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2010
DPS /ACS
TM
TM

Technical Manual

219 100 388

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.

2 1 9

1 0 0

3 8 8

2010
DPS/ACS
Technical Manual

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™
Outlander™

Renegade™
XPS™

This document contains the trademarks of the following companies:
AMP® is a trademark of Tyco Electronics Corporation
Loctite® is a trademark of Loctite Corporation
Snap-on® is a trademark of Snap-on Tools Corporation

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

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, whether authorized or not by
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 Indicates an instruction which, if not
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.

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

INTRODUCTION

INTRODUCTION
This Technical Manual covers the following BRP made 2010 Can-Am ATVs with a DPS or ACS system.
OUTLANDER™
ENGINE

500

650

800R

MODEL

COLOR

MODEL NUMBER

Yellow, Red, Camo

2UAA, 2UAB, 2UAC, 2UAD, 2UAE

XT-P

Black

5JAB

MAX XT

Yellow, Red, Camo

2XAA, 2XAB, 2XAC, 2XAD, 2XAE

MAX XT-P

Black

5KAC

MAX LTD

Steel grey

5NAA

Yellow, Red, Camo

2PAA, 2PAB, 2PAC, 2PAD, 2PAE, 2PAF

XT-P

Black

5GAB

MAX XT

Yellow, Red, Camo

2SAA, 2SAB, 2SAC, 2SAD, 2SAE, 2SAF

MAX XT-P

Black

5HAC

Yellow, Red, Camo

2JAA, 2JAB, 2JAC, 2JAE, 2JAF

XT-P

Black

5EAB, 5EAE

MAX XT

Yellow, Red, Camo

2LAA, 2LAB, 2LAC, 2LAD, 2LAF

MAX XT-P

Black

5FAC, 5FAF, 5FAJ

MAX LTD

Red, Steel grey

2MAA, 2MAB, 2MAC, 2MAD

RENEGADE™
ENGINE

MODEL

COLOR

MODEL NUMBER

800R

X xc

Black

4DAA, 4DAB, 4DAC

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

BEIGE

ORANGE

BLACK

BLUE

RED

BROWN

VIOLET

GREEN

WHITE

GRAY

YELLOW

vmr2010-002

III

vmr2010-002

SERVICE TOOLS INDEX

FLUKE 115 MULTIMETER
(P/N 529 035 868)

Page: 9, 11, 32, 35, 37–38, 43–44
OETIKER PLIERS
(P/N 295 000 070)

Page: 44
SPRING REMOVER
(P/N 529 036 007)

Page: 46

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

SNAP-ON® TELESCOPING GAUGE SET....................................... LST 52616

Page

........................................... 20

SERVICE PRODUCTS
Description

Part Number

Page

XPS SYNTHETIC GREASE............................................................. 293 550 010 ........................................... 19

vmr2010-003

Section 01 TECHNICAL MANUAL
Subsection 01 (DYNAMIC POWER STEERING (DPS))

XPS synthetic
grease (400 g)

38 Nm
(28 lbfft)
If torqued
by screw head

XPS synthetic
grease (400 g)

If torqued
by elastic nuts
24.5 Nm
(18 lbfft)
NEW

NEW

NEW 24.5 Nm
(18 lbfft)

NEW
NEW
24.5 Nm
(18 lbfft) NEW

NEW
72 Nm
(53 lbfft)

vmr2010-003-001_a

vmr2010-003

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:
– Engine RPM
– 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

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

Section 01 TECHNICAL MANUAL
Subsection 01 (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
DPS module.
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.

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.

DPS Unit Protection
To protect the DPS electronic components, the
steering assist behavior will change as follows.
CONDITION
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)

DPS BEHAVIOR

Steering assist
will gradually
decrease.

Steering assist is
stopped.

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.

vmr2010-003

Section 01 TECHNICAL MANUAL
Subsection 01 (DYNAMIC POWER STEERING (DPS))

Steering Torque Sensor

PART ADJUSTED OR
REPLACED
– DPS unit
– Steering column
bearing
– Tie rod
– Tie rod end
– Knuckle
– Wheel bearing
– Ball joint
– Front suspension arm
(lower/upper)
– Steering alignment

rmr2008-019-017

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.

