2003 Expedition/Navigator Workshop Manual

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2003 Expedition/Navigator Contents/Index

GROUP 04: Suspension SECTION 204-00: Suspension System — General Information SECTION 204-01A: Front Suspension — 4x2 SECTION 204-01B: Front Suspension — 4x4 SECTION 204-02: Rear Suspension SECTION 204-04: Wheels and Tires SECTION 204-05: Vehicle Dynamic Suspension — 4-Wheel

2003 Expedition/Navigator

Workshop Manual

file://C:\tso\tsocache\STEVENSTOSHIBA_1220\S3J~us~en~file=s3jmain.htm~gen~ref.htm 5/10/2008

2003 Expedition/Navi Contents/Inde GROUP Suspens

SECTION 204-05: Vehicle Dynamic Suspension — 4-Wheel SPECIFICATIONS

2003 Expedition/Navigator Workshop Manual

General Specifications
SECTION 204-05: Vehicle Dynamic Suspension — 4Wheel SPECIFICATIONS DESCRIPTION AND OPERATION Vehicle Dynamic Suspension DIAGNOSIS AND TESTING Vehicle Dynamic Suspension —4Wheel Air Suspension Air Spring Solenoid Inspection and Verification 4-Wheel Air Suspension (4WAS) Module Diagnostic Trouble Code (DTC) Index Symptom Chart Pinpoint Tests Component Test Relay GENERAL PROCEDURES Ride Height Adjustments Inflation and Deflation of the Air Suspension System Calibration Ride Height Resetting Air Leaks Ai Li Fl id

Item Lubricants Multi-Purpose Grease XG-4 Silicone Brake Caliper Grease and Dielectric Compound XG-3

Specification

ESR-M1C159A ESE-M1C171A

Torque Specifications Description Shock absorber-to-lower arm bolt and nut (front) Nm lb-ft lb-in 400 295 — — — — 80 80 — —

Shock absorber-to-lower arm bolt and flag nut (rear) 475 350 Air spring upper mount-to-frame nuts Shock absorber-to-upper mount nut Compressor bracket bolts Control module bracket nuts Height sensor (upper) bracket bolts Height sensor (lower) bracket nuts 35 30 9 9 30 33 26 22 — — 22 17

2003 Expedition/Navigator Workshop Manual

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SECTION 204-05: Vehicle Dynamic Suspension — 4-Wheel DESCRIPTION AND OPERATION

2003 Expedition/Navigator Workshop Manual

Vehicle Dynamic Suspension
The four wheel air suspension system is comprised of the following components: service switch control module two front height sensors one rear height sensor compressor and drier assembly (includes vent solenoid) air lines front and rear air spring and shock absorber assemblies four air spring solenoids compressor relay

WARNING: The service switch for the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the jack storage area in the rear of the passenger compartment. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations.

WARNING: Do not remove an air spring under any circumstances when there is pressure in the air spring. Do not remove any components supporting an air spring without either exhausting the air or providing support for the air spring to prevent vehicle damage or personal injury. Air Suspension Pneumatic Diagram

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Item 1 2 3 4 5

Part Number 5319 5B322 5B321 — 18945/5311

Description Air compressor and drier Air line T-fitting Air line union Air line Y-fitting Air spring and solenoid

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2003 Expedition/Navigator Workshop Manual

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SECTION 204-05: Vehicle Dynamic Suspension — 4-Wheel DIAGNOSIS AND TESTING

2003 Expedition/Navigator Workshop Manual

Vehicle Dynamic Suspension —4-Wheel Air Suspension
Refer to Wiring Diagrams Cell 41 , Programmable Ride Control for schematic and connector information.

Special Tool(s) Worldwide Diagnostic System (WDS) 418-F224 New Generation STAR (NGS) Tester 418-F052 or equivalent scan tool Vacuum Tester or equivalent 014-R1054

73 Digital Multimeter or equivalent 105-R0051

Principles of Operation The 4-wheel air suspension (4WAS) module commands changes in vehicle height that are necessary for both the load leveling and the vertical height adjustment features. The 4WAS load leveling feature automatically makes adjustments in vehicle height so that the vehicle is always at target height, and that constant front-to-rear vehicle attitudes are maintained over the load range of the vehicle. Adjustments in height that are necessary to correct height differences between the vehicle left and right sides for the 4WAS system are restricted to what can be reliably achieved with three height sensors. The height adjustment feature has three vehicle target heights within a two-inch span: Kneel height — improves the ease of entering and exiting by lowering the vehicle one inch below the trim height in the front and rear when the vehicle ignition is in the OFF or LOCK positions and the vehicle is stationary. Trim height — normal vehicle ride position; vehicle moves to trim position when the ignition is ON, when the transmission is initially shifted to DRIVE or REVERSE mode, when all doors are closed or when speed of more than 24 km/h (15 mph) is detected. Off-road height — improves ground clearance by raising the vehicle one inch above trim height in the front and rear when the vehicle is at 4x4 low modes and the vehicle speed is less than 40 km/h (25 mph).

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For additional information about UBP. neither are replaceable as individual items. A4WD. the 4WAS system is inoperative at speeds below 24 km/h (15 mph) and will not react when the vehicle is raised or lowered. The system then maintains this height regardless of the addition or removal of a load. The system will remain active for 40 minutes after the ignition is turned off to make limited height adjustments as necessary.. file://C:\tso\tsocache\STEVENSTOSHIBA_1220\S3J~us~en~file=S3J45003. Vehicle Height Modes Ignition State OFF Transfer Case Mode 4x2. module communications network for sending and receiving various signals. a "CHECK SUSP" will appear in the RH corner of the instrument cluster. A4WD. information from the three height sensors. refer to Section 418-00 . passes pressurized air through the compressor air drier that contains silica gel (a drying agent).htm~gen~ref. the message center will display "SUSPENSION SWITCHED OFF" Air Compressor The air compressor: consists of the compressor and vent solenoid. Without the module receiving this signal. (UBP). At speeds above 24 km/h (15 mph). 4x4 HI ON and RUN ON and RUN OFF 4x4 Low 4x4 Low 4x4 Low Air Suspension Service Switch The air suspension service switch signal is needed to wake up the 4WAS module. is powered by an electromechanical or solid state relay. Vehicles without message center When the air suspension service switch is in the OFF position and the ignition switch is in the RUN position. The 4WAS system holds vehicle height when any door or rear hatch is opened. which is controlled by the 4WAS module.. The system returns to its commanded height when all doors are closed or vehicle speed exceeds 24 km/h (15 mph).. 4x4 HI Speed or Speed Range N/A All speeds Below 13 km/h (8 mph) Above 40 km/h (25 mph) N/A Resulting Vehicle Height Kneel (TRIM . is a single cylinder electric motor driven unit that provides pressurized air as required. Vehicles with message center When the air suspension service switch is in the OFF position and the ignition switch is in the RUN position.25 mm) TRIM Off-Road (TRIM + 25 mm) TRIM Stays at current position (prior to ignition transition) ON and RUN 4x2.2003 Expedition/Navigator Workshop Manual Page 2 of 29 The 4WAS module uses the universal bus protocol. and the air suspension service switch. the system will be active as if the air suspension service switch is in the ON position. The system stores front and rear vehicle height the moment any door is detected open. 5/10/2008 .

The air springs provide a varying spring rate proportional to the system's air pressure and volume.2003 Expedition/Navigator Workshop Manual Page 3 of 29 Moisture is then removed from the compressor air drier when vented air passes out of the system during vent operation. Therefore. has a single port drier that can be installed separately. Air Suspension Height Sensors There are two sensors used for the front suspension and one sensor used for the rear suspension.htm~gen~ref. Air Lines and Fittings NOTE: Apply a soapy water solution to the air lines to verify the location of air leaks.. The rear height sensor is mounted to the frame and the link is attached to the rear lower arm ball stud. the air compressor will turn on and pump compressed air to the system. The compressor assembly output line is divided by the use of a fitting to supply the front and rear air springs.84 in) at the front wheels and 240 mm (9. The sensors send a voltage signal to the 4WAS module. The sensors have a usable range of ± 45° compared to total suspension travel of 196 mm (7. shares a common electrical connector with the air compressor motor.. is part of the air compressor cylinder head.50 volt at maximum height (when the vehicle is high or in full rebound). the sensors are mounted to the suspension at a point where full suspension travel at the wheel is relative to the travel at the height sensor. 5/10/2008 . Compressor Relay file://C:\tso\tsocache\STEVENSTOSHIBA_1220\S3J~us~en~file=S3J45003. is installed with the air compressor as a unit. opens when the 4WAS module determines that lowering is required. which forms an integral valve housing that allows the valve tip to enter the pressurized side of the system. When the height sensor indicates that the vehicle is lower than trim under normal driving conditions. has a 1034 kPa (150 psi) internal relief valve. Air Spring The 4WAS system has front and rear air springs. Vehicle height is maintained by the addition and removal of air in each air spring through an air spring solenoid installed in the upper spring cap and energized through the 4WAS module command. is enclosed in the cylinder head casting. The output ranges from approximately 4.50 volts at minimum height (when the vehicle is low or in full jounce) to 0. has an O-ring seal that prevents air leakage past the valve tip. Increasing air pressure (compressing) raises the vehicle.6 in) at the rear wheels. The air suspension system regulates the air pressure in each air spring by compressing and venting the system's air. Nylon air lines with quick connect fittings connect to the air compressor and air spring solenoids. The left and right sensors are not interchangeable. Fittings are also used to divide the air supply to the RH and LH air spring solenoids. a service repair kit is available. provides an escape route for pressurized air when system pressures exceed safe operating levels. When the sensor indicates that the vehicle is raised above trim under normal driving conditions. decreasing air pressure (venting) lowers the vehicle. this will cause the air to be vented from the system to lower the vehicle to its trim height level. The front height sensors are mounted to the frame and the links are attached to the upper arm ball studs. The vent solenoid: allows air to escape from the system during venting actions.. ruptured or leaking. If the air lines are cut.

Air Spring Solenoid WARNING: Never rotate an air spring solenoid valve to the release slot in the end cap fitting until all pressurized air has escaped from the spring to prevent damage or injury. the air suspension will not work correctly. 20 file://C:\tso\tsocache\STEVENSTOSHIBA_1220\S3J~us~en~file=S3J45003. Inspection and Verification 1. Visual Inspection Chart Mechanical Restricted suspension Electrical Battery junction box (BJB) fuses 11 (10) (later built vehicles).2003 Expedition/Navigator Workshop Manual Page 4 of 29 A (electromechanical or solid state) relay is used in the air suspension system for compressor control. NOTE: If the door ajar indicator is illuminated when all doors. The relay switches high current loads in response to low power signals and is controlled by the logic of the 4WAS module. and liftgate glass are closed. is electrically operated and controlled by the 4WAS module. 4-Wheel Air Suspension (4WAS) Module NOTE: The 4WAS module must receive a ride height adjustment calibration and must pass a pneumatic test when it is installed new or swapped. The air spring solenoid: allows air to enter and exit the air spring during leveling operations.. two-way connector. liftgate. The 4WAS module is keyed so that it cannot be plugged into an incorrect harness. and contains self-test and communication software for testing the vehicle and related components. The 4WAS module also controls vehicle height adjustments by monitoring the three height sensors and other universal bus protocol (UBP) signals. The 4-wheel air suspension (4WAS) module controls the air compressor motor (through an electromechanical or solid state relay). Verify the customer concern. The compressor (electromechanical or solid state) relay is energized by the 4WAS module to have high current flow from the battery to the compressor motor. is only replaced as a unit (the air spring solenoid is serviced separately from the air spring). Visually inspect for obvious signs of mechanical and electrical damage. 2. There are two harness hardshell connectors and each is uniquely colored and keyed to prevent reversed connections. The 4WAS module conducts all fail-safe and diagnostic strategies. and provides power to front and rear height sensors. 5/10/2008 . The 4WAS module monitors and controls the air suspension system through a 26-pin. refer to Section 413-01 .htm~gen~ref. Repair door ajar indicator.. all air spring solenoids..

