Installation Instructions

Air Lift

™

PERFORMANCE

Kit 78543

Ford Focus (MK3)

Ford Focus ST

Front Application

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.

Air Lift Performance

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TABLE OF CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Notation Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Important Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Installation Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Hardware List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installing the Air Suspension . . . . . . . . . . . . . . . . . . . . . 4

Stock Suspension Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Air Suspension Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Damping Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Aligning the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Adjusting Extended or Drop Height Using Lower Mount . . . . . . . . . . . . . . . . . . . . .11

Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Post-Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Product Use, Maintenance and Servicing . . . . . . . . . . . 14

Suggested Driving and Maximum Air Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Frequently Asked Questions . . . . . . . . . . . . . . . . . . . . . 14

Tuning the Air Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Fixing Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Limited Warranty and Returns Policy . . . . . . . . . . . . . . 16

Replacement Information . . . . . . . . . . . . . . . . . . . . . . . . 17

Contact Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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2


Introduction

The purpose of this publication is to assist with the installation, maintenance and troubleshooting of this Ford Focus Performance 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, step-by-step installation information, maintenance tips, safety information and a troubleshooting guide.

Air Lift 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 Lift Company at

(800) 248-0892 or visit our website at www.airliftcompany.com.

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

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.

NOTE

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.

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Installation Diagram

F

C

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fig. 1

D OR E

A

B

HARDWARE LIST

Item Part # Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Qty

A 35342

B 35341

ASM, Strut, Focus RF .................................. 1

ASM, Strut, Focus LF ................................... 1

C 20997

D 21810

E 21987

F

Leader Hose, 1/4” ID.................................... 2

Union, 1/4” FNPT X 1/4” PTC, DOT ............. 2

Union, 1/4” FNPT X 3/8” PTC, DOT ............. 2

Spanner Wrench .......................................... 1

STOP!

Missing or damaged parts? Call Air Lift customer service at (800) 248-0892 for a replacement part.

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4


Installing the Air Suspension

STOCK SUSPENSION REMOVAL

1. Begin in the engine compartment by removing the two screws and four plastic pins from the cowl (fig. 2).

fig. 2

2. Lift the cowl enough to access the two bolts from the strut tower cover. Remove this cover (fig. 3).

Cover

fig. 3

3. Loosen the three upper mount bolts (fig. 4). Do not remove at this time.

fig. 4

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4. Elevate and support the vehicle on approved lifting points.

5. Remove the front wheels (fig. 5).

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6. Remove the brake line attaching bolt (fig. 6).

fig. 5

7. Unbolt the stabilizer end link from the strut (fig. 7).

fig. 6 fig. 7

5

6


8. Support the hub/knuckle and remove the lower strut pinch bolt (fig. 8). Slide the knuckle off the strut (fig. 9).

fig. 8 fig. 9

9. Unthread the three upper mount bolts and remove the strut from the vehicle (fig. 10).

fig. 10

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AIR SUSPENSION INSTALLATION

1. Install the leader line into the air spring. Apply thread sealant to the threads of the leader hose. Tighten the appropriate fitting to the air line (one and three-quarter turns beyond hand-tight). Tighten the leader line into the air spring (one and three-quarter turns beyond hand-tight) (fig. 11).

fig. 11

2. Attach the camber plate to the chassis (fig. 12). Torque nuts to 27 Nm (20 lbs.-ft.).

fig. 12

3. Insert the strut into the knuckle and reinstall the lower pinch bolt (fig. 13). Torque to

80 Nm + 180 degrees (59 lbs.-ft. + 180 degrees).

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fig. 13

7


4. Reattach the stabilizer end link and bracket to the strut (fig. 14). Torque to 48 Nm

(35 lbs.-ft.).

fig. 14

5. Reapply the brake line bracket (figs. 15 and 16) and torque bolt to 11 Nm (8 lbs.-ft.).

8

fig. 15

6. Reinstall the plastic strut tower cover with the two bolts.

fig. 16 fig. 17

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7. Lower the cowl cover down and attach in place with the previously removed pins and bolts (figs. 18 and 19).

fig. 17 fig. 18

8. Fully compress the suspension using a jack. With the suspension compressed, review the best routing for the leader hose that is clear of all suspension components and axle.

