Page 1
2010
TM
TM
219 100 388
DPS
DPS
/ACS
/ACS
Technical Manual
Page 2
2010
DPS/ACS
Technical Manual
Page 3
Legal deposit:
National Library of Quebec
National Library of Canada 2009
All rights reserved. No parts of this manual may be reproduced in any form without the prior written
permission of Bombardier Recreational Products Inc. (BRP)
©
Bombardier Recreational Products Inc. (BRP) 2009
Printed in Canada
Technical Publications
Bombardier Recreational Products Inc. (BRP)
Valcourt (Quebec) Canada
®
™ and the BRP logo are trademarks of Bombardier Recreational Products Inc. (BRP) or its affiliates.
Can-Am™
DPS™
Renegade™
XPS™
Outlander™
This document contains the trademarks of the following companies:
®
AMP
Loctite
is a trademark of Tyco Electronics Corporation
®
is a trademark of Loctite Corporation
Snap-on®is a trademark of Snap-on Tools Corporation
Page 4
TABLE OF CONTENTS
SAFETY NOTICE ......................................................................................................... II
INTRODUCTION ......................................................................................................... III
COLOR CODE LEGEND .............................................................................................. III
01 TECHNICAL MANUAL
01 – DYNAMIC POWER STEERING (DPS) ......................................................................... 3
GENERAL...................................................................................................... 5
SYSTEM DESCRIPTION (FEATURES)....................................................................... 5
SYSTEM DESCRIPTION (COMPONENTS).................................................................. 6
ADJUSTMENT ................................................................................................ 7
TORQUE OFFSET RESET................................................................................... 7
DPS ASSIST MODE......................................................................................... 7
TROUBLESHOOTING........................................................................................ 8
PROCEDURES................................................................................................. 9
DPS UNIT ................................................................................................... 9
PITMAN ARM............................................................................................. 22
02 – AIR CONTROLLED SUSPENSION (ACS)................................................................... 23
GENERAL.................................................................................................... 25
SYSTEM DESCRIPTION (FEATURES)..................................................................... 25
SYSTEM DESCRIPTION (COMPONENTS)................................................................ 27
TROUBLESHOOTING...................................................................................... 30
DIAGNOSTIC TIPS ........................................................................................ 30
TROUBLESHOOTING GUIDELINES ...................................................................... 30
TROUBLESHOOTING WITH B.U.D.S. .................................................................... 31
PROCEDURES............................................................................................... 31
ACS SOLENOID VALVE ................................................................................... 31
ACS MANIFOLD .......................................................................................... 33
ACS MODULE ............................................................................................ 35
ACS COMPRESSOR RELAY (R5) ......................................................................... 37
ACS COMPRESSOR ...................................................................................... 37
ACS AIR FILTER........................................................................................... 42
PRESSURE TRANSDUCER (ACS AUXILIARY LINE) ...................................................... 43
ACS HOSES............................................................................................... 44
SHOCK ABSORBERS ..................................................................................... 45
I
Page 5
SAFETY NOTICE
SAFETY NOTICE
This manual has been prepared as a guide to correctly service and repair the DPS™ and ACS systems on 2010 Can-Am™ ATVs.
This edition was primarily published to be used by
mechanical technicians who are already familiar
with all service procedures relating to BRP products. Mechanical technicians should attend training courses given by B.R.P.T.I.
Please note that the instructions will apply only
if proper hand tools and special service tools are
used.
It is understood that this manual may be translated into another language. In the event of any
discrepancy, the English version shall prevail.
The content depicts parts and/or procedures applicable to the particular product at time of writing.
Service and Warranty Bulletins may be published
to update the content of this manual. Make sure
to read and understand these. It does not include
dealer modifications, whetherauthorized or notby
BRP, after manufacturing the product.
In addition, the sole purpose of the illustrations
throughout the manual, is to assist identification
of the general configuration of the parts. They are
not to be interpreted as technical drawings or exact replicas of the parts.
The use of BRP parts is most strongly recommended when considering replacement of any
component. Dealer and/or distributor assistance
should be sought in case of doubt.
The engines and the corresponding components
identified in this document should not be utilized
on product(s) other than those for which it was
designed.
NOTICE
followed, could severely damage vehicle components or other property.
NOTE: Indicates supplementary information
needed to fully complete an instruction.
Although the mere reading of such information
does not eliminate the hazard, your understanding of the information will promote its correct
use. Always use common shop safety practice.
BRP disclaims liability for all damages and/or injuries resulting from the improper use of the contents. We strongly recommend that any services
be carried out and/or verified by a highly skilled
professional mechanic. It is understood that certain modifications may render use of the vehicle
illegal under existing federal, provincial and state
regulations.
Indicates an instruction which, if not
WARNING
Unless otherwise specified, engine should be
turned OFF and cold for all maintenance and
repair procedures.
This manual emphasizes particular information denoted by the wording and symbols:
WARNING
Indicates a potential hazard, if not avoided,
could result in serious injury or death.
CAUTION Indicates a hazard situation
which, if not avoided, could result in minor or
moderate injury.
II vmr2010-002
Page 6
INTRODUCTION
INTRODUCTION
This Technical Manual covers the following BRP made 2010 Can-Am ATVs with a DPS or ACS system.
OUTLANDER™
ENGINE MODEL COLOR MODEL NUMBER
XT Yellow, Red, Camo 2UAA, 2UAB, 2UAC, 2UAD, 2UAE
XT-P Black 5JAB
500
650
800R
ENGINE MODEL COLOR MODEL NUMBER
800R X xc Black 4DAA, 4DAB, 4DAC
MAX XT
MAX XT-P Black
MAX LTD
XT
XT-P Black
MAX XT Yellow, Red, Camo 2SAA, 2SAB, 2SAC, 2SAD, 2SAE, 2SAF
MAX XT-P Black 5HAC
XT Yellow, Red, Camo 2JAA, 2JAB, 2JAC, 2JAE, 2JAF
XT-P Black 5EAB, 5EAE
MAX XT
MAX XT-P Black
MAX LTD
Yellow, Red, Camo 2XAA, 2XAB, 2XAC, 2XAD, 2XAE
5KAC
Steel grey
Yellow, Red, Camo 2PAA, 2PAB, 2PAC, 2PAD, 2PAE, 2PAF
Yellow, Red, Camo 2LAA, 2LAB, 2LAC, 2LAD, 2LAF
Red, Steel grey 2MAA, 2MAB, 2MAC, 2MAD
RENEGADE™
5NAA
5GAB
5FAC, 5FAF, 5FAJ
The information and component/system descriptions contained in this manual are correct at time of writing. BRP however, maintains a policy of continuous improvement of its products without imposing upon
itself any obligation to install them on products previously manufactured.
Due to late changes, there may be some differences between the manufactured product and the description and/or specifications in this document.
BRP reserves the right at any time to discontinue or change specifications, designs, features, models or
equipment without incurring obligation.
COLOR CODE LEGEND
COLOR CODE
BE
BK
BU
BR
GN
GR
vmr2010-002 III
=
BEIGE OR
=
BLACK PK
=
BLUE RD
=
BROWN
=
GREEN
=
GRAY
VI
WH
YL
=
=
=
=
=
=
ORANGE
PK
RED
VIOLET
WHITE
YELLOW
Page 7
IV vmr2010-002
Page 8
FLUKE 115 MULTIMETER
(P/N 529 035 868)
Page: 9, 11, 32, 35, 37–38, 43–44
OETIKER PLIERS
(P/N 295 000 070)
SERVICE TOOLS INDEX
Page: 44
SPRING REMOVER
(P/N 529 036 007)
Page: 46
1
Page 9
2
Page 10
Section 01 TECHNICAL MANUAL
Subsection 01 (DYNAMIC POWER STEERING (DPS))
DYNAMIC POWER STEERING (DPS)
SERVICE TOOLS
Description Part Number Page
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ....................................... 9, 11
SERVICE TOOLS – OTHER SUPPLIER
Description Part Number Page
SNAP-ON®TELESCOPING GAUGE SET....................................... LST 52616 ...........................................20
SERVICE PRODUCTS
Description Part Number Page
XPS SYNTHETIC GREASE............................................................. 293 550 010 ...........................................19
vmr2010-003 3
Page 11
Section 01 TECHNICAL MANUAL
Subsection01 (DYNAMIC POWER STEERING (DPS))
38 Nm
(28 lbfft)
If torqued
by screw head
24.5 Nm
(18 lbfft)
NEW
NEW
XPS synthetic
grease (400 g)
NEW
NEW
XPS synthetic
grease (400 g)
NEW
24.5 Nm
NEW
(18 lbfft)
If torqued
by elastic nuts
24.5 Nm
(18 lbfft)
NEW
vmr2010-003-001_a
72 Nm
(53 lbfft)
4 vmr2010-003
Page 12
Section 01 TECHNICAL MANUAL
Subsection 01 (DYNAMIC POWER STEERING (DPS))
GENERAL
During assembly/installation, use the torque values and service products as in the exploded view.
WARNING
Torque wrench tightening specifications
must be strictly adhered to.
Locking devices (e.g.: locking tabs, elastic
stop nuts, cotter pins, etc.) must be replaced.
Hoses, cables or locking ties removed during a
procedure must be reinstalled as per factory standards.
SYSTEM DESCRIPTION
(FEATURES)
The Dynamic Power Steering (DPS) provides
a computer controlled, variable power assist,
achieved by an electric motor to optimize the
amount of steering input required by the rider.
Steering torque may also come from the wheels
due to rough terrain. Steering kickback is reduced
while providing feedback to the driver.
The greater the power steering assist, the greater
the load on the electrical system.
When the electrical system is under high load
(battery not at full charge, operating the vehicle
for prolonged periods of time at slow speed and
low RPM which, requires higher power steering
assist), the battery power reserve will gradually
decrease. This further increases the load on the
charging system and the electrical system voltage will drop. As system voltage drops, so does
power steering assist.
NOTE: It is important to maintain the battery at
a full state of charge to ensure proper DPS operation. The magneto output is increased to 650
watts minimize battery drain and system voltage
drop.
DPS Assist Mode
The DPS system normally provides two rider selectable modes of operation.
