Automatic Level Control Description and Operation wo/F45

The Automatic Level Control (ALC) system automatically adjusts the rear height of the vehicle in response to changes in vehicle loading.

The ALC system consists of a height sensor, an air compressor assembly,an ALC compressor relay, an intake hose and filter, an air tube,and two rear shock absorbers. The air compressor assembly consists of an air compressor and an air dryer mounted on a bracket. The air compressor head is a replaceable part of the air compressor. The exhaust solenoid is a non-replaceable part of the air compressor head.

The compressor is activated when the ignition is on, and weight is added to the vehicle. The exhaust solenoid is connected directly to the battery (+), enabling the system to exhaust with the ignition off when excess weight is removed.

When a load is added to the vehicle, the vehicle body moves down causing the suspension position sensor actuating arm to rotate upward. An arm movement of about 25 mm (1 in) amounts to a height change of approximately 12 mm (0.5 in) at the rear bumper. The upward arm movement activates an internal timing circuit inside the position sensor, and after an initial fixed delay of 17-27 seconds, the sensor provides a ground to complete the compressor relay circuit. The 12V (+) circuit to the compressor is then complete and the compressor runs, sending pressurized air to the shock absorbers through the air tubes.

As the shock absorbers inflate, the vehicle body moves upward rotating the actuating arm towards its original position. Once the body reaches its original height, the position sensor opens the compressor relay circuit, and the compressor is turned off.

In order to reduce current draw during air compressor starting, the position sensor performs an air compressor head relief sequence before air compressor operation. This sequence reduces the air pressure in the air compressor cylinder during start-up. The air compressor head relief sequence occurs as follows:

1. The exhaust solenoid is energized by the position sensor.
2. The air compressor is activated 1.3 seconds after the exhaust solenoid is energized.
3. The exhaust solenoid is de-energized 0.5 seconds after the air compressor is activated.

When a load is removed from the rear of the vehicle, the body rises, causing the position sensor actuating arm to rotate downward. This again activates the internal timing circuit. After the initial fixed delay, the sensor provides a ground to complete the exhaust solenoid circuit, energizing the solenoid. Now, air starts exhausting out of the shock absorbers, back through the air dryer and exhaust solenoid valve, and into the atmosphere.

As the vehicle body lowers, the actuating arm rotates to its original position. When the vehicle body reaches its original height, the position sensor opens the exhaust solenoid circuit, which closes the exhaust solenoid and prevents air from escaping.

The position sensor actuating arm position is checked when the ignition is turned on. If the sensor indicates that no height adjustment is needed, an internal timer circuit is activated. After about 35-55 seconds, the compressor is turned on for 3-5 seconds. This ensures that the shocks are filled with the proper residual pressure. If weight is added to or removed from the vehicle during the time delay, the air replenishment cycle is overridden, and the vehicle rises or lowers after the normal delay.

The air compressor is a positive displacement air pump, powered by a 12 volt DC permanent-magnet motor. The air compressor head contains intake and exhaust ports plus a solenoid-operated exhaust valve that releases air from the ALC system when energized. Air compressor intake air is drawn through an intake air hose and filter, mounted in the right side body rail. The air compressor is a serviceable part and is mounted on a bracket. The bracket is mounted to the underbody, right side, rear of the rear suspension.

The air dryer is attached to the air compressor head assembly at the pressure outlet and provides a dual function:

1. It contains a moisture-absorbing desiccant chemical that absorbs moisture from the compressed air before it is delivered to the rear shocks. Moisture is removed from the air dryer and returned to the atmosphere when air is exhausted out of the shocks during lowering.
2. It contains valving that maintains a residual system pressure of 48-97 kPa (7-14 psi). This system pressure is maintained for improved ride characteristics and improved air sleeve reliability.

The exhaust solenoid is a non-serviceable part of the air compressor head and provides a dual function:

1. When energized, it exhausts air from the rear shocks.
2. It acts as a relief valve to limit the maximum air pressure output of the compressor.

The relay, located in the relay center under the rear seat, completes the 12V (+) circuit to the compressor motor when it is energized. The sensor controls the relay.

The solid-state sensor detects height changes at the rear of the vehicle and, in turn, controls the functions of the compressor and exhaust solenoid. To prevent energizing the compressor relay or exhaust solenoid during normal ride motions, the sensor circuit provides a fixed delay before ground is completed to either circuit.

In addition, the sensor limits compressor run time and exhaust solenoid energized time to a range of 4.5-7.5 minutes. This prevents continuous compressor operation in case of a severe system leak or continuous exhaust solenoid operation. The timer circuitry is reset whenever the ignition is cycled OFF and ON, or the sensor exhaust or compress output signal changes.

The sensor is mounted to the left front side of the rear suspension support assembly. The actuation arm is attached to the left rear control arm by a short link.

The rear air adjustable shock absorbers are constructed with a rubber-like air sleeve attached to the dust tube and reservoir. This sleeve forms a flexible chamber which extends the shock absorber when pressure in the chamber is increased. When air pressure is reduced, the weight of the vehicle collapses the shock absorber. In order to maintain proper operation and reliability of the air adjustable shock absorbers, a system pressure from 48-97 kPa (7-14 psi) must be maintained at all times.

The air tube is a non-serviceable item consisting of the following:

At the rear shock absorbers, the air tube connectors are held on with spring clips which snap into the grooves of the shock absorber air fittings. Air tube connectors are sealed using two o-rings.

Although the tubes are flexible, care should be taken not to kink them and to keep them from contacting the exhaust system.