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

Transcription

1 ʻ92-ʼ00 Civic/ʼ94-ʼ01 Integra/ ʻ93-ʼ97 Del Sol/ʼ90-ʼ97 Accord/ ʻ92-ʼ95 CRX Front Kit Part No MN-513 (08409) NPR 4778 Please read these instructions completely before proceeding with installation Warranty Information 1. 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 /4 Pipe - 1/2 Tube Straight 2 C mm Nylock Nut 4 D mm x 80mm x 1.5 Bolt 4 E mm Flat Washer 8 Remove Figure 1 IMPORTANT: Always keep safety in mind when working on your vehicle. Completely read these instructions before installing the kit. I. Preparing the Vehicle 1. Jack up the front of the vehicle and support the body on jackstands. 2. Remove the front wheels. II. Strut Removal 1. 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 1). 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. 1. 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 /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 1 1 /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 1 /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" 1 /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 10 Figure 11 Figure 12 New Nylock Nut Existing Washer Grind Off Flashing from Spindle 1. 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 10). 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 11). 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. 1. It will be necessary to grind the inside of the flashing off the spindle arm that attaches to the upper control arm (Figure 12). 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 13). 1. 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 11). 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 13). 3. The top bar for the upper control arm will also need to be trimmed. Grind 1/8 off of a 3 area (Figure 11). 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. 1. 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 16). Figure 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 1 1/2 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 15). Figure 14 NOTE: It may be necessary to grind the access hole or tighten the upper strut mount to get the socket over the fitting (Figure 17). 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 15 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 1. Using the supplied tie straps, fasten the brake line to the lower clevis (Figure 14). Repeat the installation for the other side of the vehicle. Technical Support Figure 16

6 Figure 17 Figure 18 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. 1. 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 1. Inflate and deflate system (do not exceed 150 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 100 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 #27671, 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 10 p.s.i. 150 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. 1. 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 (10 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 For Technical Assistance call Technical Support Local Phone: (517) Fax: (517) The Choice of the Professional Installer 10 Printed in the USA 10

9 90-97 Honda Accord Rear Kit Part No MN-547 (04602) ECR 5596 Please read these instructions completely before proceeding with installation Warranty Information 1. 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 Upper Strut Mount 2 B /8-16 x 1 Countersunk Bolt 4 C /8 Lock Washer 4 D /8-16 Hex Nut 4 E Rubber Spacer 2 F mm-1.25 x 80mm Bolt GD8 2 G mm Flat Washer 10 H Rear Strut Assembly 2 I /4 NPT to 1/2 Tube Straight 2 Figure 1 IMPORTANT: Always keep safety in mind when working on your vehicle. Completely read these instructions before installing the kit. I. Preparing the Vehicle 1. Jack the vehicle up and support the body on jackstands. 2. Remove the rear wheels (Figure 1). II. Strut Removal Figure 2 1. Remove the bolt in the lower strut mount and retain for later use (Figure 2). 2. emove the O.E.M retaining nut, one flatwasher, and the rubber bushing from the upper strut mount (Figure 3). Retain for later use. NOTE: These are located behind the back-seats on the inside of the vehicle. 3. Compress the spring and remove the strut assembly from the vehicle (Figure 4). Figure 3 NOTE: The use of a spring compressor is helpful in removing the strut safely from the vehicle. Figure 4 Technical Support

11 III. Removing the Upper Strut Mounting Bracket 1. Remove the two nuts from the upper strut mount and discard. NOTE: These are located behind the back-seat on the inside of the vehicle. IV. Installing the Upper Strut Mount 1. Place the upper strut mount (A) with the counter-sunk side downwards, in place where the O.E.M. mount was previously located. Figure 5 2. Place the counter-sunk bolts (B) into the holes and place the lock washers (C) and hex nuts (D) onto the bolts on the upper strut tower from the inside of the vehicle. Tighten securely. Figure 6 Technical Support