DPS MAX provides maximum steering assist for
technical low speed riding in rough or muddy terrain, or for touring.
DPS MIN provides less steering assist for increased feedback and aggressive trail riding.
A third mode of operation is available as an accessory to adjust the steering assist level for operation with an approved BRP track kit.
vmr2010-003-014_a
1. Dynamic power steering unit (DPS)
The DPS system uses the following parameters to
determine how much steering assist it provides:
–EngineRPM
– Battery/electrical system voltage
– Vehicle speed
– DPS shaft torque sensor input.
The amount of steering assist provided is dependent on the handlebar effort (steering torque),
electrical power available, and vehicle speed.
The greater the handlebar effort (torque), the
greater the assist will be.
The slower the vehicle speed, the greater the assist will be.
If the electrical system is activated but the engine
is not running, there is no power assist provided.
When the handlebar is in the straight ahead position, there is no steering assist.
vmr2010-003 5
How to View DPS Assist Mode Selection
1. To view the active DPS ASSIST mode, press
and release the OVERRIDE/DPS button on the
LH multifunction switch assembly.
vmo2010-004-006_a
1. OVERRIDE/DPS button
Page 13
Section 01 TECHNICAL MANUAL
Subsection01 (DYNAMIC POWER STEERING (DPS))
The active DPS mode will be displayed in the
lower portion of multifunction gauge.
vmr2010-003-003
DPS UNIT
The DPS module provides DC power to the motor. The amount and duration of that DC power is
determined by the inputs to the DPS module. The
direction in which the motor turns is changed by
reversing the polarity of the circuit current.
The DPS motor does not "spin", but rather turns in
very small increments based on the amount, duration, and direction of DC power delivered by the
vmo2010-004-004_a
1. DPS mode indication
How to Change DPS Assist Mode
To change DPS ASSIST mode, press and hold
the OVERRIDE/DPS button for approximately
4 seconds, the DPS system will toggle to the
other available mode. The newly activated DPS
mode will be briefly displayed in the multifunction
gauge.
NOTE: The DPS mode cannot be changed if
the vehicle is in reverse, of if the ACS mode is
displayed in the multifunction gauge on vehicles
equipped with an Air Controlled Suspension.
DPS module.
DPS Unit Protection
To protect the DPS electronic components, the
steering assist behavior will change as follows.
When motor internal
temperature reaches a certain
temperature (DPS continuously
estimates it)
DPS internal board temperature
is above 85°C (185°F)
DPS internal board temperature
is above 100°C (212°F)
CONDITION DPS BEHAVIOR
Steering assist
will gradually
decrease.
Steering assist is
stopped.
SYSTEM DESCRIPTION
(COMPONENTS)
DPS Unit
The DPS unit is a self contained unit that includes
the steering gear, the DPS module, the DPS motor, and the torque sensor.
6 vmr2010-003
When the DPS unit temperature is back within
normal operating range:
– Turn the ignition key OFF.
– Wait 30 seconds.
– Turn the ignition key ON.
Steering assist should resume normal operation.
Page 14
Section 01 TECHNICAL MANUAL
Subsection 01 (DYNAMIC POWER STEERING (DPS))
Steering Torque Sensor
rmr200 8-019-017
The steering column is connected to the shaft on
the DPS unit. A small area of the DPS shaft is
magnetized. Inside the DPS unit, a torque sensor
surrounds the magnetized area of the DPS shaft.
When the handlebar is turned, torque is applied to
the shaft which tends to twist the shaft slightly,
deforming the magnetic field in the shaft. The
sensor detects the torque by measuring the deviation of the magnetic field.
The torque sensor is very sensitive and can detect very small changes in the magnetic field.
The harder the handlebar is turned, the greater
the magnetic deviation, the greater the power
steering assist.
PART ADJUSTED OR
REPLACED
–DPSunit
– Steering column
bearing
–Tierod
–Tierodend
– Knuckle
– Wheel bearing
– Ball joint
– Front suspension arm
(lower/upper)
– Steering alignment
1. Ensure proper
STEERING ALIGNMENT
WHAT TO DO
Reset Torque Offset
in Setting, DPS
, refer
to appropriate Shop Manual subsection.
2. Connect vehicle to the latest B.U.D.S. software.
3. In B.U.D.S., select Read Data.
4. Choose the Setting tab.
5. At the bottom LH corner of the Setting page,
choose the DPS tab.
NOTICE
Ensure handlebar is free and centered within ±10 degrees of center position.
There MUST NOT be any effort applied to the
steering column.
6. Press Reset Torque Offset button.
ADJUSTMENT
TORQUE OFFSET RESET
When replacing the following parts or adjusting
steering alignment, the sensor torque offset must
be reset to zero) for proper system operation.
vmr2010-003 7
vmr2010-003-002_a
DPS TORQUE OFFSET RESET
1. Setting page tab
2. DPS tab
3. Reset Torque Offset button
DPS ASSIST MODE
1. To view the active DPS ASSIST mode, press
and release the OVERRIDE/DPS button on the
LH multifunction switch assembly.
Page 15
Section 01 TECHNICAL MANUAL
Subsection01 (DYNAMIC POWER STEERING (DPS))
TROUBLESHOOTING
NO POWER STEERING ASSIST
1. DPS malfunction.
- If theCHECK ENGINE light ison and a DPS FAULT
message is visible in the gauge, check for fault
codes using B.U.D.S. and carry out service action.
2. No power to DPS unit.
- Carry out a DPS UNIT FUSE TEST as detailed in
this subsection. Replace as required.
- Carry out a DPS UNIT INPUT VOLTAGE TEST
(POWER SIDE) as detailed in this subsection.
Repair or replace wiring/connectors as required.
vmo2010-004-006_a
1. OVERRIDE/DPS button
The active DPS mode will be displayed in the
lower portion of multifunction gauge.
- Carry out a DPS UNIT INPUT VOLTAGE TEST
(CONTROL SIDE) as detailed in this subsection.
Repair or replace wiring/connectors as required.
3. No ground to DPS unit.
- Carry out a DPS UNIT GROUND CIRCUIT TEST
as detailed in this subsection. Repair or replace
wiring/connectors as required.
vmo2010-004-004_a
1. DPS mode indication
2. To change DPS ASSIST mode, press and hold
the OVERRIDE/DPS button for approximately
4 seconds, the DPS system will toggle to the
other available mode. The newly activated DPS
mode will be briefly displayed in the multifunction gauge.
NOTE: The DPS mode of operation cannot be
changed if the vehicle is in reverse, of if the ACS
mode is displayed in the multifunction gauge.
4. No engine RPM signal from ECM.
- If engine RPM can be displayed in the multifunction gauge when the engine is running, carry out a
DPS UNIT COMMUNICATION LINK (CAN) CONTINUITY TEST as detailed in this subsection. Repair or replace wiring/connector as required.
- If engine RPM cannot be displayed in the multifunction gauge, use B.U.D.S. to check for applicable fault codes. Carry out service actions.
LOW POWER STEERING ASSIST
1. Low battery voltage.
- Check battery terminals. Clean, repair, replace or
tighten as required.
- Test battery voltage. Recharge or replace battery
as required.
- Carry out a DPS UNIT INPUT VOLTAGE TEST
(POWER SIDE) as detailed in this subsection. Ensure power connector pins (DPS2-A and DPS2-B)
are clean, corrosion free, tight, and make good
contact. Repair or replace wiring/connectors as
required.
- Carry out a DPS UNIT GROUND CIRCUIT TEST as
detailed in this subsection. Ensure ground post
connections and DPS connector pins are clean,
corrosion free, tight, and make good contact. Repair or replace wiring/connectors as required.
- Carry out a DPS SYSTEM LOAD TEST as detailed
in this subsection.
2. Low input voltage to DPS unit.
- Carry out a DPS UNIT INPUT VOLTAGE TEST
(POWER SIDE) as detailed in this subsection. Ensure power connector pins (DPS2-A and DPS2-B)
are clean, corrosion free, tight, and make good
contact. Repair or replace wiring/connectors as
required.
8 vmr2010-003
Page 16
Subsection 01 (DYNAMIC POWER STEERING (DPS))
3. Faulty DPS ground circuit.
- Carry out a DPS UNIT GROUND CIRCUIT TEST.
Ensure DPS ground connector pins (DPS3-A and
DPS3-B) and frame ground post are clean, corrosion free, tight, and make good contact. Repair
or replace wiring/connector as required.
ASYMMETRICAL POWER STEERING
ASSIST (SIDE TO SIDE)
1. Torque sensor not reset to zero.
- Ensure steering alignment is within specification
and carry out the TORQUE OFFSET RESET procedure detailed in this subsection.
DPS WILL NOT CHANGE MODES OF
OPERATION
Section 01 TECHNICAL MANUAL
vmo2010-004-202_a
TYPICAL - OUTLANDER 800R LTD ILLUSTRATED
1. Rear fuse box (PF2)
1. Faulty OVERRIDE/DPS switch.
- Set transmission to reverse with engine running.
- Press the OVERRIDE/DPS button.
- Look for the OVERRIDE message to appear in the
multifunction gauge. If it comes on, button and
wiring to gauge are good.
- If OVERRIDE message does not appear in gauge,
test drive vehicle to determine if OVERRIDE function can be activated. If the function can not be
activated, test the OVERRIDE/DPS switch and
wiring. If the function is activated, test wiring
from switch to multifunction gauge.
PROCEDURES
DPS UNIT
DPS Unit Power Fuse Test
A 40 A DPS fuse located in the rear fuse box (PF2F3) next to the voltage regulator/rectifier unit provides power for the DPS motor.
1. To remove fuse box cover, simultaneously
squeeze tabs inwards on each end of fuse box
cover as you pull on the cover.
vmr2010-003-004_a
1. Squeeze and pull these tabs to remove cover
2. Using a FLUKE 115 MULTIMETER (P/N 529 035
868)
set to selection, remove and test the
DPS fuse.
vmr2010-003 9
529035868
Page 17
Section 01 TECHNICAL MANUAL
Subsection01 (DYNAMIC POWER STEERING (DPS))
If NO voltage is measured, test the 40 A DPS fuse
in the rear fuse box (PF2-F3). If good, check wires
and connector pins. Replace or repair defective
parts and reset fault codes.
