ʻ92-ʼ00 Civic/ʼ94-ʼ01 Integra/ ʻ93-ʼ97 Del Sol/ʼ90-ʼ97 Accord/ ʻ92-ʼ95 CRX

Transcription

1 ʻ92-ʼ00 Civic/ʼ94-ʼ0 Integra/ ʻ93-ʼ97 Del Sol/ʼ90-ʼ97 Accord/ ʻ92-ʼ95 CRX Front Kit Part No MN-53 (08409) NPR 4778 Please read these instructions completely before proceeding with installation Warranty Information. All goods come with a one year manufacturerʼs warranty against defects. 2. Warranty will be void if the strut is altered for any reason and/or adapted to applications other than those suggested. 3. Any abrasions or rub marks on the spring portion of the strut will not be covered under warranty. The customer is responsible for all repair charges. 4. Driving at a low PSI can cause the strut to bottom out. Repeated bottoming out can cause the strut to fail. Failure resulting from repeated bottoming out is not covered under warranty. 5. The customer is responsible for all shipping costs to Air Lift Company for all warranty claims. 6. Please call tech support at before shipping a product to Air Lift Company. Technical Support

2 Hardware Item P/N Description Qty. A Strut Assembly 2 B 226 /4 Pipe - /2 Tube Straight 2 C mm Nylock Nut 4 D mm x 80mm x.5 Bolt 4 E mm Flat Washer 8 Remove Figure IMPORTANT: Always keep safety in mind when working on your vehicle. Completely read these instructions before installing the kit. I. Preparing the Vehicle. Jack up the front of the vehicle and support the body on jackstands. 2. Remove the front wheels. II. Strut Removal. Remove the two mounting nuts on the top of the strut. These are located on the inside of the engine compartment above the spring pocket (Figure ). Figure 2 Remove 2. Remove the bolts holding the brake lines to the strut body and discard. 3. Remove the strut lower mounting bolt that is on the side of the clevis (Figure 3). 4. Remove the bottom nut and bolt that holds the lower strut mount to the lower control arm (Figure 4). 5. Pull the lower strut mount away from the strut and let the mount rest on the lower axle shaft. Remove the strut from the vehicle. Figure 3 Remove Figure 4 Technical Support

3 III. Top Strut Mount NOTE: The top strut mount will be re-used on the air-strut. It will be necessary to use a strut spring removal tool to remove the mount from the strut. Use caution and follow all safety rules from the strut tool manufacturer in the removal process.. Remove the top strut mount from the stock strut. Retain the large washer on the top and all of the rubber pieces including the rubber spring isolator that is on the inside above the spring. Also remove and retain the steel spacer that goes on the inside of the strut mount bushings (Figure 5). NOTE: This steel spacer may come off on the shaft of the strut. In order to correctly mount the top strut assembly, the spacer must be on the inside of the bushings (Figure 8). Driver-Side Modifications Figure 5 /4" 2. A slot must be made in the top strut mount for the fitting. Hold the strut mount with the stud at the top and facing you. Strike a vertical mark at /4 and a mark at 2 3 /4. Measure clockwise for the markings on the left side and counter clockwise when marking the right side. Figures 6 and 7 show the left side. 3. Measure down /2 from the flat edge of the strut mount (Figure 7). Cut this area out of the upper strut mount (Figure 8). Smooth the rough edges and paint the exposed areas. 4. If the rubber isolator was previously removed, set it back in the upper strut mount. Trim the rubber away with a pair of wire cutters (Figure 8). Driver-Side Modifications Figure /4" /2" Figure 7 Rubber Isolator Steel Spacer Technical Support Figure 8

