ACTIVE HEIGHT CONTROL SYSTEM

AHC SYSTEM. PART 1

01/01/2010

Active Height Control (ALC) - System Basics

System Description

The active body height control system (ANS) allows you to change the height of the
vehicle body from the road surface depending on the speed and load. This system was
used on Toyota Land Cruiser 100 and Lexus LX470. It increases the vehicle's cross-
country ability and cornering stability, which is necessary when driving on Russian
roads. It also makes it easier for passengers to get in and out of the car and allows
them to maintain the level of ground clearance, regardless of how loaded the car is.

The body height control system (AHC) uses a special working fluid

"Active suspension fluid AHC".

The main modes of the active ride height control system are:

1) Forced change in body height.

There are three operating modes of this system: “LO”, “N” and “HI”.

The "LO" mode is selected when the luggage compartment of the car is loaded. When
this operating mode is selected, the front part of the car body is lowered by
approximately 50 mm, and the rear part by 40 mm relative to the position of the body in
“N” mode.

The "N" mode is recommended to be used when driving on good roads, the vehicle
height corresponds to the standard one.

It is advisable to use the "HI" mode when driving on bumpy roads and to overcome
water obstacles.

When switching to "HI" mode, the front of the car rises by 50 mm and the rear by 40
mm.
Switching between modes "LO" → "N" and "N" → "HI" occurs within 10 - 15 seconds
and depends on the vehicle load. Switching between "HI" → "N" and "N" → "LO" occurs
within 3 - 8 seconds.

2) Automatic body height adjustment.

This function allows you to automatically maintain a constant height of the car body,
regardless of the number of passengers and cargo of the car.

3) Automatic suspension control depending on speed.

This feature automatically adjusts the ride height based on vehicle speed to ensure
maximum stability and passenger comfort.

If the car starts to drive at a If the car starts to drive at a If the car starts to drive at a speed of more
speed of more than 5 km/h, the speed of more than 30 than 50 km/h, the system moves to an
ANS system switches to normal km/h, the ANS system intermediate position (the height of the
mode and is fixed in it (when theswitches to normal mode. body is 25 mm higher than the "N"
speed decreases, it does not "N" mode will not change position). When the speed decreases to 20
return to “LO” mode) when speed decreases km/h, the “N” mode changes to “HI”

* - When driving in the “LOW” range of the transfer case.

4) "Extra HI" mode.

If, when driving a car on an uneven road in the “HI” mode in the “LOW” range of the
transfer case, one of the wheels begins to slip, then the vehicle’s body height
automatically increases by 30 mm (front) and 20 mm (rear).

5) Prohibition of adjusting the height of the car body .

When jacking up the vehicle or towing it, it is necessary to turn off the body height
adjustment system by pressing the corresponding switch. The ride height control
system will be activated automatically when the vehicle is traveling at a speed of over
80 km/h in N mode or when driving at a speed above 30 km/h in HI or LO mode.

Attention : the system may not increase the height of the body relative to the road
surface if the total vehicle load exceeds 570 kg in N mode or 440 kg in other modes.
6) In addition to the described operating modes, the ANS system provides a hydraulic
connection between the shock absorbers of the left and right wheels, which ensures
better stability and controllability of the vehicle when cornering.

Basically, the hydraulic circuit between the left and right wheel shock absorbers is open.
This makes it possible to increase the smoothness of the suspension when the wheels
begin to move in opposite phases, which provides better tire traction when driving on a
winding road. When you turn the steering wheel, the hydraulic circuit closes, which
limits the increase in vehicle roll during frequent turns.

AHC system components and their purpose

The body height change system is controlled using not only the sensors of this system,
but also signals from sensors of other systems, such as: sensor for turning on the
center differential lock, sensor for turning on the "L4" mode of the transfer case, brake
light switch, door limit sensors and signal "L" generator.
 Location of
AHC system components.
1 - pump damper,
2 - diagnostic connector,
3 - pump and fluid pressure
sensor,
4 - control valve block,
5 - rear right AHC drive,
6, 8, 9 - door limit switches,
7 - rear body height control
sensor ,
10 - rear left drive,
11 - hydraulic accumulator,
12 - front drives,
13 - pump relay,
14 - front wheel speed
sensors,
15 - front body height
control sensors,
16 - main system relay,
17 - AHC electronic control
unit ,
18 - instrument cluster
(indicators),
19 - steering wheel position
sensor,
20 - brake light switch,
21 - DLC3 connector,
22 - AHC system switch
block.

