D3 yellow suspension warning light

[Iherbst87]

Hey all. Cheers for letting me join the group.
I have an 05 tdv6 D3 which i haven't had for long, and i am really starting to pull my hair out with a suspension issue. I had a right rear height sensor fault, which I replaced the sensor and got the suspension calibrated. In amongst the fault codes i ignored the ' lost communication with ride level control module' fault. So the yellow warning light can come on at random times now, can be fine for a few days or even a week, then at a random time either a dead flat road, or a slightly rough road in offroad height i get a BING with 'Suspension Fault' on the dash.

Every time i check the fault code its 'Lost communication with ride level control module', and its always an intermittent fault too. We have the top-of-the-wazza Autel and i can read pretty much all the data and it all seems good, i also had a mate with a GAP tool check the readings and all is well, and when we drive the car with the scan tools on, it never faults, typical 🙄.

I have put dielectric grease at the chassis to body connectors behind the Left Rear wheel, pulled the battery out and the same at all the connectors behind the battery, and even put dielectric grease at the EAS module. I am a mechanic, and i am learning more about these really integrated suspension wiring nightmares, but sadly i am starting tobregret buying this thing, even tho myself and my family love it.

Please help 😢

[loanrangie]

The compressor needing a service can cause this , do you ever get a suspension raising slowly message on the dash ?
Can you hear the system venting when shutting down ?

[PerthDisco]

Yes, ‘lost communication’ seems to always come with another fault that shuts down the system first.

While you always need to be wary of physical damage or a rodent eating through the wires the system is otherwise simple and robust. Strong compressor - operational valve blocks - leak free - and level sensors.

And don’t forget the air compressor relay and large fuse. Cheap to replace as these handle a heavy load and deteriorate quietly.

Start with the simple stuff.

[Iherbst87]

Thanks loanrangie. Yeah the compressor is good, i swapped it out from a family members D4 which is pretty new and still the same fault.

I checked the codes again today at work with my autel and found the same lost communication fault code, then also fir the first time since replacing my Right rear sensor a few weeks ago, the right rear sensor fault came back on which i found a bit odd, i then cleared the faults and ran a graph test, all the sensors working perfectly fine, i then proceeded with the autel on and BAM the yellow light came back on as i drove off, i was stoked! Checked the live view and found the sensor was working fine and no spikes or anything, but the code for Right Rear sensor came back up. I still find this odd as the sensor is new, but i have got another sensor coming under warranty just incase. I will swap this out and see how it goes after i try do a calibration.

[loanrangie]

D4 would have an amk ?, check the wiring behind the Lh front guard liner for breakage.

[DiscoJeffster]

D4 would have an amk ?, check the wiring behind the Lh front guard liner for breakage.

No, D4 switched to AMK during its cycle. My 2010 has a Hitachi. I think it was around 2012 but not quite sure.

[loanrangie]

No, D4 switched to AMK during its cycle. My 2010 has a Hitachi. I think it was around 2012 but not quite sure.He said it was quite new so assuming it is a later model.

[Airmech953]

Hey all. Cheers for letting me join the group.
I have an 05 tdv6 D3 which i haven't had for long, and i am really starting to pull my hair out with a suspension issue. I had a right rear height sensor fault, which I replaced the sensor and got the suspension calibrated. In amongst the fault codes i ignored the ' lost communication with ride level control module' fault. So the yellow warning light can come on at random times now, can be fine for a few days or even a week, then at a random time either a dead flat road, or a slightly rough road in offroad height i get a BING with 'Suspension Fault' on the dash.

Every time i check the fault code its 'Lost communication with ride level control module', and its always an intermittent fault too. We have the top-of-the-wazza Autel and i can read pretty much all the data and it all seems good, i also had a mate with a GAP tool check the readings and all is well, and when we drive the car with the scan tools on, it never faults, typical 🙄.

I have put dielectric grease at the chassis to body connectors behind the Left Rear wheel, pulled the battery out and the same at all the connectors behind the battery, and even put dielectric grease at the EAS module. I am a mechanic, and i am learning more about these really integrated suspension wiring nightmares, but sadly i am starting tobregret buying this thing, even tho myself and my family love it.

Please help 😢
I found a chafed wire in a databus connector at the rear wheel arch. The continuity check was good but with the conductors exposed there was enough resistance in the circuit to generate a fault message.

[Iherbst87]

Where abouts was it? Before or after the main connectors? Do you think it could be possible to run new wiring straight from the rhr wheel arch across to the left rear and join it in there?

[Iherbst87]

Well all, i replaced the wiring and from the right rear sensor to the EAS module, turns out it must have been the earth wire as i did that last. I cleared the codes with an Autel and drove it a faur bit on a rough track and the only fault that came up was ' slow to fill tank' or something like that. Oretty happy at this point till i drive it in the next few days.