4 Small Washer IV. Fitting Access Hole in Body NOTE: It will be necessary to create an access hole in the upper spring seat area to install the fitting and hose for the air-strut. Figure 9 Figure 0 Figure Figure 2 New Nylock Nut Existing Washer Grind Off Flashing from Spindle. Make sure the small washer is on top of the upper air-strut end cap (Figure 9). 2. Set the modified top strut mount onto the air-strut. Install the previously saved stock washer, and a supplied nylock nut, loosely to the top of the air-strut assembly (Figure 0). 3. Set the assembly up into the spring pocket with the fitting hole pointing inward toward the engine. Finger tighten the two existing upper strut mount nuts onto the upper strut mount studs. 4. Take note of where the hole points toward the upper spring seat pocket. Use a china or felt marker and mark the area where the fitting will go. 5. Remove the air-strut. Center punch and drill a hole large enough to get a socket over the fitting to tighten the fitting into the upper air-strut end cap (Figure ). CAUTION: Be sure to move any electrical connectors or wires that are on the inside of the engine compartment before drilling or cutting. V. Spindle Casting Flash IMPORTANT: This step is critical to the life and performance of your air bags.. It will be necessary to grind the inside of the flashing off the spindle arm that attaches to the upper control arm (Figure 2). Caution: Failure to grind the flashing may cause the air bag to rub against the spindle arm flashing and rupture. This will void the air bag warranty. NOTE: Make sure the face is smooth and clear of burrs. VI. Trimming the Upper A-Arm NOTE: It will be necessary to trim the flange off of the upper A-arm in order to make clearance for the flex member (Figure 3).. Remove the control arm mounting hardware and replace with bolts (D), flatwashers (E), and nylock nuts (C) being sure to insert them with the bolt heads facing the inside of the control mount in order to provide adequate clearance for the air strut (Figure ). 2. The inside flange on the upper control arm can be trimmed by using a die grinder with a cut-off wheel or grinding bit. Be sure Technical Support

5 all sharp edges are removed, and paint the exposed area when complete (Figure 3). 3. The top bar for the upper control arm will also need to be trimmed. Grind /8 off of a 3 area (Figure ). Trim Flange VII. Installing the Strut NOTE: Be sure the area on the body is clear of anything protruding from it including the line/ hose clips from the engine compartment.. Set the air-strut assembly in place. Hand tighten the top nuts onto the upper strut mount studs. Make sure the fitting lines up with the hole that was previously made in the upper spring retainer (Figure 6). Figure 3 2. Slide the lower mount onto the strut tube. Be sure to line up the small tab of the brake line bracket/spacer with the slot in the lower strut mount. Align the indent in the lower air-strut with the bolt hole in the clevis. Insert the existing bolt and finger tighten. 3. Insert the lower bolt into the lower strut mount and the lower control arm. Push the bolt all the way through and finger tighten the stock nut onto the bolt. 4. While the assembly is still loose, install and tighten the upper air fitting into the top air-strut upper end plate. Tighten the fitting (B) finger-tight plus /2 turns being careful to tighten on the metal hex nut only. NOTE: The fitting needs to be turned so that a base of the hex nut is parallel to the end cap (Figure 5). Figure 4 NOTE: It may be necessary to grind the access hole or tighten the upper strut mount to get the socket over the fitting (Figure 7). 5. Once the fitting is installed, tighten the supplied nylock nut on the upper air-strut. NOTE: By holding the air-strut, you can index the fitting slightly while tightening this nut. 6. Tighten the two upper strut mount nuts. 7. Tighten the clevis bolt. Correct Air Fitting Installation: Hex Nut edges are parallel with top and bottom upper end cap edges. Figure 5 Incorrect Air Fitting Installation: Hex Nut point extends over bottom of upper end cap edge and could puncture air bag. NOTE: It may be necessary to jack the lower control arm up to take the slack out of the lower control arm/strut assembly. 8. Tighten the bottom strut mount/control arm bolt and nut. VIII. Brake Line Attachment. Using the supplied tie straps, fasten the brake line to the lower clevis (Figure 4). Repeat the installation for the other side of the vehicle. Technical Support Figure 6