Component Purpose

AHC system Indicates the selected operating

operating mode of the ride height control
mode system.
indicator
In each mode, the corresponding
indicator lights up. When the
height changes, the indicator of the
previously selected mode goes out
and the indicator of the selected
mode begins to blink, indicating
that the height of the body is
 changing (at the end of the process
the indicator begins to light
without blinking).

- Lights up when the "ANS OFF"

switch is pressed.

ANS system - Flashes when a malfunction is

"OFF" detected in the ride height control
indicator system.

- Output of diagnostic codes

ANS system
Selecting the operating mode of the
operating
body height control system
mode switch

Sets a ban on changing the height of

the body.

Attention : the height prohibition

system will turn off automatically
Switch "ANS
when the vehicle is moving at a
OFF"
speed of more than 80 km/h in
“N” mode or when driving at a
speed of more than 30 km/h in
“HI” or “LO” mode.

Wheel speed They determine the speed of each wheel and transmit a signal to the ANS system control
sensors unit (via the ABS control unit)

Body height
control Determine the height of the body
sensors
Steering
Determines the direction of rotation
wheel position
of the steering wheel and its angle
sensor

Electric pump Creates the working fluid pressure necessary to increase the height of the body. Includes:
of the ANS working fluid reservoir, pump, check valve, pressure and temperature sensors of working
system fluid.

Gas damper (1.96 MPa) with a

volume of 2 cm 3 is designed to
Pump damper reduce the pulsation of pressure of
the working fluid pumped by the
electric pump

Hydraulic
accumulator Stores hydraulic pressure to increase the rate of change in body height relative to the
of the ANS road surface
system

Control valve Consists of control valves for adjusting body height and bypass valves for controlling the
block hydraulic circuit between the left and right wheel shock absorbers

Component Purpose

ANS system drive Performs the same functions as the gas chamber of a conventional shock absorber
(gas chamber) (additional shock absorber chamber)

Telescopic shock absorbers serve to dampen

Shock absorbers vibrations in a similar way to conventional
shock absorbers.
High pressure Serves as a hydraulic circuit connecting the drive (gas chamber) and the shock
hose absorber of the ANS system

ANS system Controls the entire system, making calculations to control ride height based on
control unit signals from sensors and switches

The "ANS MAIN" relay supplies power to the elements of the ANS system, and the
Control relays
"ANS MOTOR" relay supplies power to the electric pump of the ANS system

Body height control sensors

The system contains three

sensors: two front sensors
for each wheel and one rear
sensor, located in the
central part of the cross
member above the rear
axle.

The sensor consists of a

brush connected to a shaft,
which slides over a resistor
that forms a support plate.
The voltage at the sensor
output varies in proportion
to the angle of rotation of
the sensor shaft.

Electric pump of the ANS system

The ANS system pump includes a working fluid reservoir, a pump, a check valve,
pressure and temperature sensors of the working fluid.
- Gear pump with DC motor.

- Check valve.

This valve is used to open/close the hydraulic circuit between the control valve block
and the hydraulic fluid reservoir. The check valve is designed in such a way that its
closure occurs due to high fluid pressure generated by the electric pump.

Normally, a spring holds the check valve open (see picture). When the electric pump of
the ANS system starts to work (when the car body is raised), the working fluid coming
out of it puts pressure on the valve, moving it to the left. Thus, the circuit between the
control valve block and the reservoir is closed, and the fluid leaving the pump begins to
move towards the control valve block.

Hydraulic accumulator of the ANS system

The hydraulic accumulator consists of a cylinder (volume 945 cm3 ) filled with nitrogen
(5.9 MPa), a free piston and an electromagnetic valve.

When the body is lifted, the hydraulic accumulator releases the stored fluid under high
pressure, further increasing the speed of body lifting. In normal condition, the solenoid
valve remains closed. When the body height begins to increase or when the fluid in the
main accumulator runs out, the solenoid valve opens according to a signal received from
the ANS control unit.

Control valve block

The block consists of two control valves and two bypass valves.