WHAT TO DO

Reset Torque Offset
in Setting, DPS

1. Ensure proper STEERING ALIGNMENT, 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.
vmr2010-003-002_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.

vmr2010-003

Section 01 TECHNICAL MANUAL
Subsection 01 (DYNAMIC POWER STEERING (DPS))

TROUBLESHOOTING
NO POWER STEERING ASSIST
1. DPS malfunction.
- If the CHECK ENGINE light is on and a DPS FAULT
message is visible in the gauge, check for fault
codes using B.U.D.S. and carry out service action.

vmo2010-004-006_a

1. OVERRIDE/DPS button

The active DPS mode will be displayed in the
lower portion of multifunction gauge.

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.
- 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.
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

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.

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.
vmr2010-003

Section 01 TECHNICAL MANUAL
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.
vmo2010-004-202_a

DPS WILL NOT CHANGE MODES OF
OPERATION
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.

TYPICAL - OUTLANDER 800R LTD ILLUSTRATED
1. Rear fuse box (PF2)

1. To remove fuse box cover, simultaneously
squeeze tabs inwards on each end of fuse box
cover as you pull on the cover.

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.

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.

529035868

vmr2010-003

Section 01 TECHNICAL MANUAL
Subsection 01 (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 DPS UNIT INPUT VOLTAGE TEST (CONTROL 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
Side)

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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.

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.
MULTIMETER PROBE
POSITIONS

VOLTAGE

DPS control connector (pin A)
and battery ground

Battery voltage

rmr2008-028-093_a

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
DPS power
connector pin A
DPS power
connector pin B

VOLTAGE

Battery ground

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

vmr2010-003

Section 01 TECHNICAL MANUAL
Subsection 01 (DYNAMIC POWER STEERING (DPS))

MULTIMETER PROBE
POSITIONS

RESISTANCE @
20°C (68°F)

DPS control connector (pin C)
and diagnostic connector (pin 1)

rmr2008-028-094_a
vmr2010-003-013_c

DPS control connector (pin D)
and diagnostic connector (pin 2)

1. DPS ground connector (GDN)

Below 1

2. Test for continuity between DPS3-A and
DPS3-B to battery ground.
MULTIMETER PROBE
POSITIONS
DPS GDN
connector pin A
DPS GDN
connector pin B

Battery ground

READING

Continuity
(close to 0 )

rmr2008-028-094_b

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

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 UNIT COMMUNICATION LINK (CAN) CONTINUITY TEST.

DPS System Load 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 diagnostic connector.
Test continuity of CAN Bus Wires at DPS1-C and
DPS1-D.

vmr2010-003

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 FLUKE 115 MULTIMETER (P/N 529 035 868) set to Vdc to the rear fuse
box battery terminal.
2. Connect the black multimeter lead to the battery ground.

Section 01 TECHNICAL MANUAL
Subsection 01 (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.
DPS SYSTEM LOAD TEST
PROBE POSITIONS
Battery
(-)
terminal

Rear fuse
box battery
terminal

STEERING
POSITION
LH stop
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.

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.

vmr2010-003

Section 01 TECHNICAL MANUAL
Subsection 01 (DYNAMIC POWER STEERING (DPS))

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.

vmr2010-003-007

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 following DPS UNIT CURRENT TEST.

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.

vmr2010-003-010_a

TYPICAL - RH TURN
1. Torque sensor indication (positive)
2. DPS current indication (negative)

vmr2010-003-008_a

Step 1: Press Data button
Step 2: Select Monitoring page tab
Step 3: Select DPS tab

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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
60 amps, then drop off close to 0 amps as torque
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.

Section 01 TECHNICAL MANUAL
Subsection 01 (DYNAMIC POWER STEERING (DPS))

– Steering column shim adjustment at half bushings as described in the DPS UNIT INSTALLATION procedure detailed in this section.
– TORQUE OFFSET RESET procedure detailed in
this section.
– Replace DPS unit.

DPS Unit Removal
1. Remove the following items:
– Seat
– Center panel
– 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
housing duct to the throttle body.

