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Inflation and Deflation of the Air Suspension System WARNING: Do not remove an air spring under any circumstances when there is pressure in the air spring. Do not remove any components supporting an air spring without either exhausting the air or providing support for the air spring to prevent vehicle damage or personal injury. WARNING: Disconnecting an air line that is connected to the air compressor can cause personal injury or damage to components as high pressure air is vented uncontrolled. 1. Turn the air suspension switch on. 2. Turn the ignition switch to the RUN position. 3. Connect NGS Tester to the data link connector (DLC). 4. Select Air Suspension Control Module under Active Command Mode: ? VENT FRNT to deflate the front down. ? LIFT FRNT to inflate the front up. ? VENT REAR to deflate the rear down. ? LIFT REAR to inflate the rear up. Calibration Front Ride Height Resetting — Clear B2140 DTC 1. Turn the ignition key OFF and turn it back to RUN; exit the vehicle, close all doors and allow the system to vent the vehicle down to kneel height (approximately 30 seconds). 2. Connect New Generation STAR (NGS) Tester to the data link connector (DLC). 3. Select the proper vehicle year, model and engine type. 4. Select 4WAS-AIR SUSP/EVO (4×2 and 4×4) module. 5. Select “Parameter Reset Command (Clear Ride Height) under Active Command Modes” menu, trigger through the warning messages and reset (trigger from OFF to ON): ? NGS version 10.0 — “Front” and “Rear.” ? NGS version 11.0+ — “Front CLR.” 6. Back out the torsion bar adjustment bolt (approximately 40 mm from the bolt head to the bottom surface of the torsion bar adjuster). 7. Deflate the front air shocks by using the NGS “Vent Front” command in “Air Suspension Control” menu (should take about 30 seconds), and jounce the front of the vehicle to fully lower the front of the vehicle. 8. Adjust and measure the vehicle ride height; refer to Section 204-01B. 9. NOTE: Do not save rear ride heights. The air suspension control module has precalibrated values already stored. Refer to Rear Ride Height Mechanical Resetting. Select the “Save Calibration Values (Store Ride Height)” NGS command to calibrate the air suspension control module. Trigger through the warning message(s) and save “FRONT” (trigger from OFF to ON).

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Removal WARNING: All vehicles are equipped with gas pressurized shock absorbers which will extend unassisted. Do not apply heat or flame to the shock absorbers during removal or component servicing. Failure to follow these instructions can result in personal injury. CAUTION: Suspension fasteners are critical parts because they affect the performance of vital components and their failure can result in major service expense. They must be replaced with the same part number or an equivalent part if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to ensure proper retention of these parts. Vehicles equipped with air suspension 1. WARNING: The electrical power to the air suspension system must be turned off prior to hoisting, jacking or towing an air suspension vehicle. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Turn the air suspension service switch off. All vehicles 2. Raise and support the vehicle. For additional information, refer to Section 100-02. 3. Use the special tool 014-00942 or equivalent to support the rear axle. Vehicles equipped with air suspension 4. WARNING: Do not remove an air spring under any circumstances when there is air pressure in the air spring. Do not remove any components supporting an air spring without exhausting the air. Release the air pressure from the air springs. For additional information, refer to Section 204-05. All vehicles 5. NOTE: Replace shock absorbers individually as required. It is not necessary to replace in pairs. NOTE: To assist in removing the upper attachment on shock absorbers, use a plastic dust tube and place an open end wrench on the hex stamped into the dust tube’s metal cap. For shock absorbers with a steel dust tube, simply grasp the tube to prevent stud rotation when loosening the retaining nut. Remove the shock absorber upper retaining nut, washer and insulator from the stud on the upper side of the frame. 6. Remove and discard the nut. Disconnect the shock absorber lower stud from the mounting bracket on the rear axle assembly. Installation All vehicles 1. To install, reverse the removal procedure. Vehicles equipped with air suspension 2. Inflate the air springs. For additional information, refer to Section 204-05.