If battery voltage is measured, carry out the following
TROL SIDE)
NOTE: This test may also be carried out by connecting a 12 Vdc test light between each DPS
PWR connector pins (A and B), and the battery (-)
negative terminal. The test light must come on
bright.
DPS Unit Input Voltage Test (Control
vmr2010-003-005_a
1. 40 amp DPS fuse (PF2-F3)
3. Replace fuse as required.
DPS Unit Input Voltage Test (Power
Side)
1. Disconnect the DPS PWR (power) connector.
Side)
1. Disconnect DPS CTRL (control) connector and
turn ignition switch ON.
2. Set the ignition switch to ON.
3. Set the engine RUN/STOP switch to RUN.
4. Test for 12 Vdc power to the DPS module at
DPS1-A as per following table.
DPS UNIT INPUT VOLTAGE TEST (CON-
.
vmr2010-003-013_d
1. DPS PWR connector (motor power)
2. Test for 12 Vdc DPS motor power at DPS2-A
and DPS2-B as per following table.
MULTIMETER PROBE POSITIONS VOLTAGE
DPS power
connector pin A
Battery ground
DPS power
connector pin B
Battery
voltage
MULTIMETER PROBE
POSITIONS
DPS control connector (pin A)
and battery ground
rmr2008-028-093_a
VOLTAGE
Battery voltage
If NO voltage is measured, check wires and connector pins from DPS unit to the Relays/Speedo
fuse in front fuse box (PF1-F4). Replace or repair
defective parts and reset fault codes.
If battery voltage is measured, carry out the following
DPS UNIT GROUND CIRCUIT TEST
.
NOTE: This test may also be carried out by connecting a 12 Vdc test light between the DPS control connector (pin A), and the battery (-) negative
terminal. The test light must come on bright.
DPS Unit Ground Circuit Test
1. Disconnect the DPS ground connector (GDN).
rmr2008-028-091_a
10 vmr2010-003
Page 18
Section 01 TECHNICAL MANUAL
Subsection 01 (DYNAMIC POWER STEERING (DPS))
vmr2010-003-013_c
1. DPS ground connector (GDN)
2. Test for continuity between DPS3-A and
DPS3-B to battery ground.
MULTIMETER PROBE
POSITIONS
DPS GDN
connector pin A
Battery ground
DPS GDN
connector pin B
READING
Continuity
(close to 0
)
If there is NO continuity or a high resistance is
measured, check wires and connector pins from
DPS unit to chassis ground post. Replace or repair defective parts and reset fault codes.
If there is good continuity, carry out the following
DPS UNIT COMMUNICATION LINK (CAN) CONTINUITY TEST
.
NOTE: This test may also be carried out by connecting a 12 Vdc test light between each GDN
connector pin and the battery (+) positive terminal. The test light must come on bright.
DPS Unit Communication Link (CAN)
Continuity Test
NOTE: DPS unit must receive an RPM signal to
provide power steering assist.
Disconnect the DPS control connector and the di-
agnostic connector.
Test continuity of CAN Bus Wires at DPS1-C and
DPS1-D.
MULTIMETER PROBE
POSITIONS
DPS control connector (pin C)
and diagnostic connector (pin 1)
rmr2008-028-094_a
DPS control connector (pin D)
and diagnostic connector (pin 2)
rmr2008-028-094_b
RESISTANCE @
20°C (68°F)
Below 1
If resistance measured is out of specification,
check wires and connector pins. Carry out repairs as required and reset fault codes using
B.U.D.S software.
If resistance measured is good, replace the DPS
unit and reset fault codes using B.U.D.S software.
DPS System Load Test
If the charging system cannot sustain normal voltage when the DPS is operating, DPS ASSIST may
be greatly reduced or nonexistent. Carry out the
following steps.
1. Connect the red lead of a
TER (P/N 529 035 868)
box battery terminal.
2. Connect the black multimeter lead to the battery ground.
FLUKE 115 MULTIME-
set to Vdc to the rear fuse
vmr2010-003 11
Page 19
Section 01 TECHNICAL MANUAL
Subsection01 (DYNAMIC POWER STEERING (DPS))
vmr2010-003-006_a
1. Negative (-) battery terminal
2. Rear fuse box battery terminal
3. Measure the battery voltage.
NOTE: If battery voltage is low, recharge battery.
4. Ensure the vehicle transmission is set to PARK.
5. Start the engine.
6. Note the voltage on the multimeter with the engine running (charging system voltage).
7. Press the RANGE button repeatedly to select
Manual Range 6 0.
mmr2009-023-027_e
1. MIN function selected
9. Turn the handlebar momentarily against the
steering frame stops to each side.
NOTE: Do not hold steering against frame stops
for and extended period of time.
10. Read the MIN charging system voltage
recorded while the handlebar was turned
against each stop.
mmr2009-023-027_a
VDC SELECTED TO MANUAL RANGE 6 0
8. Press the MIN MAX button on the multimeter
to engage the MIN function.
DPS SYSTEM LOAD TEST
PROBE POSITIONS
Rear fuse
(-)
terminal
box battery
terminal
STEERING
POSITION
LH stopBattery
RH stop
VOLTAGE
READING
At least
12 Vdc
NOTE: Turning the handlebar momentarily
against the frame stops generates maximum
DPS load (maximum current draw on electrical
system). Electrical system must sustain at least
12 Vdc for proper DPS operation.
12 vmr2010-003
Page 20
Subsection 01 (DYNAMIC POWER STEERING (DPS))
vmr2010-003-007
If the electrical system cannot sustain at least
12 Vdc, check the following:
–Battery
– Battery connections
– DPS unit power and ground connections
– Charging system
– Frame and engine ground studs.
If the previously listed items, carry out the follow-
DPS UNIT CURRENT TEST
ing
.
Section 01 TECHNICAL MANUAL
5. With the vehicle engine running in PARK, turn
the handlebar side to side, momentarily against
each stop and observe the indications on the
B.U.D.S. DPS Monitoring page.
The DPS Torque Sensor Nm increase with torque
applied to handlebar.
The DPS Current ammeter should increase proportionately to the torque applied, and decrease
with the torque as steering assist is provided.
vmr2010-003-009_a
TYPICAL - LH TURN
1. Torque sensor indication (negative)
2. DPS current indication (positive)
DPS Unit Current Test
1. Connect vehicle to the latest B.U.D.S. software.
2. Click on the Read Data button.
3. Choose the Monitoring page tab.
4. At the bottom of the Monitoring page, choose
the DPS tab.
vmr2010-003-008_a
Step 1: Press Data button
Step 2: Select Monitoring page tab
Step 3: Select DPS tab
vmr2010-003-010_a
TYPICAL - RH TURN
1. Torque sensor indication (positive)
2. DPS current indication (negative)
NOTE: Increase and decrease in torque and current readings is very brief as steering assist is
quickly provided. Current draw should remain
within green scale but may momentarily peak to
60amps,thendropoffcloseto0ampsastorque
applied is nulled out by steering assist. A residual
torque of 2 N•m (18 lbf•in) with a corresponding
current draw is acceptable.
If current draw tends to remain high, carry out the
following:
– Steering alignment check.
vmr2010-003 13
Page 21
Section 01 TECHNICAL MANUAL
Subsection01 (DYNAMIC POWER STEERING (DPS))
– Steering column shim adjustment at half bush-
ings as described in the
TION
procedure detailed in this section.
TORQUE OFFSET RESET
–
DPS UNIT INSTALLA-
procedure detailed in
this section.
–ReplaceDPSunit.
DPS Unit Removal
1. Remove the following items:
–Seat
–Centerpanel
– LH and RH side panels
– LH and RH inner fender panels.
2. Lift up on the dash board (gauge support) and
disconnect the following:
–Gauge
– Ignition switch
– 12 Vdc power outlet.
3. Remove dash board from vehicle.
4. Remove the screw securing the shift lever
guide plate to the engine air filter housing.
vmr2010-003-012_a
1. Gear clamp to loosen
6. Remove the screws securing the engine air filter housing.
7. Move the shift lever and guide plate slightly to
the right.
8. Lift up on the air filter housing to release it from
the throttle body and move the filter housing
towards the RH side of the vehicle.
NOTE: Moving the air filter housing to the right
provides access required for CVT air inlet duct removal.
9. Remove the CVT air inlet duct assembly.
vmr2006-014-055_d
TYPICAL
1. Shift lever guide plate
2. Guide plate screws (forward screw not visible)
NOTE: It is not necessary to disconnect the shift
lever.
5. Loosen the gear clamp securing the air filter
vmr2010-003-011_a
1. CVT air inlet duct
10. Remove the ECM from it's support bracket.
11. Disconnect the 3 electrical connectors from
the DPS unit.
housing duct to the throttle body.
14 vmr2010-003
Page 22
Subsection 01 (DYNAMIC POWER STEERING (DPS))
vmr2010-003-013_a
1. DPS connectors (3x)
12. Cut the locking tie securing the bellows at the
bottom of steering column near the DPS unit,
and pull the bellows upwards sufficiently to
access the steering column pinch bolt.
Section 01 TECHNICAL MANUAL
14. Remove and discard the elastic nuts from
the 2 hexagonal screws that secure steering
column half bushings to the support on the
frame.
vmr2010-003-018_a
1. Elastic nuts to remove and discard
2. Frame support
3. Steering column half bushings
vmr2010-003-016_a
1. Cut this locking tie
2. Steering column bellows
13. Remove the steering column pinch bolt and
retaining nut. Discard the retaining nut.
