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SECTION 2A

SUSPENSION DIAGNOSIS
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . General Specifications . . . . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . General Diagnosis . . . . . . . . . . . . . . . . . . . . . Input & Output Devices and Damping Force Control Logic . . . . . . . . . . . . . . . . . Input & Output Devices . . . . . . . . . . . . . . . . . . System Layout . . . . . . . . . . . . . . . . . . . . . . . . 2A-1 2A-1 2A-3 2A-3 2A-5 2A-5 2A-5
Damping Force Control Logic . . . . . . . . . . . . . 2A-6 Normal Control . . . . . . . . . . . . . . . . . . . . . . . . 2A-6 Self-Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . 2A-7 Actuator Inspection . . . . . . . . . . . . . . . . . . . . . 2A-8 Schematic and Routing Diagrams . . . . . . . . 2A-9 ECS Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-9 Self Diagnosis Test . . . . . . . . . . . . . . . . . . 2A-12 Diagnosis Test . . . . . . . . . . . . . . . . . . . . . . . 2A-12

SPECIFICATIONS
GENERAL SPECIFICATIONS
Application ECS Control Type Shock Absorber Max. Length (mm) Compressed Length (mm) Stroke (mm) Front Rear

3-stage Variable Damping Force Control Type


344 - 350 245 3 102 517 - 523 331 3 188

2A-2 SUSPENSION DIAGNOSIS

GENERAL SPECIFICATIONS (Cont'd)


Application Body Vertical and Lateral Acceleration Sensor Power Voltage (V) Consuming Current (mA) Output Current (mA) Operating Characteristics
(Vertical Acceleration Sensor)

Description 4.75 - 5.25 Less than 10 Less than 2.0


(Lateral Acceleration Sensor)

Output Voltage 4.25

Output Voltage 4.25

2.5 0.75 -1.5g 1g Acceleration 3.5g

2.5 0.75 -1g 0g Acceleration 1g

Damping Force Switching Actuator

Type Voltage Rating (V) Current Rating (A) Current Time (mS)

3-stage Rotary Step Motor Type DC12 Less than 2.5 95 - 105 4.75 - 5.25 Less than 10 Less than 2.0
Output Voltage 4.25

Axle Vertical Acceleration Sensor (Wheel G Sensor)

Power Voltage (V) Consuming Current (mA) Output Current (mA) Operating Characteristics

2.5 0.75 -9g 1g Acceleration 11g

SUSPENSION DIAGNOSIS 2A-3

DIAGNOSIS
GENERAL DIAGNOSIS
Problems in the steering, the suspension, the tires, and the wheels involve several systems. Consider all systems when you diagnose a complaint. Some problems, such as abnormal or excessive tire wear and scuffed tires, may by the result of hard driving. Always road test the vehicle first. If possible, do this road test with the customer. Proceed with the following preliminary checks. Correct any substandard conditions.

Vehicle Rolling
Checks Broken Stabilizer Bar Faulty Shock Absorber Action Replace Replace

Abnormal Noises
Checks Loosened Mountings Damaged or Worn wheel Bearing Damaged Shock Absorber Damaged Tire Action Retightening Replace Replace Replace

Poor Riding
Checks Over Inflated Tire Faulty Shock Absorber Loosened wheel Nut Bent or Broken Coil Spring Damaged Tire Worn Bushing Action Pressure Adjustment Replace Tighten as Specified Replace Replace Replace

Vehicle Pulls to Right or Left


Checks Deformed Arm Assembly Worn Bushing Bent or Broken Coil Spring Difference Between L/H & R/H Heights Action Replace Replace Replace Adjust

Hard Steering
Checks Incorrect Wheel Alignment Excessive Resistance of Lower Arm Ball Joint Insufficient Tire Pressure Faulty Power Steering Action Repair Replace Adjust Repair or Replace

2A-4 SUSPENSION DIAGNOSIS


Steering Instability
Checks Incorrect Front wheel Alignment Worn or Loosened Lower Arm Bushing Action Replace Repair or Replace