Vehicle in PARK. The transmission is in PARK. use the scan tool connected to the data link connector (DLC) to retrieve continuous diagnostic trouble codes (DTCs) and to execute On-Demand Self Test diagnostics for the 4WAS module. If the On-Demand Self Test is passed and no DTCs are retrieved. Install a battery charger for the Trim Height Test to prevent battery drain. crimped air line(s) Unmounted height sensor(s) Damaged front air spring(s) Damaged rear air spring (s) (30A). fuse 27 (5A). Test is used to clear DTCs C1990 and C1991. Trim Height Test (or Accurate Trim Test) The trim height test is used to make the vehicle level to within 2 mm (0. liftgate. Battery voltage greater than 11 volts for duration of test. The air suspension service switch is in the ON position. The vehicle speed is less the 3 km/h (1. Verify that the following conditions are met before running the Pneumatic Test. corroded. All doors. Fulfill the pre-conditions.. and liftgate glass must be closed. If DTCs are retrieved. If the inspection reveals an obvious concern that can be readily repaired. severed. It also verifies that the air compressor. The vehicle speed is less than 3 km/h (1. 4. GO to Symptom Chart to continue diagnostics. Pneumatic Test This test verifies that the air lines are connected and that they are not restricted. and liftgate glass must be closed. If the 4WAS module cannot be accessed by the scan tool. 5/10/2008 . Accurate trim test should be run before setting vehicle alignment. If the concern remains after the inspection. correct the concern before continuing with Inspection and Verification.. liftgate.. Go To Pinpoint Test A . go to the 4WAS Module Diagnostic Trouble Code (DTC) Index in this section. The air suspension service switch must be in the ON position. 1. or disconnected connectors Air suspension service switch is in the OFF position Damaged solenoid valve(s)/height sensor(s) 3. The ignition switch is in the ON position.htm~gen~ref. NOTE: The 4WAS module is also referred to as the Vehicle Dynamic Module (VDM).87 mph). file://C:\tso\tsocache\STEVENSTOSHIBA_1220\S3J~us~en~file=S3J45003. All doors.08 in) of the calibrated trim height.2003 Expedition/Navigator Workshop Manual Page 5 of 29 movement Excessive vehicle load Cut.87 mph). air compressor vent solenoid and air spring solenoid valves are functioning properly. 2. and fuse 111 (50A) Loose.

Troubleshoot any On-Demand Self Test DTCs first. The ignition switch is in the ON position. All doors. 1. Run the air suspension On-Demand Self Test. GO to Symptom Chart . 5.. Fulfill the pre-conditions..2003 Expedition/Navigator Workshop Manual Page 6 of 29 3. 5/10/2008 . The vehicle is not in 4L mode. Action B1317 Battery voltage high B1318 Battery voltage low B1342 ECU is defective B1566 Door circuit failure B2477 VAPS II steering assist curve not complete C1445 Vehicle speed signal circuit failure C1724 Air suspension height sensor power circuit 4WAS module 4WAS module 4WAS module 4WAS module file://C:\tso\tsocache\STEVENSTOSHIBA_1220\S3J~us~en~file=S3J45003. Go To Pinpoint Test C . 4-Wheel Air Suspension (4WAS) Module Diagnostic Trouble Code (DTC) Index 4-Wheel Air Suspension (4WAS) Module Diagnostic Trouble Code (DTC) Index NOTE: Repair all other DTCs before C1725 and C1726. Go To Pinpoint Test D . Repair DTCs C1990 and C1991 last. and liftgate glass must be closed. REFER to the Symptom Chart. CARRY OUT the pneumatic test. Run the Trim Height Test.. 4. SET the ride height. Retrieve stored DTCs.87 mph). Repeat the On-Demand Self Test and clear DTCs after repairs are completed. REFER to Air Suspension Control Module . TEST the system for normal operation. 2. INSTALL a new 4WAS module. Self-Test Verify that the following conditions are met before running the On-Demand Self Test.htm~gen~ref. REFER to Section 211-00 . Install a battery charger for the On-Demand Self Test to prevent battery drain. 6. Record all listed DTCs. The transmission is in PARK. liftgate. 3. 7. The vehicle speed is less than 3 km/h (1. DTCs Description Source 4WAS module 4WAS module 4WAS module Go To Pinpoint Test C . REFER to Ride Height Adjustments .

Go To Pinpoint Test F . Go To Pinpoint Test F . Navigator: If no DTCs are found. Go To Pinpoint Test H . Go To Pinpoint Test H . Go To Pinpoint Test J . CARRY OUT the pneumatic test. REPEAT the self-test. 5/10/2008 . Go To Pinpoint Test H .htm~gen~ref. CLEAR the DTC.. Go To Pinpoint Test G .. REFER to Section 418-00 . REFER to the Pneumatic Test in this section. Go To Pinpoint Test F . procedure is complete. RETRIEVE any DTCs. REFER to Section 211-00 to download the VAPS information. Go To Pinpoint Test H . If any DTCs are found.2003 Expedition/Navigator Workshop Manual Page 7 of 29 failure C1725 Air suspension front pneumatic failure C1726 Air suspension rear pneumatic failure C1760 Air suspension rear height sensor signal circuit failure C1770 Air suspension vent solenoid output circuit failure C1790 Air suspension LR air spring/shock solenoid output circuit failure C1795 Air suspension RR air spring/shock solenoid output circuit failure C1830 Air suspension compressor relay circuit failure C1840 Air suspension disable switch circuit failure C1873 Air suspension RF air spring solenoid output circuit failure C1877 Air suspension LF air spring solenoid output circuit failure C1881 Air suspension RF height sensor circuit failure C1889 Air suspension LF height sensor circuit failure C1897 Steering VAPS circuit loop failure U1950 UBP communication bus fault C1964 Air suspension compressor actual run time exceeded allowed run time C1990 New control module initialization (requires ride height calibration and pneumatic test pass) 4WAS module 4WAS module 4WAS module 4WAS module 4WAS module 4WAS module 4WAS module 4WAS module 4WAS module 4WAS module 4WAS module 4WAS module 4WAS module 4WAS module 4WAS module Go To Pinpoint Test E . Go To Pinpoint Test I . Expedition: If no DTCs are found. Then. 4WAS module CARRY OUT the ride height resetting procedure. REFER to the C1991 Plant ride height setting 4WAS file://C:\tso\tsocache\STEVENSTOSHIBA_1220\S3J~us~en~file=S3J45003. Allow the air compressor to cool down. Go To Pinpoint Test E . REFER to Section 211-00 . CARRY OUT the pneumatic test.. REFER to Ride Height Adjustments in this section. REPAIR as necessary.

Circuitry. Go To Pinpoint Test E .2003 Expedition/Navigator Workshop Manual Page 8 of 29 and/or tests incomplete module Pneumatic Test in this section. 4WAS module (VDM). RUN the On-Demand Self Test.. file://C:\tso\tsocache\STEVENSTOSHIBA_1220\S3J~us~en~file=S3J45003. U2235 4x4 mode status invalid U2306 Transmission PRNDL indicator or vehicle speed signal invalid 4x4 control REFER to Section 418-00 . 102 (30A). CARRY OUT the ride height resetting procedure. Solenoid. If the self-test yields no faults. procedure is complete. Unable to enter self-test Vehicle raises and/or lowers too slowly Go To Pinpoint Test B . Action Go To Pinpoint Test A . Front/rear pneumatic failure. Height sensor. Uneven vehicle height Go To Pinpoint Test E .. Front/rear pneumatic failure. Air line. 27 (5A). Air compressor assembly.. IF DTC C1991 is found. Circuitry. Height sensor. procedure is complete. Circuitry. RETRIEVE the DTCs. RETRIEVE the DTCs. Air suspension service switch. NOTE: Be sure that the ignition switch is in the ON position and the air suspension service switch is in the ON position before determining that the 4WAS module will not enter the self-test. 5/10/2008 . Cluster (IC) Symptom Chart Symptom Chart Condition No communication with the 4WAS module (VDM) Possible Sources BJB fuses 20 (30A). module Instrument REFER to Section 418-00 . 4WAS module. If the self-test yields a fault(s). Air compressor assembly. GO to Symptom Chart . Refer to Ride Height Adjustments in this section. If no DTCs are found. Solenoid. If DTC C1991 is found.htm~gen~ref. Air line.

DTC B1566: Door circuit failure Validate that all doors. Go To Pinpoint Test N . Air compressor assembly in contact with other components. Go To Pinpoint Test L . If the door ajar indicator is illuminated. Pinpoint Tests PINPOINT TEST A: NO COMMUNICATION WITH THE 4WAS (VDM) MODULE file://C:\tso\tsocache\STEVENSTOSHIBA_1220\S3J~us~en~file=S3J45003. Go To Pinpoint Test M . Air suspension relay. and liftgate glass are closed. Check the door ajar indicator in the cluster. Circuitry. Go To Pinpoint Test K . Door(s) or liftgate open during on demand self-test. DTC C1445: Vehicle Speed Signal Circuit Failure Circuitry. PCM. liftgate. UBP network communication fault. NOTE: Vehicle speed signal is sent through the UBP communication (secondary) network and it is transmitted by hardwire (primary)..htm~gen~ref. 4WAS module. BJB fuse 111 (50A). The compressor is inoperative Go To Pinpoint Test O . REFER to Section 41800 . Air suspension (electromechanical or solid state) relay. Silencer. UBP communication network. 4WAS module. REFER to Section 419-10 .. Air compressor assembly. 5/10/2008 . Circuitry. Air suspension switch.. Mounting bracket. Air compressor assembly.2003 Expedition/Navigator Workshop Manual Page 9 of 29 The air compressor continuously cycles with the ignition switch in the OFF position and no DTC is set The air suspension system is inoperative without DTCs and vehicle at rest Air suspension system operates with air suspension service switch in the OFF position Excessive air compressor noise Circuitry.