15. Remove the 2 hexagonal screws from the
ECM support.
vmr2010-003-021_a
1. Hexagonal screws to remove
2. ECM support
16. Remove and save the shim(s) from between
the rear half bushing and the steering support
on the frame.
vmr2010-003-017_a
1. Steering col
vmr2010-003 15
umn pinch bolt
Page 23
Section 01 TECHNICAL MANUAL
Subsection01 (DYNAMIC POWER STEERING (DPS))
vmr2010-003-019_a
1. Shim
2. Steering column frame support
3. Half bushings
17. Pull up on the steering column to disengage it
from the DPS unit and move it to the side.
vmr2010-003-020_a
Step 1: Pull up on steering column
Step 2: Disengage column from DPS unit
18. Remove the hardware that secures both tierod ends to the pitman arm (steering lever).
Discard cotter pins.
vmr2010-003-022_a
1. Pitman arm
2. Tie rod ends
NOTE: Leavethetierodendsonthepitmanarm
at this time. They will come off easily when the
DPS unit is lifted from its frame support.
vmr2010-003-023
TIE ROD ENDS (HARDWARE REMOVED)
19. Remove the 4 hexagonal flanged screws securing DPS unit to frame.
NOTE: Discard the 4 conical spring washers on
the DPS retaining screws. Do not remove the 2
small hexagonal forming screws from the DPS
unit unless it is being replaced.
16 vmr2010-003
Page 24
Section 01 TECHNICAL MANUAL
Subsection 01 (DYNAMIC POWER STEERING (DPS))
vmr2010-003-024_a
TYPICAL - LEFT SIDE ILLUSTRATED
Step 1: Remove DPS retaining screws (2 each side)
Step 2: Discard conical washers under screw head
20. Pull up on DPS unit to align the 2 small hexagonal forming screws with the extraction holes
in the DPS mounting bracket, then remove the
DPS unit from the bracket.
vmr2010-003-025_a
TYPICAL - RIGHT SIDE ILLUSTRATED
1. Hexagonal forming screws (1 each side)
2. Extraction holes
3. DPS unit
NOTE: As you pull the DPS unit from the frame
support, the 2 tie rod ends should release from
thepitmanarm. Becarefulnottoloosethehardened steel washers on the tie rod ends.
vmr2010-003-026_a
1. Hexagonal forming screws
2. Position the DPS unit on the frame DPS mounting bracket by engaging the two hexagonal
forming screws in the slots provided in the
bracket.
vmr2010-003-027_a
1. DPS mounting bracket
2. Engage hexagonal forming screw on DPS unit here
3. Engage the 2 tie rod ends in the pitman arm
as you lower the DPS unit on it's mounting
bracket.
NOTE: Ensure both tie rod ends has a hardened
steel washer on it.
DPS Unit Installation
NOTICE
followed as specified. Failure to do so may result in steering column/DPS misalignment and
poor DPS operation due to an induced erroneous torque on the DPS shaft.
1. If installing a new DPS unit, install the two M5
hexagonal forming screws on the mounting
flange of the DPS unit.
vmr2010-003 17
The following procedure MUST be
Page 25
Section 01 TECHNICAL MANUAL
Subsection01 (DYNAMIC POWER STEERING (DPS))
vmr2010-003-029_a
vmr2010-003-023_a
1. Pitman arm
2. Tie rod ends inserted in pitman arm
3. Hardened steel washer on tie rod end
4. Engage NEW M8 hexagonal flanged screws
through the DPS frame support and into the
DPS unit.
NOTE: Ensure each retaining screw has a NEW
conical spring washer between the screw head
and the DPS frame support. Do not tighten the
retaining screws more than half thread length at
this time.
1. O-ring seals on steering column
6. Index steering column splines with DPS unit
splines.
NOTE: The DPS shaft splines have a key which
must be aligned with the keyway in the steering
column end.
vmr2010-003-031
STEERING COLUMN INDEXED TO DPS SHAFT SPLINES
7. Fully insert steering column end onto DPS shaft
splines. If necessary, place a rag on steering
cover and gently tap on it with a plastic ham-
vmr2010-003-028_a
TYPICAL - RH SIDE ILLUSTRATED
Step 1: Engage NEW DPS mounting screws (2 each side)
Step 2: Install NEW conical washers
5. Remove the two half bushings from the steering column and ensure the two O-ring seals are
installed on the shaft and in good condition. Replace as required.
mer.
NOTICE
The following steps MUST be followed as specified. Failure to do so may result
in steering column/DPS misalignment and
poor DPS operation due to an induced erroneous torque on the DPS shaft.
8. Install steering column pinch bolt and a NEW
elastic nut. Torque nut to 24 N•m (18lbf•ft).
18 vmr2010-003
Page 26
Subsection 01 (DYNAMIC POWER STEERING (DPS))
vmr2010-003-032
Pull bellows down over steering column bolt and
edge of DPS unit housing extension. Secure bellows using the appropriate locking tie.
NOTE: Ensure the locking tie is on the tube part of
the steering column, not on the forged end. Bellows should cover end of ring flange on DPS unit
but not cover the drainage hole at the bottom of
the ring flange. Do not install a locking tie on the
DPS end of the bellows. Lower portion of bellows
MUST remain floating over the DPS housing.
Section 01 TECHNICAL MANUAL
vmr2010-003-033_a
1. Drainage hole in DPS ring flange
2. Steering column bellows
9. Apply XPS SYNTHETIC GREASE (P/N 293 550 010)
totheinsideofbothsteeringcolumnhalfbushings.
vmr2010-003-016_a
1. Locking tie location
2. Steering column bellows
vmr2010-003 19
vmr2010-003-034
10.Looselysecurethesteeringcolumntoits
frame support by installing the following parts
to provide side to side alignment of steering
column.
– Half bushings (x2)
– Metal sleeves between bushings (x2)
– O-ring seals (x2)
– M8 hexagonal screws (x2)
– M8 elastic nuts (x2).
NOTE: Do not install shims a
fasteners at this time. H
column must not be draw
nd do not torque the
and tighten only. Steering
n in towards the column
support.
Page 27
Section 01 TECHNICAL MANUAL
Subsection01 (DYNAMIC POWER STEERING (DPS))
vmr2010-003-035_a
1. These nuts installed hand tight at this time
11. Torque DPS unit mounting screws to
24.5 N•m (18 lbf•ft).
vmr2010-003-028_b
TYPICAL - RH SIDE ILLUSTRATED
1. Torque DPS mounting screws (x4)
12. Using an 8 mm (5/16 ft) telescoping gauge as
foundinthe
SET (P/N LST 52616)
SNAP-ON®TELESCOPING GAUGE
, measure the distance between the steering column shaft and the face
of the column frame support. Measurement
is taken above rear half bushing.
vmr2010-003-036
STEERING COLUMN SHIM MEASUREMENT
NOTE: Ensure the forward end of the tool is in the
center of the steering column, and the rearward
end does not protrude through the notch in the
support.
13. Measure the telescoping gauge using a
Vernier caliper (or a micrometer) and compare the measured distance to the following
table to establish the required shim thickness
vmr2010-003-037
STEERING COLUMN SHIM REQUIREMENT
MEASURED DISTANCE
TOTAL SHIM
THICKNESS REQUIRED
8.63 mm (.34 in) None
9.63 mm (.379 in) 1 mm (.039 in)
10.65 mm (.419 in) 2 mm (.079 in)
11.66 mm (.459 in) 3 mm (.118 in)
12.65 mm (.498 in) 4 mm (.157 in)
NOTE: Shimscomein1mm(.039in)and2mm
(.079 in) thicknesses. Total shim thickness must
not exceed 4 mm (.157 in).
20 vmr2010-003
Page 28
Section 01 TECHNICAL MANUAL
Subsection 01 (DYNAMIC POWER STEERING (DPS))
If total shim thickness exceeds 4 mm (.157 in),
carry out the following:
– Re-measure the distance between steering
column and support. Ensure the forward end
of the tool is in the center of the steering column, and the rearward end does not protrude
through the notch in the support.
– Check steering column support and frame to
ensure they are not bent, twisted or damaged
in any way.
– Check machined flat mounting surface on new
DPS.
– Compare old and new DPS units.
– Ensure the 4 DPS mounting screws and
the steering column pinch bolt are properly
torqued.
14. Insert appropriate shim(s) between the rear
half bushing and the steering column support.
NOTE: If torque is applied to elastic nuts instead of hexagonal screw head, use 24.5 N•m
(18 lbf•ft).
16. Install hardware on LH and RH tie rods on pitman arm. Follow parts assembly sequence as
in following illustration.
17. Torque tie rod end retaining nuts to 72 N•m
(53 lbf•ft).
vmr2010-003-022_b
1. Hardened steel washers (one each side of pitman arm)
2. Tie rod end retaining nut (torque applied)
3. NEW cotter pin installed
vmr2010-003-038_a
1. Insert required shim(s) here
15. As you hold each elastic nut with a wrench,
torque the hexagonal SCREWS retaining the
steering column to 38 N•m (28 lbf•ft).
vmr2010-003-021_b
Step 1: Hold elastic nuts with wrench (not illustrated)
Step 2: Apply specified torque to hexagonal screws
18. Turn handlebar fully to each side and check for
proper contact between pitman arm and pitman arm frame stops (both sides).
vmr2010-003-039_a
TYPICAL - LH ILLUSTRATED
1. Pitman arm
2. Contact point with frame stop
NOTE: Contactbetweenpitmanarmandpitman
arm stops must be checked with vehicle weight
on wheels.
19. Perform a
STEERING ALIGNMENT
as described in the applicable Shop Manual subsection.
vmr2010-003 21
Page 29
Section 01 TECHNICAL MANUAL
Subsection01 (DYNAMIC POWER STEERING (DPS))
20. Install and connect ECM. Torque ECM mount-
ing screws to 7 N•m (62 lbf•in).
21. Install dash board and reconnect the following:
– Multifunction gauge
– Ignition switch
– 12 Vdc accessories outlet.
22. If installing a replacement DPS unit, refer to
DPS REPLACEMENT
in this subsection.
23. Perform the torque offset reset. Refer to
TORQUE OFFSET RESET
in this subsection.
24. Install all other removed parts in the reverse
order of removal.
25. Carry out a test ride of the ATV to ensure
proper operation of the DPS unit.
DPS Unit Replacement
New DPS units do not come with the required
software programmed into the unit. A DPS unit
fault will be generated when the vehicle is powered up. The check engine light will come on and
a DPS FAULT message will appear in the multifunction gauge.
When DPS unit installation is complete, carry out
the following steps.
1. Connect the ATV to the latest B.U.D.S. soft-
ware.
2. Select the Read Data button.
3. In the Module menu, choose the DPS sub-
menu and install the latest DPS software
Update file as applicable to the type ATV (Outlander or Renegade).