12 V. Strut Assembly Installation 1. Place a rubber spacer (E) onto the threaded end of the strut. 2. Place the threaded end of the strut into the upper strut mount and attach using the O.E.M. rubber bushing and flat washer and a supplied nylock nut. Tighten securely. NOTE For Passenger-Side: The air fitting will face towards the outside of the vehicle and the welded nut on the clevis will face towards the front. Figure 7 NOTE For Driver-Side: The air fitting will face towards the outside of the vehicle and the welded nut on the clevis will face towards the rear. 3. Insert the air fitting (I) into the strut.. Tighten the fitting finger-tight plus 1 1/2 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 9). 5. Insert the previously removed bolt through the strut mount and using flat washers ( ), shim the lower strut clevis between the mount and the clevis (Figure 7). Figure 8 NOTE: The bolts (F) and flat washers (G) can be used in the case of damage to the O.E.M. bolts upon removal of the O.E.M. strut assembly. 6. Tighten all upper and lower strut mounting hardware at this time (Figures 5, 7 and 8). VI. Before Operating 1. Tighten and visually inspect all hardware after 100 miles. 2. 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. Figure 9 strut body 9-position dampening damping dial 3. Air Lift part #27669 or #27671, AutoPilot V2 Air Management System, is highly recommended for this product. 4. Please continue by reading the Maintenance and Operation section. Technical Support

13 VII. Maintenance and Operation: Minimum Pressure Maximum Pressure 10 p.s.i. 150 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. 1. 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 (10 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 Local Phone: (517) Fax: (517) For Technical Assistance call Technical Support The Choice of the Professional Installer Printed in the USA

14 Air Lift Performance Kit Details HARDWARE LIST Part # Description Qty pt Fast Air Manifold - 1/ Gen 3 Display Electrical Harness - FastAir DOT 1/4 Air Line...2ft Fuse, spade 3amp Fuse, spade, 30amp ATC Fuse holder w/ cap GA Butt Connector GA Butt Connector GA Ring Terminal 3/ Female Spade Terminal GA Female Spade Terminal Adaptor, Mini Fuse...1 Part # Description Qty ATC/ATO Fuse Adaptor /2 MNPT X 1/4 FNPT /2 MNPT Center Sunk Hex Plug DOT Swivel Elbow 1/4Pipe - 1/4 PTC DOT Swivel Elbow 1/4MNPT-1/4PTC Push Lock Valve DOT 1/4 Air Line...50ft /4-14 X 1 Heavy Duty Washer /8 Flat Washer /8-16 x 1.25 Hex Cap Screw /8-16 Nyloc Nut Compressor (200 psi) Air Tank (5 gallon)...1 STOP! Missing or damaged parts? Call Air Lift customer service at (800) for a replacement part. MN-784

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17 TABLE OF CONTENTS Installing the AutoPilot V2 Kit... 4 NPT Assembly Instructions... 6 Air Line and Fittings Helpful Hints... 6 Setup and Calibration... 7 Program Presets... 8 Troubleshooting Guide... 9 Leak Testing and Detection... 9 Use the System Electrical Schematic Warranty and Returns Policy Replacement Information Contact Information Manifold Template AutoPilot V2 Remote Control Unit Compressor Template... 19

18 Installing the AutoPilot V2 Kit Air Lift Performance INSTALL COMPONENTS (For a complete schematic please see fig. 1, pages 10-11) 1. Layout Plan component location first. Prior to mounting components, check to make sure the electrical harness connections will reach the manifold and compressor, the compressor leader hose will reach the tank, and the plumbing will route cleanly through the vehicle. NOTE: Be sure to install all components as far as possible from any heat sources. Plan and prepare harness and plumbing routing thru the vehicle. Eliminate all sharp edges that could chafe. Use grommets when passing through compartment walls. 2. Prepare and install compressor Prepare compressor intake. If inside vehicle, attach filter to port on end of compressor (Fig. 1 ). If compressor located outside vehicle, snorkel inlet filter to dry location inside vehicle. Center punch and drill four holes using the template on page 1. Attach using hardware supplied with compressor. VIAIR Max. Tank Pressure 380C C C C C 175 NOTE: If harness must be lengthened, use properly sized butt connectors and wire. If extending power/ground wires, use 8AWG wire minimum or contact Air Lift for more information. NOTE: Supplied harness is only capable of powering a single compressor. If installing dual compressors, a second dedicated power wire is required. Consult page 13 for proper wiring, and contact Air Lift for an optional second compressor harness (part number: 27679). Manifold ocate manifold above compressors and tank if possible to avoid compressor ingested water from gathering in manifold. NOTE: Do not mount manifold upside down. Position manifold in desired location make sure manifold mount surface is flat. Fasten using the two self-tapping screws. If mounting surface is not flat, add washers to space the manifold up over surface irregularities. Tank pre assembly (see fig. 1 ) NOTE: Air compressors ingest moisture and will deposit water in the tank. Tanks must be regularly purged be sure to provide easy access to drain/fill valve (preferably outside the vehicle). The AutoPilot V2 system does not include moisture separators or water traps, and does require periodic tank moisture drain. If using an engine driven compressor, proper oil and water filtration must be added as these compressors will contaminate the air suspension system. Water traps are available and sold separately through Air Lift Performance (part numbers: 1/ , 3/ , 1/ ) Apply thread sealant as necessary. Determine tank location and orientation prior to installing fittings. In the lower most tank threaded port, install drain/fill PTC fitting. Choose a tank threaded port for the compressor fitting. Choose the highest tank threaded port for manifold airline routing. Plug the remaining tank ports with hex plugs. Tank install (see fig. 1 ) Use tank feet as template, drill holes for hardware assembly. Attach tank using supplied hardware. Cut appropriate length of hose from the manifold port 5, to the PTC fitting on tank. oute drain/fill air line with schrader valve (preferably outside vehicle). Mount fitting on bottom tank port. NOTE: Use a standard hose cutter (Air Lift part number 10530) or razorblade. Cut all hose ends square and as smoothly as possible. 4 MN-754