- Control valves transfer the working fluid from the pump to the ANS system drives (gas
chambers) located on each wheel. Under normal conditions the valves are closed.
During operation of the ANS system, the valves are opened by signals received from
the control unit.

- Bypass valves connect the hydraulic circuits of the left and right shock absorbers.
Under normal conditions, the valves are open and closed only at the command of the
electronic control unit for the ANS system.

ANS system drives (gas chambers)

The gas chamber is a

membrane-type
pneumohydraulic accumulator,
with a three-layer rubber-
polymer membrane and a cavity
with a volume of 400 and 500
cm 3 for the front and rear
wheels, respectively, filled with
nitrogen.

The gas pressure in the cavities

is 2.26 MPa for front drives and
2.65 MPa for rear drives.
ACTIVE HEIGHT CONTROL (AHC) -
PART 2
How the system works
1. Normal condition, moving in a straight line.

High pressure in the gas chambers and shock absorbers is maintained by closed
control valves.

Open bypass valves connect the right and left shock absorbers.

2. Movement in a turn.

High pressure in the gas chambers and shock absorbers is maintained by closed
control valves. The bypass valves are closed, the hydraulic circuit of the right and left
shock absorbers are not connected. The stiffness of the shock absorbers is adjusted
depending on road conditions and the position of the steering wheel.

1 - reservoir,
2 - pressure sensor,
3 - check valve,
4 - hydraulic accumulator
solenoid valve,
5 - ANS hydraulic
accumulator,
6 - AHC system drive (gas
chamber),
7 - control valve,
8 - bypass valve,
9 - shock absorbers,
10 - pump damper,
11 - AHC system pump.
3. Increasing the height of the body .

After pressing the "UP" button, the electric pump is turned on.

1) The car is stationary.

The solenoid valve of the hydraulic accumulator is open, additional fluid enters the
line and increases the speed of body lifting. The front and rear control valves open
simultaneously, allowing fluid to flow to the gas chambers and shock absorbers, lifting
the front and rear body together. If the fluid stored in the accumulator runs out, the front
and rear control valves open alternately, lifting the front and rear parts of the body
separately.

2) The car is moving.

At speeds below 25 km/h, fluid from the accumulator is used in the same way as
when the vehicle is stationary.

At speeds above 25 km/h, only the fluid pumped by the pump is used to lift the body.
The front and rear control valves open alternately, lifting the front and rear sections
separately.

If the body is in the “LO” position, then at a speed of more than 5 km/h, a hydraulic
accumulator is connected to the hydraulic circuit to automatically lift the body to its
normal position.

4. Supplying fluid to the hydraulic accumulator of the ANS system .

Under normal conditions, the hydraulic accumulator contains the amount of fluid that
is necessary to lift the body once. After lifting the body from the “LO” to “N” position or
from “N” to “HI”, it is necessary to fill the hydraulic accumulator.

During filling, the control valves are closed, the solenoid valve of the accumulator is
open, and the liquid is pumped into the accumulator. If it is necessary to raise the body
before the required working fluid pressure has been created in the hydraulic
accumulator, then only the fluid pumped by the pump will be used for this.
 5. Moving the body down.

1) Speed less than 5 km/h.

When the AHC mode switch is moved to the "LO" from N or "N" from HI positions,
the front and rear control valves open simultaneously, and fluid from the gas chambers
and shock absorbers is diverted into the reservoir,

lowering the front and rear parts of the body together.

If the rear end lowers faster than expected due to heavy load and there is a
significant difference between the front and rear travel speeds, the rear control valve
closes, allowing only the front end to lower. This is necessary to prevent the headlights
from being raised too high.

2) Speed more than 5 km/h.

When the AHC mode switch is moved to the "N" position from HI, the front and rear
control valves open alternately, lowering the front and rear body parts separately.

When the speed is more than 5 km/h, the body cannot be moved from the “N”
position to the “LO” position.
Main system malfunctions
Troubleshooting that occurs in the ANS system should begin with the simplest
operations and continue in order of increasing complexity. The following describes
system problems and troubleshooting procedures.

The indicator that does not correspond to the selected operating mode of the ANS
system is lit.

1. Make sure that the "ANS OFF" switch is not pressed.

2. Read fault codes.

3. Check in test mode (signal input).

The body height control system does not work.

