Lesson 3

 Air Suspension and

Troubleshooting

Air Suspension
Air suspension is a type of vehicle suspension powered by an electric or engine-
driven air pump or compressor. This compressor pumps the air into a flexible bellows,
usually made from textile-reinforced rubber. Unlike hydro pneumatic suspension, which
offers many similar features, air suspension does not use pressurized liquid, but
pressurized air. The air pressure inflates the bellows, and raises the chassis from the
axle.
Overview. Air suspension is used in place of conventional steel springs in heavy
vehicle applications such as buses and trucks, and in some passenger cars. It is widely
used on semi-trailers and trains trailers (primarily passenger trains). The purpose of air
suspension is to provide a smooth, ride quality, but in some cases is used for sports
suspension. Modern electronically controlled systems in automobiles and light trucks
almost always feature self-levelling along with raising and lowering functions. Although
traditionally called air bags or air bellows, the correct term is air spring (although these
terms are also used to describe just the rubber bellows element with its end plates). Air
suspension systems essentially replace a vehicle's coil springs with air springs. The air
springs are simply tough rubber and plastic bags inflated to a certain pressure and
height to mimic the coil springs. But the similarities end there. By adding in an on-
board air compressor, sensors and electronic controls, today's air suspension systems
provide several advantages over all-metal, conventional springs, including near-instant
tuning, and the ability to adapt handling to different situations and vary load capability.
Modern Automobiles. Vehicles that have used air suspension include models
from Maybach, Rolls-Royce, Lexus, Jeep, Ram, Cadillac (GM), Mercedes-
Benz, Porsche, Land Rover, SsangYong, Audi, Subaru, Volkswagen, Lincoln, Ford,
and Tesla, among others. Some Citroën vehicles feature Hydractive suspension, a
computer controlled version of their Hydropneumatic system, which features sport and
comfort modes, lowers the height of the car at high speeds and continues to maintain
ride height when the engine is not running. The air suspension designs from Lincoln,
Land Rover, SsangYong, Chrysler, Subaru, Audi, Volkswagen, Tesla, Porsche, and Lexus
models feature height adjustable suspension suitable for making it easier to enter the
vehicle, clear bumps, or clear rough terrain. The Lincoln Continental, Town Car,
Navigator and Mark VIII also featured an air suspension system which offered a
controlled but smooth ride. Porsche has taken this to the next level on
the Panamera with a system that changes the spring rate and damping settings, among
other changes, for their sport/track modes. The Mark VIII suspension settings were also
linked to the memory seat system, meaning that the car would automatically adjust the
suspension to individual drivers. The control system in the Mark VIII can lower the
suspension by about 25 mm (1 inch) at speeds exceeding about 100 km/h (60 mph) for
improved aerodynamic performance. One way automakers strive to improve gas
mileage is by utilizing active suspension technology. Tesla Motors offers an included
"Active Air Suspension" on the Model S and Model X to lower or raise the vehicle for
aerodynamics and increased range.

Air Suspension System Components

1. Air bags. Air bags replaced toe coil springs. The bag was inflated to the correct
pressure or height with an outside compressor through a valve on the bag. Changes in
technology and use added more components, and control, to the system. But today's
air suspension systems all have a basic stock of similar components that vary little from
maker to maker. The differences come mainly in controls and ease of installation. The
bag is a composite of rubber and polyurethane, which provides structural integrity, air-
tight construction, toughness against light abrasion from road debris and sand, and
resistance to salt and chemical corrosion.
The bags come in three basic shapes:

Double-convoluted bag. This bag is shaped like an hourglass. The design allows for a
little more lateral flexibility than the other designs.
Tapered sleeve. This air bag performs the same as any other but is designed to fit in
a tighter area and offers a little more adjustability on ride height.
Rolling sleeve. This is also a specific-application air bag. The pertinent differences
between the two sleeves are really about ride height and spring control, and what's
best for the vehicle and the application.

Most air suspension systems now come with an on-board compressor. The
compressor is an electric pump feeding air to the bags through a series of compressed
air lines. The compressor is generally mounted on the vehicle's frame, or in the trunk.
The vast majority of compressors come with an attached drier. The compressor works
by drawing outside air into the pump, compressing it and moving it to the bags.
Outside air is often laden with moisture, and moisture can wreak havoc in a closed
system. The drier uses a substance known as a desiccant to absorb as much moisture
from the air as possible before the air is sent through the system.

2. Lines. Lines carry the compressed air to the bags. The lines are similar to common
high-pressure air lines and are routed along the frame of the vehicle. While most lines
are a rubber/polyurethane composition, they can be replaced with custom steel lines,
offering a cleaner look and a more rugged construction.

3. Height Control Valves. The height control valves (HCV from now on) are kind of
the brains of the system. They dictate how much air is in the air bags. This dictates
the height the vehicle sits at, thus, Height Control Valve. Most HCVs are mechanical
valves but electronic HCVs are available. The HCV is mounted to the frame of the
vehicle. An L shaped linkage attaches the HCV to the axle. As the axle moves up and
down in relationship to the frame, the linkage moves the valve or electronic
mechanism. With mechanical valves, there is an airline from the air supply to the
HCV. There is an airline from the HCV to the air bag or bags+ that it controls. The HCV
also has an exhaust port. When the connecting linkage moves up, the HCV connects
the air supply to the air bag(s), inflating the bag(s). When the connecting linkage
moves down, the HCV connects the air bag(s) to the exhaust port, deflating the
bag(s). This controls the height of the vehicle. If the HCV is electronic, as the linkage
moves, the sensors in the HCV send information to an electronic control. These
controls will open or close air solenoid valves as needed to inflate or deflate the bags.
4. Solenoids. Solenoids are used in electronically-controlled systems to fill and vent
each air bag. As the system adjusts for different conditions, it commands each solenoid
to open or close, changing the amount of air in each of the bags.
5. ECAS Computer. Electronically controlled air suspension (ECAS) computer which
communicates with the car's main computer the BeCM and decides where to route air
pressure.

