Eas
Eas
Eas
to 98MY
03/06/98
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Introduction
The electronically controlled air suspension (EAS) system allows different ride heights to be either manually or automatically selected. By changing the volume of air in each of the air springs, the system maintains ride height and quality regardless of load. Four height sensors monitor vehicle height - one for each wheel. Data received from each sensor by the electronic control module is used to maintain, add or release air in each spring by a series of solenoid valves. Seven valves work together in a valve block to manage system heights and air storage. An electric air compressor, regenerative air dryer, and a supply reservoir are used to manage the air used in the system. Range Rover Classic and New Range Rover use basically the same system, differing only in a few details.
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RANGE ROVER CLASSIC CONNECTOR DETAILS......................................................20 NEW RANGE ROVER CONNECTOR DETAILS .............................................................25 PNEUMATIC DIAGRAMS.................................................................................................28 EXPECTED HEIGHT SENSOR BIT COUNTS.................................................................32
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BECM
NEW RANGE ROVER ONLY The BeCM provides basic inputs to the ECU, receives fault messages and controls the message center.
DISABLE SWITCH
RANGE ROVER CLASSIC ONLY The disable switch is located on the back of the right front seat. This switch simulates a door open input to disable height changes by the ECU. The vehicle will gradually drop due to air leakage. For safety reasons, height changes are enabled at 35 mph.
CONTROL SWITCHES
RANGE ROVER CLASSIC Two momentary contact switches and one latching switch are located on the drivers side of the dash. These switches are used to change ride position as well as indicate system status with integral lamps. NEW RANGE ROVER The rocker switches are located in the upper center console and are used to indicate current system status and make manual height changes.
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AIR COMPRESSOR
The electric air compressor has an internal thermal switch which protects the motor from overheating by signaling the ECU if the temperature exceeds 120 C. To meet altitude and pressure requirements the compressor has a compression ratio of 22:1. RANGE ROVER CLASSIC The compressor, valve block, valve driver, and air dryer are attached to the chassis under the passengers seat. Because these components are located below the wade height of the vehicle, the inlet filter is located in the right rear quarter panel. NEW RANGE ROVER The compressor, valve block, valve driver, and air dryer are located under the hood on the left inner fender. A serviceable inlet filter is located on the compressor crankcase.
AIR DRYER
The air dryer is located between the compressor and the reservoir. A diaphragm valve directs exhausting air through the dryer in the opposite direction, removing accumulated moisture from the dryer and thereby regenerating the dryer. The mounting position of the dryer on New Range Rover models is vertical, taking advantage of gravity, to better expel moisture during the exhaust process.
RESERVOIR
CAUTION: The later style reservoirs (for both New Range Rover and Classic) have a different size drain plug. This will require an adapter when performing a pressure test on a later style reservoir. Use the following when doing the pressure test: Early styleLRT-60-001 Later styleLRT-60-001 and LRT-60-006 RANGE ROVER CLASSIC A ten-liter supply tank is attached to the chassis on the drivers side. One nylon air line serves as both inlet and outlet for the system. The reservoir should be depressurized and the drain plug removed and inspected for moisture at 30,000-mile intervals. If moisture is found, the dryer should be replaced. Two different reservoirs are specified depending on VIN: up to VIN SA654292 use NTC9825; from VIN SA654293 and up use ANR3754. NEW RANGE ROVER A nine-liter supply tank is mounted to the chassis on the right side. As in the Classic, a single nylon line serves as both inlet and outlet. The inspection interval is also 30,000 miles, with dryer replacement required if moisture is encountered. As in the Classic, two reservoirs are specified depending on VIN: up to VIN TA340460 use ANR3645; from VIN TA340461 and up use ANR5135.
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VALVE BLOCK
The valve block controls the flow of air in the system in response to decisions made by the ECU. This is accomplished through the use of solenoids, one-way check valves and a fabricated block or manifold. Six hit and drop solenoids (explained below) are used, one for each corner and one each for inlet and exhaust. One direct acting diaphragm solenoid is used to control the direction of airflow in the dryer and is energized by the compressor relay. A blow-off valve is located on the valve block in the event the system pressure exceeds 12.5 BAR (180 psi).