6 Figure 7 Figure 8 IX. Finishing Touches NOTE: Be sure to check clearances in an inflated and deflated condition to avoid early flex member failure. Grind area for clearance if necessary.. Use silicone, or something pliable, around the fittings and the body to seal holes off. This will keep the elements from entering the engine compartment. 2. Before operating, note the wheel clearance. Keep the wheels straight when deflating the front air-struts so wheels do not hit on the fender quarter panel. 3. A finished installation is shown in figure Air Lift recommends the installation of a strut bar with this air-strut kit. X. Before Operating. Inflate and deflate system (do not exceed 50 p.s.i) to check for clearance or binding issues. With air springs deflated, check clearances on everything so as not to pinch brake lines, vent tubes, etc. Clear lines if necessary. 2. Tighten and visually inspect all hardware after 00 miles. 3. The struts for this vehicle come with a nine-position damping dial (shown below) for added adjustability. To start, we recommend setting the dial at the third position for the most versatility. 4 Air Lift part #27669 or #2767, AutoPilot V2 Air Management System, is highly recommended for this product. strut body 9-position dampening damping dial Technical Support

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8 XI. Maintenance and Operation: Minimum Pressure Maximum Pressure 0 p.s.i. 50 p.s.i. Failure to maintain correct minimum pressure (or pressure proportional to load), By following these steps, vehicle owners should obtain the longest life and best results from their air-struts.. Always maintain Ride Height. 2. Always adjust the air pressure to maintain Ride Height. Increase or decrease pressure from the system as necessary to attain Ride Height for optimal ride and handling. 3. Should it become necessary to raise the vehicle by the frame or do any service work, make sure the system is at minimum pressure (0 p.s.i.) for safety and to reduce the tension on the suspension/brake components. Thank you for purchasing Air Lift Performance Products Mailing Address: Street Address: AIR LIFT COMPANY AIR LIFT COMPANY P.O. Box Snow Rd. Lansing, MI Lansing, MI 4897 For Technical Assistance call Technical Support Local Phone: (57) Fax: (57) The Choice of the Professional Installer 0 Printed in the USA 0

9 92-00 Civic/ 94-0 Integra/ Del Sol/ CRX Rear Kit Part No MN-54 (06409) NPR 4762 Please read these instructions completely before proceeding with installation Warranty Information. All goods come with a one year manufacturer s warranty against defects. 2. Warranty will be void if the strut is altered for any reason and/or adapted to applications other than those suggested. 3. Any abrasions or rub marks on the spring portion of the strut will not be covered under warranty. The customer is responsible for all repair charges. 4. Driving at a low PSI can cause the strut to bottom out. Repeated bottoming out can cause the strut to fail. Failure resulting from repeated bottoming out is not covered under warranty. 5. The customer is responsible for all shipping costs to Air Lift Company for all warranty claims. 6. Please call tech support at before shipping a product to Air Lift Company. Technical Support

10 Hardware Item P/N Description Qty. A Strut Assembly 2 B 226 /4 NPT x /2 Tube Straight 2 C /6 Spacer 4 Figure Remove IMPORTANT: Always keep safety in mind when working on your vehicle. Completely read these instructions before installing the kit. I. Preparing the Vehicle. Jack the vehicle up and support the body on jackstands. 2. Remove the rear wheels. Figure 2 II. Strut Removal NOTE: Begin on the driver-side. Remove the top two nuts holding the upper strut mount to the body (Figure ). 2. Remove the lower strut bolt. NOTE: It may be necessary to replace the bolt and the lower control arm bushing if the bolt is corroded to the bushing (Figure 2). 3. Remove the inside lower control arm bolt (Figure 2). 4. If equipped with ABS brakes, unclip the ABS line from the lower control arm. Retain the bolts to re-attach the line later (Figure 2). 5. Disconnect the sway bar if so equipped. 6. Pull the lower control arm down far enough to remove the strut. Technical Support