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1. CVT air inlet duct

10. Remove the ECM from it's support bracket.
11. Disconnect the 3 electrical connectors from
the DPS unit.

vmr2010-003

Section 01 TECHNICAL MANUAL
Subsection 01 (DYNAMIC POWER STEERING (DPS))

14. Remove and discard the elastic nuts from
the 2 hexagonal screws that secure steering
column half bushings to the support on the
frame.

vmr2010-003-013_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.

vmr2010-003-018_a

1. Elastic nuts to remove and discard
2. Frame support
3. Steering column half bushings

15. Remove the 2 hexagonal screws from the
ECM support.

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1. Cut this locking tie
2. Steering column bellows

13. Remove the steering column pinch bolt and
retaining nut. Discard the retaining nut.

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 column pinch bolt

vmr2010-003

Section 01 TECHNICAL MANUAL
Subsection 01 (DYNAMIC POWER STEERING (DPS))

vmr2010-003-022_a
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.

1. Pitman arm
2. Tie rod ends

NOTE: Leave the tie rod ends on the pitman arm
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.

vmr2010-003

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.

vmr2010-003-026_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

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
the pitman arm. Be careful not to loose the hardened steel washers on the tie rod ends.

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 The following procedure 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.
1. If installing a new DPS unit, install the two M5
hexagonal forming screws on the mounting
flange of the DPS unit.
vmr2010-003

Section 01 TECHNICAL MANUAL
Subsection 01 (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

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.

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 hammer.
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 (18 lbf•ft).

vmr2010-003

Section 01 TECHNICAL MANUAL
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.

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)
to the inside of both steering column half bushings.

vmr2010-003-034

vmr2010-003-016_a

1. Locking tie location
2. Steering column bellows

vmr2010-003

10. Loosely secure the steering column to its
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 and do not torque the
fasteners at this time. Hand tighten only. Steering
column must not be drawn in towards the column
support.

Section 01 TECHNICAL MANUAL
Subsection 01 (DYNAMIC POWER STEERING (DPS))

vmr2010-003-036

vmr2010-003-035_a

STEERING COLUMN SHIM MEASUREMENT

1. These nuts installed hand tight at this time

11. Torque DPS unit mounting
24.5 N•m (18 lbf•ft).

screws

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

vmr2010-003-028_b

TYPICAL - RH SIDE ILLUSTRATED
1. Torque DPS mounting screws (x4)

12. Using an 8 mm (5/16 ft) telescoping gauge as
found in the SNAP-ON® TELESCOPING GAUGE
SET (P/N LST 52616), measure the distance between the steering column shaft and the face
of the column frame support. Measurement
is taken above rear half bushing.

vmr2010-003-037

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: Shims come in 1 mm (.039 in) and 2 mm
(.079 in) thicknesses. Total shim thickness must
not exceed 4 mm (.157 in).

vmr2010-003

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

18. Turn handlebar fully to each side and check for
proper contact between pitman arm and pitman arm frame stops (both sides).

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).

vmr2010-003-039_a

TYPICAL - LH ILLUSTRATED
1. Pitman arm
2. Contact point with frame stop

vmr2010-003-021_b

Step 1: Hold elastic nuts with wrench (not illustrated)
Step 2: Apply specified torque to hexagonal screws
vmr2010-003

NOTE: Contact between pitman arm and pitman
arm stops must be checked with vehicle weight
on wheels.
19. Perform a STEERING ALIGNMENT as described in the applicable Shop Manual subsection.
21

Section 01 TECHNICAL MANUAL
Subsection 01 (DYNAMIC POWER STEERING (DPS))

20. Install and connect ECM. Torque ECM mounting 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.

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.

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. software.
2. Select the Read Data button.
3. In the Module menu, choose the DPS submenu and install the latest DPS software
Update file as applicable to the type ATV (Outlander or Renegade).

vmr2010-003-040

DPS SOFTWARE UPDATE

4. Once the correct DPS software file is installed,
go to the Faults page and clear the fault codes.
5. Carry out the TORQUE OFFSET RESET procedure as described in this subsection.

vmr2010-003

Section 01 TECHNICAL MANUAL
Subsection 02 (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

Section 01 TECHNICAL MANUAL
Subsection 02 (AIR CONTROLLED SUSPENSION (ACS))

53 Nm
(39 lbfft)
53 Nm
(39 lbfft)
ACS hose
ACS solenoid
release valve
Loctite
592
(pipe
sealant)

NEW
NEW
53 Nm
(39 lbfft)

ACS
module

ACS
compressor
vmr2010-004-033_a

vmr2010-004

Section 01 TECHNICAL MANUAL
Subsection 02 (AIR CONTROLLED SUSPENSION (ACS))

GENERAL

ACS SUSPENSION SETTINGS

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 working on the system. Refer to RELEASING AIR
PRESSURE IN SYSTEM FOR SERVICING.