6. Test drive the ATV to ensure proper DPS operation.
PITMAN ARM
If the pitman arm requires replacement, the DPS
unit MUST be replaced.
WARNING
DO NOT attempt to replace or repair the pitman arm. Do not use a torch or arc welder on
the pitman arm. Failure to comply will result
in DPS unit malfunction.
vmr2010-003-040
DPS SOFTWARE UPDATE
4. Once the correct DPS soft
go to the Faults page an
5. Carry out the
TORQUE OFFSET RESET
ware file is installed,
d clear the fault codes.
proce-
dure as described in this subsection.
22 vmr2010-003
Page 30
Section 01 TECHNICAL MANUAL
Subsection02 (AIR CONTROLLED SUSPENSION (ACS))
AIR CONTROLLED SUSPENSION (ACS)
SERVICE TOOLS
Description Part Number Page
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ............. 32, 35, 37–38, 43–44
OETIKER PLIERS........................................................................... 295 000 070 ...........................................44
SPRING REMOVER....................................................................... 529 036 007 ...........................................46
SERVICE PRODUCTS
Description Part Number Page
LOCTITE 592 (PIPE SEALANT) ..................................................... 293 800 018 ......................... 33–34, 41, 47
vmr2010-004 23
Page 31
Section 01 TECHNICAL MANUAL
Subsection02 (AIR CONTROLLED SUSPENSION (ACS))
53 Nm
(39 lbfft)
53 Nm
(39 lbfft)
ACS solenoid
release valve
Loctite
592
(pipe
sealant)
NEW
NEW
ACS hose
vmr2010-004-033_a
53 Nm
(39 lbfft)
ACS
module
ACS
compressor
24 vmr2010-004
Page 32
Section 01 TECHNICAL MANUAL
Subsection02 (AIR CONTROLLED SUSPENSION (ACS))
GENERAL
During assembly/installation, use torque values
and service products as in the exploded views.
WARNING
Torque wrench tightening specifications
must be strictly adhered to.
Locking devices (e.g.: locking tabs, cotter
pins, etc.) must replaced with new ones.
Hoses, cables or locking ties removed during a
procedure must be reinstalled as per factory standards. Hoses must be properly inserted.
Be careful while manipulating nylon hoses, they
must not be kinked.
CAUTION Always wear safety goggles
when working with pressurized air system.
CAUTION The ACS suspension system
may be under high pressure (up to 6 bar
(85 PSI)). Release air pressure prior to workingonthesystem. Referto
PRESSURE IN SYSTEM FOR SERVICING
RELEASING AIR
.
ACS SUSPENSION SETTINGS
SETTING PRESSURE
ACS 1 0.5 bar (8 PSI) Softest
ACS 2 1bar(15PSI) Soft
ACS 3 2bar(30PSI) Semi-soft
ACS 4 4bar(55PSI) Semi-firm
ACS 5 5bar(70PSI) Firm
ACS 6 6bar(85PSI) Firmest
RIDING
COMFORT
RECOMMENDED
LOAD
Operator only
Transporting a
passenger OR
a cargo
Transporting a
passenger AND
a cargo
Changing ACS Setting
To change the ACS setting proceed as follows:
– Press selector button several times until
AIR_SUSP
– Press and release ACS button until the re-
quested setting is displayed.
is displayed.
SYSTEM DESCRIPTION
(FEATURES)
The ACS suspension automatically keeps air pressure constant with changing rider weights or loads
applied. The system can be adjusted on the fly to
suit rider's preferences.
The multifunction gauge indicates suspension setting as follows.
vmo2010-004-005_d
1. Requested setting (set point)
2. Actual setting (pressure transducer reading)
Refer to the following table to know the ACS pressure related to multifunction gauge setting.
vmo2010-004-005_a
1. Selector button
2. AIR_SUSP displayed
vmo2010-004-006_a
TYPICAL
1. ACS button
vmr2010-004 25
Page 33
Section 01 TECHNICAL MANUAL
Subsection02 (AIR CONTROLLED SUSPENSION (ACS))
The requested setting is controlled by the ACS
electronic module. The module is equipped with
a pressure transducer to keep air pressure constant in the system. Depending on the rider adjustment, the module will increase pressure using
the compressor or release pressure using the solenoid release valve.
ACS Setting Acknowledgement
If ACS suspension was set to
fore shutting down the vehicle, the multifunction
gauge will scroll an acknowledgement message
at startup.
To acknowledge the ACS suspension setting,
press and release ACS button while message
appears.
ACS 5orACS 6
be-
vmo2010-004-201_a
1. Auxiliary line adaptor to inflate tire
To ensure that the use of the auxiliary line will
not change the pressure setting inside shock
absorber, the system has been divided in two
zones using check valves. With this layout, both
pressure zones are independent to eliminate any
air pressure variation.
NOTE: The auxiliary line output pressure will vary
according to the ACS suspension setting. The
ACS 1
the
adjustment will provide less pressure than
ACS 6
adjustment.
vmo2010-004-006_a
TYPICAL
1. ACS button
NOTE: If the message is not acknowledged, the
suspension will automatically return to setting
ACS 3
.
NOTE: If the selector button in the multifunction
gauge is pressed while the acknowledgement
message appears, the suspension will directly
return to setting
ACS 3
.
NOTE: If the vehicle transmission is set to REVERSE position at startup, the override message
will be displayed instead of acknowledgement
message.
Using the Auxiliary Line to Inflate Tires
The ACS system is equipped with an auxiliary line
specially designed to inflate tires. The air pressure
in this auxiliary line is controlled by a second pressure transducer connected to the ACS module.
NOTICE
Never inflate tires above the recom-
mended pressure.
ACS SYSTEM
PRESSURE
ZONE LINK WITH
High-pressure
zone
Low-pressure
zone
absorbers
Auxiliary line
Shock
TRANSDUCER
LOCATION
Inside ACS
module
In line between
solenoid release
valve and
compressor
Releasing Air Pressure in System for
Servicing
It is recommended to release air pressure in the
system before servicing any components.
1. Remove seats.
2. Remove RH side panel.
3. Unscrew pneumatic valve cap.
26 vmr2010-004
Page 34
Section 01 TECHNICAL MANUAL
Subsection02 (AIR CONTROLLED SUSPENSION (ACS))
vmr2010-004-001_a
1. Pneumatic valve cap
4. Push and hold pneumatic valve pin using a small
screwdriver.
vmr2010-004-002
5. Wait until the system is completely empty of
air.
NOTE: Make sure to wait enough time in order to
let the system expel the air. (no more pressurized
air sound from the valve).
6. Reinstall pneumatic valve cap.
vmo2007-003-017_b
TYPICAL - FRONT SERVICE COMPARTMENT
1. Front fuse box
ACS Compressor Relay (R5)
Compressor relay is located in the front fuse box,
under front service compartment panel. Note that
therelayisnotatthesamepositionona500LTD
andona800RLTDmodels. Refertothefollowing
table.
RELAY (R5)
TERMINAL
86 6D 11B
85
30 7D 12B
87
FRONT FUSE BOX PIN
500 LTD 800R LTD
7C
6C
12A
11A
Outlander 500 LTD
SYSTEM DESCRIPTION
(COMPONENTS)
Fuse and Relay
ACS Fuse (F14)
1. ACS fuse (F14) is located in the front fuse box.
FRONT FUSES BOX
NO DESCRIPTION RATING
F14 ACS 20 A
vmr2010-004 27
vmr2010-004-107_a
OUTLANDER 500 LTD MODEL
1. ACS compressor relay (R5)
Page 35
Section 01 TECHNICAL MANUAL
Subsection02 (AIR CONTROLLED SUSPENSION (ACS))
Outlander 800R LTD
vmr2010-004-105_a
OUTLANDER 800R LTD MODEL
1. ACS compressor relay (R5)
28 vmr2010-004
Page 36
Section 01 TECHNICAL MANUAL
Subsection02 (AIR CONTROLLED SUSPENSION (ACS))
ACS Main Components
ACS COMPONENTS MAIN FUNCTION
Filter To filter air intake of the compressor
Compressor
Solenoid release valve
To pressurize the system
To release air in the system
Electronic module To control the compressor or the solenoid release valve
Manifold
To split the air hoses and allows to manually release air in the
system
Pressure transducer (Low-pressure zone) To monitor the air pressure of the auxiliary line
Pressure transducer (High-pressure zone) To monitor the air pressure of the shock absorbers
Check valve (compressor)
Check valve (between both zones)
To protect the compressor
To eliminate air pressure variation between low and high
pressure zone
Auxiliary line To inflate tire
Cluster
Pneumatic
Electric
Check-valve
To monitor the air pressure setting
Low pressure
zone
Auxiliary
output
Check-valve
High pressure
Release
valve
zone
Shock 1
Filter
Cluster
vdd2010-001-601_en
Compressor
Pressure
transducer
Manifold
Shock 2
Pressure
transducer
Electronic
module
vmr2010-004 29
Page 37
Section 01 TECHNICAL MANUAL
Subsection02 (AIR CONTROLLED SUSPENSION (ACS))
TROUBLESHOOTING
DIAGNOSTIC TIPS
Error Code (AIR FAULT) Displayed in
Gauge
The error code AIR FAULT can appear on the mul-
tifunction gauge for different reasons that are not
necessarily related to a failure of the ACS system.
If the error code appears on the multifunction
gauge, it indicates a disparity between the requested and the actual suspension settings. The
system should react to correct this situation and
the error code will disappear.
If the error code remains active for a long period,
it may indicates a major leak in the system. In this
case, the module will automatically shut down the
compressor to prevent it from overheating. The
shut down procedure of the compressor will stay
active until the next restart of the vehicle (key OFF,
key ON).
If there is a major leak in the system, check the
system for leakage, refer to
TEST (TROUBLESHOOTING WITH B.U.D.S.)
section.
Error Code Displayed and Suspension Setting
Can Not Be Adjusted
If there is no leak, it is probably an electrical problem. In this case, an electrical failure of the compressor or the solenoid valve will result the impossibility to change the actual suspension setting.
After multiple attempts to change suspension
setting, the module will activate error code AIR
FAULT. Refer to
LINES
for further troubleshooting procedure.
