LifeSTYLE. Kit Installation GuidE. Scion tc. front application

Transcription

1 LifeSTYLE Kit Scion tc front application MN-716 (01905) ERN 6606 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.

2 Introduction Lifestyle The purpose of this publication is to assist with the installation, maintenance and troubleshooting of this Scion Lifestyle kit. It is important to read and understand the entire installation guide before beginning installation or performing any maintenance, service or repair. The information includes a hardware list, tool list, step-by-step installation information, maintenance tips, safety information and a troubleshooting guide. 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 INDICATES IMMEDIATE HAZARDS WHICH WILL RESULT IN SEVERE PERSONAL INJURY OR DEATH. INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN SEVERE PERSONAL INJURY OR DEATH. INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN DAMAGE TO THE MACHINE OR MINOR PERSONAL INJURY. Indicates a procedure, practice or hint which is important to highlight. IMPORTANT SAFETY NOTICEs The installation of this kit does not alter the Gross Vehicle Weight Rating (GVWR) 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 size and inflation pressure data is shown on the vehicle s Safety Compliance Certification Label. Payload: The combined, maximum allowable weight of cargo and passengers that the vehicle is designed to carry. Payload is GVWR minus the Base Curb Weight. WARNING CAUTION Do not inflate air springs while off of the vehicle. damage to assembly may result and void warranty. do not weld to, or modify Lifestyle Struts/Shocks in any way. damage to unit may occur and will void warranty.

3 Installation Diagram E D A C B F G H fig. 1 HARDWARE LIST Item Part # Description... Qty A Strut Assembly - Right...1 B Strut Assembly - Left...1 C /4 MNPT X 3/8 PTC...2 D /8 Flat Washer...6 E /8-16 Nyloc Nut...6 F /4-20 X.75 Bolt...2 G Flat Washer...4 H /4-20 Nyloc Nut...2 TOOLS LIST Description Jack or hoist Jack stands Metric Wrenches Standard Wrenches Torque Wrench

4 Installing the Lifestyle Kit NOTE Preparing the vehicle 1. Elevate the vehicle and support the body with a hoist or jack stands. 2. Remove the front wheels. Removing the strut This procedure works for left and right strut. 1. Remove cap from the wiper arms, mark the position of the arm to the inner spindle. Unthread both wiper arm nuts and remove both arms from the vehicle (fig. 2). 2. Carefully remove the hood cowl seal. Remove all push-pins from the cowl and remove left and right cowl portions (fig. 2). fig Disconnect the sway bar link from the strut. Save nut for re-installation. (fig. 3) fig. 3

5 4. Unbolt/unclip the speed sensor and brake line from the strut. Discard bolt. (fig. 4) fig Support the hub assembly. Remove the three upper strut mount bolts within the engine compartment (fig. 5). fig. 5 NOTE 6. Clearly mark the location of the lower spindle bolts before removing. Unbolt the lower spindle mounting bolts and save for later re-installation (fig. 6). These bolts are used for stock camber adjustment. Switching the bolts may change camber angle depending on stock set up. Further camber adjustment can be achieved by purchasing different factory bolts from your Scion dealership. fig. 6

6 installing the new strut assembly 1. Prior to installing the strut, attach the air fitting (21851) provided to the threaded port at the top of the air spring (fig. 7). Seal with Teflon tape. 2. Apply Teflon tape or thread sealant to the fitting threads and install into the top of the air spring. Thread fitting in hand tight and torque 1-3/4 turns beyond hand tight. Correct air fitting installation: Hex nut edges are parrallel with top and bottom upper end cap edges. Incorrect air fitting installation: Hex nut point extends over bottom of upper end cap edge and could puncture the air bag. fig Before inserting the new strut assembly, look at the top of the supplied upper mount. Left and right struts are indicated on this mount with either a large R or L along with an arrow. This arrow must point toward the front of the vehicle (fig. 8). Insert the appropriate strut into the pocket, align the upper bracket with the arrow pointing to the front of the vehicle, and reinstall the upper mount nuts. Torque to 44 Nm (33 ft./lbs.). fig Install lower mounting bolts. Torque to 240 Nm (177 ft./lbs.). 5. Reattach the speed sensor and brake line to the tab. Use the supplied bolt (17175), washers (18444) and nyloc nut (18425), to securely attach through the lower hole of the tab. 6. Reattach the swaybar link. Torque to 74 Nm (55 ft./lbs.). 7. Install the left and right cowl, snapping the center section together. Insert the push-pins through the cowl into the body. Reattach the cowl seat. 8. Take the wiper arms and align with the previous mounting mark. Securely fasten the wiper arms in place and clip the wiper caps back on. 9. Install wheel and torque to 103 Nm (76 ft./lbs.). NOTE ALIGNING THE VEHICLE 1. Using the control system, set the vehicle height to the new custom ride height. 2. If the custom ride height is lower than stock, we recommend loosening all pivot points (bolts, nuts) on any control arm, strut arm or radius rod that contains bushings. Once they have been loosened, re-torque to stock specifications (fig. 9). It may be necessary to cycle the suspension to loosen the bushing up from its mount. This will help re-orient the bushing at its new position based on the custom ride height.