SETTING

PRESSURE

RIDING
COMFORT

ACS 1

0.5 bar (8 PSI)

Softest

ACS 2

1 bar (15 PSI)

Soft

ACS 3

2 bar (30 PSI)

Semi-soft

ACS 4

4 bar (55 PSI)

Semi-firm

ACS 5

5 bar (70 PSI)

Firm

ACS 6

6 bar (85 PSI)

Firmest

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 is displayed.
– Press and release ACS button until the requested setting 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_a

1. Selector button
2. AIR_SUSP displayed

vmo2010-004-005_d

1. Requested setting (set point)
2. Actual setting (pressure transducer reading)
vmo2010-004-006_a

Refer to the following table to know the ACS pressure related to multifunction gauge setting.
vmr2010-004

TYPICAL
1. ACS button

Section 01 TECHNICAL MANUAL
Subsection 02 (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 ACS 5 or ACS 6 before 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.

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 adjustment will provide less pressure than
the ACS 6 adjustment.
NOTICE Never inflate tires above the recommended pressure.
ACS SYSTEM

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.

ZONE

LINK WITH

PRESSURE
TRANSDUCER
LOCATION

High-pressure
zone

Shock
absorbers

Inside ACS
module

Auxiliary line

In line between
solenoid release
valve and
compressor

Low-pressure
zone

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.

vmr2010-004

Section 01 TECHNICAL MANUAL
Subsection 02 (AIR CONTROLLED SUSPENSION (ACS))

vmr2010-004-001_a

vmo2007-003-017_b

1. Pneumatic valve cap

4. Push and hold pneumatic valve pin using a small
screwdriver.

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
the relay is not at the same position on a 500 LTD
and on a 800R LTD models. Refer to the following
table.
FRONT FUSE BOX PIN

RELAY (R5)
TERMINAL

500 LTD

800R LTD

11B

12A

12B

11A

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.

Outlander 500 LTD

SYSTEM DESCRIPTION
(COMPONENTS)
Fuse and Relay
ACS Fuse (F14)
1. ACS fuse (F14) is located in the front fuse box.

vmr2010-004-107_a

OUTLANDER 500 LTD MODEL
1. ACS compressor relay (R5)

FRONT FUSES BOX
NO

DESCRIPTION

RATING

F14

ACS

20 A

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Section 01 TECHNICAL MANUAL
Subsection 02 (AIR CONTROLLED SUSPENSION (ACS))

Outlander 800R LTD

vmr2010-004-105_a

OUTLANDER 800R LTD MODEL
1. ACS compressor relay (R5)

vmr2010-004

Section 01 TECHNICAL MANUAL
Subsection 02 (AIR CONTROLLED SUSPENSION (ACS))

ACS Main Components
ACS COMPONENTS

MAIN FUNCTION

Filter

To filter air intake of the compressor

Compressor

To pressurize the system

Solenoid release valve

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)

To protect the compressor

Check valve (between both zones)

To eliminate air pressure variation between low and high
pressure zone

Auxiliary line

To inflate tire

Cluster

To monitor the air pressure setting
Low pressure
zone

Pneumatic
Electric

High pressure
zone

Auxiliary
output
Release
valve
Check-valve

Filter

Manifold

Compressor
Pressure
transducer

Cluster

Shock 1

Check-valve

Shock 2
Pressure
transducer
Electronic
module

vdd2010-001-601_en

vmr2010-004

Section 01 TECHNICAL MANUAL
Subsection 02 (AIR CONTROLLED SUSPENSION (ACS))

TROUBLESHOOTING
DIAGNOSTIC TIPS
Error Code (AIR FAULT) Displayed in
Gauge
The error code AIR FAULT can appear on the multifunction 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 ACS SYSTEM LEAK
TEST (TROUBLESHOOTING WITH B.U.D.S.) subsection.
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 TROUBLESHOOTING GUIDELINES for further troubleshooting procedure.

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 ACS MODULE to see the complete testing procedures.

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 ACS COMPRESSOR to see the complete
testing procedures.