19 Air Lift Performance INSTALL HARNESS 1. Disconnect battery ground while installing system. 2. Compressor / manifold connections (see fig. 1 ) Attach the manifold connector, it will click into place once fully seated. Mount the compressor relay in a preferred location using a self-tapping screw. Cut off the spade and eyelet from the compressor power and ground wires. Strip of wire casing from the compressor wires. Strip of wire casing from the black and pink harness wires. NOTE: Use an appropriate terminal crimp tool to ensure a good connection. Using butt connector attach the ED compressor wire to the PI K harness wire. Using butt connector attach the B ACK compressor wire to the B ACK harness wire. Carefully apply heat (preferably with a heat gun) to seal these connections. 3. Battery / ignition connections (see fig. 1 ) Identify the power, ground, ignition leg of the harness. round 10AW black wire Power 10AW red wire Ignition 18AW pink wire. oute power and ground leg of the harness free from any heat source to the battery. Using butt connector attach red wire to fuse holder. Attach 3/8 eyelet to the other end of the fuse holder and attach to positive battery ( ) terminal. Attach 3/8 eyelet to the black wire and attach to battery ground. oute the 18AW pink wire to a key switched I ITIO source that remains on during cranking. Examples include ECU, fuel pump. Do not select an accessory source. If the AutoPilot 2 display shuts off while starting vehicle this is not a true ignition source. Using butt connector attach the pink ignition wire to a fuse holder. Select ignition source and attach the fused ignition wire. Use fuse adaptors as necessary. 4. Display oute display cable as desired to the preferred operating location. Attach the display cable to the main harness cable (small white 3 cavity connector). 5. Reconnect battery INSTALL AIR LINES NOTE: Use a standard hose cutter (Air Lift part number 10530) or razorblade. Cut all hose ends square and as smoothly as possible. Route and attach air lines to air springs oute air lines free from abrasive edges and heat sources. Attach manifold port FL or 1 to the front, drivers side left spring. Attach manifold port FR or 2 to the front, passengers side right spring. Attach manifold port RL or 3 to the rear, drivers side left spring. Attach manifold port RR or 4 to the rear, passengers side right spring. Attach manifold port T or 5 to the PTC fitting previously installed on the tank. Manifold port E or 6 is the exhaust port. Port E can be left open, or routed to a preferred exhaust location. NOTE: Air lines should be pushed in firmly, with a slight back and forth rotational twist check the connection by pulling on each line to verify a robust connection. NOTE: Release the air line from the fitting by releasing air, pushing on the line, depressing the ring towards the fitting, and then pulling the hose out of the fitting. MN-754 5