7 Description Nm ft./lbs. Lower Control Arm to Crossmember bolt Upper Mount Nuts Sway Bar Link Brake Line Tab 5 4 Wheel Mounting Nuts fig To adjust camber, reference your vehicle bolts to fig. 10 or fig. 11 depending on the direction of desired adjustment. Installed Bolt 1 is the upper and Installed Bolt 2 is the lower bolt. Determine adjustment letter and refer to fig. 12 for bolt replacement. The table below will adjust camber positive (fig. 10). NOTE Replace one bolt at a time. fig. 10 The table below will adjust camber negative (fig. 11). NOTE Replace one bolt at a time fig. 11

8 lifestyle fi g mm fi g. 13 Before operating 1. Some struts for this vehicle come with a nine-position damping dial for added adjustability (fi g. 14). If not, proceed to 2. Before driving your vehicle, set the new struts to their highest setting by turning the black dial on the shaft of the strut as far as it will go to the right (position 9). Decrease damping (softer ride) Increase damping (stiffer ride) fi g. 14 CAUTION 2. Next, completely deflate and reinflate the air bags 2-3 times. This procedure will purge any trapped air in the dampers and allow for maximum performance. For ride performance and the most versatility, Lifestyle recommends setting the strut dial (if equipped) to position 6 or higher. MAkE SURE THE FRONT WHEELS ARE STRAIGHT WHEN DEFLATING AND REINFLATING AIR BAGS. 3. Infl ate and defl ate the system (do not exceed 125 PSI) to check for clearance or binding

9 Product Use, Maintenance and Servicing Suggested Driving Air Pressure Maximum Air Pressure 75 PSI 125 PSI Failure to maintain adequate minimum pressure (or pressure proportional to load) will result in bottoming out, over-extension or rubbing against another component and will void the warranty. maintenance guidelines NOTE CAUTION By following these steps, vehicle owners will obtain the longest life and best results from their air spring. 1. Check the air pressure before driving. 2. Never inflate beyond 125 PSI. 3. If you develop an air leak in the system, use a soapy water solution to check all air line connections, before deflating and removing the spring. 4. When increasing load, always adjust the air pressure to maintain normal ride height. Increase or decrease pressure from the system as necessary to attain normal ride height for optimal ride and handling. Remember that loads carried behind the axle (including tongue loads) require more leveling force (pressure) than those carried directly over the axle. for your safety and to prevent damage to your vehicle, do not exceed maximum gross vehicle weight rating (GVWR), as indicated by the vehicle manufacturer. although your air springs are rated at a maximum inflation pressure of 125 psi, the air pressure actually needed is dependent on your load. 5. Always add air to the springs in small quantities, checking the pressure frequently. Sleeves require less air volume than a tire and inflate quickly. 6. Should it become necessary to raise the vehicle by the frame, make sure the control system is turned off before lifting. Troubleshooting Guide 1. Leak 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. Loosen or replace the strap and replace leaking components. 3. Inspect the air line for holes and cracks. Replace as needed. 4. Look for a kink or fold in the air line. Reroute as needed.

10 Frequently Asked Questions Q. Will installing air springs increase the weight ratings of a vehicle? No. Adding air springs will not change the weight ratings (GAWR, GCWR and/or GVWR) of a vehicle. Exceeding the GVWR is dangerous and voids the Air Lift warranty. Q. How long should air springs last? If the air springs are properly installed and maintained they can last indefinitely. Q. Will raising the vehicle on a hoist for service work damage the air springs? Tuning the Air Pressure Checking for leaks Fixing Leaks No. The vehicle can be lifted on a hoist for short-term service work such as tire rotation or oil changes. However, if the vehicle will be on the hoist for a prolonged period of time, support the axle with jack stands in order to take the tension off of the air springs. Pressure determination comes down to three things level vehicle, ride comfort, and stability. 1. 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. Raise the air pressure to correct either of these problems and level 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. See Air Lift suggested driving air pressure. 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 additional air pressure, strut damping, or both. 1. Inflate the air spring to 80 PSI. 2. Spray all connections and the inflation valves with a solution of 1/5 liquid dish soap and 4/5 water. Spot leaks easily by looking for bubbles in the soapy water. 3. After the test, deflate the springs to the minimum pressure required to restore the system to normal ride height. 4. Check the air pressure again after 24 hours. A 2-4 PSI loss after initial installation is normal. Retest for leaks if the loss is more than 5 lbs. 1. 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 1 off the end of the air line. Be sure the cut is clean and square (see fig. 15). Reinsert the air line into the push-to-connect fitting.