TROUBLESHOOTING GUIDE-
ACS SYSTEM LEAK
sub-
TROUBLESHOOTING
GUIDELINES
2. Check fuse (F14).
3. Check ACS module signal continuity.
4. Check ACS module input voltage.
5. Check ACS module ground.
Refer to
ing procedures.
ACS MODULE
to see the complete test-
Suspension Setting Can Be Reached to
Decrease Pressure Only
1. Check relay (R5).
2. Check ACS compressor operation.
3. Check ACS compressor input voltage.
Refer to
testing procedures.
ACS COMPRESSOR
to see the complete
Suspension Setting Can Be Reached
To Increase Pressure Only
1. Check ACS solenoid valve operation.
2. Check ACS solenoid valve input voltage.
Refer to
plete testing procedures.
ACS SOLENOID VALVE
to see the com-
No Pressure Output from the Auxiliary
Line
1. Ensure that ACS suspension setting is adjusted
to
ACS 6
in the auxiliary line.
2. Check pressure transducer for air leakage.
3. Check signal continuity of the auxiliary line pressure transducer.
4. Check input voltage of the auxiliary line pressure transducer.
5. Check ground of the auxiliary line pressure
transducer.
6. Check compressor operation.
to provide the maximum air pressure
Requested Setting Display Does Not
Change in Gauge
1. Check the override/ACS button as detailed in
OVERRIDE SWITCH
AND ACCESSORIES
priate Shop Manual.
in the
subsection of the appro-
LIGHTS GAUGE
Multifunction Gauge Display Flickers
OFF and Back ON
1. Check diode (D7) of the solenoid valve.
NOTE: The diode (D7) is located on the main harness near the ACS sub-harness junction. Refer to
the appropriate
WIRING DIAGRAM
for location.
Suspension Setting Can Not Be
Changed
1. Check the override/ACS button as detailed in
OVERRIDE SWITCH
AND ACCESSORIES
priate Shop Manual.
30 vmr2010-004
in the
subsection of the appro-
LIGHTS GAUGE
Page 38
Subsection02 (AIR CONTROLLED SUSPENSION (ACS))
TROUBLESHOOTING WITH
B.U.D.S.
ACS System Leak Test
1. Connect vehicle to B.U.D.S. Refer to
NICATION TOOLS AND B.U.D.S. SOFTWARE
subsection of the appropriate Shop Manual.
2. Select Activation page.
3. Select ACS folder.
4. Press Te st S TA RT button to proceed.
vmr2010-004-201_a
Step 1: Activation page
Step 2: ACS folder
Step 3: Leak Test START button
COMMU-
Section 01 TECHNICAL MANUAL
vmr2010-004-401_a
1. Auxiliary line check valve
ACS Air Pressure Monitoring
To monitor air pressure in the system during troubleshooting operation, proceed as follows:
1. Connect vehicle to B.U.D.S. Refer to
NICATION TOOLS AND B.U.D.S. SOFTWARE
subsection of the appropriate Shop Manual.
2. Select Monitoring page.
3. Select ACS folder.
COMMU-
After pressing Tes t S TA RT button, the compressor will pressurize the air system at 6.5bar
(90PSI) for approximately 2 minutes and B.U.D.S.
will monitor the system for any leakage. The
result will be indicated in the TEST STATUS box.
If a leak is detected, pressurize the system again
and inspect hoses and fittings with soapy water
to locate the faulty component.
If no leak is detected from hoses or fittings, inspect the compressor check valve and the auxiliary line check valve with soapy water.
vmr2010-004-301_a
Step 1: Monitoring page
Step 2: ACS folder
PROCEDURES
ACS SOLENOID VALVE
ACS Solenoid Valve Operation Test
1. Connect vehicle to B.U.D.S. Refer to
NICATION TOOLS AND B.U.D.S. SOFTWARE
subsection of the appropriate Shop Manual.
2. Select Activation page.
3. Select ACS folder.
4. Press Relief Valve button to proceed.
COMMU-
vmr2010-004-202_b
1. Compressor check valve
vmr2010-004 31
Page 39
Section 01 TECHNICAL MANUAL
Subsection02 (AIR CONTROLLED SUSPENSION (ACS))
4. Set suspension mode to ACS 2 using the ACS
button.
5. Wait until the actual setting shows 2 (LH display).
vmr2010-004-201_b
Step 1: Activation page
Step 2: ACS folder
Step 3: Solenoid valve operation test button
5. Verify that air exits from side port to confirm
proper solenoid operation.
vmr2010-004-101_a
1. Actual setting (pressure transducer reading)
vmr2010-004-202_a
1. Side port
ACS Solenoid Valve Input Voltage Test
1. Remove seats and RH side panel.
2. Place ignition switch to ON position.
3. Press selector button several times until
AIR_SUSP
is displayed.
NOTE: Make sure to wait enough time in order to
let the system adjust the air pressure.
6. Set the FLUKE 115 MULTIMETER (P/N 529 035
868)
to Vdc.
7. Back probe solenoid connector (without disconnecting).
vmr2010-004-102
8. Set suspension mode to ACS 1 using the ACS
button.
9. Measure voltage between solenoid connector
terminals as per the following table.
TEST PROBES VOLTAGE
Pin 2 (YL/GN)
Pin1(BK)
Battery voltage
(± 12 Vdc)
ACS Solenoid Valve Removal
vmo2010-004-005_a
1. Selector button
2. AIR_SUSP displayed
32 vmr2010-004
1. Release air pressure, refer to
PRESSURE IN SYSTEM FOR SERVICING
subsection.
RELEASING AIR
in this
Page 40
Section 01 TECHNICAL MANUAL
Subsection02 (AIR CONTROLLED SUSPENSION (ACS))
2. Disconnect solenoid valve connector.
vmr2010-004-003_a
1. Solenoid valve connector
3. Unscrew solenoid valve from manifold while
holding support.
– Module hose
– Shocks hose.
vmr2010-004-005_a
1. Manifold air inlet hose (from compressor)
2. Module hose
3. Shocks hose
4. To disconnect hoses, proceed as follows:
4.1 Push fitting ring toward manifold.
4.2 Hold ring in place.
4.3 Pull air hose.
vmr2010-004-004_a
1. Solenoid valve
ACS Solenoid Valve Installation
The installation procedure is the reverse of removal procedure, however pay attention to the
following.
Apply
018)
LOCTITE 592 (PIPE SEALANT) (P/N 293 800
on solenoid valve male threads.
ACS MANIFOLD
ACS Manifold Removal
1. Release air pressure, refer to
PRESSURE IN SYSTEM FOR SERVICING
subsection.
2. Remove solenoid valve. Refer to
NOID VALVE REMOVAL
3. Disconnect the following hoses from manifold
air fittings.
– Manifold air inlet hose (from compressor)
vmr2010-004 33
RELEASING AIR
.
in this
ACS SOLE-
vmr2010-004-008_a
1. Fitting
2. Fitting ring
5. From underneath support, remove manifold retaining screws.
Page 41
Section 01 TECHNICAL MANUAL
Subsection02 (AIR CONTROLLED SUSPENSION (ACS))
vmr2010-004-007_b
Install air fittings, pneumatic valve and check valve
as follows.
vmr2010-004-006_a
1. Retaining screws
6. Unscrew air fittings, pneumatic valve and check
valve.
vmr2010-004-007_a
1. Manifold air inlet fitting (from compressor)
2. Auxiliary line check valve
3. Pneumatic valve
4. Shocks fitting
5. Module fitting
ACS Manifold Installation
The installation procedure is the reverse of removal procedure, however pay attention to the
following.
If fitting is the one previously removed (old one),
apply LOCTITE 592 (PIPE SEALANT) (P/N 293 800 018)
on all male threads.
If fitting is a new one, do not apply sealant, it
should be already applied on male threads.
On pneumatic valve, check valve, and solenoid
valve, apply LOCTITE 592 (PIPE SEALANT) (P/N 293
800 018)
Install check valve with arrows pointing toward
manifold.
on all male threads.
vmr2010-004-007_a
RETAINING SCREWS ARE OFFSET TOWARD MODULE FITTING
1. Manifold air inlet fitting (from compressor)
2. Auxiliary line check valve
3. Pneumatic valve
4. Shocks fitting
5. Module fitting
Ensure that air hoses are properly inserted into fittings, refer to the following illustrations.
vmo2010-011-102_a
PUSH HOSE UNTIL THE MARK IS COMPLETELY INSERTED
1. Fitting
2. Mark
A. Must be inserted into fitting
34
vmo2010-011-103
HOSE PROPERLY INSERTED INTO FITTING
vmr2010-004
Page 42
Subsection02 (AIR CONTROLLED SUSPENSION (ACS))
ACS MODULE
ACS Module Signal Circuit Continuity
Te st
1. Remove seats and RH side panel.
2. Disconnect multifunction gauge from vehicle.
Refer to
subsection of the appropriate Shop Manual.
3. Disconnect ACS module connector.
LIGHTS, GAUGE AND ACCESSORIES
Section 01 TECHNICAL MANUAL
vmr2010-004-011_a
1. Module connector
3. Set the FLUKE 115 MULTIMETER (P/N 529 035
868)
to Vdc.
4. Place ignition switch to ON position.
5. Measure voltage as per the following table.
vmr2010-004-011_a
1. Module connector
4. Set the FLUKE 115 MULTIMETER (P/N 529 035
868)
to .
5. Measure resistance as per the following tables.
TEST PROBES RESISTANCE
Gauge pin 18 (BK/BE)
Modulepin5(BE/GN)
TEST PROBES RESISTANCE
Gauge pin 19 (BE/GN)
Module pin 6 (WH/BE)
Closeto0
Closeto0
ACS Module Input Voltage Test
1. Remove seats and RH side panel.
2. Disconnect module connector.
TEST PROBES VOLTAGE
Pin12(OR/GN)
Battery negative (-) post
Battery voltage
(± 12 Vdc)
ACS Module Ground Test
1. Remove seats and RH side panel.
2. Disconnect module connector.
vmr2010-004-011_a
1. Module connector
vmr2010-004 35
3. Set the FLUKE 115 MULTIMETER (P/N 529 035
868)
to Vdc.