Ride height. Ride height is simply the distance between the frame of the vehicle and the
vehicle axles that the vehicle rides at. Ride height is determined by the vehicle or chassis
manufacturer. Ride height varies between vehicles and manufacturers. Ride height information
must be obtained from the vehicle or chassis manufacturer. The manufacturer will supply the
correct measurements and measuring points on the chassis. An example would be: Ride height
should be seventeen inches measured between the centers of the top shock mounting bolt to
the center of the bottom shock mounting bolt. Remember, this is only an example of what the
ride height information may be. The second thing you must understand is that air is highly
compressible. What this means is the frame of the vehicle will move up or down (without
adding air to or exhausting air from the air bags) when weight is removed or added to the
vehicle. Although this is true of any suspension, air, spring or torsion, vehicles with a spring or
torsion suspension will remain raised or lowered when weight is removed or added. Because of
the height control valves, vehicles with air suspensions should always remain at the proper ride
height. The ride height for other suspensions will change when weight is added or
removed. Also, vehicles with an air suspension will not “settle” with age as a spring or torsion
suspension will.

Fig. 3-2.Height Control Valves and Ride Height

Fig. 3-3.schematic example of the height control valve in the neutral position, inflate position
and deflate or exhaust position.
How the air suspension functions. The vehicle is supported on the frame with an
arrangement of air bags. The vehicle air system, engine air compressor, tanks, lines, etc.,
supplies air to the height control valves (HCV) mounted to the frame of the vehicle. The height
control valves are connected to the air bags with an air line. The linkage which connects the
HCVs to the axles rotates the HCV valving as it moves up and down. When weight is added to
the vehicle or transferred through the suspension of the vehicle, the air in the air bag(s) is
compressed, the frame moves closer to the axle. This forces the HCV linkage up. As the
linkage moves up, the valving of the HCV connects the air supply to the air bag(s). The added
pressure and volume inflates the air bag(s), causing the frame to move away from the axle. As
the frame moves back to the proper ride height, the HCV linkage moves to the neutral
position. This moves the valving away from the air supply and locks the air in the air bag to
maintain the proper ride height. As weight is removed from the vehicle or the suspension shifts
weight away, the existing pressure in the air bag(s) can push the frame away from the
axle. The HCV linkage is pulled down. This connects the air bag(s) to the HCV exhaust port. As
air is exhausted from the air bag(s), the frame lowers back down towards the axle. As the
linkage moves up to the neutral position, the exhaust port is closed and the air is again locked
in the air bag(s), maintaining proper ride height.

Fig 3-1. Passenger vehicle air spring system

Suspension Troubleshooting
Suspension issues can be difficult to diagnose. It’s usually pretty easy to tell the
symptoms, but identifying the source of the issue is another animal. Faulty or worn shocks,
struts, springs, tie rods or ball joints can wreak havoc on your vehicle and make your car or
truck unsafe to drive. Wear and tear is only an issue if you actively ignore the problem and
allow your vehicle to run itself into the ground! Pay attention to how your vehicle handles and
what you’re hearing—and address problems immediately as they arise.

CONDITION POSSIBLE CAUSES AND CORRECTION

Rough Ride Conventional rigid axle suspension
 The leaves of the spring may be rusted or corroded
resulting in excessive friction. The lubrication of the
springs should be done immediately to reduce friction.
 The pins in the shackles may have seized, which should be
set right at once.
 Shock absorbers may be defective, which must be
replaced.
 Lubricating pads at the ends of leaves may be worn. They
should be replaced.

Independent suspensions
  The pivots on the suspension arms may be seized. The
remedy is the immediate lubrication.
 In the case of torsion bars; their adjustment may not be
correct, which should be adjusted properly.
Suspension too flexible  The manufacturer might have specified that the springs
should not be lubricated, which precaution might have
been violated thus decreasing friction. The remedy is to
clean the springs thoroughly.
 Due to constant use, the springs may have become weak.
The only remedy in this case is the replacements.
 Some of the leaves of the springs may be broken which
must be replaced.
 The shock absorber might have developed some defects.
Sagging Springs  The spring on the sagging side may have become weak
(With the sagging due to constant use.
springs the vehicle sags  Any or more leaves of the sagging spring may be broken.
on one side.)  In case of independent systems, the coil spring may be
incorrectly adjusted.
Vehicle bouncing  Worn out shock absorbers, which must be replaced.
after crossing bump  Damaged or slipped leaf springs, which have to be
checked, repaired or replaced.
Knocking during  The shock absorbers or the struts may have worn out. In
crossing of bump such a situation, shock absorbers and/or strut bearings
have to be replaced.
 Ball joints may be loose or worn out, which may be
checked and serviced or replaced as required.
Noises  Lack of lubrication may result in spring noise
 U-bolts may be loose
 There may be a side play in shackles
 The shackle pins and bushes may be loose.
 There may be some defect in the shock absorbers
Wander or poor  Loose stabilizer bar. Tighten or replace stabilizer bar or
steering stability bushes.
 Broken or sagging springs. The spring needs to be
replaced.
 Check or adjust steering gear case torque.
 Front wheel alignment
Low or uneven trim  Broken or sagging springs. Replaced if broken
height  Check possible overloading
 The spring maybe incorrect. Replace