11 fig. 15 b. Check the threaded connection by tightening the swivel fitting another ½ turn. If it still leaks, deflate the air spring, remove the fitting, and re-coat the threads with thread sealant. Reinstall by hand tightening as much as possible and then use a wrench for an additional two turns.

12 LifeSTYLE Kit Scion tc rear application MN-717 (01905) ERN 6606 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.

13 Introduction Lifestyle The purpose of this publication is to assist with the installation, maintenance and troubleshooting of this Scion Lifestyle kit. It is important to read and understand the entire installation guide before beginning installation or performing any maintenance, service or repair. The information includes a hardware list, tool list, step-by-step installation information, maintenance tips, safety information and a troubleshooting guide. 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 INDICATES IMMEDIATE HAZARDS WHICH WILL RESULT IN SEVERE PERSONAL INJURY OR DEATH. INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN SEVERE PERSONAL INJURY OR DEATH. INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN DAMAGE TO THE MACHINE OR MINOR PERSONAL INJURY. Indicates a procedure, practice or hint which is important to highlight. IMPORTANT SAFETY NOTICEs The installation of this kit does not alter the Gross Vehicle Weight Rating (GVWR) 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 size and inflation pressure data is shown on the vehicle s Safety Compliance Certification Label. Payload: The combined, maximum allowable weight of cargo and passengers that the vehicle is designed to carry. Payload is GVWR minus the Base Curb Weight. WARNING CAUTION Do not inflate air springs while off of the vehicle. damage to assembly may result and void warranty. do not weld to, or modify Lifestyle Struts/Shocks in any way. damage to unit may occur and will void warranty.

14 Installation Diagram K J H I G F E D fig. 1 A B do not remove dust cover TOOLS LIST Description Jack or hoist Jack stands Metric Wrenches Torque Wrench HARDWARE LIST C Item Part # Description... Qty A Shock Assembly...2 B /4 MNPT X 3/8 PTC...2 C Washer...4 D Washer...2 E Stock Bottom Washer...2 F Stock Bottom Bushing...2 G Stock Bushing Sleeve...2 H Stock Upper Mount...2 I Stock Top Bushing...2 J Stock Top Washer...2 K M10 X 1.5, Nyloc Nut...2

15 Installing the Lifestyle Kit Preparing the vehicle 1. Remove the tonneau cover and floor matting from the trunk compartment. Fold the rear seats flat. 2. Unclip the plastic tabs on the tie hooks on the floor behind the rear seat. Remove the bolts underneath the clip and remove deck floor. 3. Remove the foam floor compartments by removing the plastic rivets. 4. Lift up and remove the rear trim piece where the hatch latch is located. 5. Unthread the hex bolt and Phillips screws from the trunk side panels. Pull the plastic storage hooks from the top of the panels. Carefully pull at the rear of the panel and unclip as you move forward. The trunk light needs to be unclipped from its connector during this process. The front of the panel hooks into the joining backseat panel. Rotate the end of the panel towards the center of the vehicle. The front of the panel should now be unhooked. Remove the panels from the trunk. 6. Lift the rear of the vehicle with either a hoist or lift-jack in the approved lift points found in your vehicle owners manual. Once the wheels are off the ground, support the vehicle with the jack stands. Removing the shock 1. Disconnect the skid control sensor from the connector. Unthread the bolt from the sensor wire and remove bracket (fig. 2). fig Separate the rear stabilizer end links from the stabilizer bar. Support the suspension arm.

16 3. Unbolt the lower shock mount and remove bolt (fig. 3) fig Inside the trunk, unthread the three upper mount nuts (fig. 4). fig Clear the shock eye from its mount toward the stabilizer bar end link and remove the assembly.