4. Place ignition switch to ON position.
5. Measure voltage as per the following table.
TEST PROBES VOLTAGE
Pin 7 (BK)
Battery positive (+) post
Battery voltage
(± 12 Vdc)
Page 43
Section 01 TECHNICAL MANUAL
Subsection02 (AIR CONTROLLED SUSPENSION (ACS))
ACS Module Removal
1. Release air pressure, refer to
PRESSURE IN SYSTEM FOR SERVICING
subsection.
2. Disconnect module hose from manifold air fitting as follows:
2.1 Push fitting ring toward manifold.
2.2 Hold ring in place.
2.3 Pull air hose.
RELEASING AIR
in this
vmr2010-004-012_a
1. Module retaining bolt
5. Remove module from vehicle.
ACS Module Installation
The installation procedure is the reverse of removal procedure, however pay attention to the
following.
If a new ACS module is installed, check diode (D7)
of the solenoid valve to ensure that it is not de-
vmr2010-004-010_a
1. Module hose
NOTICE
Do not attempt to disconnect hose
from module.
3. Disconnect module connector.
fective as it can damage the ACS module. The
diode (D7) is located on the main harness near the
ACS sub-harness junction. Refer to the appropriate
WIRING DIAGRAM
Ensure that air hoses are properly inserted into fittings, refer to the following illustrations.
for diode location.
vmr2010-004-011_a
1. Module connector
4. Remove module retaining bolts and nuts.
36
vmo2010-011-102_a
PUSH HOSE UNTIL THE MARK IS COMPLETELY INSERTED
1. Fitting
2. Mark
A. Must be inserted into fitting
vmo2010-011-103
HOSE PROPERLY INSERTED INTO FITTING
vmr2010-004
Page 44
Section 01 TECHNICAL MANUAL
Subsection02 (AIR CONTROLLED SUSPENSION (ACS))
ACS COMPRESSOR RELAY (R5)
ACS Relay Continuity Test
1. Remove relay (R5), refer to
at the beginning of this section.
2. Set the
868)
FLUKE 115 MULTIMETER (P/N 529 035
to .
3. Measure resistance as per the following table.
TEST PROBES RESISTANCE
Term in al 3 0
Term in al 8 7
4. Apply 12 volts on terminals 86 and 85.
5. Measure resistance again as per the following
table.
TEST PROBES RESISTANCE
Term in al 3 0
Term in al 8 7
If results are not as per the above tables, replace
relay.
FUSE AND RELAY
Open (OL)
Closeto0
Outlander 800R LTD
TEST PROBES VOLTAGE
Fusebox pin 12B (BE/PK)
Battery negative (-) post
Battery voltage
(± 12 Vdc)
If voltage is not as specified, check wiring, connector and terminal condition.
ACS Relay Ground Wire Continuity
Tes t
1. Remove relay (R5), refer to
at the beginning of this section.
2. Disconnect module connector.
FUSE AND RELAY
ACS Relay Input Voltage Test
1. Remove relay (R5), refer to
at the beginning of this section.
2. Set the
868)
FLUKE 115 MULTIMETER (P/N 529 035
to Vdc.
3. Place ignition switch to ON position.
4. Measure voltage as per the following tables.
Outlander 500 LTD
TEST PROBES VOLTAGE
Fuse box pin 6D (OR/GN)
Battery negative (-) post
Outlander 800R LTD
TEST PROBES VOLTAGE
Fuse box pin 12A
(OR/GN)
Battery negative (-) post
Outlander 500 LTD
TEST PROBES VOLTAGE
Fuse box pin 7D (BE/PK)
Battery negative (-) post
FUSE AND RELAY
Battery voltage
(± 12 Vdc)
Battery voltage
(± 12 Vdc)
Battery voltage
(± 12 Vdc)
vmr2010-004-011_a
1. Module connector
3. Set the FLUKE 115 MULTIMETER (P/N 529 035
868)
to .
4. Measure resistance as per the following table.
Outlander 500 LTD
TEST PROBES RESISTANCE
Module pin 8 (OR/PK)
Fuse box pin 7C (OR/PK)
Close to 0
Outlander 800R LTD
TEST PROBES RESISTANCE
Module pin 8 (OR/PK)
Fuse box pin 11B
(OR/PK)
Close to 0
ACS COMPRESSOR
ACS Compressor Operation Test
1. Connect vehicle to B.U.D.S. Refer to
NICATION TOOLS AND B.U.D.S. SOFTWARE
subsection of the appropriate Shop Manual.
COMMU-
vmr2010-004 37
Page 45
Section 01 TECHNICAL MANUAL
Subsection02 (AIR CONTROLLED SUSPENSION (ACS))
2. Select Activation page.
3. Select ACS folder.
4. Press Compressor button to proceed.
vmr2010-004-201_c
Step 1: Activation page
Step 2: ACS folder
Step 3: Compressor operation test button
5. Verify if compressor works properly.
ACS Compressor Power Wire
Continuity Test (from Relay)
1. Remove relay, refer to
beginning of this section.
2. Disconnect compressor connector.
FUSE AND RELAY
at the
Outlander 800R LTD
TEST PROBES RESISTANCE
Compressor pin C (BE/VI)
Fuse box pin 11A (BE/VI)
Close to 0
ACS Compressor Input Voltage Test
1. Release air pressure, refer to
PRESSURE IN SYSTEM FOR SERVICING
subsection.
2. Set the
868)
FLUKE 115 MULTIMETER (P/N 529 035
to Vdc.
3. Disconnect compressor connector.
vmr2010-004-103_a
1. Compressor connector
RELEASING AIR
in this
vmr2010-004-103_a
1. Compressor connector
3. Set the FLUKE 115 MULTIMETER (P/N 529 035
868)
to .
4. Measure resistance as per the following t
able.
Outlander 500 LTD
TEST PROBES RESISTANCE
Compressorpin C (BE/VI)
Fuse box pin 6C (BE/VI)
Closeto0
4. Place ignition switch to ON position.
5. Probe compressor connector.
6. Press selector button several times until
AIR_SUSP
vmo2010-004-005_a
1. Selector button
2. AIR_SUSP displayed
is displayed.
7. Set suspension mode to ACS 2 using the ACS
button.
38 vmr2010-004
Page 46
Section 01 TECHNICAL MANUAL
Subsection02 (AIR CONTROLLED SUSPENSION (ACS))
vmr2010-004-101_a
1. Actual setting (pressure transducer reading)
8. Measure voltage between compressor connector terminals as per the following table.
TEST PROBES VOLTAGE
Pin C (BE/VI)
Pin A (BK)
Battery voltage
(± 12 Vdc)
ACS Compressor Removal
1. Release air pressure, refer to
PRESSURE IN SYSTEM FOR SERVICING
subsection.
2. Remove LH side panel.
3. Remove storage tray.
RELEASING AIR
in this
vmr2010-004-014_a
1. Connector of auxiliary line pressure transducer
8. Disconnect compressor connector.
vmr2010-004-015_a
1. Compressor connector
9. Disconnect the following hoses from compressor air fittings.
– Compressor air inlet hose
– Compressor air outlet hose
– Auxiliary line hose.
vmr2010-004-013_a
1. Storage tray
4. Remove solenoid valve. Refer to
NOID VALVE REMOVAL
5. Remove manifold. Refer to
REMOVAL
.
6. Remove module. Refer to
MOVAL
7. Remove connect
transducer f
vmr2010-004 39
.
or of auxiliary line pressure
rom support.
ACS SOLE-
.
ACS MANIFOLD
ACSMODULERE-
vmr2010-004-016_a
1. Compressor
2. Compressor air outlet hose
3. Auxiliary line hose
air inlet hose
Page 47
Section 01 TECHNICAL MANUAL
Subsection02 (AIR CONTROLLED SUSPENSION (ACS))
10. To disconnect hoses, proceed as follows:
10.1 Push fitting ring toward manifold.
10.2 Hold ring in place.
10.3 Pull air hose.
11. Remove compressor side retaining bolts and
nuts.
vmr2010-004-019_a
1. Front retaining screws
13. Remove compressor from vehicle by pulling it
upwards.
vmr2010-004-017_a
1. RH side retaining bolt
vmr2010-004-018_a
1. LH side retaining bolt
12. Remove compressor front retaining screws.
vmr2010-004-020
14. Detach compressor connector from front support.
15. Remove mounting nuts from compressor
front support.
16. Remove front support from compressor.
40 vmr2010-004
Page 48
Section 01 TECHNICAL MANUAL
Subsection02 (AIR CONTROLLED SUSPENSION (ACS))
vmr2010-004-022_a
1. Front support mounting nuts
2. Compressor connector
3. Front support
NOTICE
Do not remove rear support from
compressor.
17. Remove the following fittings from compressor.
– Compressor air inlet fitting
– Compressor T-fitting
– Compressor check valve.
vmr2010-004-025_a
A. 45°
Ensure that check valve is installed with arrows
pointing toward T-fitting.
vmr2010-004-024_a
Ensure that air hoses are properly inserted into fittings, refer to the following illustrations.
vmr2010-004-023_a
1. Compressor air inlet fitting
2. Compressor T-fitting
3. Compressor check valve
ACS Compressor Installation
The installation procedure is the reverse of removal procedure, however pay attention to the
following.
If fitting or valve is the one previously removed
(old one), apply
(P/N 293 800 018)
If fitting or valve is a new one, do not apply
sealant, it should be already applied on male
threads.
Install T-fitting with an angle of 45° as shown on
following illustration.
vmr2010-004 41
LOCTITE 592 (PIPE SEALANT)
on all male threads.
vmo2010-011-102_a
PUSH HOSE UNTIL THE MARK IS COMPLETELY INSERTED
1. Fitting
2. Mark
A. Must be inserted into fitting
vmo2010-011-103
HOSE PROPERLY INSERTED INTO FITTING
Page 49
Section 01 TECHNICAL MANUAL
Subsection02 (AIR CONTROLLED SUSPENSION (ACS))
ACS AIR FILTER
ACS Air Filter Removal
1. Remove seat.
2. Remove central panel.
vmo2006-007-026_a
1. Central panel
2. Tabs to pull
3. Lift dashboard upwards.
5. Locate ACS compressor air filter.
6. Unscrew ACS compressor air filter from air box.
vmo2010-004-009_a
1. ACS compressor air filter
7. Push tabs then open cover.
vmr2008-068-002_a
TYPICAL
1. Central panel
2. Dashboard
4. Release clamps and remove air filter box cover.
vmo2006-007-027_a
1. Release clamps
vmo2010-004-010_a
1. tabs
8. Remove prefilter (foam) and filter (disc).
vmo2010-004-011_a
1. Prefilter (foam)
2. Filter (disc)
The installation is the reverse of removal procedure.