TEST the system for normal operation. harness side and ground. TEST the system for normal operation. 5/10/2008 . harness side and ground. A3 CHECK CIRCUIT 875 (BK/LG) FOR AN OPEN Key in OFF position. circuit 1524 (DB). circuit 1003 (GY/YE). REFER to Air Suspension Control Module in this section.. harness side and ground. and between 4WAS module C2131a pin 15. Yes CHECK the UBP communication network. REFER to Section 418-00 . No REPAIR circuit 875 (BK/LG). circuit 1524 (DB). Measure the voltage between 4WAS module C2131a pin 1. Measure the voltage between 4WAS module C2131b pin 4. circuit 875 (BK/LG). Are the voltages greater than 10 volts? A2 CHECK CIRCUIT 1003 (GY/YE) Key in ON position.htm~gen~ref. No Go To Pinpoint Test A . B1 CHECK THE COMMUNICATION TO THE 4WAS MODULE Verify that the following conditions have been met: ignition switch is in the ON position air suspension service switch is in the ON position vehicle speed is less than 3 km/h (2 mph) transmission selector is in PARK battery voltage is greater than 10 volts Does scan tool communicate with the 4WAS module? Yes INSTALL a new 4WAS module. Is the voltage greater than 10 volts? Result / Action to Take Yes GO to A2 .2003 Expedition/Navigator Workshop Manual Page 10 of 29 Test Step A1 CHECK CIRCUIT 1524 (DB) FOR POWER Disconnect: 4WAS Module C2131a. harness side and ground. TEST the system for normal operation. Is the resistance less than 5 ohms? PINPOINT TEST B: UNABLE TO ENTER SELF-TEST Test Step Result / Action to Take NOTE: Be sure that the ignition switch is in the ON position and the air suspension service switch is in the ON position before determining that the 4WAS module will not enter the self-test. No REPAIR circuit 1524 (DB).. PINPOINT TEST C: DTC B1317/B1318 — BATTERY VOLTAGE HIGH/LOW file://C:\tso\tsocache\STEVENSTOSHIBA_1220\S3J~us~en~file=S3J45003. REPEAT the self-test. No REPAIR circuit 1003 (GY/YE). Measure the resistance between 4WAS module C2131b pin 19. Yes GO to A3 ..

REFER to Air Suspension Control Module in this section. and ground. No REPAIR circuit 875 (BK/LG). No REFER to Section 414-00 . REPEAT the self-test.2003 Expedition/Navigator Workshop Manual Page 11 of 29 Test Step C1 CHECK THE BATTERY VOLTAGE Measure the battery voltage between the positive and negative battery posts with the key ON engine OFF (KOEO). circuit 429 (PK/LG). circuit Yes GO to D2 . Disconnect: RF Height Sensor C1151. Disconnect: LF Height Sensor C1153. REPEAT the self-test. harness side and rear height sensor C4084 pin 3. harness side and ground: 4WAS Module Connector C2131a Pin No. Result / Action to Take file://C:\tso\tsocache\STEVENSTOSHIBA_1220\S3J~us~en~file=S3J45003. and between 11 and 18 volts with the engine running? C2 CHECK VOLTAGE TO THE 4WAS MODULE Key in OFF position. and with the engine running.. Circuit 1524 (DB) 1003 (GY/YE) 1524 (DB) Is the voltage between 10 and 13 volts with KOEO. No REPAIR circuit 426 (RD/BK) or circuit 429 (PK/LG). PINPOINT TEST D: DTC C1724 — AIR SUSPENSION HEIGHT SENSOR POWER CIRCUIT FAILURE Test Step D1 CHECK AIR SUSPENSION HEIGHT SENSOR POWER CIRCUITS FOR OPEN Disconnect: 4WAS Module C2131a. TEST the system for normal operation. harness side and between LF height sensor C1153 pin 3. 1 4 15 Result / Action to Take Yes GO to C2 . Measure the resistance between 4WAS module C2131b pin 17. REPEAT the self-test. and between 11 and 18 volts with the engine running? C3 CHECK CIRCUIT 875 (BK/LG) FOR AN OPEN Key in OFF position. REPEAT the self-test. Measure the resistance between 4WAS module C2131a pin 19 circuit 875 (BK/LG). CLEAR the DTC.. CLEAR the DTCs. CLEAR the DTCs. circuit 426 (RD/BK).. Yes GO to C3 . circuit 426 (RD/BK) and between 4WAS module C2131b pin 8. Measure the voltage between the following 4WAS module C2131a pins. Disconnect: Rear Height Sensor C4084. Is the battery voltage between 10 and 13 volts with KOEO. and RF height sensor C1151 pin 3.htm~gen~ref. 5/10/2008 . Disconnect: 4WAS Module C2131a. harness side. No REPAIR circuit 1524 (DB) or circuit 1003 (GY/YE). Key in ON position. Are the resistances less than 5 ohms? Yes INSTALL a new 4WAS module.

CLEAR the DTC. mounting brackets.htm~gen~ref. RF. RESET front ride height. circuit 432 (BK/PK). REFER to Ride file://C:\tso\tsocache\STEVENSTOSHIBA_1220\S3J~us~en~file=S3J45003. circuit 432 (BK/PK). harness side and ground. harness side and LF and RF height sensor C1151 and C1153 pin 1. REPEAT the self-test. REFER to Suspension Height Sensor in this section. and air lines OK? Yes GO to E2 . circuit 429 (PK/LG). Are the air suspension height sensors. and between 4WAS module C2131b pin 8. CLEAR the DTC. 5/10/2008 . REPEAT the self-test. Is the resistance greater than 10. and rear air suspension height sensor for correct installation at the upper and lower ball stud bracket for damage. AND REAR HEIGHT SENSORS Connect: 4WAS Module C2131b. Measure the voltages at C1153 (LF). CLEAR the DTCs.. No REPAIR circuit 426 (RD/BK) or circuit 429 (PK/LG). E1 CHECK THE AIR SUSPENSION HEIGHT SENSORS Inspect the LF. harness side and ground and between rear height sensor C4084 pin 3. PINPOINT TEST E: DTCS C1725/C1726— AIR SUSPENSION FRONT/REAR PNEUMATIC FAILURE Test Step Result / Action to Take NOTE: It may be necessary to vent air from the front air suspension air springs during this pinpoint test. Is the resistance less than 5 ohms? D2 CHECK AIR SUSPENSION HEIGHT SENSOR POWER CIRCUITS FOR SHORT TO GROUND Measure the resistance between 4WAS module C2131b pin 17... circuit 426 (RD/BK) and ground. REPEAT the self-test. If the height sensor mounting brackets are installed or repaired. No REPAIR as necessary. circuit 432 (BK/PK). Yes GO to D3 . circuit 432 (BK/PK) and between 4WAS module C2131b pin 20. Are the voltages 5 volts? Yes INSTALL a new height sensor. REFER to Air Suspension Control Module in this section. between LF height sensor C1153 pin 3 and ground. harness side and rear height sensor C4084 pin 1. circuit 429 (PK/LG). REPEAT the self-test. Key in ON position. Verify that all air lines are fully seated. circuit 432 (BK/PK) and pin 3. circuit 426 (RD/BK). No REPAIR circuit 432 (BK/PK).2003 Expedition/Navigator Workshop Manual Page 12 of 29 429 (PK/LG). Yes GO to D4 . and C4084 (rear) height sensors between pin 1. No INSTALL a new 4WAS module. RF. Inspect the air suspension height sensor mounting brackets for damage. CLEAR the DTC. circuit 429 (PK/LG) and ground.000 ohms? D3 CHECK AIR SUSPENSION HEIGHT SENSOR SIGNAL RETURN CIRCUITS Measure the resistance between 4WAS module C2131b pin 10. Is the resistance less than 5 ohms? D4 CHECK VOLTAGE AT THE LF. between RF height sensor C1151 pin 3. C1151 (RF).

Yes RECONNECT air suspension height sensors. and rear air suspension height sensors at the up and down full travel positions. Does the vehicle raise evenly and hold the new height? E4 VERIFY THAT THE VEHICLE CAN BE LOWERED TRIGGER the 4WAS module vent front and rear air suspension active commands. RF.. No TRIGGER the 4WAS module off active command. E6 CHECK AIR COMPRESSOR PRESSURE OUTPUT Yes CAUTION: The 4WAS module limits the air GO to E8 . Monitor LF. rear air suspension height sensors up and down its full travel. REFER to Air Suspension Compressor . TRIGGER the 4WAS module front and rear suspension fill active commands. file://C:\tso\tsocache\STEVENSTOSHIBA_1220\S3J~us~en~file=S3J45003. slowly move the LF. No INSTALL a new height sensor.. press "cancel". The ignition switch must be in the OFF position to allow the compressor thermal switch to cool. REFER to Suspension Height Sensor in this section.htm~gen~ref. GO to E3 . Yes TRIGGER the 4WAS module off active command. CLEAR the DTC.50 volts and 4. RF.2003 Expedition/Navigator Workshop Manual Page 13 of 29 Height Adjustments in this section. REPEAT the self-test. then press off. No GO to E8 . GO to E4 . Does the air compressor run (slight buzzing noise from RF fender)? Yes TRIGGER the 4WAS module compressor off active command. CLEAR the DTCs. The ignition switch No must be in the OFF position to allow the compressor GO to E7 . REPEAT the self-test. INSTALL a new air compressor. rear height sensor PID display. REPEAT the self-test.50 volts? E3 VERIFY THAT THE VEHICLE CAN BE RAISED NOTE: To trigger the OFF active command using the NGS. GO to E5 . Disconnect the lower end of the LF and RF. it will not restart until it cools down. it will not restart until it cools down. While monitoring the 4WAS module LF. Connect the diagnostic tool. No TRIGGER the 4WAS module compressor off active command. CLEAR the DTCs. 5/10/2008 . If the air compressor overheats. compressor run time. and rear air suspension height sensors. TRIGGER the 4WAS module compressor on active command. Allow the vehicle to raise for 30 seconds. Record the voltage levels for the LF. Does the vehicle lower evenly? Yes INSTALL a new 4WAS module.. NOTE: The voltage increases as the suspension is compressed. Do the voltages vary between 0. E2 CHECK THE AIR SUSPENSION HEIGHT SENSOR OPERATION Turn the air suspension switch to the OFF position. REPEAT the self-test. GO to E6 . and rear height sensor PIDs. RF. Allow the front and rear to lower for 30 seconds. E5 CHECK OPERATION OF AIR COMPRESSOR CAUTION: The 4WAS module limits the air compressor run time. REFER to Air Suspension Control Module in this section. RF. If the air compressor overheats.