VALVE DRIVER
The six solenoid valves are relatively large because of the response time required by the system. If these solenoid valves were operated for long periods of time under conditions of high temperature or high currents, they would overheat and fail. To prevent this, the valve driver controls the amount of current that flows through each solenoid coil. Because the current required to open the solenoid is considerably higher than the current required to hold the solenoid open, a hit and drop signal is used. Upon a valve open request the control voltage is near 0V for 0.050 seconds (50 milliseconds) then is pulsed to limit current through the coil. The pulsed voltage will read approximately 9 volts with a high impedance DVOM or can be viewed with an oscilloscope to be a 24 KHz 12-volt square waveform. The steady state current passing through each coil is approximately 1 amp.
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AIR SPRINGS
The air springs are mounted in the same position as the conventional coil springs. The air spring unit consists of a top plate, a rubber diaphragm, and a lower piston. Front and rear air springs are not interchangeable. Upon failure the entire unit must be replaced.
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TestBook screen 2: Ensure inhibit switch is not depressed. Turn ignition to position 2. Do not start engine. Does Air Suspension lamp illuminate? Answer: NO.
TestBook screen 3: Disconnect Black diagnostic connector. Does Air Suspension warning lamp illuminate? Answer: YES. You will then be prompted to initialize the ECU. If further problems are experienced, refer to page 12 of this document to locate the problem.
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SYSTEM CALIBRATION
In an effort to adjust for variations between sensors and their locations on the chassis, it is necessary to calibrate the vehicles body to specific sensor bit counts. This is accomplished by supplying height measurements to specific height sensor outputs. At the start of the routine, all existing sensor target values are over-written with new default values. This way a consistent starting point is used with all vehicles. During the calibration routine both the pressure switch and the thermal switch are ignored. The routine should be completed as quickly as possible in order to avoid potential compressor damage. If the first attempt fails, your new calibration data points become those calculated by the ECU during the first attempt. This enables further tuning to reach the final goal of 790 7mm at Standard Ride Height (See TIB 60/02/94/US).
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Pay particular attention to sensor outputs over the vehicles range of suspension travel (See TIB 60/05/95). Perform System Test. TestBook will generally find the problem. The diagnostics following will be divided into two categories: FAULT MESSAGE DIAGNOSIS This will give an explanation of what sets the message and some suggested TIB references as well as information relevant to the message. SYMPTOM DIAGNOSIS To be used in case of the absence of fault messages or warning lamp illumination. Probable causes of symptoms will be provided.
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SYMPTOM DIAGNOSIS
THE SYSTEM WILL NOT INITIALIZE TestBook establishes communications during power-up of the ECU, pressing the initialize button momentarily interrupts the power allowing TestBook to start communications. Check that the delay relay clicks when the initialize button is pressed. If it does not, check the power and ground to the relay. If the relay is functioning properly, the power supply to the VCSI brick must be confirmed. Current flow should be approximately 40 mA when checked at the battery positive terminal. Confirm that TestBook is functional by trying it on another vehicle. THE COMPRESSOR DOES NOT RUN All of the following must be true for the compressor to run: The engine speed must achieve 500 rpm and then cannot drop below 150 rpm. The pressure switch must be open. The thermal switch must be off (closed, grounded). The exhaust valve must be closed, no height changes taking place. The compressor relay must be closed and the 30-amp maxifuse must be intact. SYSTEM DOES NOT BUILD PRESSURE FAST ENOUGH Connect TestBook. Select Air Suspension and perform a Health Check . Use the pressure switch test to validate all system components. A rough measure is zero to 10 BAR (140psi) in six minutes with a door open, vehicle speed equal to zero. Check for leaks from the exhaust port when the compressor is running. This indicates a problem with the diaphragm valve or solenoid. VEHICLE LEANS TO ONE SIDE Using Dynamic Tests, verify that each sensor can meet its target value. Inspect the sensors for mechanical damage and range with TIB 60/05/95/US. The vehicle should not drop more than 15mm (0.6 in.) per day due to leakage. THE COMPRESSOR CYCLES ON AND OFF FREQUENTLY Leave door open to prevent height changes. The compressor should then run until the pressure switch closes or the thermal switch trips. Run a pressure switch test using TestBook if the compressor runs too long. Inspect height sensor readings for range and stability per TIB 60/05/95/US. THE COMPRESSOR TURNED OFF AND WILL NOT RUN FOR SEVERAL MINUTES The compressor has probably overheated. If the thermal trip (127 C) occurs, there will be a three-minute cool down period during which compressor operation will not occur. This cool down period can be overridden by turning the ignition off and allowing the system to power down. THE VEHICLE IS SLOW TO LOWER Perform a Health Check. There is either a restriction in a hose or the inlet valve is stuck open during the exhaust period. Use Valve Cycling and listen for valve clicking. NOTE: There is no way to determine that the ECU is in a cooling period. The Compressor and Speeds screen on TestBook can only monitor the active state of the thermal switch. Refer to Connector C333 detail. COMPRESSOR NOT RUNNING WHEN ON Under Dynamic Tests/Compressor and Speeds , the compressor does not follow the operation indicated by TestBook directly. Specifically, the compressor will stop for system leveling even though TestBook indicates that it is still ON. To correctly use this screen, leave a door open to prevent leveling (exhausting). Other problems could result from compressor or associated wiring. Trouble shoot with the ETM. Use Valve Cycling function on TestBook. Rover Group 1998 Page 13 of 32