Suspension Setting Can Be Reached
To Increase Pressure Only
1. Check ACS solenoid valve operation.
2. Check ACS solenoid valve input voltage.
Refer to ACS SOLENOID VALVE to see the complete testing procedures.

No Pressure Output from the Auxiliary
Line
1. Ensure that ACS suspension setting is adjusted
to ACS 6 to provide the maximum air pressure
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.

Requested Setting Display Does Not
Change in Gauge

Multifunction Gauge Display Flickers
OFF and Back ON

1. Check the override/ACS button as detailed in
OVERRIDE SWITCH in the LIGHTS GAUGE
AND ACCESSORIES subsection of the appropriate Shop Manual.

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 in the LIGHTS GAUGE
AND ACCESSORIES subsection of the appropriate Shop Manual.
30

vmr2010-004

Section 01 TECHNICAL MANUAL
Subsection 02 (AIR CONTROLLED SUSPENSION (ACS))

TROUBLESHOOTING WITH
B.U.D.S.
ACS System Leak Test
1. Connect vehicle to B.U.D.S. Refer to COMMU-

NICATION TOOLS AND B.U.D.S. SOFTWARE
subsection of the appropriate Shop Manual.
2. Select Activation page.
3. Select ACS folder.
4. Press Test START button to proceed.
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 COMMU-

NICATION TOOLS AND B.U.D.S. SOFTWARE
subsection of the appropriate Shop Manual.
2. Select Monitoring page.
3. Select ACS folder.
vmr2010-004-201_a

Step 1: Activation page
Step 2: ACS folder
Step 3: Leak Test START button

After pressing Test START button, the compressor will pressurize the air system at 6.5 bar
(90 PSI) 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 COMMU-

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.
vmr2010-004-202_b

1. Compressor check valve

vmr2010-004

Section 01 TECHNICAL MANUAL
Subsection 02 (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)

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).

vmr2010-004-202_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.
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)

Battery voltage
(± 12 Vdc)

Pin 1 (BK)

ACS Solenoid Valve Removal
vmo2010-004-005_a

1. Selector button
2. AIR_SUSP displayed
32

1. Release air pressure, refer to RELEASING AIR
PRESSURE IN SYSTEM FOR SERVICING in this
subsection.
vmr2010-004

Section 01 TECHNICAL MANUAL
Subsection 02 (AIR CONTROLLED SUSPENSION (ACS))

2. Disconnect solenoid valve connector.

– Module hose
– Shocks hose.

vmr2010-004-003_a

1. Solenoid valve connector

3. Unscrew solenoid valve from manifold while
holding support.

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 LOCTITE 592 (PIPE SEALANT) (P/N 293 800
018) on solenoid valve male threads.

ACS MANIFOLD

vmr2010-004-008_a

1. Fitting
2. Fitting ring

5. From underneath support, remove manifold retaining screws.

ACS Manifold Removal
1. Release air pressure, refer to RELEASING AIR
PRESSURE IN SYSTEM FOR SERVICING in this
subsection.
2. Remove solenoid valve. Refer to ACS SOLENOID VALVE REMOVAL.
3. Disconnect the following hoses from manifold
air fittings.
– Manifold air inlet hose (from compressor)
vmr2010-004

Section 01 TECHNICAL MANUAL
Subsection 02 (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

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
vmr2010-004-007_a

1.
2.
3.
4.
5.

Manifold air inlet fitting (from compressor)
Auxiliary line check valve
Pneumatic valve
Shocks fitting
Module fitting

Ensure that air hoses are properly inserted into fittings, refer to the following illustrations.

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) on all male threads.
Install check valve with arrows pointing toward
manifold.

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

Section 01 TECHNICAL MANUAL
Subsection 02 (AIR CONTROLLED SUSPENSION (ACS))

ACS MODULE
ACS Module Signal Circuit Continuity
Test
1. Remove seats and RH side panel.
2. Disconnect multifunction gauge from vehicle.
Refer to LIGHTS, GAUGE AND ACCESSORIES
subsection of the appropriate Shop Manual.
3. Disconnect ACS module connector.