17 Stock Upper Mount Removal and Install Lifestyle 1. Secure the shock assembly into a coil spring compressor and compress the spring. 2. Insert a hex wrench into the end of the shock rod, unthread nut from rod. 3. Slowly remove pressure from the assembly and remove upper bracket, bushings, bushing sleeve and washers. Remove the washer from the jounce bumper. Note the orientation of the washers and bushings for reinstallation. 4. Reinstall the upper mount with the previously removed upper nuts. Torque to 80 Nm (59 ft./lbs.). CAUTION Air Assembly Install 1. Apply Teflon tape or thread sealant to the fitting threads and install into the top of the air spring. Thread fitting in hand tight and torque 1-3/4 turns beyond hand tight. Do not remove the dust cover. For this application the sleeve type air spring is mounted upside down requiring a dust cover to keep debris from collecting in this rolling sleeve. removal of this cover could significantly reduce the life of the air spring and will void the warranty. So please do the wisest thing and leave the dust cover on! CAUTION 2. Assemble the supplied washer (D), the stock jounce bumper washer (E) followed by the bushing (F) and sleeve (G) (fig. 1). Failure to include this part could cause air fitting failure and premature wear of the upper bushing. 3. Insert shock assembly into upper mount and locate the lower shock eye into the lower suspension arm bracket. 4. With the end of the shock rod showing through the upper mount (H), install the bushing (I) and retaining washer (J) in its previous orientation. Thread the supplied nut (K) to the shock rod end, securing the upper mount assembly. Torque to 41 Nm (30 ft./lbs.). 5. Insert spacers (C) on each side shock eye bushing and reinstall the shock bolt and nut. Do not torque at this point. Please read Aligning the Vehicle. 6. Reinstall the skid control sensor bracket and connection. Torque the bracket to 5 Nm (44 inch/lbs.) 7. Reattach the sway bar link. Torque to 44 Nm (32 ft./lbs.). 8. Install air line into the fitting and inflate to 60psi. Check for leaks. 9. Lower vehicle down from lift-jack and set to the new ride height. 10. Some vehicles may experience toe link interference to the rear suspension member subassembly (chassis reinforcement bracket). If a snapping noise is heard while traversing large bumps, clearancing of the rear suspension member sub-assembly may be required. (fig. 5)

18 fig. 5 ALIGNING THE VEHICLE 1. Using the control system, set the vehicle height to the new custom ride height. 2. If the new custom ride height is lower than stock, we recommend loosening all pivot points (bolts, nuts) on any control arm, strut arm or radius rod that contains bushings. Once they have been loosened, re-torque to stock specifications (fig. 6). NOTE It may be necessary to cycle the suspension to loosen the bushing up from its mount. This will help re-orient the bushing at its new position based on the custom ride height. Description Nm ft./lbs. inch/lbs. Upper Mount Nuts (3 per side) Stabilizer Link Skid Control Bracket 5 44 Shock Eye Bolt Suspension Arm Bushing (3 bolts per side) fig. 6

19 lifestyle Before operating 1. Some struts for this vehicle come with a nine-position damping dial for added adjustability (fi g. 7). If not, proceed to 2. Before driving your vehicle, set the new struts to their highest setting by turning the black dial on the shaft of the strut as far as it will go to the right (position 9). Decrease damping (softer ride) Increase damping (stiffer ride) fi g. 7 CAUTION 2. Next, completely deflate and reinflate the air bags 2-3 times. This procedure will purge any trapped air in the dampers and allow for maximum performance. For ride performance and the most versatility, Lifestyle recommends setting the strut dial (if equipped) to position 6 or higher. MAkE SURE THE FRONT WHEELS ARE STRAIGHT WHEN DEFLATING AND REINFLATING AIR BAGS. 3. Infl ate and defl ate the system (do not exceed 125 PSI) to check for clearance or binding issues. With the air springs defl ated, check clearances on everything so as not to pinch brake lines, vent tubes, etc. Clear lines if necessary. 4. Infl ate the air springs to 75PSI - 90PSI and check all connections for leaks. 5. Air Lift part #27741 or #27630, High Performance 4 Path Air Management System, is highly recommended for this product.