SYSTEM CALIBRATION
In an effort to adjust for variations between sensors and their locations on the chassis, it is necessary to calibrate the system. Unlike Classic, this vehicle calibrates the chassis to the axles. Special blocks (LRT-60-003), which place the chassis at a known height above the axles where the corresponding sensor bit counts are recorded, accomplish this. It may be necessary at times to select the vehicle model as Range Rover Classic to enable direct access to air suspension main menu. This is very useful when difficulties are experienced when trying to clear a Corrupt Sensor Data fault message. However, do not attempt to calibrate a late model Range Rover using a Classic routine. Refer to TIB 60/02/94/US. At the start of the routine, all existing sensor values are overwritten with known default values. This way a consistent starting point is used for all vehicles. If the calibration routine is not successfully completed, the system will set a fault message for Corrupt Sensor Data. This means that the system is operating with default sensor data. This message can only be cleared by successfully completing a calibration. During the calibration routine both the pressure switch and the thermal switch are ignored. Complete the routine as quickly as possible in order to avoid potential compressor damage. When calibration is complete, there should be 100 4mm (4.0 .2 in.) between the front bump stop stud and the front axle pad, while the rear, measured similarly, should be 105 4mm (4.2 .2 in.) standard ride height.
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Rear valve stuck closed may be confused with inlet valve stuck closed or exhaust valve stuck closed. Exhaust valve stuck closed may be confused with front valve stuck closed or rear valve stuck closed.
Pay particular attention to sensor outputs over the vehicles range of suspension travel (See TIB 60/05/95). Perform System Test. TestBook will generally find the problem. The diagnostics following will be broken up into two categories: FAULT MESSAGE DIAGNOSIS This will give an explanation of what sets the message and some suggested TIB references as well as information relevant to the message. SYMPTOM DIAGNOSIS To be used in case of the absence of fault messages or warning lamp illumination. Probable causes of symptoms will be provided.
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SYMPTOM DIAGNOSIS
THE SYSTEM WILL NOT INITIALIZE Verify that the delay relay is powering the system. This can be observed by watching the lamp of the unlatched inhibit switch. Turn the ignition on, but do not start the engine. The switch lamp should illuminate if the ECU has power at pin 1. If not, check fuses 24 and 44 in the engine compartment. The lamp should go out when the remote button on the TestBook lead is depressed. Also check the TestBook VCSI current for a current flow of approximately 40 mA at fuse F33. Confirm that TestBook is functional by trying it on another vehicle. THE COMPRESSOR DOES NOT RUN All of the following must be true for the compressor to run: The engine speed must be greater than 500 rpm and then cannot drop below 150 rpm. The pressure switch must be open. The thermal switch must be off (closed, grounded). The exhaust valve must be closed, no height changes taking place. The compressor relay must be closed and the 30-amp maxifuse MF2 must be intact.
SYSTEM DOES NOT BUILD PRESSURE FAST ENOUGH Connect TestBook. Select Air Suspension and perform a Health Check . Use the pressure switch test to validate all system components. A rough measure is zero to 10 BAR (140 psi) in 7.5 minutes with any door or tailgate open, vehicle speed equal to zero. Check for leaks from the exhaust port when the compressor is running indicating a problem with the diaphragm valve or solenoid. VEHICLE LEANS TO ONE SIDE Using Dynamic Tests, verify that each sensor can meet its target value. Inspect the sensors for mechanical damage and range with TIB 60/05/95/US. The vehicle should not drop more than 15mm (.6 in.) per day due to leakage. THE COMPRESSOR CYCLES ON AND OFF FREQUENTLY Leave door or tailgate open to prevent height changes. The compressor should then run until the pressure switch closes or the thermal switch trips. Run a pressure switch test using TestBook if the compressor runs too long. Inspect sensor readings for range and stability with TIB 60/05/95/US. THE COMPRESSOR TURNED OFF AND WILL NOT RUN FOR SEVERAL MINUTES The compressor has probably overheated. If the thermal trip (127 C) occurs, there will be a three-minute cool down period during which compressor operation will not occur. This cool down period can be overridden by turning the ignition off and allowing the system to power down. THE COMPRESSOR IS NOISY Perform a system pressure test using TestBook to ensure that the compressor can build pressure properly. If the compressor is operating properly, check the compressor mounts. A new mounting system is currently under investigation. See TIB 60/06/95/US.