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.
TEST PROBES

VOLTAGE

Pin 12 (OR/GN)

Battery voltage
(± 12 Vdc)

Battery negative (-) post

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
Gauge pin 18 (BK/BE)
Module pin 5 (BE/GN)
TEST PROBES
Gauge pin 19 (BE/GN)
Module pin 6 (WH/BE)

ACS Module Ground Test
1. Remove seats and RH side panel.
2. Disconnect module connector.

RESISTANCE
Close to 0
RESISTANCE
Close to 0

ACS Module Input Voltage Test
1. Remove seats and RH side panel.
2. Disconnect module connector.

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.
TEST PROBES

VOLTAGE

Pin 7 (BK)

Battery voltage
(± 12 Vdc)

Battery positive (+) post

vmr2010-004

Section 01 TECHNICAL MANUAL
Subsection 02 (AIR CONTROLLED SUSPENSION (ACS))

ACS Module Removal
1. Release air pressure, refer to RELEASING AIR
PRESSURE IN SYSTEM FOR SERVICING in this
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.
vmr2010-004-012_a

1. Module retaining bolt

5. Remove module from vehicle.

ACS Module Installation

vmr2010-004-010_a

1. Module hose

NOTICE Do not attempt to disconnect hose
from module.
3. Disconnect module connector.

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 defective 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 for diode location.
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
vmr2010-004-011_a

1. Module connector

4. Remove module retaining bolts and nuts.

vmo2010-011-103

HOSE PROPERLY INSERTED INTO FITTING

vmr2010-004

Section 01 TECHNICAL MANUAL
Subsection 02 (AIR CONTROLLED SUSPENSION (ACS))

ACS COMPRESSOR RELAY (R5)
ACS Relay Continuity Test
1. Remove relay (R5), refer to FUSE AND RELAY
at the beginning of this section.
2. Set the FLUKE 115 MULTIMETER (P/N 529 035
868) to .
3. Measure resistance as per the following table.
TEST PROBES
Terminal 30
Terminal 87

RESISTANCE
Open (OL)

4. Apply 12 volts on terminals 86 and 85.
5. Measure resistance again as per the following
table.
TEST PROBES
Terminal 30
Terminal 87

Outlander 800R LTD
TEST PROBES
Fuse box pin 12B (BE/PK)
Battery negative (-) post

VOLTAGE
Battery voltage
(± 12 Vdc)

If voltage is not as specified, check wiring, connector and terminal condition.

ACS Relay Ground Wire Continuity
Test
1. Remove relay (R5), refer to FUSE AND RELAY
at the beginning of this section.
2. Disconnect module connector.

RESISTANCE
Close to 0

If results are not as per the above tables, replace
relay.

ACS Relay Input Voltage Test
1. Remove relay (R5), refer to FUSE AND RELAY
at the beginning of this section.
2. Set the FLUKE 115 MULTIMETER (P/N 529 035
868) to Vdc.
3. Place ignition switch to ON position.
4. Measure voltage as per the following tables.

Outlander 500 LTD
TEST PROBES
Fuse box pin 6D (OR/GN)
Battery negative (-) post

Fuse box pin 12A
(OR/GN)
Battery negative (-) post

Battery voltage
(± 12 Vdc)

Fuse box pin 7D (BE/PK)
Battery negative (-) post

vmr2010-004

TEST PROBES

RESISTANCE

Module pin 8 (OR/PK)
Fuse box pin 7C (OR/PK)

Close to 0

Outlander 800R LTD
VOLTAGE
Battery voltage
(± 12 Vdc)

Outlander 500 LTD
TEST PROBES

3. Set the FLUKE 115 MULTIMETER (P/N 529 035
868) to .
4. Measure resistance as per the following table.

Outlander 500 LTD
VOLTAGE

Outlander 800R LTD
TEST PROBES

vmr2010-004-011_a

1. Module connector

TEST PROBES
Module pin 8 (OR/PK)
Fuse box pin 11B
(OR/PK)

RESISTANCE
Close to 0

ACS COMPRESSOR
VOLTAGE
Battery voltage
(± 12 Vdc)

ACS Compressor Operation Test
1. Connect vehicle to B.U.D.S. Refer to COMMU-

NICATION TOOLS AND B.U.D.S. SOFTWARE
subsection of the appropriate Shop Manual.
37

Section 01 TECHNICAL MANUAL
Subsection 02 (AIR CONTROLLED SUSPENSION (ACS))

2. Select Activation page.
3. Select ACS folder.
4. Press Compressor button to proceed.

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 RELEASING AIR
PRESSURE IN SYSTEM FOR SERVICING in this
subsection.
2. Set the FLUKE 115 MULTIMETER (P/N 529 035
868) to Vdc.
3. Disconnect compressor connector.
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 FUSE AND RELAY at the
beginning of this section.
2. Disconnect compressor connector.
vmr2010-004-103_a

1. Compressor connector

4. Place ignition switch to ON position.
5. Probe compressor connector.
6. Press selector button several times until
AIR_SUSP is displayed.