11 III. Upper Strut Mount NOTE: The top strut mount will be re-used on the air strut. It will be necessary to use a strut spring removal tool to remove the mount from the strut. Use caution and follow all safety rules from the strut tool manufacturer in the removal process.. Remove the top strut mount from the stock strut. Retain the large washer on the top and all of the rubber pieces including the rubber spring isolator that is on the inside above the spring. Also remove and retain the steel spacer that goes on the inside of the strut mount bushings. Figure 3 NOTE: This spacer may come off on the shaft of the strut. In order to correctly mount the top strut assembly, the spacer must be on the inside of the bushings. 2. A slot must be made in the top strut mount for the fitting. Set the upper spring mount onto the air-strut. Loosely install the stock flat washer and supplied nylock nut onto the strut shaft. 3. Hold the upper strut mount in place with the two,previously removed, nuts. Set the lower clevis of the strut around lower control arm and loosely insert the bolt. IMPORTANT NOTE: The air port faces toward the inside of the car. Make sure that the upper strut mount is aligned with the mounting holes prior to marking the strut mount for cutting. Figure 4. Mark the area on the upper strut mount where the fitting goes into the upper air-strut end cap (Figure 3). 5. Remove the strut and upper strut mount. Cut or grind out the marked area to make room for the fitting. 6. If the rubber isolator was previously removed, set it back in the upper strut mount. Trim the rubber away with a pair of wire cutters (Figure 4). IV. Strut Assembly Installation. Place the assembled strut in the vehicle and mark where the air fitting will pass through the strut tower. Using a hole saw, make a hole in the strut tower that is /8 -/4 bigger than the diameter of the air fitting to ensure ade uate clearance. 2. Install the upper strut mount back onto the top of the air-strut assembly. Be sure the small washer is in between the air-strut upper end plate and strut mount. Loosely attach the upper strut mount with the previously saved stock upper washer and new nylock nut. Technical Support

12 3. Set the assembly in place. Attach the top two existing nuts onto the upper strut mount to hold the assembly in place. Tighten securely. 4. Using the existing hardware, attach the lower control arm to the inside mount. NOTE: It may be necessary to slightly twist the lower control arm to get the bolt to start threading correctly. Tighten securely. 5. Attach the strut to the lower control arm and tighten securely. Figure 5 NOTE: In order to fit the 996 and newer Civics, you will have to use the provided spacers (C) on each side of the lower strut mount to reduce the space between the A-arm and the strut. 6. If the ABS lines and/or sway bar were detached, re-attach them at this time. 7. Repeat steps one through four for the other side of the vehicle. V. Finishing Touches Figure 6 NOTE: Be sure to check clearances in an inflated and deflated condition to avoid early flex member failure.. Install the air fitting (B). Tighten the fitting finger-tight plus /2 turns being careful to tighten on the metal hex nut only. NOTE: The fitting needs to be turned so that a base of the hex nut is parallel to the end cap (Figure 7). Correct Air Fitting Installation: Hex Nut edges are parallel with top and bottom upper end cap edges. Figure 7 Incorrect Air Fitting Installation: Hex Nut point extends over bottom of upper end cap edge and could puncture air bag. 2. Before operating, note the wheel clearance. 3. A finished installation is shown in figure.. Using a silicone sealer, seal the holes where the air fitting and air lines enter the car. Technical Support

13 VI. Before Operating. Inflate and deflate system (do not exceed 5 p.s.i) to check for clearance or binding issues. With air springs deflated, check clearances on everything so as not to pinch brake lines, vent tubes, etc. Clear lines if necessary. 2. Tighten and visually inspect all hardware after 00 miles. 3. The struts for this vehicle come with a nine-position damping dial (shown right) for added adjustability. To start, we recommend setting the dial at the third position for the most versatility. 4. Air Lift part #27669 or #2767, AutoPilot V2 Air Management System, is highly recommended for this product. 5. Please continue by reading the Maintenance and Operation section. strut body 9-position dampening damping dial VII. Maintenance and Operation: Minimum Pressure Maximum Pressure 0 p.s.i. 50 p.s.i. Failure to maintain correct minimum pressure (or pressure proportional to load), By following these steps, vehicle owners should obtain the longest life and best results from their air-struts.. Always maintain Ride Height. 2. Always adjust the air pressure to maintain Ride Height. Increase or decrease pressure from the system as necessary to attain Ride Height for optimal ride and handling. 3. Should it become necessary to raise the vehicle by the frame or do any service work, make sure the system is at minimum pressure (0 p.s.i.) for safety and to reduce the tension on the suspension/brake components. Thank you for purchasing Air Lift Performance Products Mailing Address: Street Address: AIR LIFT COMPANY AIR LIFT COMPANY P.O. Box Snow Rd. Lansing, MI Lansing, MI 4897 Local Phone: (57) Fax: (57) For Technical Assistance call Technical Support The Choice of the Professional Installer 0 0 Printed in the USA

