Compressor/Pump: Service and Repair

The content of this article reflects the changes identified in TSB 05-03-99-003


AIR SPRING COMPRESSOR REPLACEMENT

REMOVAL PROCEDURE

CAUTION: DO NOT REMOVE AN AIR SUPPLY PIPE IN AN ATTEMPT TO DEPRESSURIZE THE AIR SUSPENSION. ALWAYS FOLLOW THE AIR SUSPENSION DEPRESSURIZATION PROCEDURE IN AIR SUSPENSION. FAILURE TO FOLLOW THIS PROCEDURE MAY CAUSE PERSONAL INJURY OR DAMAGE TO THE VEHICLE.






1. Depressurize the air suspension system.
2. Raise and support the vehicle. Refer to Vehicle Lifting.
3. Support the compressor assembly with a suitable stand.
4. Disconnect the air inflator switch electrical connector.
5. Disconnect the compressor electrical connector.
6. Disconnect the ground strap.






7. Remove the rear compressor mounting bolts.






IMPORTANT: Note the port location of the air lines for reassembly.

9. Disconnect the air lines.
10. Remove the compressor assembly from the vehicle.






11. Set the compressor assembly on a bench or suitable support.

IMPORTANT: Refer to the following procedures when removing compressor components:

Control Module Removal
- Remove the control module retention screw.
- Slide the control module forward and remove.

Filter/Air Dryer Assembly Removal
- Remove the air pipes from the filter/air dryer.
- Remove the nuts from the filter/air dryer assembly.
- Remove the filter/air dryer.

Air Valve Manifold Assembly Removal
- Unlock and disconnect the electrical connector from the pressure transducer/sensor by turning the connection counter clockwise.
- Remove the air pipes.
- Remove the pigtail harness from the compressor assembly mounting bracket.
- Remove the mounting screws.
- Remove the Air Valve Manifold Assembly.

Compressor Removal; includes exhaust valve
- Remove the filter/air dryer.
- Remove the electrical harness from the compressor assembly mounting bracket.
- Remove the compressor mounting bolts.
- Remove the compressor.

Isolator Removal
- Remove the isolator bolts.
- Remove the isolators.

INSTALLATION PROCEDURE

NOTE: Refer to Fastener Notice in Service Precautions.

1. Set the compressor assembly on a bench or suitable support.

IMPORTANT: Refer to the following procedures when replacing compressor components:

Control Module Replacement
- Slide the control module rearward to install.
- Install the control module retention screw.

Tighten
Tighten the screw to 2.5 N.m (22 lb in).

Filter/Air Dryer Assembly Replacement
- Install the filter/air dryer.
- install the nuts to the filter/air dryer assembly.

Tighten
Tighten the screw to 12 N.m (106 lb in).

- Install the air pipes to the filter/air dryer.

Air Valve Manifold Assembly Replacement
- Install the Air Valve Manifold Assembly.
- Install the mounting screws.

Tighten
Tighten the screw to 3.5 N.m (31 lb in).

- Install the pigtail harness to the compressor assembly mounting bracket.
- Connect and lock the electrical connector to the pressure transducer/sensor by turning the connection clockwise.
- Install the air pipes.

Compressor Replacement; includes exhaust valve
- Install the compressor.
- Install the compressor mounting bolts.

Tighten
Tighten the nuts to 20 N.m (15 lb ft).

- Install the electrical harness to the compressor assembly mounting bracket.
- Install the filter/air dryer.

Isolator Replacement
- Install the isolators.
- Install the isolator bolts.

Tighten
Tighten the nuts to 20 N.m (15 lb ft).

IMPORTANT: Check the air supply lines for deep scores or cuts. If the air supply lines are damaged the lines must be replaced.

2. Install the air lines.
3. Install the rear air spring compressor mounting nuts and bolts.

Tighten
Tighten the bolts to 50 N.m (37 lb ft).






4. Install the front air spring compressor mounting bolts.

Tighten
Tighten the bolts to 50 N.m (37 lb ft).






5. Connect the air spring compressor electrical connector.
6. Connect the ground strap.

Tighten
Tighten bolt to 6 N.m (53 lb in).

7. Connect the air inflator switch electrical connector
8. Remove the support from the compressor.

Important: If the rear axle was allowed to hang unsupported, lower the vehicle far enough to allow the air spring to be manually engaged to the support on the axle
tube with minimal distortion of the air spring bladder. Ensure that the air spring is fully engaged to the axle support.

9. Pressurize the air springs.
10. Perform the suspension position calibration procedure.
11. heck for leaks. If a leak is found at the air supply line connections replace the air supply lines.