20 Product Use, Maintenance and Servicing Suggested Driving Air Pressure Maximum Air Pressure 75 PSI 125 PSI Failure to maintain adequate minimum pressure (or pressure proportional to load) will result in bottoming out, over-extension or rubbing against another component and will void the warranty. maintenance guidelines NOTE CAUTION By following these steps, vehicle owners will obtain the longest life and best results from their air spring. 1. Check the air pressure before driving. 2. Never inflate beyond 125 PSI. 3. If you develop an air leak in the system, use a soapy water solution to check all air line connections, before deflating and removing the spring. 4. When increasing load, always adjust the air pressure to maintain normal ride height. Increase or decrease pressure from the system as necessary to attain normal ride height for optimal ride and handling. Remember that loads carried behind the axle (including tongue loads) require more leveling force (pressure) than those carried directly over the axle. for your safety and to prevent damage to your vehicle, do not exceed maximum gross vehicle weight rating (GVWR), as indicated by the vehicle manufacturer. although your air springs are rated at a maximum inflation pressure of 125 psi, the air pressure actually needed is dependent on your load. 5. Always add air to the springs in small quantities, checking the pressure frequently. Sleeves require less air volume than a tire and inflate quickly. 6. Should it become necessary to raise the vehicle by the frame, make sure the control system is turned off before lifting. Troubleshooting Guide 1. Leak 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. Loosen or replace the strap and replace leaking components. 3. Inspect the air line for holes and cracks. Replace as needed. 4. Look for a kink or fold in the air line. Reroute as needed.

21 Frequently Asked Questions Q. Will installing air springs increase the weight ratings of a vehicle? No. Adding air springs will not change the weight ratings (GAWR, GCWR and/or GVWR) of a vehicle. Exceeding the GVWR is dangerous and voids the Air Lift warranty. Q. How long should air springs last? If the air springs are properly installed and maintained they can last indefinitely. Q. Will raising the vehicle on a hoist for service work damage the air springs? Tuning the Air Pressure Checking for leaks Fixing Leaks No. The vehicle can be lifted on a hoist for short-term service work such as tire rotation or oil changes. However, if the vehicle will be on the hoist for a prolonged period of time, support the axle with jack stands in order to take the tension off of the air springs. Pressure determination comes down to three things level vehicle, ride comfort, and stability. 1. 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. Raise the air pressure to correct either of these problems and level 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. See Air Lift suggested driving air pressure. 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 additional air pressure, strut damping, or both. 1. Inflate the air spring to 80 PSI. 2. Spray all connections and the inflation valves with a solution of 1/5 liquid dish soap and 4/5 water. Spot leaks easily by looking for bubbles in the soapy water. 3. After the test, deflate the springs to the minimum pressure required to restore the system to normal ride height. 4. Check the air pressure again after 24 hours. A 2-4 PSI loss after initial installation is normal. Retest for leaks if the loss is more than 5 lbs. 1. 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 1 off the end of the air line. Be sure the cut is clean and square (see fig. 8). Reinsert the air line into the push-to-connect fitting.

22 fig. 8 b. Check the threaded connection by tightening the swivel fitting another ½ turn. If it still leaks, deflate the air spring, remove the fitting, and re-coat the threads with thread sealant. Reinstall by hand tightening as much as possible and then use a wrench for an additional two turns.

23 Operational Instructions Operational Instructions (Cont.) Ride-height button: The ride-height button has different functionality based on the length of time it is pressed. Short Press (less than 1 second) If in auto-mode, the system returns to manual-mode. If not in auto-mode, the system engages ride-height using the previously saved ride-height settings. If auto-pressureregulation is enabled, the system enters auto-mode and maintains the airbag pressures automatically. If auto-pressure-regulation is not enabled, the sytem reverts to manual-mode after the airbag pressures are set. If the air tank pressure is too low (less than 135 psi), Low Air will be displayed and the system will remain in manual mode. If any air bag pressure is at less than 30 psi, the system will initially attain pressures that are 10 psi greater than the ride height settings. The system will establish the desired ride height setting in approximately 15 seconds. Medium Press (between 1 and 3 seconds - Set Ride Ht is displayed) If the system is in auto-mode, Set Ride Ht is not displayed and the system remains in auto-mode at the current settings. If the system is not in auto-mode, it reads the current air bag pressures, saves these as the new settings, and then engages ride-height. If auto-pressure-regulation is enabled, the system enters auto-mode and maintains the air bag pressures automatically. If auto-pressure-regulation is not enabled, the system reverts to manual-mode after the air bag pressures are set. If the airbag pressures are outside the allowed range for ride height ( psi) Range will be displayed and the system will not accept the new settings. Long Press (greater than 3 seconds - Edit Options is displayed) The system enters option-mode to allow editing of the system options. Use the right-front buttons to select an op- 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. LifeSTYLE Lifestyle Digital Controller Kit No p.s.i. Kit No p.s.i. Please read these instructions completely before proceeding with installation Failure to read these instructions can result in mis-installation Tuning MN-714 (01901) ECR 6615 LifeSTYLE WARNING: In case of battery failure- unplug the controller before jump starting vehicle!