Wait five minutes. No GO to E9 . No GO to E9 . REPEAT the self-test. TRIGGER the 4WAS module compressor on active command.034 kPa (150 psi) within 30 seconds and hold developed pressure during the five minutes? E7 CHECK THE AIR DRIER FOR LEAKS CAUTION: The 4WAS module limits the air compressor run time. Check the compressor air drier for water or the front air spring for oil.. REFER to Air Suspension Compressor Drier in this section.. Run the air compressor for 30 seconds. Yes INSTALL a new air drier. No Yes INSTALL new or REPAIR the air line where necessary.. CLEAR the DTCs. NOTE: Apply a soap and water solution to the air lines and air line connections when checking for air suspension system leakage. LR. Is the air drier leaking at the air compressor? E8 CHECK AIR LINE FROM AIR DRIER CAUTION: The 4WAS module limits the air compressor run time. CLEAR the DTCs. Does the vehicle lower at an acceptable rate? Yes INSTALL new air drier. kinks or pinched air lines? E9 CHECK FOR A PLUGGED AIR DRIER Disconnect the air drier from the air compressor while leaving the air line connected.723 kPa [250 psi] maximum reading) with common fittings to the air line going to the compressor air drier. NOTE: If fluid is present when disconnecting an air line. If the air compressor overheats. Thoroughly inspect the air drier-to-air compressor connection.2003 Expedition/Navigator Workshop Manual Page 14 of 29 thermal switch to cool. CLEAR the DTCs. clear the air lines. it will not restart until it cools down. kinked or pinched air lines between the air compressor and LF. Disconnect air line T-fitting at the right front shock tower. TRIGGER the 4WAS module compressor on active command. Check for excessive air leaks. The ignition switch must be in the OFF position to allow the compressor thermal switch to cool. REFER to Air Suspension Compressor Drier in this section. REPEAT the self-test. NOTE: Apply a soap and water solution to the air lines and air line connections when checking for air suspension system leakage. 5/10/2008 . REPEAT the self-test. Did the compressor produce 1. Connect an air pressure gauge (1. RF. TRIGGER the 4WAS module compressor vent on active command. The ignition switch must be in the OFF position to allow the compressor thermal switch to cool. it will not restart until it cools down. TRIGGER the front and rear suspension vent active commands. refer to Air Line Fluid Purge procedure in this section. and RR air spring solenoids and between the air compressor and the air pressure gauge. TRIGGER the 4WAS module compressor on active command. If the air compressor overheats. Are there any excessive leaks. file://C:\tso\tsocache\STEVENSTOSHIBA_1220\S3J~us~en~file=S3J45003.htm~gen~ref.

Is the same air suspension height sensor DTC set? Yes GO to F2 . Yes REPAIR the blockage in the affected air line(s).. Result / Action to Take file://C:\tso\tsocache\STEVENSTOSHIBA_1220\S3J~us~en~file=S3J45003. REFER to Air Spring Solenoid Valve in this section. REPEAT the self-test. RF. 5/10/2008 . C1881 (RF). circuit 432 (BK/PK) and 4WAS module C2131a pin 20 (front sensors).. C1889 (LF)— AIR SUSPENSION HEIGHT SENSOR SIGNAL CIRCUIT FAILURE Test Step F1 VALIDATE DTC ERROR CARRY OUT the 4WAS module On-Demand Self Test.. refer to Air Line Fluid Purge in this section. LR. Measure the resistance between the suspect height sensor connector pin 1 harness side. Does each corner of the vehicle lower? Yes INSTALL a new 4WAS module. F2 CHECK SUSPECT AIR SUSPENSION HEIGHT SENSOR SIGNAL RETURN CIRCUIT Key in OFF position. or RR air spring. Disconnect the air line at the LF. C2131a pin 10 (rear sensor).htm~gen~ref. PINPOINT TEST F: DTC C1760 (REAR). LR. REFER to Air Suspension Control Module in this section. If a different DTC is retrieved. Air Suspension Air Suspension Height Sensor Yes GO to F3 . Can a vacuum be drawn and held? E11 CHECK THE SPRINGS FOR CORRECT OPERATION NOTE: If fluid is present when disconnecting an air line. clear the air lines. REPEAT the self-test. RF. RF. No If no DTC is retrieved. E10 CHECK FOR BLOCKAGE IN AIR LINE TO LF OR RF AIR SPRING NOTE: If fluid is present when disconnecting an air line. Turn the air suspension service switch to the OFF position. Disconnect: 4WAS Module C2131a. REPEAT the self-test. clear the air lines. No GO to E11 . CLEAR the DTCs. LR. Connect the vacuum tester at the suspect air spring air line and try to draw a vacuum. No REPAIR circuit 432 (BK/PK). harness side. Check the air compressor air drier for water and check the air springs for oil. Disconnect the air line at the air drier. REFER to the 4WAS Module Diagnostic Trouble Code (DTC) Index. REPEAT the self-test. CLEAR the DTCs. and RR air spring solenoid valve vent active commands. CLEAR the DTCs. Check the air compressor air drier for water and check the air springs for oil. or RR air spring solenoids. GO to F5 . No INSTALL a new air spring solenoid valve. TRIGGER the 4WAS module LF. Disconnect the air line at LF.2003 Expedition/Navigator Workshop Manual Page 15 of 29 GO to E10 . refer to Air Line Fluid Purge in this section. Disconnect: Air Suspension Service Switch C4169.

Disconnect the suspect height sensor ball stud from the height sensor bracket. No CHECK the 4WAS module and air compressor harness connectors for bent or pushed out pins. Does the voltage vary from 0. Key in ON position. Move the suspect height sensor arm through its full range of motion. circuit 432 (BK/PK) harness side and pin 3. Disconnect: Air Suspension Service Switch C4169. CARRY OUT the pneumatic test. Key in ON position.. Using the scan tool. C1153 C1151 C4084 Is the resistance less than 5 ohms? F3 CHECK 4WAS MODULE POWER AND RETURN CIRCUITS Key in OFF position. PINPOINT TEST G: DTC C1770 — AIR SUSPENSION VENT SOLENOID OUTPUT CIRCUIT FAILURE Test Step G1 VALIDATE DTC C1770 Carry out 4WAS module On-Demand Self Test. Turn the air suspension service switch to the OFF position. REPEAT the self-test. circuit 432 (BK/PK) harness side and pin 3. For DTC's C1881 (RF) or C1889 (LF). REPEAT the Result / Action to Take file://C:\tso\tsocache\STEVENSTOSHIBA_1220\S3J~us~en~file=S3J45003. monitor the suspect height sensor PID (s). Yes REPAIR circuit 429 (PK/LG). For DTC C1760. Turn the air suspension service switch to the OFF position.5 volts? Yes INSTALL a new 4WAS module. No Go To Pinpoint Test D . Is voltage present? F5 CHECK THE HEIGHT SENSOR OUTPUT Connect: Height Sensor(s). circuit 426 (RD/BK) harness side. measure the voltage between rear height sensor C4084 pin 1.2003 Expedition/Navigator Workshop Manual Page 16 of 29 Height Sensor Left Front (LF) Right Front (RF) Rear Connector No. Turn the air suspension service switch to the OFF position. Is the voltage approximately 5 volts? F4 CHECK AIR SUSPENSION HEIGHT SENSOR POWER CIRCUIT Key in OFF position. REFER to Air Suspension Control Module in this section. circuit 429 (PK/LG) harness side and ground. No Go To Pinpoint Test D . circuit 429 (PK/LG) harness side.. Yes GO to F5 . measure the voltage between C1151 or C1153 height sensor pin 1.htm~gen~ref. No GO to F4 . 5/10/2008 . Is the same air suspension DTC set? Yes GO to G2 . corrosion or damage. Measure the voltage between suspect height sensor connector pin 3.50 to 4..

REPEAT the self-test. Yes If O appeared. Yes GO to G6 . REFER to Air Suspension Compressor in this section. moisture. Inspect the pins and terminals of the air compressor assembly connector for corrosion. component side. Measure the resistance between air compressor C1179 pin 2 and pin 3. harness side. Is the resistance less than 5 ohms? G7 CHECK CIRCUIT 421 (PK) FOR SHORT TO GROUND Disconnect: 4WAS Module C2131b. No REPAIR circuit 57 (BK). G. If other DTCs are present. CLEAR the DTCs.. GO to G5 . REPEAT the self-test. GO to G3 . TRIGGER the 4WAS module vent on and vent off active command. Yes RECONNECT the air compressor assembly C1179. Measure the resistance between 4WAS module C2131b pin 5.2003 Expedition/Navigator Workshop Manual Page 17 of 29 self-test. bent or broken pins. REFER to the 4WAS Module Diagnostic Trouble Code (DTC) Index. CLEAR the DTC.htm~gen~ref. 5/10/2008 . GO to G4 . No REPAIR the connector as necessary. No CLEAR the DTCs. Yes GO to G5 . CLEAR the DTCs. CLEAR the DTCs. file://C:\tso\tsocache\STEVENSTOSHIBA_1220\S3J~us~en~file=S3J45003.. or other damage. If G appeared.. G2 CHECK VENT SOLENOID CONNECTOR Key in OFF position. circuit 421 (PK). circuit 421 (PK). REPEAT the self-test. REPEAT the self-test. harness side and ground. or B appear next to the ON/OFF text for the air suspension vent solenoid? G4 CHECK CIRCUIT 57 (BK) FOR AN OPEN Measure the resistance between air compressor assembly C1179 pin 2. Yes Yes GO to G7 . GO to G7 . REPEAT the self-test. Is the resistance between 17 and 22 ohms? G6 CHECK CIRCUIT 421 (PK) Disconnect: 4WAS Module C2131b. Do the letters O. No INSTALL a new air compressor. Is the resistance less than 5 ohms? G5 CHECK THE VENT SOLENOID FOR AN OPEN Disconnect: Air Compressor C1179. No REPAIR circuit 421 (PK). harness side and air compressor assembly C1179 pin 3. Turn the air suspension service switch to the OFF position. Is the air compressor assembly C1179 OK? G3 CHECK VENT SOLENOID PID Turn the air suspension service switch to the ON position. If B appeared. Key in ON position. Disconnect: Air Compressor Assembly C1179. circuit 57 (BK).

Turn the air suspension service switch to the OFF position. No If no DTCs are retrieved. GO to H3 . Yes INSTALL a new 4WAS module. 5/10/2008 . REFER to Air Suspension Control Module in this section.. CLEAR the DTCs. Is the air suspension air spring solenoid connector(s) OK? H3 CHECK AIR SPRING SOLENOID PID(S) Turn the air suspension service switch to the ON position. C1795 (RR). Key in ON position. bent or broken pins. C1795. No GO to H10 . C1873 (RF). Monitor the air spring solenoid PID. PINPOINT TEST H: DTC C1790 (LR).. C1873. GO to H4 . file://C:\tso\tsocache\STEVENSTOSHIBA_1220\S3J~us~en~file=S3J45003. Is the voltage at zero? GO to G8 . Measure the voltage between 4WAS module C2131b pin 5. GO to H10 . Disconnect: 4WAS Module C2131b.htm~gen~ref. Yes RECONNECT the air suspension air spring solenoid connector(s). No REPAIR circuit 421 (PK). or other damage. Result / Action to Take H2 CHECK AIR SUSPENSION AIR SPRING SOLENOID CONNECTOR(S) Key in OFF position. circuit 421 (PK).. GO to H9 . If different DTCs are retrieved. or C1877 set? Yes GO to H2 . Key in ON position. No REPAIR the connector(s) as necessary.000 ohms? G8 CHECK CIRCUIT 421 (PK) FOR SHORT TO POWER Key in OFF position. G. circuit 421 (PK).2003 Expedition/Navigator Workshop Manual Page 18 of 29 Measure the resistance between 4WAS module C2131b pin 5. Inspect the pins and terminals of the air suspension air spring solenoid connector(s) for corrosion. No REPAIR circuit 421 (PK). REPEAT the self-test. Is DTC C1790. GO to H7 . REPEAT the self-test. CLEAR the DTCs. Disconnect: Air Suspension Air Spring Solenoid Connector. Is the resistance greater than 10. harness side and ground. Turn the air suspension service switch to the OFF position. moisture. CLEAR the DTCs. Do the letters O. C1877 (LF)— AIR SUSPENSION AIR SPRING SOLENOID OUTPUT CIRCUIT FAILURE Test Step H1 VALIDATE DTC Carry out the 4WAS module On-Demand Self Test. or B appear next to the ON/OFF text for the air suspension air spring solenoid? Yes If O appeared. REFER to 4WAS Module Diagnostic Trouble Code (DTC) Index. If B appeared. REPEAT the self-test. harness side and ground. REPEAT the self-test. If G appeared.

