AIR SPRINGS
The front and rear air springs are essentially pneu-
matic cylinders that replace the steel coil springs.
The air filled springs allow the vehicle suspension
height to be adjusted for all weight conditions. The air springs allow for the reduction of spring
rates to improve vehicle ride characteristics.
FRONT/REAR SPRING SOLENOIDS
The front and rear solenoids control air flow in and
out of the front and rear springs. The Air Suspension
Control Module (ASCM) opens the solenoids when
the system requires air to be added to or exhausted
from the air springs. The solenoids operate at a cur-
rent draw range of 0.6 to 1.5 amps.
HEIGHT SENSOR
A magnetic switch type sensor. Located in the
right rear shock absorber and left and right front
struts, (Fig. 2) monitors vehicle height. The sensors
transmit signals to the (ASCM) relating to vehicle
height status (low, trim, medium, high).
CONTROL MODULE
The Air Suspension Control Module (ASCM). Is a
device that controls the ground circuits for the Com-
pressor Relay, Compressor Exhaust Solenoid Valve
and Front and Rear Solenoid Valves. The (ASCM)
limits the compressor pump operation time to 170 to
190 seconds. This controlled operation time is to pre- vent damage to the compressor motor.
To prevent excessive cycling between the compres-
sor and the exhaust solenoid circuits during normal
ride conditions. A 14 to 16 second delay is incorpo-
rated in the microprocessor logic. The system is non-operation when one of the fol-
lowing conditions exists. A door(s) is/are open, the
trunk is open, the service brake is applied or the
throttle position sensor is 65% to 100% open. System
operation is inhibited during high speed cornering
activities or if there is a charging system failure.
The control module is on the CCD bus system.
COMPRESSOR ASSEMBLY
The compressor assembly is driven by an electric
motor and supplies air pressure between 930 to 1241
kPa (135 to 180 psi) (Fig. 3). A solenoid operated ex-
haust valve. Located in the compressor head assem-
bly, releases air when energized. A heat actuated circuit breaker. Located inside the
compressor motor housing. Is used to prevent damage
to the compressor motor in case of control module
failure.
COMPRESSOR AIR DRYER
The air dryer is attached to the compressor (Fig. 3).
This component serves two purposes. It absorbs mois-
ture from the atmosphere before it enters the system
Fig. 2 Front and Rear Air Springs
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