14 Air Lift PERFORMANCE Kits and M - 2 (030 ) EC INSTALLATION GUIDE For maximum effectiveness and safety, please read these instructions completely before proceeding with installation. Failure to read these instructions can result in an incorrect installation.

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16 TABLE OF CONTENTS Introduction... 2 Important Safety Notice...2 otation Explanation...2 Installation Diagram...3 Hardware List....4 Installing the Air Management System...4 Assembling the Air Tank...4 ecommended Compressor ocations...5 Attaching the Compressor...5 Wiring the System...5 Attaching the Air ines Assembling the Pneumatic Paddle Switches...6 Troubleshooting Guide....6 Tuning the Air Pressure...6 Checking for Leaks...7 Fixing Leaks....7 Warranty and Returns Policy...8 Replacement Information...9 Contact Information...9

17 Introduction Air Lift Performance The purpose of this publication is to assist with the installation, maintenance and troubleshooting of the Air Management System. It is important to read and understand the entire installation guide before beginning installation or performing any maintenance, service or repair. The information here includes a hardware list, tool list, step-by-step installation information, maintenance guidelines and troubleshooting guide. Air ift Company reserves the right to make changes and improvements to its products and publications at any time. For the latest version of this manual, contact Air ift Company at (800) or visit our website at IMPORTANT SAFETY NOTICE The installation of this kit does not alter the ross ehicle Weight ating ( W ) or payload of the vehicle. Check your vehicle s owner s manual and do not exceed the maximum load listed for your vehicle. Gross Vehicle Weight Rating: The maximum allowable weight of the fully loaded vehicle (including passengers and cargo). This number along with other weight limits, as well as tire, rim si e and inflation pressure data is shown on the vehicle s Safety Compliance Certification abel. Payload: The combined, maximum allowable weight of cargo and passengers that the vehicle is designed to carry. Payload is W minus the Base Curb Weight. NOTATION EXPLANATION Hazard notations appear in various locations in this publication. Information which is highlighted by one of these notations must be observed to help minimize risk of personal injury or possible improper installation which may render the vehicle unsafe. Notes are used to help emphasize areas of procedural importance and provide helpful suggestions. The following definitions explain the use of these notations as they appear throughout this guide. DANGER WARNING CAUTION NOTE I DICATES IMMEDIATE HA A DS WHICH WI ESU T I SE E E PE SO A I U O DEATH. I DICATES HA A DS O U SAFE P ACTICES WHICH COU D ESU T I SE E E PE SO A I U O DEATH. I DICATES HA A DS O U SAFE P ACTICES WHICH COU D ESU T I DAMA E TO THE MACHI E O MI O PE SO A I U. Indicates a procedure, practice or hint which is important to highlight. 2 MN-726

18 Air Lift Performance Installation Diagram MM S NN MM AA EE AA X or Y CC Z DD 30 AMP Z Existing Fuse KK T B2 (5 Gal. Tank) LL P W U S R B (2 Gal. Tank) Q O V E E A BB Ground D C T C D Splice into keyed on ignition wire. L Connector Power (Red) Inside View of Connector J I Ground M M N F G JJ JJ JJ JJ PP DEL SUP Air Bags are for Reference Only Not included with air management system. HH OO fig. II MN-726 3