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 table.

Outlander 500 LTD
TEST PROBES

RESISTANCE

Compressor pin C (BE/VI)
Fuse box pin 6C (BE/VI)

Close to 0

vmo2010-004-005_a

1. Selector button
2. AIR_SUSP displayed

7. Set suspension mode to ACS 2 using the ACS
button.

vmr2010-004

Section 01 TECHNICAL MANUAL
Subsection 02 (AIR CONTROLLED SUSPENSION (ACS))

vmr2010-004-101_a

1. Actual setting (pressure transducer reading)

vmr2010-004-014_a

1. Connector of auxiliary line pressure transducer

8. Measure voltage between compressor connector terminals as per the following table.
TEST PROBES

VOLTAGE

Pin C (BE/VI)

Battery voltage
(± 12 Vdc)

Pin A (BK)

8. Disconnect compressor connector.

ACS Compressor Removal
1. Release air pressure, refer to RELEASING AIR
PRESSURE IN SYSTEM FOR SERVICING in this
subsection.
2. Remove LH side panel.
3. Remove storage tray.
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 ACS SOLENOID VALVE REMOVAL.
5. Remove manifold. Refer to ACS MANIFOLD
REMOVAL.
6. Remove module. Refer to ACS MODULE REMOVAL.
7. Remove connector of auxiliary line pressure
transducer from support.
vmr2010-004

vmr2010-004-016_a

1. Compressor air inlet hose
2. Compressor air outlet hose
3. Auxiliary line hose
39

Section 01 TECHNICAL MANUAL
Subsection 02 (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

vmr2010-004-020

vmr2010-004-018_a

1. LH side retaining bolt

14. Detach compressor connector from front support.
15. Remove mounting nuts from compressor
front support.
16. Remove front support from compressor.

12. Remove compressor front retaining screws.

vmr2010-004

Section 01 TECHNICAL MANUAL
Subsection 02 (AIR CONTROLLED SUSPENSION (ACS))

vmr2010-004-025_a
vmr2010-004-022_a

1. Front support mounting nuts
2. Compressor connector
3. Front support

NOTICE Do not remove rear support from
compressor.

A. 45°

Ensure that check valve is installed with arrows
pointing toward T-fitting.

17. Remove the following fittings from compressor.
– Compressor air inlet fitting
– Compressor T-fitting
– Compressor check valve.

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 LOCTITE 592 (PIPE SEALANT)
(P/N 293 800 018) on all male threads.
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

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
41

Section 01 TECHNICAL MANUAL
Subsection 02 (AIR CONTROLLED SUSPENSION (ACS))

ACS AIR FILTER
ACS Air Filter Removal

5. Locate ACS compressor air filter.
6. Unscrew ACS compressor air filter from air box.

1. Remove seat.
2. Remove central panel.

vmo2010-004-009_a

1. ACS compressor air filter
vmo2006-007-026_a

1. Central panel
2. Tabs to pull

7. Push tabs then open cover.

3. Lift dashboard upwards.

vmo2010-004-010_a

1. tabs

8. Remove prefilter (foam) and filter (disc).
vmr2008-068-002_a

TYPICAL
1. Central panel
2. Dashboard

4. Release clamps and remove air filter box cover.

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 AIR

FILTER REMOVAL.

vmo2006-007-027_a

1. Release clamps

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.
vmr2010-004

Section 01 TECHNICAL MANUAL
Subsection 02 (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.

4. Set the FLUKE 115 MULTIMETER (P/N 529 035
868) to .
5. Measure resistance as per the following table.
TEST PROBES
Pressure transducer
pin 2 (PK/BR)

RESISTANCE
Close to 0

Module pin 3 (PK/BR)

Refer to the following illustration for the pressure
transducer connector pinout.