24 ECU Diagram Operational Instructions ECU Diagram 1. Press and hold the "B" button for three seconds until the menu is accessed. ECU not tuned Manual How to "tune" your ECU. B A. All Lowered B. Ride Height and Access Menu Features C. All Raised D. Right Rear Deflate E. Right Rear Inflate F. Left Rear Inflate G. Left Rear Deflate H. Left Front Inflate I. Left Front Deflate J. Right Front Inflate K. Right Front Deflate L. Display Screen 2. Press the "J" button to scroll through the menu options until you see "Tune". 91 Tune 86 Off 3. Press button "F" to turn the tune function on. 4. Make sure your tank is full. Check to ensure all is clear for the system to be cycled. Press button "B". Your System should now be tuning. 91 Tune 50 F On 56 0 Tuning How to set your "Ride Height". 1. Make sure you have your system tuned. "See Above" 2. In Manual Mode lift your vehicle to your desired Height and pressure. B J Three Basic Operation Modes: Manual-Mode Auto-Mode Option-Mode Settings: The system displays the actual airbag pressures, and the user controls the pressure manually. The system displays the pressure settings and automatically maintains the prescribed airbag pressures. The user can examine and change all option settings. The system keeps the user s option settings in non-volatile memory so that they will be maintained each time the system is powered up. On power-up, the options settings are read and acted on appropriately. Ride Ht Auto Leak Volts Tank Bright Seq Tune The system will immediately restore the airbag pressures to the saved setting values on power-up. When ride-height is selected (either through Ride Ht option setting or user selection during operation), the system will automatically maintain the airbag pressure at the current settings. The system will display detected leaks in any of the airbag circuits. A leak is shown by the letter L next to the pressure reading. The display will show the system voltage. If both Volts and Tank are enabled, the display will alternate between them every 20 seconds. The display will show the current tank pressure. If both Volts and Tank are enabled, the display will alternate between them every 20 seconds. Controls the display intensity. If the display intensity is changed while it is dimmed automatically by the vehicle lights connection, it will remain at the selected brightness until the next time the vehicle lights are turned on. The system will perform pressure regulation on the airbags sequentially (left front, right front, left rear, right rear). If not enabled, the system will simultaneously adjust all airbag pressures. To use the TUNE function, the tune option must be set to ON and it must be displayed when the ride height button is used to exit option-mode. The TUNE function will test the response of the system by exercising the airbags individually. The results are stored by the system for use in accurately controlling airbag pressures. The TUNE function must only be accomplished in a stationary vehicle on level ground. If Ride Ht is enabled, the system will set the airbag pressures to the saved setting values on start-up. If Auto is enabled, the system will then enter auto-mode. If Auto is not enabled, the system will then go to manual-mode after the pressures are properly set. User Interface: Front and rear button groups: These eight (8) buttons open the corresponding solenoid valve when pressed. In auto-mode, the system returns to the manual-mode if any of these buttons are pressed. In option-mode, the right-front buttons scroll through the options, while the left-rear buttons modify the displayed option s value. All-up/all-down buttons: Open all fill or dump solenoid valves when pressed. In auto-mode, the system returns to manual-mode if either of these buttons are pressed. Operational Instructions 91 Ride 86 On B 3. Hold "B" for two seconds until "Ride" Appears on the screen. These pressures are now set as your ride height.