.. REFER to Air Shock Absorber—Front or Air Shock Absorber—Rear in this section. Measure the resistance between the suspect air suspension air spring solenoid pin 1 and pin 2 (component side). Measure the resistance between the 4WAS module C2131b pin (harness side) and the suspect air suspension air spring solenoid pin 2. H6 CHECK AIR SPRING SOLENOID OUTPUT CIRCUIT(S) Disconnect: 4WAS Module C2131b. No REPAIR the affected circuit(s)..htm~gen~ref. REPEAT the self-test. Measure the resistance between the suspect air spring solenoid(s) pin 1 and pin 2 (component side). REFER to Air Suspension Control Module in this section. REPEAT the self-test. Turn the air suspension service switch to the OFF position. (harness side) as follows: Air Suspension Air Spring Solenoid Output Circuit 1114 (BR/PK) 1115 (TN/WH) 414 (OG/RD) 415 (LG/RD) Yes INSTALL a new 4WAS module. CLEAR the DTC. Disconnect: Air Spring Solenoid connector. Turn the air suspension service switch to the OFF position. REFER to Air Yes GO to H8 . air spring solenoid pin 1. file://C:\tso\tsocache\STEVENSTOSHIBA_1220\S3J~us~en~file=S3J45003. For front air spring solenoid. REPEAT the self-test. harness side and ground. REPEAT the self-test. Is the resistance between 15 and 18 ohms? H5 CHECK GROUND CIRCUIT 57 (BK) FOR OPEN Measure the resistance between the suspect Yes GO to H6 . Disconnect: Air Suspension Air Spring Solenoid. Yes INSTALL a new 4WAS module.2003 Expedition/Navigator Workshop Manual Page 19 of 29 H4 CHECK AIR SUSPENSION AIR SPRING SOLENOID COIL(S) FOR OPEN Key in OFF position. Yes GO to H5 . CLEAR the DTC. REFER to Air Shock Absorber—Front in this section. No INSTALL a new air suspension air spring solenoid. circuit 57 (BK). REFER to Air Shock Absorber—Rear in this section. for rear air spring solenoid. CLEAR the DTC (s). No Is the resistance less than 5 ohms? REPAIR circuit 57 (BK). Is the resistance 15 to 18 ohms? H8 CHECK OUTPUT CIRCUIT FOR SHORT TO GROUND Disconnect: 4WAS Module C2131b. 4WAS Module C2131B Pin (LR) 13 (RR) 14 (RF) 2 (LF) 16 Is the resistance less than 5 ohms? H7 CHECK AIR SUSPENSION AIR SPRING SOLENOID COIL FOR SHORT Key in OFF position. No INSTALL a new air spring solenoid. 5/10/2008 .

REPEAT the self-test. C2131b pin (harness side) and ground. REPEAT the self-test. Disconnect: 4WAS Module C2131b. REFER to Air Air Suspension Air 4WAS Module Spring Solenoid Output Suspension Control Module in this section. C2131B Pin Circuit (LR) 13 (RR) 14 (RF) 2 (LF) 16 Is voltage present? H10 CHECK AIR SUSPENSION AIR SPRING SOLENOID CONNECTOR FOR DAMAGE Key in OFF position. Inspect the pins and terminals of the air suspension air spring solenoid for corrosion. CLEAR the DTC. No REPAIR the connector(s) as necessary.htm~gen~ref. 4WAS Module C2131B Pin (LR) 13 (RR) 14 (RF) 2 (LF) 16 Is the resistance greater than 10. CLEAR the DTC (s).. REPAIR the affected circuit(s). Measure the voltage between 4WAS module REPEAT the self-test. or other damage. If a DTC is retrieved. 5/10/2008 . moisture. Air Suspension Air Spring Solenoid Output Circuit 1114 (BR/PK) 1115 (TN/WH) 414 (OG/RD) 415 (LG/RD) Suspension Control Module in this section.000 ohms? H9 CHECK OUTPUT CIRCUIT FOR SHORT TO POWER Yes Key in OFF position. inspect the wiring near the connector for damage.2003 Expedition/Navigator Workshop Manual Page 20 of 29 Measure the resistance between 4WAS module pin (harness side) and ground. bent or broken pins. Turn the air suspension service switch to the OFF position. REPEAT the self-test. REPEAT the self-test. Is the air suspension air spring solenoid connector OK? Yes RECONNECT the air suspension air spring solenoid connector. 1114 (BR/PK) 1115 (TN/WH) 414 (OG/RD) 415 (LG/RD) PINPOINT TEST I: DTC C1830 — AIR SUSPENSION COMPRESSOR RELAY CIRCUIT FAILURE Test Step I1 VALIDATE DTC C1830 Result / Action to Take file://C:\tso\tsocache\STEVENSTOSHIBA_1220\S3J~us~en~file=S3J45003. If no DTCs are retrieved. REFER to 4WAS Module Diagnostic Trouble Code (DTC) Index.. the system is OK. Turn the air suspension service switch to the ON position. No REPAIR the affected circuit(s). Disconnect: Suspect Air Suspension Air Spring Solenoid.. No INSTALL a new 4WAS module. CLEAR the DTC. REPEAT the self-test.

circuit 420 (DB/YE). GO to I4 . Yes RECONNECT air compressor relay C1300. or other damage. Is the voltage greater than 10 volts? I5 CHECK POWER TO AIR SUSPENSION RELAY Yes Measure the voltage between air compressor relay C1300 pin 3. No REPAIR the circuit. Disconnect: Air Suspension Relay C1300. moisture. Yes If O appeared. REPEAT the self-test. No If no DTC is retrieved. component side and ground. REPEAT the self-test. Is the connector OK? I3 CHECK THE AIR COMPRESSOR PID Turn the air suspension service switch to the ON position. Inspect the pins and terminals of the air compressor relay for corrosion. (LB/PK). If a different DTC is retrieved. CLEAR the DTC. Do the letters O or B appear next to the ON/OFF text for the air compressor? I4 CHECK POWER TO AIR SUSPENSION RELAY COIL Key in OFF position. Yes GO to I5 . circuit 833 (PK/LB). Yes GO to I7 . Disconnect: Air Compressor Relay C1300.2003 Expedition/Navigator Workshop Manual Page 21 of 29 Carry out the 4WAS module On-Demand Self Test. GO to I3 .htm~gen~ref. CLEAR the DTC. No GO to I9 .. CLEAR the DTC. No Is the voltage greater than 10 volts? REPAIR the circuit. circuit 1053 GO to I6 . CLEAR the DTC. harness side. Key in ON position. Measure the resistance between 4WAS module C2131b pin 18. REPEAT the self-test. I6 CHECK CIRCUIT 420 (DB/YE) FOR AN OPEN Disconnect: 4WAS Module C2131b. GO to I8 . For vehicles built after 2/03. file://C:\tso\tsocache\STEVENSTOSHIBA_1220\S3J~us~en~file=S3J45003. If B appeared. Turn the air suspension service switch to the OFF position. GO to I8 . Measure the voltage between air compressor relay C1300 pin 1. No REPAIR circuit 420 (DB/YE).. REFER to 4WAS Module Diagnostic Trouble Code (DTC) Index. Is the same air suspension DTC set? Yes GO to I2 . bent or broken pins. TRIGGER the 4WAS module compressor on and off active command.. carry out the Air Compressor Relay Component test. Refer to Cell 149. circuit 420 (DB/YE). Turn the air suspension service switch to the OFF position. 5/10/2008 . I2 CHECK AIR COMPRESSOR RELAY AND CONNECTOR Key in OFF position. No REPAIR as necessary. harness side and air compressor relay C1300 pin 2. REPEAT the self-test.

J2 CHECK THE AIR SUSPENSION SERVICE SWITCH Result / Action to Take file://C:\tso\tsocache\STEVENSTOSHIBA_1220\S3J~us~en~file=S3J45003. position. Measure the voltage between 4WAS module C2131b pin 18. Disconnect: Air Compressor Relay C1300. Turn the air suspension service switch to the ON position. Disconnect: Air Compressor Relay C1300. the system is OK. Yes REPAIR the circuit. circuit 420 (DB/YE). harness side and ground. REPEAT the self-test. moisture. TEST the system for normal operation. Measure the resistance between 4WAS module C2131b pin 18. 5/10/2008 . Yes GO to I8 .htm~gen~ref. REPEAT the self-test.000 ohms? I8 CHECK CIRCUIT 420 (DB/YE) FOR SHORT TO POWER Key in OFF position.2003 Expedition/Navigator Workshop Manual Page 22 of 29 Is the resistance less than 5 ohms? I7 CHECK CIRCUIT 420 (DB/YE) FOR SHORT TO GROUND Disconnect: 4WAS Module C2131b. CLEAR the DTC. PLACE the air suspension service switch in the ON position. REFER to 4WAS Module Diagnostic Trouble Code (DTC) Index. Turn the air suspension service switch to the OFF position. If DTC C1840 is retrieved. Disconnect: 4WAS Module C2131b. No REPAIR circuit 420 (DB/YE).. PINPOINT TEST J: DTC C1840 — AIR SUSPENSION SERVICE SWITCH CIRCUIT FAILURE Test Step J1 CHECK POSITION OF AIR SUSPENSION SERVICE SWITCH Verify that the air suspension service switch is in the ON Yes GO to J2 . bent or broken pins. Is the connector OK? Yes RECONNECT air compressor relay. GO to J2 ... Is the air suspension service switch ON? No Turn ON the air suspension service switch. CLEAR the DTC. If a DTC is retrieved. inspect the wiring near the connector for damage. REPEAT the self-test. Inspect the pins and terminals of the air compressor relay for corrosion. or other damage. circuit 420 (DB/YE). REFER to Air Suspension Control Module in this section. CLEAR the DTC. harness side and ground. Turn the air suspension service switch to the OFF position. REPEAT the self-test. REPEAT the self-test. No INSTALL a new 4WAS module. CLEAR the DTC. Is the resistance greater than 10. If no DTCs are retrieved. Key in ON position. No REPAIR as necessary. Is the voltage greater than zero volts? I9 CHECK AIR COMPRESSOR RELAY CONNECTOR Key in OFF position.