Vehicle Bottoming
Checks Worn or Broken Coil Spring Action Replace

SUSPENSION DIAGNOSIS 2A-5

INPUT & OUTPUT DEVICES AND DAMPING FORCE CONTROL LOGIC


INPUT & OUTPUT DEVICES
Damping force of shock absorber will rotate shock absorber control rod in 3 modes by driving actuator on the upper shock absorber when signaled from ECS. Rotary valve in the shock absorber will control hydraulic flow according to rotation of control rod to adjust damping force of shock absorber in SOFTMEDIUMHARD. Speed Sensor Axle Vertical Acceleration Sensor (Wheel G Sensor) Stop Lamp Switch Body Vertical Acceleration Sensor (Vertical Sensor) ECS Switch Body Lateral Acceleration Sensor (Lateral Sensor) Self-Diagnosis Connector
ECS (ECU)

Indicator Lamp Actuator Damping Force Adjustment Shock Absorber

SYSTEM LAYOUT

1 ECS (ECU) 2 Body Vertical Acceleration Sensor (Vertical Sensor) 3 Body Lateral Acceleration Sensor (Lateral Sensor)

4 ECS Mode Switch 5 Stop Lamp Switch 6 Axle Vertical Acceleration Sensor (Wheel G Sensor) 7 Mode Actuator

2A-6 SUSPENSION DIAGNOSIS

DAMPING FORCE CONTROL LOGIC


Control Logic that applies on damping force variable suspension is comprised of road sensing driving comfort control logic to increase driving comfort and vehicle speed sensing control logic, anti-roll control logic and anti-dive control logic to secure control safety. Sensor Logic Road Sensing Driving Comfort Control Logic Anti-bounce Control Logic Anti-roll Control Logic Anti-dive Control Logic Vehicle Speed Sensing Control Logic Speed
Axle Vertical Lateral Acceleration Sensor (2.5g) Sensor (1g) Sensor (10g)

Brake

NORMAL CONTROL
Initial Stage When ignition switch is "ON", system initialization will be performed for approx. 3 seconds. During this time, warning lamp will stay ON and damping force will be switched to Hard status. After 3 seconds, warning lamp will turn off and normal control status will be restored. Normal Damping Force Control Establishment Damping force will have SoftMediumHard status in AUTO mode and MediumHard status in SPORT mode. When double control items are satisfied at the same time it will be HardMediumSoft in order. Normal Damping Force Control Release Control mode release will be "HardMediumSoft"or "MediumSoft". In case that returned from Hard status to Medium status during control, it will be done after elapse of setting times. Returning from Medium status to Soft status will be done immediately without delay.

SUSPENSION DIAGNOSIS 2A-7

SELF-DIAGNOSIS
ECS-ECU indicates ECS circuit defectives to the driver by flickering ECS indicator lamp in the meter cluster 0.5 second of interval if there are defectives. Code 01 Defects Body vertical acceleration sensor Judging Conditions When sensor output voltage is less than 0.5-4.5V, more than 4.5V. Set Time Remedy Stop antibounce ride control
Release Conditions

Set Time

Sensor Voltage 2.0 0.1V 3.0 0.1V

0.9 - 1.1sec.

0.9 - 1.1sec.

02

Body lateral acceleration sensor

When sensor output Stop anti-roll 0.9 1.1sec. voltage is less than control 0.550.15V, more than 4.450.1V. When sensor output voltage is less than 0.5-4.5V, more than 4.5V. Stop ride control

Sensor Voltage 2.0 0.1V 3.0 0.1V

0.9 - 1.1sec.

03

Axle vertical acceleration sensor (wheel G sensor)

0.9 - 1.1sec.

Sensor Voltage 2.0 0.1V 3.0 0.1V

0.9 - 1.1sec.

04

Front actuator

Check step motor Stop control power supply detecting 0.4 - 0.6sec. after returning circuit for open and to the previshort. ous mode check for relative connectors. When defective detectStop control ing circuit has detected 0.4 - 0.6sec. after returning defectives during to the previous output OFF. mode When ECU does not work normally. 0.4 - 0.6sec. Stop control

IGN+ SW. OFF ON

05

Rear actuator

IGN+ SW. OFF ON

06

ECU

Reset

1. Turn the ignition switch ON and if ECS system is normal, ECS indicator lamp will turn on for 3 seconds and then go off. However if defective, ECS indicator lamp will flicker in the interval of 0.5 second continuously. 2. Identify fault code with Scanner.