25 Checking the System Installing the Compressor and Manifold Troubleshooting 1. Inspect all air line connections with a solution of 1/5 dish soap to 4/5 water. Should a leak be detected in a push-lock-fitting, reinstall the air line to the fitting. Make sure air line is cut off squarely and that the air line is completely pushed into the fitting. To Add a Second Compressor 85 Troubleshooting Guide 2. If the compressor or the solenoid fails to function, check the 20 AMP fuse and ground connection. Repair and replace as necessary. Problem Cause Solution Compressor doesn t run. Solenoid doesn t work. 30 Compressor runs all the time. From ECU blue dot (-12V compressor activation) Relay 2 (not included) To compressor 2 (not included) +12V Power Battery Figure 12 Relay 1 There is a blown fuse, bad ground, or poor electrical connections. There is a blown fuse or poor electrical connection The compressor relay is defective or there is a leak. + To compressor 1 From ECU red dot (+12V switched) Replace the fuse, check the ground wire, or check the compressor connector. Replace the fuse or check the solenoid connector. Replace the relay or locate the leak and repair. 1. Attach the filter to the port on the end of the compressor (Figure 1). 2. Attach air fittings to the remaining three ports on each manifold (Figures 1 and 8). 3. Select a ridgid mounting location on your vehicle s frame or crossmember that shields the compressor from the elements and heat sources (Figure 1). 1 To Relay To Air Tank Ground Figure 1 4. Attach the compressor to the frame rail or crossmember using Figure 1 as a guide. NOTE: The compressor and manifolds must be mounted within reach of the wires when the wiring harness is plugged in. 5. Attach the brackets to the manifold using the provided screws. 6. Attach the brackets to the chosen mounting location using the provided self-tapping screws. Front Left 2 F1 Front Front Right Rear Left L R L R FRONT 3 R1 Rear Right REAR Rear Installing the Digital Controller Vehicle does not maintain ride height. The vehicle is overloaded. Remove excess load from the vehicle. Compressor Centerpunch and drill four 1/4 diameter holes using the compressor feet as a template. Attach using four supplied screws. Fasten using four supplied washers and nuts. Nothing happens when the vehicle is started. There is a blown fuse or a poor connection. Replace the fuses and check the electrical connections. Manifold Centerpunch and drill two 3/16 diameter holes for each using the manifold as a template. Attach using the supplied lock washers and bolts. The display does not light up. There is a blown fuse or a poor connection. Replace the fuses and check the electrical connections. CAUTION Mount the compressor and manifolds at least 6 from any heat sources. DO NOT mount the compressor or the manifolds in the engine compartment.

26 Installing the Air Tank and Components Mounting the Display Panel Installing the Digital Controller N W C Front Transducer Wires L B X K O N X Figure 2 W C 1. Attach a 1/2 x 1/2 tube elbow to the the other end. L 2. Attach a 1/2 x 1/8 bushing to the port of the air tank that will be facing upwards and attach an inflation valve to the port. 3. Attach a 1/2 x 1/4 bushing to the port on the air tank that will be facing downwards and attach the drain valve to this bushing. 4. Attach two 1/2 hex head pipe plugs to two of the four ports on the front of the tank. Installing the Electrical Components R L R P Q IMPORTANT: Depending on the orientation of the tank when it is mounted, the fittings may go into different ports on the tank. The drain valve must always be put into the port facing downwards (Figure 2). IMPORTANT: Apply the provided thread sealant to all of the air tank fittings that have not been pre-coated with sealant. IMPORTANT: When choosing a mounting location for the air tank, be sure that there is ample room for the air lines and that they will be clear of any heat sources. 5. Attach a 1/2 x 1/8 bushing to one of the remaining ports on the front of the air tank. Attach the transducer to this bushing. 6. Attach a 1/2 x 1/2 tube elbow to the remaining port. 7. Mount the air tank in the chosen location using the provided bolts, flat washers and nyloc nuts. Rear 1. Run the harness from the dash to the manifold/ Transducer Wires compressor location. NOTE: Place a grommet or silicone sealant around any holes that the harness passes through to protect it from abrasive surfaces. 1. Determine the mounting location of the display panel. NOTE: The display panel can be mounted by either placing the bracket on top of something or by attaching the bracket to hang below something (Figure 10). 2. Cut the velcro into 1 squares and attach two hook pieces of the velcro to the mounting bracket and attach the two corresponding loop pieces of the velcro to the back of the display panel (Figure 10). Figure Stick the display unit to the mounting bracket. 4. Attach the mounting bracket to its mounting location in the same manner. Place three hook pieces of the velcro onto the bracket and place three loop pieces of the velcro onto the chosen mounting location (Figure 10). 5. Stick the bracket to the mounting location. Attaching the ECU and Display Panel 1. Choose a mounting location inside the cab of the vehicle for mounting the ECU. NOTE: This can be under the dash panel. 2. Attach the bracket to the chosen mounting location using the provided screws (Figure 11). 3. Attach the brackets to the display panel using the provided screws and attach the bracket to a chosen mounting location. 4. Tighten the ECU and display panel hardware. 5. Connect one end of the CAT 5 cable to the ECU and the other to the display panel (Figure 11). Installing the Digital Controller 2. Connect the transducer wires to the corresponding transducers on the manifolds (Figure 3). IMPORTANT: Ensure that the cable seal is in place before connecting the transducer wires. F1 Figure 3 R1 Failure to make sure the cable seal is in place will promote corrosion of the connectors and will cause premature failure of the Digital Control System. Display Figure 11