PRESSURE TRANSDUCER (ACS
AUXILIARY LINE)
Pressure Transducer Signal Circuit
Continuity Test
1. Remove seats and RH side panel.
2. Disconnect module connector.

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

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 voltage
(± 12 Vdc)

Battery negative (-) post

Refer to the following illustration for the pressure
transducer connector pinout.
vmr2010-004-104_a

1. Pressure transducer connector

vmr2010-004

Section 01 TECHNICAL MANUAL
Subsection 02 (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 OETIKER PLIERS (P/N 295 000 070).
7. Connect pressure transducer connector.
8. Ensure that there is no air leaks from pressure
transducer hose. Refer to ACS SYSTEM LEAK
TEST (WITH B.U.D.S.).
vmr2010-004-104_a

ACS HOSES

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 voltage
(± 12 Vdc)

Battery positive (+) post

Refer to the following illustration for the pressure
transducer connector pinout.

vmr2010-004-108

Pressure Transducer Replacement

ACS Hose and Fitting Replacement
1. Release air pressure, refer to RELEASING AIR
PRESSURE IN SYSTEM FOR SERVICING in this
subsection.
2. Locate hose or fitting to be replaced.
3. Remove it from vehicle.
4. Install the new hose or fitting.
5. Perform a ACS SYSTEM LEAK TEST (WITH
B.U.D.S.).

Auxiliary Line Adapter Replacement
1. Release air pressure, refer to RELEASING AIR
PRESSURE IN SYSTEM FOR SERVICING in this
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.

1. Release air pressure, refer to RELEASING AIR
PRESSURE IN SYSTEM FOR SERVICING in this
subsection.
2. Disconnect pressure transducer connector.
3. Remove Oetiker clamp.
44

vmr2010-004

Section 01 TECHNICAL MANUAL
Subsection 02 (AIR CONTROLLED SUSPENSION (ACS))

vmo2010-011-103

HOSE PROPERLY INSERTED INTO FITTING

SHOCK ABSORBERS
Shock Absorber Removal
vmr2010-004-031_a

1. Auxiliary line adapter
2. Fitting ring

3. Drill retaining rivets.

1. Lift rear 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 fitting 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 fittings, refer to the following illustrations.

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.

vmo2010-011-102_a

PUSH HOSE UNTIL THE MARK IS COMPLETELY INSERTED
1. Fitting
2. Mark
A. Must be inserted into fitting

vmr2010-004

Section 01 TECHNICAL MANUAL
Subsection 02 (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.
1
vmr2010-004-028_a

1. Shock absorber lower bolt

5. Remove the shock absorber upper bolt and nut.
A14F0BA

TYPICAL
1. Clamp here

NOTICE Do not clamp directly on shock
body.

vmr2010-004-029_a

1. Shock absorber upper bolt

6. Remove shock absorber from vehicle.

Shock Absorber Disassembly
NOTICE Be careful while manipulating or
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 SPRING REMOVER (P/N 529 036 007).

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 compression and extension stroke.
Replace shock absorber if any faults are present.

Shock Absorber Assembly and
Installation

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

Assembly and installation are the reverse of disassembly and removal procedures, however pay
attention to the following.
Assemble shock absorber as per the following illustrations.

vmr2010-004

Section 01 TECHNICAL MANUAL
Subsection 02 (AIR CONTROLLED SUSPENSION (ACS))

vmr2010-004-701_a

1. Sleeve
2. O-ring

vmr2010-004-703_a

vmr2010-004-702_a

1. Sleeve
2. O-ring

vmr2010-004

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 LOCTITE 592 (PIPE SEALANT) (P/N 293 800 018) on air
hose sleeve male threads.
While holding shock fitting with a wrench, tighten
air hose fitting to 19 N•m (168 lbf•in).

Section 01 TECHNICAL MANUAL
Subsection 02 (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 ACS SYSTEM
LEAK TEST (WITH B.U.D.S.).
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.

vmr2010-004

NOTES

2010
DPS /ACS
TM
TM

Technical Manual

219 100 388

DPS/ACS TECHNICAL MANUAL / ENGLISH
MANUEL TECHNIQUE DPS/ACS / ANGLAIS
FAIT AU / MADE IN CANADA

U/M:P.C.

2 1 9

1 0 0

3 8 8

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