20 Air Lift Performance NPT Assembly Instructions 1. Inspect port and fitting to ensure both are free of contaminants and excessive burrs and nicks. 2. Apply a stripe of li uid pipe sealant around the male threads leaving the first two threads uncovered. 3. Screw finger tight into the port.. Wrench tighten the fitting to the correct turns past finger tight position (see table 1). CAUTIO E E BACK OFF A I STA ED PIPE FITTI TO ACHIE E P OPE A I ME T. OOSE I I STA ED PIPE FITTI S WI CO UPT THE SEA A D CO T IBUTE TO EAKA E A D FAI U E. Torque Specifications Fitting Si e Dash Si e Turns Past Finger Tight Tor ue lb/ft 1/8 PT / PT /8 PT /2 PT / PT PT PT PT PT Table 1 Air Line and Fittings Helpful Tips Hose bend radius 3/8 hose 1.5 hose bend radius 1/ hose 1 hose bend radius Hose to fitting o side loading on fitting from hose. Hose straight for 1 before bending. Hose cutting Cut hose perpendicular to hose length. Inspect hose for scratches that run lengthwise on hose prior to insertion. Use proper hose cutter, cigar cutter, or ra or on flat surface. DOT/SAEJ844 air brake hose data Maximum working pressure of 1 5 PSI. ot to be used for frame (body) to un-sprung mass connection, use a braided leader hose for this moving connection. 6 MN-754

21 Air Lift Performance Setup and Calibration AutoPilot 2 is an advanced pressure-based air suspension control system, that uses state-of-the-art software algorithms to calibrate or map the control system to your vehicle. Once the system is calibrated, the algorithm predicts re uired valve open time to move the air suspension to achieve preset target pressures. AutoPilot 2 has 8 programmable presets, allowing the user to input 8 different combinations of the corner air spring pressures. After installing AutoPilot 2 in your vehicle, please follow the steps below to properly setup your new system If changes are made after installing and calibrating the system such as changes to air springs, lines, tank, compressor, or other vehicle modifications the system must be recalibrated. SYSTEM CALIBRATION AND SETTINGS 1. Key-on/power up, and compressor should come on to fill the tank. Check to make sure system is triggered by I ITIO source. While starting the engine, the system should be O. If not, please refer back to Install Harness on page Press buttons 1 and 5 at the same time (1 5) and hold for 5-10 seconds until settings and diagnostics mode main page appears (fig. 2). 3. Press button 1 (TA K AD UST). Set tank pressure preference by pressing MI and MA up/down buttons (fig. 3). Press buttons 1 5 to exit to settings and diagnostics mode. NOTE: If tank MAX settings are changed, a system re-calibration is necessary for optimal performance. Calibrate to your vehicle NOTE: System will automatically deflate to 0 PSI and inflate to 100 PSI during calibration.. Press button 2 to enter CA IB ATE (fig. ). Press S STEM CA (button 1), follow instructions to calibrate AutoPilot 2 system to your vehicle. Once calibration is complete, Press buttons 1 5 to exit to the settings and diagnostics mode. 5. Press button 3 to enter BACK I HT (fig. 5). Set display backlight to your preference by pressing the and on ( ed), ( reen), B (Blue). Press buttons 1 5 to exit to the settings and diagnostics mode. Automatic preset maintenance. Press button to enter P ESET MAI TAI (fig. ). Press button 8 to turn O or OFF. When O, this function actively monitors air spring pressure and will fill to maintain active preset pressure. NOTE: This function will not exhaust pressure. If air spring pressure is higher than preset target, only the operator pressing the preset button again will activate the system to exhaust air spring pressure (for safety). Press buttons 1+5 to exit. NOTE: P ESET MAI TAI should be off for performance/ track driving or if operating in extremely hilly areas. fig. 1 fig. 2 fig. 3 fig. 4 fig. 5 fig LF RF T LR RR MIN 145 Button Definition TANK ADJUST CALIBRATE BACKLIGHT PRESET MAIN BACKLIGHT R G ADJ B PRESET MAINTAIN? ON MAX 175 CALIBRATION MENU 1 SYSTEM CAL 2. ADJUST SYSTEM MN-754 7