Is the voltage 5 volts? PINPOINT TEST K: THE AIR COMPRESSOR CONTINUOUSLY CYCLES WITH THE IGNITION SWITCH IN THE OFF POSITION AND NO DTC IS SET Test Step K1 CHECK FOR MODULE ACTIVITY NOTE: The 4WAS module is powered for 40 minutes after the ignition is turned OFF. Does the air compressor still cycle after the module goes to sleep? K2 CHECK THE 4WAS MODULE Turn the air suspension service switch to the OFF position. the air suspension system is still active and may activate system components. No INSTALL a new air suspension service switch. Key in ON position. CLEAR the DTC. Press the air suspension service switch ON and measure the resistance between pin 1 and 2. Measure the resistance between the air suspension service switch C4169 pin 2. Result / Action to Take file://C:\tso\tsocache\STEVENSTOSHIBA_1220\S3J~us~en~file=S3J45003. circuit 418 (PK/LG) and ground. Yes GO to J5 . REPEAT the self-test. During this time. Measure the voltage between the air suspension service switch C4169 pin 1 (harness side).. REPEAT the self-test. and 4WAS module C2131b pin 25 (harness side). Is the resistance greater than 10. No REPAIR circuit 429 (PK/LG). CLEAR the DTC. Key in OFF position. Yes GO to K2 .. REPEAT the self-test. Disconnect: Air Suspension Service Switch C4169. Yes GO to K3 .. INFORM the owner of system operations.htm~gen~ref. circuit 429 (PK/LG) and ground. Check to see if the air compressor still cycles 50 minutes after the ignition is turned OFF. No REPAIR circuit 418 (PK/LG). No The system is OK. Is the resistance less than 5 ohms? J4 CHECK CIRCUIT 418 (PK/LG) FOR SHORT TO GROUND Measure the resistance between the air suspension service switch C4169 pin 2 (harness side). Disconnect: 4WAS Module C2131b. circuit 418 (PK/LG) (harness side). No REPAIR circuit 418 (PK/LG). Yes INSTALL a new 4WAS module. REFER to Air Suspension Control Module in this section. REPEAT the self-test. Disconnect: 4WAS Module C2131b. CLEAR the DTC. circuit 418 (PK/LG). J5 CHECK CIRCUIT 429 (PK/LG) FOR VOLTAGE Connect: 4WAS Module C2131b.2003 Expedition/Navigator Workshop Manual Page 23 of 29 Turn the air suspension service switch to the OFF position. REPEAT the self-test. CLEAR the DTC. Is the resistance less than 5 ohms? J3 CHECK CIRCUIT 418 (PK/LG) FOR OPEN Key in OFF position. Yes GO to J4 . 5/10/2008 .000 ohms? Yes GO to J3 .

REPEAT the self-test.2003 Expedition/Navigator Workshop Manual Page 24 of 29 Does the air compressor still cycle? No INSTALL a new 4WAS module. Is the resistance less than 10. REFER to Air Suspension Control Module in this section. Result / Action to Take file://C:\tso\tsocache\STEVENSTOSHIBA_1220\S3J~us~en~file=S3J45003. Does the PID indicate that the ignition switch is in the ON position? L2 CHECK 4WAS MODULE FOR IGNITION SWITCH OFF INPUT NOTE: The ignition switch must initially be in the ON position for this test step to be valid. TEST the system for normal operation. No REPAIR circuit 1003 (GY/YE). Does the door status PID change between CLOSED and AJAR states? Yes GO to L4 .. No GO to K4 . TEST the system for normal operation. TEST the system for normal operation. Yes REPAIR circuit 538 (GY/RD). TEST the system for normal operation. open and close one door.htm~gen~ref. While observing the scan tool. PINPOINT TEST L: AIR SUSPENSION SYSTEM INOPERATIVE WITHOUT DTCS AND VEHICLE AT REST Test Step L1 CHECK 4WAS MODULE FOR IGNITION SWITCH ON INPUT Enter the following diagnostic mode on the diagnostic tool: Scan Tool. Monitor 4WAS module ignition switch position PID. K3 CHECK THE AIR COMPRESSOR RELAY Disconnect: Air Compressor Relay C1000.000 ohms? Yes INSTALL a new air suspension relay. Does the PID indicate that the ignition switch is in the ON position? L3 CHECK 4WAS MODULE FOR DOOR AJAR INPUT Monitor 4WAS module door position status PID. liftgate. TEST the system for normal operation.. REFER to Section 418-00 . 5/10/2008 . and liftgate glass. Yes GO to L3 . Close all doors. Key in OFF position. No REPAIR circuit 420 (DB/YE). Yes GO to L2 .. No CHECK for a UBP network fault. No REPAIR circuit 1003 (GY/YE). Does the air compressor still cycle? K4 CHECK CIRCUIT 420 (DB/YE) FOR SHORT TO GROUND Measure the resistance between the air compressor relay C1000 pin D and ground.

Disconnect: Air Suspension Service Switch C4169. Select NEUTRAL. NOTE: The 4x4 light on the instrument panel will turn off when the system is in 2H mode. 5/10/2008 . REFER to Section 418-00 . Place the mode switch into 2H mode.000 ohms? M2 CHECK CIRCUIT 418 (DG/YE) FOR VOLTAGE Disconnect: Air Suspension Service Switch C4169. Is the resistance greater than 10. Press the brake pedal. Measure the voltage between air suspension service switch C4169 pin 2. Does VSS PID track the speedometer within 8 km/h (5 mph)? Yes GO to L6 . No INSTALL a new air suspension service switch. Place the mode switch into 4L mode. Yes INSTALL a new 4WAS module. TEST the system for normal operation.2003 Expedition/Navigator Workshop Manual Page 25 of 29 L4 CHECK 4WAS MODULE FOR 4X4 STATE INPUT Monitor 4WAS module PID 4WDLOW. Yes GO to M2 . circuit 418 (DG/YE). Key in ON position. and did the cluster indicators agree with PID 4WDLOW? L5 CHECK 4WAS MODULE FOR VSS INPUT Monitor 4WAS module VSS PID. Does Park/Neutral switch PID show OFF with the vehicle in Drive and ON with the vehicle in Park? Yes RETRIEVE all DTCs and REFER to the 4WAS Module Diagnostic Trouble Code (DTC) Index and Symptom Chart for further diagnostics.. Test drive the vehicle at different speeds.htm~gen~ref. Select DRIVE. No CHECK for a UBP network fault. PINPOINT TEST M: AIR SUSPENSION SYSTEM OPERATES WITH AIR SUSPENSION SERVICE SWITCH IN THE OFF POSITION Test Step Result / Action to Take NOTE: The air suspension system will operate at speeds greater that 24 km/h (15 mph) with the air suspension service switch in the OFF position. No CHECK for a UBP network fault. Yes GO to L5 . Measure the resistance between air suspension service switch terminals. Turn the air suspension service switch to the OFF position. Did PID 4WDLOW show OFF in 2H and ON in 4L.. Select PARK.. REPEAT the self-test. M1 CHECK AIR SUSPENSION SWITCH Key in OFF position. L6 CHECK PARK/NEUTRAL INPUT TO 4WAS MODULE Monitor 4WAS module Park/Neutral switch PID. TEST the system for normal operation. No REPAIR circuit 679 (GY/BK). REFER to Air Suspension Control Module in this section. file://C:\tso\tsocache\STEVENSTOSHIBA_1220\S3J~us~en~file=S3J45003. REFER to Section 418-00 .

loose fasteners. No GO to N4 . REFER to Air Suspension Compressor in this section. The air compressor can overheat and stop operating due to an internal temperature sensitive thermal breaker. stones or other foreign objects). Connect the diagnostic tool. Check for anything contacting the air compressor (other wire harnesses.. REFER to Air Suspension Compressor in this section. No RECHECK the mountings and bracket for damage.. Result / Action to Take file://C:\tso\tsocache\STEVENSTOSHIBA_1220\S3J~us~en~file=S3J45003. TEST the system for Yes ADJUST air compressor wiring harness so that it does not contact non-mounting components or FASTEN/REMOVE objects so they no longer contact the air compressor assembly. TEST the system for normal operation. 5/10/2008 . TEST the system for normal operation. Remove the air compressor assembly. Are any faults in the mounts present? Yes INSTALL a new air compressor and bracket assembly.htm~gen~ref. N3 CHECK AIR COMPRESSOR MOUNTS FOR DAMAGE Check the air compressor mounts for signs of cracks or breaking away of insulation material. TEST the system for normal operation.. REFER to Air Suspension Compressor in this section. Is the air compressor bracket making contact with other components? Yes REPAIR the air compressor and bracket assembly or other components as necessary. TEST the system for normal operation. N4 CHECK AIR COMPRESSOR FOR NOISE CAUTION: Do not run the air compressor for more than three minutes.2003 Expedition/Navigator Workshop Manual Page 26 of 29 harness side and ground. air lines. No GO to N2 . TEST the system for normal operation. INSTALL a new air compressor assembly. hoses. If damaged. Is the air compressor wiring contacting non-mounting components or is anything contacting the compressor assembly besides the mounts? N2 CHECK FOR BENT AIR COMPRESSOR BRACKET Check the air compressor bracket for any damage/bends that may contact other components within the engine compartment. PINPOINT TEST N: EXCESSIVE AIR COMPRESSOR NOISE Test Step N1 CHECK FOR AIR COMPRESSOR AND/OR AIR COMPRESSOR WIRING CONTACTING OTHER COMPONENTS Check the air compressor wiring to see if it is contacting other components inside the engine compartment at any place other than the mounting points. No GO to N3 . but leave it connected electrically. TRIGGER the 4WAS module compressor Yes INSTALL a new air compressor assembly. Is the voltage approximately 0 volts? No REPAIR circuit 418 (DG/YE). REFER to Air Suspension Compressor in this section.

harness side. Measure the resistance between air compressor relay C1000 pin 5. Is the voltage greater than 10 volts? Yes GO to O3 .2003 Expedition/Navigator Workshop Manual Page 27 of 29 on active command. file://C:\tso\tsocache\STEVENSTOSHIBA_1220\S3J~us~en~file=S3J45003. O1 CHECK AIR COMPRESSOR RELAY CONNECTOR Disconnect: Air Compressor Relay C1000. relay component for schematic and connector information. O5 CHECK AIR COMPRESSOR AFTER COOL DOWN PERIOD Turn the air suspension service switch to the OFF position. TEST the system for normal operation. No REPAIR the circuit. circuit 1053 (LB/BK). PINPOINT TEST O: THE COMPRESSOR IS INOPERATIVE Test Step NOTE: This test is for the harness side of the relay circuitry.. No REPAIR the circuit. Refer to Wiring Diagrams Cell 149 . TEST the system for normal operation. TRIGGER the 4WAS module vent on active command. TEST the system for normal operation.. circuit 577 (LG/RD). Key in ON position. or other damage. Allow the vehicle to sit for 60 minutes to give the air compressor assembly time to cool off. TRIGGER the 4WAS module compressor on Yes GO to O8 . No GO to O6 . Is the air compressor noisy? normal operation. harness side and air compressor assembly C194 pin 4. 5/10/2008 . moisture. harness side and ground.. Turn the air suspension service switch to the ON position. harness side and ground. TEST the system for normal operation. bent or broken pins. Yes GO to O2 . Is the resistance less than 5 ohms? Yes RECONNECT air compressor relay C1000 and air compressor assembly C194. Is the resistance less than 5 ohms? O4 CHECK CIRCUIT 577 (LG/RD) Measure the resistance between air compressor assembly C194 pin 1. Inspect the pins of the air compressor relay connector for corrosion. GO to O5 . Result / Action to Take O3 CHECK CIRCUIT 538 (GY/RD) Disconnect: Air Compressor Assembly C194. No REPAIR the circuit. circuit 538 (GY/RD).htm~gen~ref. Yes GO to O4 . No REPAIR as necessary. circuit 538 (GY/RD). Is the air compressor relay C1000 OK? O2 CHECK CIRCUIT 1053 (LB/BK) Measure the voltage between air compressor relay C1000 pin 1.