27 Attaching the Air Lines Installing the Electrical Components Installing the Digital Controller 1. Insert three 3/8 x 1/2 air fittings into the ports of the manifolds. There are two ports on one side and one port on the other (Figure 9). 2. Using a standard tube cutter, a razor blade, or a very sharp knife, squarely cut two pieces of 1/2 air line to go between each of the front air springs and the two ports of the manifold (Figure 9). 3. Repeat step 2 for the rear air bags with the rear manifold. 4. Cut a length of air line to go between the front manifold and an end port of the air tank. FRONT Ground FRONT L R 5. Cut another length of air line to go between the rear manifold and one of the front ports of the air tank. NOTE: A definite click will be heard/felt when the air line is properly seated. The air line should go in approximately 9/ Attach the fitting at the end of the braided leader hose on the compressor to the end port of the air tank (Figure 9). REAR L R REAR 3. Connect the transducer with the three black wires to the open port in the front of the air tank as shown in Figure Attach the corresponding connectors from the ECU to the manifold (Figure 5). 5. Using a butt connector, attach the 12 gauge wire from terminal 30 on the back of the relay to one end of the 30 amp fuse holder (Figure 6). 6. If choosing to use the ring terminal, attach it to the other end of the fuse wire (Figure 6). 7. Choose an appropriate 12+ volt source on the vehicle. NOTE: A direct connection to the battery is suggested. 8. Attach a ground terminal to the small white wire coming out of the back of the ECU/Display Connector (Figure 7). 9. Using a butt connector, attach the 5 amp fuse to the small red wire on the ECU and then attach the wire and fuse to an accessory terminal in the fuse panel. IMPORTANT: Power to the ECU must connect to an accessory source. The accessory source powers the radio, sunroof and other items powered through the accessory circuit and NOT the ignition circuit. Failure to connect to an accessory source WILL CAUSE THE DISPLAY TO FAIL and will void the warranty. Ground Front Left F2 F1 Front Right Rear Left Figure 5 Figure 6 Rear Right L R L R FRONT REAR R2 R1 Installing the Digital Controller For Reference Only Not included in kit Figure 9 For Reference Only Not included in kit Figure 4 Figure 7

28 Kit Diagram Kit Diagram Hardware List Installing the Digital Controller Item Part No. Description Quantity A Compressor 1 B Gallon Air Tank 1 C /8-16 x 1.25 Bolt 4 D /8 Air Line 40 ft. E Digital Controller 175 psi 1 or Digital Controller 145 psi 1 F Dig. Cntrl. ECU/Harness 175psi 1 or Dig. Cntrl. ECU/Harness 145psi 1 G Manifold 2 I Pressure Transducer/Sensor 1 J Display to ECU Line 1 K /2 MNPT x 1/4 FNPT Bushing 2 L Drain Cock 1 N /2 MNPT x 1/8 FNPT Bushing 2 O Inflation Valve 1 IMPORTANT: Power to the ECU must connect to an accessory source. The accessory source powers the radio, sunroof and other items powered through the accessory circuit and NOT the ignition circuit. Failure to connect to an accessory source WILL CAUSE THE DISPLAY TO FAIL and will void the warranty. For Reference Only Not included in kit Passenger Side Right Driver Side Left FRONT To +12 Volt DC Accessory Power Source P /2 Hex Head Pipe Plug 2 Q /2 MNPT x 3/8 Tube Elbow 2 Item Part No. Description Quantity R Air Line Cutter 1 S /8 MNPT x 3/8 Tube Elbow 6 T Self-Tapping Screw 2 U Thread Sealant 1 V Self-Tapping Screw 10 W /8-16 Nyloc Nut 4 X /8 Flat Washer 8 Y Display Mounting Bracket 1 Z Velcro 1 AA Manifold Mounting Brackets 4 CC /4-20 x 3/8 Screw 8 To +12 Volt Power Source 5 AMP Display 30 AMP E Back View Compressor (OUT) (7) Z Display Mounting Bracket Y D J A S V Ground CC V N AA W C Left Front G V Ground B L FRONT R X Right Front F1 FRONT F2 T S K O S L F N X CC V Left Rear G AA W C L P Q R1 REAR R2 REAR S R Right Rear T CC TANK SENSOR I For Reference Only Not included in kit REAR Right Left Installing the Digital Controller Figure 8 AIR LIFT SYSTEMS SUSPENSION SYSTEMS