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THE VEHICLE IS SLOW TO LOWER Inspect the exhaust filter for restriction. Perform a Health Check. There is either a restriction in a hose or the inlet valve is stuck open during the exhaust period. Use Valve Cycling and listen for valve clicking. NOTE: There is no way to determine that the ECU is in a cooling period. The Compressor and Speeds screen on TestBook can only monitor the active state of the thermal switch. Refer to Connector C151 detail. COMPRESSOR NOT RUNNING WHEN ON Under Dynamic Tests/Compressor and Speeds , the compressor does not follow the operation indicated by TestBook directly. Specifically, the compressor will stop for system leveling even though TestBook indicates that it is still ON. To correctly use this screen, leave a door or tailgate open to prevent leveling (exhausting). Other problems could result from compressor or associated wiring. Trouble shoot with the ETM. Use Valve Cycling function on TestBook.
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Position
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NOTE: Range Rover Classic connectors shown are for 1995 MY vehicles. Most descriptions and colors are the same for 1993 MY and 1994 MY, but connector numbers may differ. Refer to the ETM for clarification if required. C333
1. 2. 3. 4.
Compressor Connector
Color Black/Orange Black Brown/L Green Thermal Switch Monitor, Open to Enter Cooling Period Ground E300 Power from Compressor Relay Description
Position
Color
Refer to C331 Refer to C331 Black/Slate
Description
Height Sensor Source, 5V from ECU Height Sensor Wiper, Voltage is Height dependent Height Sensor Ground
C362
Position
C365
Position
1. 2. 3. 4. 5.
Description
Serial Communications RECEIVE
C377
Position
1. 2.
Description
12V from Delay Relay via 1K Resistor Output, 12V when Closed
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C118
1 2 3 4 5 6 7 8 9
Position
C139
Position
C142
1. 2.
Position
C151
1. 2. 3. 4.
Compressor Connector
Color Black/Purple Black Purple/Lt Green Thermal Switch Monitor, Open to Enter Cooling Period Ground, E154 Power Supply Description
Position
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C213
1. 2. 3. 4. 5. 6. 7. 8.
Position
C214
1. 2. 3. 4. 5. 6.
Position
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Range Rover Classic Valve Block Quick Reference Table Port Number 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Destination Rear Left Air Spring Rear Right Air Spring Front Left Air Spring Front Right Air Spring Dryer Reservoir Dryer Pressure relief Exhaust Compressed Air Inlet Diaphragm Exhaust Pressure Switch (with later style valve block) Red Blue Yellow Green Brown Screw-on Valve Violet Compression fitting Screw-on switch Color Tag
New Range Rover Valve Block Quick Reference Table Port Number 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Destination Rear Left Air Spring Rear Right Air Spring Front Left Air Spring Front Right Air Spring Dryer Reservoir Dryer Pressure Relief Exhaust Compressed Air Inlet Diaphragm Exhaust Pressure Switch Red Blue Green Violet Screw-on Valve Screw-on Filter Compression Fitting Screw-on Switch Color Tag
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1. 2. 3. 4. 5.
Air compressor runs and supplies pressure to system. Diaphragm solenoid is ON. The diaphragm valve is closed forcing air through the dryer and into valve block. The inlet valve is closed forcing air through to the reservoir. The pressure switch turns off the compressor when specified pressure is achieved.
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1. 2. 3.
The rear air spring valves are opened allowing air pressure to escape. The inlet valve is closed and the exhaust valve is opened to allow pressure to escape. The diaphragm solenoid is OFF allowing the diaphragm valve to lift off its seat and pass air to the exhaust silencer.
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1. The inlet valve opens and allows air pressure into system from the reservoir. 2. The rear valves open and allow pressure into the air springs.
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New Range Rover Ride State High Standard Low Access Front Sensor Range (bits) 120-180 95-150 75-140 50-110 Rear Sensor Range (bits) 105-150 85-130 75-120 50-100
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