2A-8 SUSPENSION DIAGNOSIS

ACTUATOR INSPECTION
Output position of the actuator should be changed as below when battery voltage is applied between actuator connector terminals. Connector Battery Voltage terminal
1 (White) 2 (Black) 3 (Red) 1 (White) 2 (Black) 3 (Red) 1 (White) 2 (Black) 3 (Red) -

Position of The Actuator Output

Remark

OPEN
+ + -

SOFT Mode

MEDIUM Mode

OPEN OPEN
+ -

HARD Mode

SUSPENSION DIAGNOSIS 2A-9

SCHEMATIC AND ROUTING DIAGRAMS

ECS CIRCUIT

2A-10 SUSPENSION DIAGNOSIS

SUSPENSION DIAGNOSIS 2A-11


Connector Pin Number and Circuits
NO.
1 2 3 4 5 6 7 8 9 10 11 12 13

Circuit Ignition Actuator R-MEDIUM Actuator R-SOFT Actuator F-HEAD Select Switch Speed Sensor Wheel G Sensor Vertical G Sensor Sensor +5V Chassis Ground Indicator Lamp

NO.
14 15 16 17 18 19 20

Circuit Chassis Ground Actuator R-HEAD Actuator F-MEDIUM Actuator F-SOFT Brake Switch Lateral G Sensor
15 16 17 18 19 20 21 22 23 24 25 26 2 3 4 5 6 7 8 9 10 11 12 13

Wheel G Sensor Ground 21 Lateral G Sensor Ground


22 Vertical G Sensor Ground 23 24 25 26

Diagnosis K Line Diagnosis L Line -

2A-12 SUSPENSION DIAGNOSIS

SELF DIAGNOSIS TEST


DIAGNOSIS TEST
Special Tool Requirements : Scanner

1. Position the ignition switch to 'OFF'. 2. Connect Scanner harness connector to the engine compartment diagnosis socket. 3. Turn the ignition switch to 'ON' position. 4. Select "Electronic control vehicle diagnosis" from function selection display and press "Enter". 5. Select "Musso ('98 model year)" from vehicle model selection display and press 'Enter'. 6. Select "Electronic suspension system (ECS)" from control system selection display and press 'Enter'. 7. Select "Self-diagnosis" from diagnosis item selection display. Notice Check sensor value output display, if necessary. 8. Determine the fault code and check defective component. Notice Refer to self-diagnosis list.

SUSPENSION DIAGNOSIS 2A-13


Self - Diagnosis List
Fault Code 01 Defects Vertical Acceleration Sensor Service Hint 1. Check sensor supply voltage ! Condition - IGN ON ! Standard value - voltage between pin 11 and 8 of ECU : 4.5 - 5.0V 2. Check sensor output voltage ! Condition - IGN ON ! Standard value - voltage between pin 20 and 11 of ECU : 0.5 - 4.5V 3. Check the sensor. 4. Check circuit for open. 5. Check connection of other connectors. 1. Check sensor supply voltage ! Condition - IGN ON ! Standard value - voltage between pin 11 and 8 of ECU : 4.5 - 5.0V 2. Check sensor output voltage ! Condition - IGN ON ! Standard value - voltage between pin 10 and 11 of ECU : 0.5 - 4.5V 3. Check the sensor. 4. Check circuit for open. 5. Check connection of other connectors. 1. Check sensor supply voltage ! Condition - IGN ON ! Standard value - voltage between pin 11, 8 and pin 7,11 of ECU : 4.5 - 5.0V 2. Check sensor output voltage 3. Check the sensor. 4. Check circuit for open. 5. Check connection of other connectors. 1. Check step motor supply voltage. 2. Check circuit for open. 3. Check connection of other connectors. 1. Check step motor supply voltage. 2. Check circuit for open. 3. Check connection of other connectors. 1. Check connectors of ECU. 2. Replace the ECU.

02

Lateral Acceleration Sensor

03

Wheel Acceleration Sensor

04

Front Step Motor

05

Rear Step Motor

06

ECU