19 Hardware List Item Part No. Description Quantity Quantity A 380 iair Compressor B allon Air Tank B2 0 5 allon Tank C 8 3/8 Flat Washer 8 8 D 88 3/8 - x.25 Bolt 4 E /8 yloc ut 4 F Dual eedle auge 2 20 / Air ine 80 ft. 0 ft. H 32 /2 Self-Tapping Screw 3 3 I auge ing Terminal 2 53 uick Splice 3 K Butt Connector auge ed Wire 8 ft. 8 ft. M 2 auge Black Wire 8 ft. 8 ft. 2 5 auge Female Terminal 4 2 O 250 3/8 Street Tee P 2 35 /8 F PT x 3/8 M PT Bushing 2 38 / F PT x /8 F PT Bushing 2 0 / M PT x /8 F PT Bushing S 23 Inflation alve /8 M PT T 2 5 / M PT Drain Cock Air Lift Performance Item Part No. Description U 2 3 Plug 28 3/8 x / PTC Elbow W PSI Pressure Switch X Fuse Tap 2 5 Mini Fuse Adapter 2 2 auge Butt Connector AA auge Female Terminal BB 2 3 / x Self-Tapping Screw CC 2 2 auge ed Wire DD 2 53 Fuse Holder EE AMP Fuse Spade FF 2358 Thread Sealant 0530 Air ine Cutter HH 03 Panel II 28 2 Fitting 2838 Tee KK 2 0 /2 Plug 22 / x /2 Bushing MM /8 /2 Bushing 225 /8 x /2 Bushing OO 3 8 3/ Stainless Steel Screws PP 2 03 Paddle Switch Quantity ft STOP! Missing or damaged parts Call Air ift customer service at (800) for a replacement part. Installing the Air Management System The following instructions correspond to Figure on the previous page of this instruction manual. ASSEMBLING THE AIR TANK NOTE All fittings must be pre-coated with thread sealant.. Install a /8 bushing (P) to the top port of the street tee (O) and a / bushing ( ) to the other port. 2. Attach the pressure switch (W) to the /8 bushing previously installed onto the street tee. 3. Attach the street tee assembly to the end port of the air tank (B).. Install a drain cock (T) to the port that is at the base of the tank. NOTE If the tank is mounted with the feet up, the drain cock must be installed on the other side of the tank. The drain must always be installed in the port that is facing downward. 5. Install a / x /8 bushing ( ) to the port that is facing upwards on the air tank. Attach an inflation valve (S) to the bushing.. Install an air fitting ( ) to the remaining end port of the air tank.. Install plugs (U) to the two ports on the front of the air tank. 8 Find a suitable mounting location for the air tank and mount using the provided bolts (D), flat washers (C), and nyloc nuts (E). 4 MN-726

20 Air Lift Performance RECOMMENDED COMPRESSOR LOCATIONS Important OCATE COMP ESSO I D, P OTECTED A EA O EHIC E. DI ECT SP ASH O E CESSI E MOISTU E CA DAMA E THE COMP ESSO A D CAUSE S STEM FAI U E. Disclaimer: If you choose to mount the compressor outside the vehicle please keep in mind the compressor body must be shielded from direct splash and the intake should be snorkeled inside the vehicle. If the compressor does not include a remote mount air filter or if mounting the compressor outside the vehicle, make sure to orient the compressor intake filter so that all moisture can easily drain. Please also remember... To avoid high heat environments To avoid mounting the compressor under the hood. To check to be sure the compressor harness 2 will reach the compressor and connect to harness. The compressor can be mounted in any position vertical, upside down, sideways, etc. (please refer to the instruction manual). ATTACHING THE COMPRESSOR. Find a suitable mounting location for the compressor and mount using the hardware included with the compressor. 2. Attach the leader hose from the compressor (A) to the / x /8 bushing previously attached to the street tee. WIRING THE SYSTEM. Attach the red power wire from the compressor to the pressure switch using the attached female terminal. 2. Attach the black ground wire to a suitable location on the frame of the vehicle using a self-tapping screw (BB). 3. Cut a length of red wire ( ) long enough to go from the gauges to a keyed on ignition wire. Attach a female terminal ( ) to one end of the wire. Attach this end to the gauge panel. uick splice the two gauge bulbs together. 4. Splice the remaining end of the red power wire to a keyed on ignition wire using the provided uick splice ( ). 5. Ground the gauges by attaching the black ground wire to a suitable location using the remaining self-tapping screw (H).. Cut a length of red wire (CC) to go between the pressure switch on the air tank to a fuse holder (DD). Attach the two together using a butt connector ( ).. Install a 30 AMP fuse into the fuse holder. 8. Cut another length of red wire (CC) long enough to go between the fuse holder and the fuse box. Attach a female terminal (AA) to one end of the wire and attach the remaining end to the fuse holder using a butt connector ( ). Choose a key-on circuit. MN-726 5