ACS Air Filter Cleaning
Remove ACS compressor air filter, refer to
FILTER REMOVAL
.
Prefilter (Foam) Cleaning
1. Pour cleaning solution (P/N 219 700 341) or an
equivalent into a bucket.
2. Put the prefilter in to soak for a few minutes.
AIR
42 vmr2010-004
Page 50
Section 01 TECHNICAL MANUAL
Subsection02 (AIR CONTROLLED SUSPENSION (ACS))
3. Rinse the prefilter with warm water until all
cleaning solution disappears.
4. Let the prefilter dry completely.
Filter (Disc) Cleaning
1. Blow low pressure compressed air on filter to
clean it.
NOTICE
Do not wash the filter (disc) with any
cleaning solution.
Housing Cleaning
1. Blow low pressure compressed air in housing
to clean it.
PRESSURE TRANSDUCER (ACS
AUXILIARY LINE)
Pressure Transducer Signal Circuit
Continuity Test
1. Remove seats and RH side panel.
2. Disconnect module connector.
4. Set the FLUKE 115 MULTIMETER (P/N 529 035
868)
to .
5. Measure resistance as per the following table.
TEST PROBES RESISTANCE
Pressure transducer
pin 2 (PK/BR)
Module pin 3 (PK/BR)
Close to 0
Refer to the following illustration for the pressure
transducer connector pinout.
vmr2010-004-108
Pressure Transducer Input Voltage Test
1. Remove seats and RH side panel.
2. Disconnect pressure transducer connector.
vmr2010-004-011_a
1. Module connector
3. Disconnect pressure transducer connector.
vmr2010-004-104_a
1. Pressure transducer connector
vmr2010-004 43
vmr2010-004-104_a
1. Pressure transducer connector
3. Set the FLUKE 115 MULTIMETER (P/N 529 035
868)
to Vdc.
4. Place ignition switch to ON position.
5. Measure voltage as per the following table.
TEST PROBES VOLTAGE
Pin 3 (PK/OR)
Battery negative (-) post
Battery voltage
(± 12 Vdc)
Refer to the following illustration for the pressure
transducer connector pinout.
Page 51
Section 01 TECHNICAL MANUAL
Subsection02 (AIR CONTROLLED SUSPENSION (ACS))
4. Remove pressure transducer from hose.
vmr2010-004-108
Pressure Transducer Ground Test
1. Remove seats and RH side panel.
2. Disconnect pressure transducer connector.
vmr2010-004-030_a
1. Auxiliary line pressure transducer
2. Connector
3. Oetiker clamp
5. Install a new pressure transducer on hose.
6. Install a new Oetiker clamp using
ERS (P/N 295 000 070)
7. Connect pressure transducer connector.
8. Ensure that there is no air leaks from pressure
transducer hose. Refer to
TEST (WITH B.U.D.S.)
OETIKER PLI-
.
ACS SYSTEM LEAK
.
vmr2010-004-104_a
1. Pressure transducer connector
3. Set the FLUKE 115 MULTIMETER (P/N 529 035
868)
to Vdc.
4. Place ignition switch to ON position.
5. Measure voltage as per the following table.
TEST PROBES VOLTAGE
Pin 1 (BK/GY)
Battery positive (+) post
Battery voltage
(± 12 Vdc)
Refer to the following illustration for the pressure
transducer connector pinout.
vmr2010-004-108
Pressure Transducer Replacement
1. Release air pressure, refer to
PRESSURE IN SYSTEM FOR SERVICING
subsection.
2. Disconnect pressure transducer connector.
3. Remove Oetiker clamp.
RELEASING AIR
in this
ACS HOSES
ACS Hose and Fitting Replacement
1. Release air pressure, refer to
PRESSURE IN SYSTEM FOR SERVICING
subsection.
2. Locate hose or fitting to be replaced.
3. Remove it from vehicle.
4. Install the new hose or fitting.
5. Perform a
B.U.D.S.)
ACS SYSTEM LEAK TEST (WITH
.
Auxiliary Line Adapter Replacement
1. Release air pressure, refer to
PRESSURE IN SYSTEM FOR SERVICING
subsection.
2. Disconnect auxiliary line hose from adapter as
follows:
2.1 Push fitting ring toward adapter.
2.2 Hold ring in place.
2.3 Pull air hose.
RELEASING AIR
in this
RELEASING AIR
in this
44 vmr2010-004
Page 52
vmr2010-004-031_a
1. Auxiliary line adapter
2. Fitting ring
3. Drill retaining rivets.
Section 01 TECHNICAL MANUAL
Subsection02 (AIR CONTROLLED SUSPENSION (ACS))
vmo2010-011-103
HOSE PROPERLY INSERTED INTO FITTING
SHOCK ABSORBERS
Shock Absorber Removal
1. Liftrear of vehicle until rear shock absorbers are
fully extended.
2. Install jack stands or blocks under the frame to
support the vehicle.
3. Unscrew air hose from shock absorber as follows:
3.1 Install an appropriate wrench on shock fit-
ting to hold it in place.
3.2 Unscrew air hose fitting using another
wrench.
vmr2010-004-032_a
1. Retaining rivets
4. Install new adapter.
5. Secure adapter support using rivets.
6. Connect auxiliary line hose into adapter.
Ensure that air hoses are properly inserted into fit-
tings, refer to the following illustrations.
vmo2010-011-102_a
PUSH HOSE UNTIL THE MARK IS COMPLETELY INSERTED
1. Fitting
2. Mark
A. Must be inserted into fitting
vmr2010-004-027_a
1. Shock absorber fitting
2. Air hose fitting
NOTICE
To avoid damaging the shock fitting
threads, install a wrench on the shock fitting to
hold it in place while unscrewing the air hose
fitting.
4. Remove the shock absorber lower bolt and nut.
vmr2010-004 45
Page 53
Section 01 TECHNICAL MANUAL
Subsection02 (AIR CONTROLLED SUSPENSION (ACS))
5. Remove spring stopper and its cap then loosen
the spring remover screw.
6. Remove spring from shock.
Shock Absorber Inspection
Inspect the spring for damage. Replace if necessary.
Secure the end of shock body in a vise with its rod
upward.
vmr2010-004-028_a
1. Shock absorber lower bolt
5. Remove the shock absorber upper bolt and nut.
vmr2010-004-029_a
1. Shock absorber upper bolt
6. Remove shock absorber from vehicle.
Shock Absorber Disassembly
NOTICE
installing the shock absorber in the spring
remover tool. The shock absorber body must
not be scratched or damaged to avoid air leakage.
1. Use the
Be careful while manipulating or
SPRING REMOVER (P/N 529 036 007).
1
A14F0BA
TYPICAL
1. Clamp here
NOTICE
Do not clamp directly on shock
body.
Inspect shock absorber as following:
1. Examine the shock absorber for leaks.
2. Extend and compress the shock absorber shaft
several times over its entire stroke.
3. Check that the shock absorber shaft moves
smoothly and with uniform resistance with its
rod upward.
Any of the following conditions will denote a defective shock absorber:
– A skip or a hang back when reversing stroke at
mid travel.
– Seizing or binding condition except at extreme
end of either stroke.
– A gurgling noise, after completing one full com-
pression and extension stroke.
Replace shock absorber if any faults are present.
Shock Absorber Assembly and
Installation
Assembly and installation are the reverse of disassembly and removal procedures, however pay
529036007
2. Place the tool in a vise.
3. Position the shock absorber in the tool and install the spring compressor pins.
4. Tighten the spring remover screw until the
spring is sufficiently compressed to remove
spring locking devices.
46 vmr2010-004
attention to the following.
Assemble shock absorber as per the following il-
lustrations.
Page 54
vmr2010-004-701_a
1. Sleeve
2. O-ring
Section 01 TECHNICAL MANUAL
Subsection02 (AIR CONTROLLED SUSPENSION (ACS))
vmr2010-004-702_a
1. Sleeve
2. O-ring
vmr2010-004-703_a
TYPICAL
1. Circlip
2. Small sleeve
3. Lower cap
4. Upper cap
5. Large sleeve
Install shock absorber cap opening at 180° from
spring stopper opening.
Torque upper and lower shock absorber bolts to
53 N•m (39 lbf•ft).
If the same shock absorber is reused, apply
TITE 592 (PIPE SEALANT) (P/N 293 800 018)
LOC-
on air
hose sleeve male threads.
While holding shock fitting with a wrench, tighten
air hose fitting to 19N•m (168lbf•in).
vmr2010-004 47
Page 55
Section 01 TECHNICAL MANUAL
Subsection02 (AIR CONTROLLED SUSPENSION (ACS))
vmr2010-004-027_a
1. Shock absorber fitting
2. Air hose fitting
Ensure that there is no air leaks from shock absorber fitting and air hose. Refer to
LEAK TEST (WITH B.U.D.S.)
.
ACS SYSTEM
NOTICE
Never screw shock absorber air
hose by using the air hose fitting only. To
avoid damaging the shock fitting threads, install a wrench on the shock fitting to hold it in
place while screwing the air hose fitting.
48 vmr2010-004
Page 56
NOTES
Page 57
NOTES
Page 58
219 100 388 CA
DPS/ACS TECHNICAL MANUAL / ENGLISH
MANUEL TECHNIQUE DPS/ACS / ANGLAIS
FAIT AU / MADE IN CANADA U/M:P.C.
® AND THE BRP LOGO ARE TRADEMARKS OF BOMBARDIER RECREATIONAL PRODUCTS INC. OR ITS AFFILIATES.
©2009 BOMBARDIER RECREATIONAL PRODUCTS INC. ALL RIGHTS RESERVED. PRINTED IN CANADA.
Loading...