Routing should also allow for the suspension to extend and steer without kinking or pulling the line tight or rubbing on other components. Following the brake line routing is often a good place to start. Check clearances to all other components.

9. With the suspension fully compressed, take a measurement from the fender to some reference point – typically the center of the axle. Record this measurement as Max

Compression.

10. Cycle the suspension to Max Extension and record the measurement from the same reference points.

11. Add ME and MC then divide by 2. Set the suspension to this point. This position will give

50% stroke in either direction and is a starting point for ride height (fig. 20).

Formula for Calculating Ride Height

(ME+MC)÷2=MID STROKE

fig. 20

12. With the suspension at this position, loosen, then re-torque the lower control arm bolts to manufacturer’s specifications (Table 1).

Location

Fitting to air spring

Stabilizer End link

Brake line tab

Upper mount to chassis nuts

Lower pinch bolt

Wheel lug

Torque Specifications

Nm Lbs.-ft..

1 and 3/4 turns beyond hand tight

48

11

27

80 + 180 degrees

135

35

8

20

59 + 180 degrees

99

Table 1

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9

NOTE


DAMPING ADJUSTMENT

The dampers in this kit have 30 settings, or “clicks,” of adjustable compression and rebound damping characteristics. Damping is changed through the damper rod using the supplied adjuster (figs. 21 & 22) or a 3 mm allen wrench.

Turn the adjuster clockwise and the damping settings are hardened. Turn the adjuster counterclockwise and the damping is softened.

Each damper is preset to “-20 clicks.” This means that the damper is adjusted 20 clicks away from full stiff. Counting down from full stiff is the preferred method of keeping track of, or setting, damping. This setting was developed on a 2014 Ford Focus ST and may need to be adjusted to different vehicles and driving characteristics.

fig. 21 fig. 22

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.

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 and increase life of the bushings based on the custom ride height.

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ADJUSTING EXTENDED OR DROP HEIGHT

USING LOWER MOUNT

Your dampers have been pre-set at the factory to provide maximum drop height while maintaining adequate tire clearance to the air spring. If you wish to gain more extended height (lift), which is the same as reducing drop height, or want to lower the chassis further and there is still adjustment available at the lower mount, please use the following procedure:

1. Support the vehicle with jack stands or a hoist at approved lifting points.

2. Remove the wheel.

3. Using the supplied spanner wrench, loosen the lower locking collar (fig. 23).

NOTE

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fig. 23

4. Deflate the air spring to 0 PSI on the corner you are adjusting.

5. Disconnect lower mount from suspension.

6. Spin the lower mount to the desired location.

Not all models will have further drop height available.

7. Re-install lower mount to suspension and torque fasteners.

8. Tighten the lower locking collar to the lower mount using significant force.

11

12

CAUTION

CAUTION


WHEN ADJUSTING HEIGHT UPWARDS, MAKE SURE THAT THE DAMPER BODY

ENGAGES ALL THE THREADS OF THE LOWER MOUNT (FIG. 24). WHEN ADJUSTING

DOWNWARDS, MAKE SURE THERE IS ADEQUATE AIR SPRING CLEARANCE TO THE

TIRE/WHEEL ASSEMBLY. CLEARANCE MUST BE CHECKED WITH SYSTEM FULLY

DEFLATED AS WELL AS FULLY INFLATED TO ENSURE THAT NO RUBBING OCCURS.

FAILURE TO MAINTAIN ADEQUATE CLEARANCE CAN RESULT IN AIR SPRING FAILURE

AND WILL NOT BE COVERED UNDER WARRANTY.

DO NOT ADJUST HEIGHT BY SPINNING AIR SPRING ON DAMPER! DOING SO MAY

CAUSE AN AIR LEAK AND COMPROMISE THE ASSEMBLY.

FOR STRUTS: FOR SHOCKS:

OK, no threads showing.