21 Air Lift Performance. Attach the female terminal to either the fuse tap ( ) or mini fuse adapter ( ). Attach this to the fuse panel. ATTACHING THE AIR LINES CAUTION WHE CUTTI O T IMMI THE AI I E, USE A HOSE CUTTE ( ), A A O B ADE O A SHA P K IFE. A C EA, S UA E CUT WI E SU E A AI ST EAKS. DO OT USE WI E CUTTE S O SCISSO S TO CUT THE AI I E. THESE TOO S MA F ATTE O C IMP THE AI I E, CAUSI IT TO EAK (SEE FI. 2).. un a length of air line ( ) from the air fitting on the compressor to the end of the switch cluster. 2. un a length of air line from the remaining air fittings on the switch to its respective air spring. 3. epeat step 2 for the remaining air fitting and air spring.. Use a tee and connect into each one of the air spring lines to connect to it s respective gauge port. 5. Test and make sure that the switches operate the appropriate air springs. ASSEMBLING THE PNEUMATIC PADDLE SWITCHES. Snap all switches into the panel so that from the back they are all oriented the same way ( ou may select a different location for switches. They do not need to be used with supplied panel). 2. Cut pieces of hose the same length (approximately 3 ). 3. Push of these hoses onto the SUP port. Attach the Fittings as shown in fig.. Troubleshooting Guide. eak test the air line connections, the threaded connection into the air spring, and all fittings in the control system. 2. Inspect the air lines to be sure none are pinched. Tie straps may be too tight. oosen or replace the strap and replace leaking components. 3. Inspect the air line for holes and cracks. eplace as needed.. ook for a kink or fold in the air line. eroute as needed. If the preceding steps do not solve the problem, it is possibly caused by a failed air spring either a factory defect or an operating problem. Please call Air ift at (800) for assistance. Tuning the Air Pressure Pressure determination comes down to three things level vehicle, ride comfort, and stability.. Level vehicle If the vehicle s headlights are shining into the trees or the vehicle is leaning to one side, then it is not level. aise the air pressure to correct either of these problems and level 6 MN-726

22 Air Lift Performance Checking for leaks the vehicle. 2. Ride comfort If the vehicle has a rough or harsh ride it may be due to either too much pressure or not enough. Try different pressures to determine the best ride comfort. 3. Stability Stability translates into safety and should be the priority, meaning the driver may need to sacrifice a perfectly level and comfortable ride. Stability issues include roll control, bounce, dive during braking and sponginess. Tuning out these problems usually requires an increase in pressure. Fixing Leaks. Inflate the air spring to suggested driving pressure as listed in the Product Use, Maintenance and Servicing section of your air springs installation manual. 2. Spray all connections and the inflation valves with a solution of /5 li uid dish soap and /5 water. Spot leaks easily by looking for bubbles in the soapy water. 3. After the test, deflate the springs to the minimum pressure re uired to restore the system to normal ride height. Do not deflate to lower than 5 PSI.. Check the air pressure again after 2 hours. A 2 - PSI loss after initial installation is. If there is a problem with a swivel fitting a. Check the air line connection by deflating the spring and removing the line by pulling the collar against the fitting and pulling firmly on the air line. Trim off the end of the air line. Be sure the cut is clean and s uare (see fig. 2). einsert the air line into the push-to-connect fitting. b. Check the threaded connection by tightening the swivel fitting another turn. If it still leaks, deflate the air spring, remove the fitting, and re-coat the threads with thread sealant. einstall by hand tightening as much as possible and then use a wrench for an additional two turns. fig If the preceding steps have not resolved the problem, call Air ift customer service at (800) MN-726 7