22 . Press button 8 to toggle to settings page 2 (fig. ). 8. Press button 5 to run a compressor test (fig. 8). This function will exhaust the tank to your specified MI tank pressure, then turn O the compressor and measure its inflate time to achieve MA pressure. AutoPilot 2 will record this fill time, allowing the operator to compare future fill times to determine compressor performance. Press buttons 1 5 to exit.. Press button to view the number of hours the compressor has been running. Rise on start 10. Press button to enter ISE O STA T (fig. ). This function will automatically activate valves to achieve preset 1 target pressures when the vehicle is keyed-on. This function allows the operator to drive away seconds after vehicle is started. Press buttons 1 5 to exit. 11. Press button 8 to toggle between PSI and BA pressure units and check software version. Press buttons 1 5 to exit. NOTE: BAR stands for DeciBar values. 12. Press buttons 1 5 to exit settings and diagnostics you are now ready to create presets Program Presets NOTE: Preset 1 should always be entered as the desired ride pressure for the RISE ON START function. 1. Determine ride pressures press buttons 1 5 to toggle display to MA UA mode. Manually activate each corner (see MA UA mode section page 12) to achieve desired normal driving ride pressure. (fig. 10) 8 programmable presets 2. Program preset 1 press buttons 1 5 to toggle display to P ESET mode. Press and hold button 1 to set 1. elease button and actual air spring pressures will appear (fig. 11). Fine-tune the pressures by pressing up/down buttons. Press hold to scroll. Press buttons 1 5 to exit. OTE If your system is not hitting presets uickly, change the AD value. Enter Settings and Diagnostics mode (press Button 1 5 for more than 5 seconds), press 2 CA IB ATE, then AD UST S STEM to toggle the value between 0 and 10 higher values increase system fill rates to overshoot target pressures. 3. ou are now free to program the additional presets to desired pressures. Typical presets can be ow set pressures to the lowest possible pressures for extreme low driving stance Front up for speed bump or driveway clearance ear up for added load of passengers, e uipment Play for those that want to en oy their air suspension fig. 7 fig. 8 fig. 9 fig. 1 fig. 10 fig. 11 fig Air Lift Performance COMP TEST COMP TIME RISE ON START PSI / BAR & SWV TANK PRESSURE RANGE PSI PROCEED? YES NO RISE ON START? ON LF RF EDIT PRESET 1 EDIT T PRESET 6 LR RR Button Definition 8 MN-754

23 Air Lift Performance freedom, AutoPilot 2 has a special function that EDIT recogni es side-to-side presets. When left side pressures are e ual, and right side pressures are e ual but 25PSI different than left, the algorithm will activate side to side fig instead of front to back. It will also e uali e all air spring PRESET 7 pressures when exiting the play preset, conserving air by using the high pressure side to inflate the low pressure side. Pairing two play presets together allows side-to-side activation that consumes far less air than manual mode activation would consume (Figs ). Troubleshooting Guide For further technical assistance please contact our customer service department by calling (800) , Monday through Friday. For calls from outside the USA or Canada, our local number is (51 ) PROBLEM CAUSE SOLUTION Compressor doesn t run. Compressor runs all the time. Air spring or tank leak. Nothing happens when the vehicle is key-on ignition active. The display does not light up. Compressor runs all the time but doesn t fill the tank. Display shows UNSUCCESSFUL There is a blown fuse or relay, bad ground, or poor electrical connections. The compressor relay is defective or there is a leak. Fitting seal or air line compromised. There is a blown fuse or a poor connection. There is a blown fuse or a poor connection. Compressor inline check valve fitting has been overtor ued. Calibration may need to be ad usted or system may need to be recalibrated. Tank pressure settings changed. ehicle load changed significantly. Air springs/air lines/tank changed. Leak Testing and Detection Leak detection eplace the fuse, check the ground wire, or check the compressor connector. eplace the relay or locate the leak and repair. Check to make sure air lines are seated in connectors. Inspect fittings with soapy water. Trim hose or re-seal fitting. eplace the fuses and check the electrical connections. eplace the fuses and check the electrical connections. oosen fitting and check again. eplace if needed. Ad ust AD value or recalibrate system to reduce number of iterations. Attempt recalibration. 1. Pressure change is directly proportional to temperature change in a container that is not leaking. a. For every 10 Fahrenheit decrease the pressure by 2 PSI. b. All other pressure changes are due to air exiting the system. 2. Spray soapy water on suspect fittings and hose connections. 3. Wipe down with rag to clean.. Soapy water recipe a. 1/5 Dawn brand dish soap to /5 water. b. Dawn brand dish soap will not corrode the metals (aluminum, brass, steel) it comes in contact with. DOT/SAEJ844 hoses and fittings (industry standard) 1. Allowable leak rate sccm - 0 (per fitting) 2. Examples a. 150 PSI in a 2.5 gallon tank - 0 for 12 hours PSI b. 150 PSI in a 5 gallon tank - 0 for 12 hours 1.08 PSI c. 100 PSI in a 1 1 in 3 (cubic inches) spring - 0 for 12 hours. PSI Assumption is that the spring keeps constant volume MN-754 9