TEST the system for normal operation. REFER to Air Suspension Compressor in this section. Yes GO to O7 . circuit 1053 (LB/BK)... Component Test Relay Refer to Wiring Diagrams Cell 149 for schematic and connector information. harness side and air compressor relay C1000 pin 5. No REPAIR circuit 577 (PK/LB). Connect a fused (50A) jumper wire (10 gauge) between air compressor relay C1000 pin 3. Does the air compressor assembly run? O6 CHECK AIR COMPRESSOR RELAY POWER Disconnect: Air Compressor Relay C1000. No INSTALL a new air compressor assembly. Is the voltage less than 10 volts? O7 CHECK AIR COMPRESSOR RELAY Key in OFF position..htm~gen~ref. RETEST to validate the system is OK. 5/10/2008 . O8 CHECK AIR COMPRESSOR THERMAL BREAKER TRIGGER the 4WAS module LR and RR air spring solenoid valve open active commands. harness side and ground. harness side. INSTALL a new air compressor. TEST the system for normal operation. TEST the system for normal operation. REFER to Air Suspension Compressor in this section. Did the air compressor assembly run for 60 seconds? Yes The thermal breaker was overheated. file://C:\tso\tsocache\STEVENSTOSHIBA_1220\S3J~us~en~file=S3J45003. INSTALL a new air compressor relay. Does the air compressor run? Yes DISCONNECT the jumper wire.2003 Expedition/Navigator Workshop Manual Page 28 of 29 active command. Measure the voltage between air compressor relay C1000 pin 2 circuit 577 (PK/LB). TEST the system for normal operation. Run the air compressor assembly for 60 seconds. No DISCONNECT the jumper wire. circuit 538 (GY/RD).

Calibration Ride Height Resetting 1. 3. NOTE: Make sure that the air suspension switch is in the ON position NOTE: Make sure that a battery voltage of at least 11 volts is maintained while carrying out this procedure.. shift the vehicle into DRIVE and then back to PARK. 2. close all doors and allow the system to vent the vehicle down to kneel height (approximately 45 seconds). VENT REAR to deflate the rear down. Exit the vehicle. Select Air Suspension Control Module under Active Command Mode: VENT FRNT to deflate the front down. With the ignition remaining in the ON position. NOTE: Make sure that the air suspension switch is in the ON position. file://C:\tso\tsocache\STEVENSTOSHIBA_1220\S3J~us~en~file=S3J45004.2003 Expedition/Navigator Workshop Manual Page 1 of 2 SECTION 204-05: Vehicle Dynamic Suspension — 4-Wheel GENERAL PROCEDURES 2003 Expedition/Navigator Workshop Manual Ride Height Adjustments Special Tool(s) Worldwide Diagnostic System (WDS) 418-F224 New Generation STAR (NGS) Tester 418-F052 or equivalent scan tool Inflation and Deflation of the Air Suspension System 1.. Turn the ignition to the ON position. Connect scan tool to the data link connector (DLC). 5/10/2008 . LIFT FRNT to inflate the front up.. Turn the ignition switch to the ON position. LIFT REAR to inflate the rear up.htm~gen~ref. NOTE: Make sure that a battery voltage of at least 11 volts is maintained while carrying out this procedure. 2.

2003 Expedition/Navigator Workshop Manual Page 2 of 2 Exit the vehicle. Connect scan tool to the data link connector (DLC). 7. select the proper vehicle year. 5.. model and engine type.. For additional information.htm~gen~ref. Select 4WAS module. 9. refer to Section 204-00 . Select the "Save Calibration Values (Store Ride Height)" scan tool command to calibrate the 4WAS module. close all doors and allow the vehicle to pump to trim (approximately 45 seconds). vent or lift the vehicle to achieve the correct ride height. 6. 8. While outside of the vehicle. 4. 3. Open the LF door. Measure the ride height. 5/10/2008 .. file://C:\tso\tsocache\STEVENSTOSHIBA_1220\S3J~us~en~file=S3J45004. Using the active command mode.

file://C:\tso\tsocache\STEVENSTOSHIBA_3160\S3J~us~en~file=S3J45005. Trim the sleeve material from both ends of the damaged line. 5.. air springs and the air compressor. air line fittings. NOTE: If a leak is detected within the air compressor.. For additional information. If a leak is detected in a line. Inflate the air suspension system. 5/10/2008 . NOTE: Check system for leaks.htm~gen~ref. Cut the line at the damaged area. 2. 4. 6.2003 Expedition/Navigator Workshop Manual Page 1 of 2 SECTION 204-05: Vehicle Dynamic Suspension — 4-Wheel GENERAL PROCEDURES 2003 Expedition/Navigator Workshop Manual Air Leaks 1. Air Line Repair 3. Install the repair filling. refer to Ride Height Adjustments in this section. Apply a soapy water solution to the air lines. Verify the location of air leak(s) and repair or install new components as necessary.. carry out the air line repair procedure. install a new compressor.

. NOTE: If oil is present in the air lines. refer to Air Suspension Compressor Drier in this section. 7. NOTE: When installing air lines. refer to Air Suspension Compressor file://C:\tso\tsocache\STEVENSTOSHIBA_3160\S3J~us~en~file=S3J45006.. NOTE: When installing the air lines. Replace the air compressor drier. NOTE: When installing the air lines..2003 Expedition/Navigator Workshop Manual Page 1 of 2 SECTION 204-05: Vehicle Dynamic Suspension — 4-Wheel GENERAL PROCEDURES 2003 Expedition/Navigator Workshop Manual Air Line Fluid Purge Special Tool(s) Worldwide Diagnostic System (WDS) 418-F224 New Generation STAR (NGS) Tester 418-F052 or equivalent scan tool 1. make sure the white air line is fully inserted into the fitting for correct installation. Replace the air compressor drier. 10. Reconnect the air line to the air compressor drier. 9. remove the air spring solenoids and inspect the solenoid filters. Reconnect the air line at the RF air spring solenoid. make sure the white air line is fully inserted into the fitting for correct installation. 5/10/2008 . NOTE: When installing the air lines. Connect the shop air line (drier end) to the disconnected air line and blow out any fluid. Connect shop air line to the disconnected air line (drier end) and blow out any fluid. 3. make sure the white air line is fully inserted into the fitting for correct installation. 5. Disconnect the air line at the RR and LR air spring solenoids. 6. make sure the white air line is fully inserted into the fitting for correct installation. For additional information.htm~gen~ref. 4. Disconnect the air line at the air compressor drier that is connected to the front fill solenoid inlet. replace the solenoid and the shock absorber. Reconnect the air line at the RR and LR air spring solenoids. Disconnect the air line at the RF and LF air spring solenoids. If oil is present in a filter. For additional information. Reconnect the air line at the rear LH and RH air spring solenoids. 8. 2. 11.

htm~gen~ref. Reconnect the air line to the air compressor drier. 5/10/2008 .. make sure the white air line is fully inserted into the fitting for correct installation. file://C:\tso\tsocache\STEVENSTOSHIBA_3160\S3J~us~en~file=S3J45006. NOTE: When installing the air lines. 12...2003 Expedition/Navigator Workshop Manual Page 2 of 2 Drier in this section.

4. 3. Compress the orange quick-connect lock ring inward while pulling outward on the air supply line... Remove the air suspension relay from the bracket (if equipped).2003 Expedition/Navigator Workshop Manual Page 1 of 2 SECTION 204-05: Vehicle Dynamic Suspension — 4-Wheel REMOVAL AND INSTALLATION 2003 Expedition/Navigator Workshop Manual Air Suspension Compressor Removal and Installation 1. file://C:\tso\tsocache\STEVENSTOSHIBA_1220\S3J~us~en~file=S3J45007. Remove the air compressor bracket bolts and remove the air compressor/drier assembly. 5. 5/10/2008 .htm~gen~ref. refer to Section 50116 . For additional information. 2. Disconnect the air compressor electrical connector. Remove the windshield washer pump and reservoir..

NOTE: When installing the air lines. 5/10/2008 ..2003 Expedition/Navigator Workshop Manual Page 2 of 2 6. To install. reverse the removal procedure. file://C:\tso\tsocache\STEVENSTOSHIBA_1220\S3J~us~en~file=S3J45007.htm~gen~ref.. make sure the white air line is fully inserted into the fitting for correct installation..

Rotate 90 degrees counterclockwise to unlock. Remove the air compressor.2003 Expedition/Navigator Workshop Manual Page 1 of 2 SECTION 204-05: Vehicle Dynamic Suspension — 4-Wheel REMOVAL AND INSTALLATION 2003 Expedition/Navigator Workshop Manual Air Suspension Compressor Drier Removal 1. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.. some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. Remove the air compressor drier.htm~gen~ref. To install. NOTE: When the battery is disconnected and reconnected. 2. refer to Air Suspension Compressor in this section. NOTE: When installing the air lines. Remove the screw. file://C:\tso\tsocache\STEVENSTOSHIBA_1220\S3J~us~en~file=S3J45008. For additional information. then remove the air compressor drier. 2. 1.. reverse the removal procedure.. make sure the white air line is fully inserted into the fitting for correct installation. NOTE: Inspect the drier O-ring for damage and replace as necessary. Installation 1. NOTE: Make sure that the drier O-ring does not remain inside of the compressor assembly. 5/10/2008 .

.2003 Expedition/Navigator Workshop Manual Page 1 of 2 SECTION 204-05: Vehicle Dynamic Suspension — 4-Wheel REMOVAL AND INSTALLATION 2003 Expedition/Navigator Workshop Manual Air Suspension Control Module Removal and Installation 1. If exposed to these charges. 3. Pull back the dash padding to expose the module mounting nuts. CAUTION: Electronic modules are sensitive to static electrical charges. file://C:\tso\tsocache\STEVENSTOSHIBA_1220\S3J~us~en~file=S3J45009.htm~gen~ref. Disconnect the electrical connectors. refer to Section 414-01 . Remove the air suspension control module nuts. NOTE: The air suspension control module is mounted to the lower left side of the dash above the parking brake control. damage may result. Disconnect the battery ground cable. 2. 5/10/2008 ... 4. For additional information.