23 Warranty and Returns Policy Air Lift Performance Air ift Company warrants its products, for the time periods listed below, to the original retail purchaser against manufacturing defects when used on catalog-listed applications on cars, vans, light trucks and motorhomes under normal operating conditions for as long as Air ift manufactures the product. The warranty does not apply to products that have been improperly applied, improperly installed, used in racing or off-road applications, used for commercial purposes, or which have not been maintained in accordance with installation instructions furnished with all products. The consumer will be responsible for removing (labor charges) the defective product from the vehicle and returning it, transportation costs prepaid, to the dealer from which it was purchased or to Air ift Company for verification. Air ift will repair or replace, at its option, defective products or components. A minimum 0.00 shipping and handling charge will apply to all warranty claims. Before returning any defective product, you must call Air ift at (800) in the U.S. and Canada (elsewhere, (5 ) ) for a eturned Materials Authori ation ( MA) number. eturns to Air ift can be sent to Air ift Company 2 2 Snow oad ansing, MI 8. Product failures resulting from abnormal use or misuse are excluded from this warranty. The loss of use of the product, loss of time, inconvenience, commercial loss or consequential damages is not covered. The consumer is responsible for installation/reinstallation (labor charges) of the product. Air ift Company reserves the right to change the design of any product without assuming any obligation to modify any product previously manufactured. This warranty gives you specific legal rights and you may also have other rights that vary from state-to-state. Some states do not allow limitations on how long an implied warranty lasts or allow the exclusion or limitation of incidental or consequential damages. The above limitation or exclusion may not apply to you. There are no warranties, expressed or implied including any implied warranties of merchantability and fitness, which extend beyond this warranty period. There are no warranties that extend beyond the description on the face hereof. Seller disclaims the implied warranty of merchantability. (Dated proof of purchase re uired.) Air Lift Lifetime Limited RideControl... Lifetime Limited LoadLifter 5000*... Lifetime Limited SlamAir... Lifetime Limited AirCell... Lifetime Limited Air Lift Performance**... Year Limited LoadController/Single... 2 Year Limited LoadController/Dual... 2 Year Limited Load Controller (I)... 2 Year Limited Load Controller (II)... 2 Year Limited SmartAir... 2 Year Limited Wireless AIR... 2 Year Limited WirelessONE... 2 Year Limited Other Accessories... 2 Year Limited *formerly SuperDuty **formerly LifeStyle & Performance 8 MN-726

24 Air Lift Performance Replacement Information If you need replacement parts, contact the local dealer or call Air ift customer service at (800) Most parts are immediately available and can be shipped the same day. Contact Air Lift Company customer service at (800) first if: Parts are missing from the kit. eed technical assistance on installation or operation. Broken or defective parts in the kit. Wrong parts in the kit. Have a warranty claim or uestion. Contact the retailer where the kit was purchased: If it is necessary to return or exchange the kit for any reason. If there is a problem with shipping if shipped from the retailer. If there is a problem with the price. Contact Information If you have any questions, comments or need technical assistance contact our customer service department by calling (800) , Monday through Friday, 8 a.m. to p.m. Eastern Time. For calls from outside the USA or Canada, our local number is (5 ) For in uiries by mail, our address is PO Box 80, ansing, MI Our shipping address for returns is 2 2 Snow oad, ansing, MI 8. ou may also contact us anytime by at sales airliftcompany.com or on the web at MN-726 9

25 Need Help? Contact our customer service department by calling (800) , Monday through Friday, 8 a.m. to p.m. Eastern Time. For calls from outside the USA or Canada, our local number is (5 ) Thank you for purchasing Air Lift Performance products! Air ift Company 2 2 Snow oad ansing, MI 8 or PO Box 80 ansing, MI Toll Free (800) ocal (5 ) Fax (5 ) Printed in the USA