24 LF RF LR RR LF RF LR RR Air Lift Performance fig Relay schematic reference Relay schematic reference Connect direct to battery Connect direct to battery Preferred Preferred Ignition Source (on while cranking) Ignition Source (on while cranking) MN-754

25 Air Lift Performance LEFT RIGHT LEFT RIGHT NOTE: MN

26 Use the System Air Lift Performance ow that your system is set up, it s time to use it. If changes are made after installing and calibrating the system such as changes to air springs, lines, tank, or compressor the system must be recalibrated. There are two modes P ESET and MA UA. Pressing buttons 1 and 5 together will toggle between modes. After 10 seconds of non-use, the display enters standby where the CD dims. Any button hit will wake-up the display and allow users to activate the system. See mode operation below for more details. PRESET mode First button press will display the programmed preset. Users can uickly view each preset prior to activating to make sure they are selecting the desired preset. A 2 nd button press of the same preset will activate it. The system will iterate up to times to achieve the preset target pressures by /- 3 PSI. Display shows P EASE WAIT as it iterates, then will flash SUCCESSFU when achieved or U SUCCESSFU if not able to achieve the target pressure window ( OTE if your system is not hitting presets uickly, change the AD value). Enter Settings and Diagnostics mode (press buttons 1 5 for more than 5 seconds), press button 2 (CA IB ATE), then AD UST S STEM to toggle the value between 0 and 10. Higher values increase system fill rates to overshoot target pressures. Micro adjust to ±1 PSI: If more accuracy is desired, double press the same preset and the system will refine pressures closer to target fig. 15 PRESET Mode fig. 16 MANUAL Mode MANUAL mode MA UA mode allows the user to fill or exhaust each spring. The display will show arrows above and below the pressures to indicate manual control mode. The arrow will be solid when the spring is filling/exhausting, and ust an outline when not active. MANUAL mode with Easy Control Tap The system detects button press time. For a very short ( 0.1sec) duration press, the system will open the valves for a defined burst, changing pressure minimally so users can fine-tune their pressures. For a longer than 0.1 sec duration press, the valves open as long as you hold the button down. If a button is held active, the fill/exhaust will time out after 10 seconds. Fill springs buttons 1 - Exhaust springs buttons MN-754

27 Air Lift Performance Electrical Schematic AUTOPILOT V2 GEN 3 PRESSURE CONTROL AUTOPILOT V2 SECOND COMPRESSOR HARNESS* * Sold seperately Air Lift Part Number fig. 17 MN

28 Air Lift Performance Warranty and Returns Policy Air ift Company warrants its performance products for one year to the original purchaser against manufacturing defects one year from the date of purchase when used on cars and trucks as specified under normal operating conditions. The warranty does not apply to products that have been improperly applied, improperly installed, 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 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, (51 ) ) 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 1. 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 conse uential damages are 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 may 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 conse uential 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. 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. Technical assistance on installation or operation is needed. 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 uestions, comments or need technical assistance contact our customer service department by calling (800) , Monday through Friday. For calls from outside the USA or Canada, our local number is (51 ) ou may also contact customer service anytime by at techsupport airliftperformance.com. For in uiries by mail, our address is PO Box 801, ansing, MI Our shipping address for returns is 2 2 Snow oad, ansing, MI 8 1. ou may also contact our sales team anytime by at sales airliftperformance.com or on the web at 14 MN-754

29 Air Lift Performance Manifold Template MN

30 Air Lift Performance 16 MN-754

31 Air Lift Performance AutoPilot V2 Remote Control Unit MN

32 Air Lift Performance 18 MN-754

33 Air Lift Performance Compressor Template HOLE PATTERN FOR BOTTOM OF COMPRESSOR MN

34 Need Help? Contact our customer service department by calling (800) , Monday through Friday. For calls from outside the USA or Canada, our local number is (51 ) Thank you for purchasing Air Lift Performance products! Air ift Company 2 2 Snow oad ansing, MI 8 1 or PO Box 801 ansing, MI Toll Free (800) ocal (51 ) Fax (51 ) Printed in the USA