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AIR LINE INSTRUCTIONS Caution: Leave sufficient airline slack to prevent any strain on fittings during axle motions. To prevent airline from melting, keep it at least 300mm from exhaust system, engine and heat sources. Caution: Avoid areas, which may cause failure of the air line. For example: battery, exhaust, engine and moving parts such as steering, suspension and cables. DUAL AIR LINE CONNECTION Figure 3 Dual Air Lines Figure 4 A. Select a location for the inflation valves in the rocker panel flange or by hood release insuring that each valve will be protected and accessible with an air hose. B. Determine and cut adequate length, not longer than 90” of airline to reach from valve location to left side air cylinder. C. Slide airline clamp onto the air line. Push the airline over the barbed end of straight fitting. Compress the ears on the air line clamp with pliers and slide it down to cover the barbed section ( Figure 5). Repeat for other side D. Connect the straight fitting to the right and left air spring and tighten securely. E. Route airline along frame or under fender panel to desired inflation valve location (Figure 3). Attach airline to the chassis with plastic straps or wire. F. Drill 8 mm hole for inflating valves and mount as illustrated (Rubber washer is for outside seal, Figure 4). G. Connect the airline to the inflation valve. H. Repeat process for right side. I. Continue with step 9.

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1. Vent the air suspension system. WARNING: DO NOT REMOVE AN AIR SPRING UNDER ANY CIRCUMSTANCES WHEN THERE IS PRESSURE IN THE AIR SPRING. DO NOT REMOVE ANY COMPONENTS SUPPORTING AN AIR SPRING WITHOUT EITHER EXHAUSTING THE AIR OR PROVIDING SUPPORT FOR THE AIR SPRING TO PREVENT VEHICLE DAMAGE OR PERSONAL INJURY . 2. Turn the air suspension switch off. WARNING: BEFORE PERFORMING MAINTENANCE ON ANY AIR SUSPENSION COMPONENTS, DISCONNECT THE POWER TO THE SYSTEM BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED ON THE LH SIDE OF THE LUGGAGE COMPARTMENT TO PREVENT VEHICLE DAMAGE OR PERSONAL INJURY . 3. Raise and support the vehicle. 4. Remove the rear air spring retainer. 5. Lift the bottom of the air spring off the rear axle. 6. Remove the air spring. 1) Disconnect the electrical connector. 2) Push up on the air line retaining ring and disconnect the air line. 3) Remove the air spring. INSTALLATION To install, reverse the removal procedure. NOTE: To avoid damage to the air spring, do not allow suspension to compress before the spring is inflated. When installing the air line into the solenoid, a minimum of 3 mm (1/8 inch) of line must be inserted for proper operation of the air spring.

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DUAL ACTION SYSTEM The suspension system incorporates a rear load leveling system that maintains the vehicle at the proper ride height under varying conditions of vehicle load, and an optional road calibrated suspension ride control system that varies the damping of the shock absorbers between soft and firm. The rear load leveling system uses air springs to support the vehicle weight. The quantity of air in the rear air spring is controlled by the vehicle dynamic module (VDM) to maintain a predetermined vehicle ride height. Each air spring has an air spring solenoid to control air flow into and out of each air spring. The optional ride control system uses four shocks with electronically controlled actuators. The shock actuators are internally mounted on the lower bodies of the front spring and shock assemblies and the rear shocks. The action of the shock actuators is controlled by the VDM. The VDM sends a signal to an appropriate shock actuator which switches to either soft or firm damping. Normally the shock actuator setting is in a soft, luxury car mode. This is done by causing an electric current flow through the actuator, which induces electromagnetic force that moves the shock actuator from a firm to a soft position. When driving situations require, the setting is switched to a firm, high performance control mode. This is done by removing power to the actuator, allowing the shock actuator to return to the firm mode.