1. Check the power supply circuit of the ANS system control unit.

2. Make sure that there are no conditions under which the system may be prohibited
(driving on uneven roads, differential locks, etc.).

3. Check the indicators.

4. Read fault codes.

5. Check the ANS system in test mode.

6. Check in test mode (input signal).

 7. If the above checks do not reveal a malfunction, then replace the ANS system
control unit.

The vehicle height does not change when switching "N" → "HI".

1. Make sure that the vehicle load does not exceed the specified value.

2. A malfunction may occur when installing additional elements of significant weight

on the vehicle (for example, a winch).

3. Make sure the fluid level is correct.

4. Read fault codes.

5. Check in test mode (input signal).

6. Check the shock absorbers.

7. Check the vehicle body height (sensor rod length).

The vehicle body does not lower when the system is switched to the "LO" position.

1. Malfunction may occur if the vehicle weight is less than the rated value.

2. Make sure that the operation of shock absorbers and springs is not interfered with
by foreign objects.

3. Read fault codes.

4. Check in test mode (signal input).

5. Check the shock absorbers.

6. Check the vehicle body height (sensor rod length).

When parked, the vehicle body position is very low.

Attention : the body may lower if the ambient temperature changes significantly while
the vehicle is parked.

1. Make sure there are no leaks in gas chambers, shock absorbers, etc.
 2. If no leaks are found, replace the control valve assembly.

The car rolls to the left or right side.

1. Make sure there is no overload on one side of the vehicle.

2. Read fault codes.

3. Adjust the height of the body.

4. Check the shock absorbers.

5. Check the control valve block (bypass valves).

6. Make sure fluid moves freely throughout the entire hydraulic circuit.

Raising the body occurs in a time exceeding the standard value.

Attention : if the air temperature is below -15 ° C and the hydraulic accumulator has
not yet been charged, then the system

topics take more time.

1. Make sure that the vehicle load does not exceed the specified value.

2. Malfunction may occur if the vehicle weight is less than the rated value.

3. Read fault codes.

4. Check the shock absorbers.

5. Check the vehicle body height (sensor rod length).

6. Make sure there is pressure in the hydraulic accumulator of the ANS system.

7. If the above checks do not reveal a malfunction, then replace the electric pump.

The body lowers for a time exceeding the standard value.

Attention : at air temperatures below -15 ° C, the system takes longer to operate.
 1. Malfunction may occur if the vehicle weight is less than the rated value.

2. Check the shock absorbers.

3. Check the vehicle body height (sensor rod length).

4. If the above checks do not reveal a malfunction, replace the control valve
assembly.

The car leans forward or backward.

1. Make sure that the "ANS OFF" switch is not pressed.

2. Make sure there are no leaks in gas chambers, shock absorbers, etc.

3. Read fault codes.

4. Check the vehicle body height (sensor rod length).

5. If the above checks do not reveal a malfunction, then replace the control valve
block.

Excessive noise during system operation.

1. Make sure fluid moves freely throughout the entire hydraulic circuit.

2. Make sure there is no play in the electric pump drive.

3. If the hydraulic circuit and pump are normal, replace the pump damper.

Different car roll when turning left and right.

1. Make sure there is no overload on one side of the vehicle.

2. Check the power supply circuit of the ANS system control unit.

3. Read fault codes.

4. Check in test mode (signal input).

 5. Make sure there are no leaks in the gas chambers (check the change in the level
of the working fluid in the tank when switching modes from “LO” to “HI” - the difference
in levels should exceed 7 divisions on the tank scale).

6. If the above checks do not reveal a malfunction, then replace the ANS system
drive or shock absorber.

Significant “dive” of the car when braking and starting to move.

1. Check the power supply circuit of the ANS system control unit.

2. Read fault codes.

3. Check in test mode (signal input).

4. If the above checks do not reveal a malfunction, then replace the ANS system
drive or shock absorber.

The ANS system diagnostic test cannot be performed.

1. Check the "ANS OFF" indicator circuit.

2. Check the "TC" output circuit of the diagnostic connector.

3. Check the power supply circuit of the ANS system control unit.

Cannot test in test mode (signal input).

1. Check the "TS" output circuit of the diagnostic connector.

2. Check the power supply circuit of the ANS system control unit.

Chechel Lyudmila

"Legion-Avtodata"