NOTE: When the battery is disconnected and reconnected. refer to Calibration Initialize System — Clear C1990 and C1991 DTCs.2003 Expedition/Navigator Workshop Manual Page 2 of 2 5. To install.. some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. reverse the removal procedure. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. For additional information. NOTE: The air suspension control module is calibrated with information from the ride height sensor.htm~gen~ref... 5/10/2008 . file://C:\tso\tsocache\STEVENSTOSHIBA_1220\S3J~us~en~file=S3J45009. A new or exchanged air suspension control module requires that the ride height adjustment calibration and pneumatic test be carried out.

2. Turn the air suspension switch to the OFF position. For additional information. jacking or towing an air suspension vehicle. vent the appropriate air spring(s).. CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense. Using the scan tool. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. Remove the nuts. 1. This can be accomplished by turning off the air suspension switch located in the LH rear quarter trim panel. Do not use a new part of lesser quality or substitute design..htm~gen~ref. file://C:\tso\tsocache\STEVENSTOSHIBA_1220\S3J~us~en~file=S3J45010. 4. A new part with the same part number must be used if installation is necessary..2003 Expedition/Navigator Workshop Manual Page 1 of 5 SECTION 204-05: Vehicle Dynamic Suspension — 4-Wheel REMOVAL AND INSTALLATION 2003 Expedition/Navigator Workshop Manual Air Shock Absorber —Front Material Item Multi-Purpose Grease XG-4 Removal and Installation Specification ESR-M1C159-A WARNING: Do not remove an air spring under any circumstances when there is pressure in the air spring. 3. 5/10/2008 . WARNING: The electrical power to the air suspension system must be shut off prior to hoisting. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. Remove the wheel and tire assembly. Do not remove any components supporting an air spring without either exhausting the air or providing support for the air spring to prevent vehicle damage or personal injury. Discard the nuts. refer to Section 204-04 .

Remove the nut.2003 Expedition/Navigator Workshop Manual Page 2 of 5 5.. NOTE: Use the hex holding feature to prevent the shock rod from turning while removing the nut. bolt and the air shock absorber. Disconnect the electrical connector.htm~gen~ref. Compress the orange quick-connect lock ring while pulling outward on the air supply line.. 7.. file://C:\tso\tsocache\STEVENSTOSHIBA_1220\S3J~us~en~file=S3J45010. 6. Remove and discard the nut. Discard the nut. 8. 5/10/2008 .

11. washer and jounce bumper. Remove the O-ring seal. a new air spring must be installed. Discard the seal and washer.. Remove and discard the O-ring seals.htm~gen~ref. 5/10/2008 . 10.. Depress the retainer tabs and remove the air spring. CAUTION: If the retainer tabs are broken.2003 Expedition/Navigator Workshop Manual Page 3 of 5 9.. file://C:\tso\tsocache\STEVENSTOSHIBA_1220\S3J~us~en~file=S3J45010. NOTE: Make an index mark on the air spring and the shock absorber for reference during the installation procedure.

14. 5/10/2008 . NOTE: Make sure to apply a thin coat of grease to the new O-ring seals.2003 Expedition/Navigator Workshop Manual Page 4 of 5 12.. reverse the removal procedure. NOTE: During installation. use assembly kit 2L74-5B303-AA..htm~gen~ref. Remove and discard the O-ring seals. 13. Do not use a hammer or damage may occur. CAUTION: Use a suitable press to install the upper mount retainer pins. file://C:\tso\tsocache\STEVENSTOSHIBA_1220\S3J~us~en~file=S3J45010. Discard the pins. To install.. Remove the retainer pins and the upper mount.

Using the scan tool. Do not remove any components supporting an air spring without either exhausting the air or providing support for the air spring to prevent vehicle damage or personal injury. jacking or towing an air suspension vehicle. 2. 4. Remove the nuts..2003 Expedition/Navigator Workshop Manual Page 1 of 5 SECTION 204-05: Vehicle Dynamic Suspension — 4-Wheel REMOVAL AND INSTALLATION 2003 Expedition/Navigator Workshop Manual Air Shock Absorber —Rear Material Item Multi-Purpose Grease XG-4 Removal and Installation Specification ESR-M1C159-A WARNING: Do not remove an air spring under any circumstances when there is pressure in the air spring. vent the appropriate air spring.htm~gen~ref. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting. 3. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. refer to Section 204-04 . Turn the air suspension switch to the OFF position. For additional information. CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense. Remove the wheel and tire assembly. 5/10/2008 . Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. Do not use a new part of lesser quality or substitute design. A new part with the same part number must be used if installation is necessary. file://C:\tso\tsocache\STEVENSTOSHIBA_1220\S3J~us~en~file=S3J45011. This can be accomplished by turning off the air suspension switch located in the LH quarter trim panel. Discard the nuts. 1...

7. Compress the quick connect lock ring while pulling outward on the air supply line.2003 Expedition/Navigator Workshop Manual Page 2 of 5 5... file://C:\tso\tsocache\STEVENSTOSHIBA_1220\S3J~us~en~file=S3J45011. Disconnect the electrical connector. Discard the flag nut. Remove the air shock absorber. 8. 5/10/2008 . Remove the bolt and flag nut.htm~gen~ref. 6..

Discard the seal and washer.. NOTE: Make an index mark on the air spring and shock absorber for reference during the installation procedure.2003 Expedition/Navigator Workshop Manual Page 3 of 5 9.htm~gen~ref. NOTE: Use the hex holding feature to prevent the shock rod from turning while removing the nut. washer and jounce bumper. a new air spring must be installed. file://C:\tso\tsocache\STEVENSTOSHIBA_1220\S3J~us~en~file=S3J45011. Remove the O-ring seal. 5/10/2008 . 10. Depress the retainer tabs and remove the air spring.. Remove and discard the nut. 11. CAUTION: If the retainer tabs are broken..

htm~gen~ref.2003 Expedition/Navigator Workshop Manual Page 4 of 5 12... 13. Discard the pins.. Remove and discard the O-ring seals. Remove the retainer pins and the upper mount. 14. 5/10/2008 . file://C:\tso\tsocache\STEVENSTOSHIBA_1220\S3J~us~en~file=S3J45011. Remove and discard the O-ring seals.

NOTE: During installation.. NOTE: Make sure to apply a thin coat of grease to the new O-ring seals.htm~gen~ref. file://C:\tso\tsocache\STEVENSTOSHIBA_1220\S3J~us~en~file=S3J45011. CAUTION: Use a suitable press to install the upper mount retainer pins... use assembly kit 2L74-5B303-AA. To install. 5/10/2008 .2003 Expedition/Navigator Workshop Manual Page 5 of 5 15. Do not use a hammer or damage may occur. reverse the removal procedure.

This can be accomplished by turning off the air suspension switch located in the LH quarter trim panel.. jacking or towing an air suspension vehicle. Remove the wheel and tire assembly.. file://C:\tso\tsocache\STEVENSTOSHIBA_1220\S3J~us~en~file=S3J45012. use the scan tool to vent the appropriate air spring(s). Compress the lock ring while pulling down on the air line and disconnect the air line. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. Turn the air suspension switch to the OFF position..2003 Expedition/Navigator Workshop Manual Page 1 of 3 SECTION 204-05: Vehicle Dynamic Suspension — 4-Wheel REMOVAL AND INSTALLATION 2003 Expedition/Navigator Workshop Manual Air Spring Solenoid Valve Material Item Silicone Brake Caliper Grease and Dielectric Compound XG-3 Removal and Installation Specification ESE-M1C171A WARNING: Do not remove an air spring under any circumstances when there is pressure in the air spring. NOTE: Front shown. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting. Do not remove any components supporting an air spring without either exhausting the air or providing support for the air spring to prevent vehicle damage or personal injury. 2.htm~gen~ref. Disconnect the electrical connector. If the air spring solenoid valve is functional. rear similar 1. 5. For additional information. refer to Section 204-04 4. 5/10/2008 . 3.

htm~gen~ref.. Rotate the air spring solenoid and remove the solenoid. 5/10/2008 . Lubricate the solenoid seal area with silicone grease. CAUTION: Remove any dirt or other debris from the air spring assembly prior to removing the air spring solenoid valve from the air spring assembly.2003 Expedition/Navigator Workshop Manual Page 2 of 3 6. Turn the solenoid to the second stage to remove the solenoid. 8. file://C:\tso\tsocache\STEVENSTOSHIBA_1220\S3J~us~en~file=S3J45012. WARNING: The air spring solenoid valve has a two stage release. When removing a nonfunctional solenoid and the air spring is inflated. Remove the air spring solenoid clip. Failure to follow these instructions when removing a non-functional air spring solenoid can cause personal injury or damage to components as high pressure air is vented uncontrolled. carefully rotate the solenoid counterclockwise until it reaches the first stage to release the air from the air spring. NOTE: Inspect the O-ring for damage and install a new O-ring as necessary.. 7..

NOTE: When installing the air lines.htm~gen~ref.. make sure the white air line is fully inserted into the fitting for correct installation. it is necessary to inflate the air suspension system. 5/10/2008 . refer to Ride Height Adjustments in this section. To install.2003 Expedition/Navigator Workshop Manual Page 3 of 3 NOTE: After installing the solenoid... For additional information. file://C:\tso\tsocache\STEVENSTOSHIBA_1220\S3J~us~en~file=S3J45012. reverse the removal procedure.

WARNING: The electrical power to the air suspension system must be shut off prior to hoisting. Vehicles with bracket mounted sensor 2. 5/10/2008 . 4.. Remove the bolts and the sensor. For additional information. rear similar All vehicles 1. refer to Section 100-02 . 3.. file://C:\tso\tsocache\STEVENSTOSHIBA_1220\S3J~us~en~file=S3J45013. Disconnect the electrical connector.htm~gen~ref. Raise and support the vehicle. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations.2003 Expedition/Navigator Workshop Manual Page 1 of 3 SECTION 204-05: Vehicle Dynamic Suspension — 4-Wheel REMOVAL AND INSTALLATION 2003 Expedition/Navigator Workshop Manual Suspension Height Sensor Removal and Installation NOTE: Front shown. jacking or towing an air suspension vehicle. Disconnect the sensor arm. This can be accomplished by turning off the air suspension switch located in the LH quarter trim panel..

7. Disconnect the sensor arm.. Disconnect the electrical connector.htm~gen~ref. 6.2003 Expedition/Navigator Workshop Manual Page 2 of 3 Vehicles with stud mounted sensor 5.. file://C:\tso\tsocache\STEVENSTOSHIBA_1220\S3J~us~en~file=S3J45013. Remove and discard the nuts. 5/10/2008 ..

2003 Expedition/Navigator Workshop Manual Page 3 of 3 All vehicles 8. NOTE: The RH (3C112) and LH (3C113) height sensors cannot be used on opposite sides of the vehicle.htm~gen~ref. 5/10/2008 ... To install. reverse the removal procedure.. file://C:\tso\tsocache\STEVENSTOSHIBA_1220\S3J~us~en~file=S3J45013.

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