Not OK, threads are showing.

Thread

MUST be showing in window.

fig. 24

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Before Operating

CAUTION

MAKE SURE THE FRONT WHEELS ARE STRAIGHT WHEN DEFLATING AND

REINFLATING AIR BAGS.

1. Inflate and deflate the system (do not exceed 125 PSI) to check for clearance or binding issues. With the air springs deflated, check clearances on everything so as not to pinch brake lines, vent tubes, etc. Clear lines if necessary.

2. Inflate the air springs to 75 PSI - 90 PSI and check all connections for leaks.

3. Air Lift Performance offers a complete line of air suspension control systems which are highly recommended for use with this product. Visit www.airliftperformance.com for more details.

4. Please continue by reading the Product Use, Maintenance and Servicing section.

INSTALLATION CHECKLIST



Clearance test — Inflate the air springs to 75-90 PSI and make sure there is at least ½” clearance from anything that might rub against each sleeve. Be sure to check the tire, brake drum, frame, shock absorbers and brake cables.



Leak test before road test — Inflate the air springs to 75 PSI - 90 PSI and check all connections for leaks. All leaks must be eliminated before the vehicle is road tested.



Heat test — Be sure there is sufficient clearance from heat sources, at least 6” for air springs and air lines. If a heat shield was included in the kit, install it. If there is no heat shield, but one is required, call Air Lift customer service at (800) 248-0892.



Fastener test — Recheck all bolts for proper torque.



Road test — The vehicle should be road tested after the preceding tests. Inflate the springs to recommended driving pressures. Drive the vehicle 10 miles and recheck for clearance, loose fasteners and air leaks.



Operating instructions — If professionally installed, the installer should review the operating instructions with the owner. Be sure to provide the owner with all of the paperwork that came with the kit.

Technician’s Signature Date

POST-INSTALLATION CHECKLIST



Overnight leak down test — Recheck air pressure after the vehicle has been used for 24 hours.

If the pressure has dropped more than 5 PSI, then there is a leak that must be fixed. Either fix the leak yourself or return to the installer for service.



Air pressure requirements — Regardless of load, the air pressure should always be adjusted to maintain adequate ride height at all times while driving.



Thirty day or 500 mile test — Recheck the air spring system after 30 days or 500 miles, whichever comes first. If any part shows signs of rubbing or abrasion, the source should be identified and moved, if possible. If it is not possible to relocate the cause of the abrasion, the air spring may need to be remounted. If professionally installed, the installer should be consulted. Check all fasteners for tightness.

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Product Use, Maintenance and Servicing

NOTE

CAUTION

Suggested Driving Air Pressure Maximum Air Pressure

35-45 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

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.

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 Lift at (800) 248-0892 for assistance.

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.

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Q . Will raising the vehicle on a hoist for service work damage the air springs?

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.

Tuning the Air Pressure

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.

Checking for leaks

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.

Fixing Leaks

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. 25). Reinsert the air line into the push-to-connect fitting.

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.

2. If the preceding steps have not resolved the problem, call Air Lift customer service at (800) 248-0892.

fig. 25

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Limited Warranty and Returns Policy

WHAT THIS WARRANTY COVERS

Air Lift Company provides a Limited Lifetime Warranty to the original purchaser of its Air Lift Performance 3H™ and

3P™ Control/Air Management Systems, that the Air Lift Performance products will be free from defects in workmanship and materials for the normal expected life of the part when used on cars and trucks as specified by Air Lift Company and under normal operating conditions, subject to the requirements and exclusions set forth below.

For all other Air Lift Performance products, Air Lift Company warrants to the original purchaser for a period of one year from the date of original purchase, that the Air Lift Performance products will be free from defects in workmanship and materials when used on cars and trucks as specified by Air Lift Company and under normal operating conditions, subject to the requirements and exclusions set forth below.

WHAT THIS WARRANTY DOES NOT COVER

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. This warranty does not apply and is void if damage or failure is caused by: accident, abuse, misuse (including but not limited to racing or off-road activities or commercial use), abnormal use, faulty installation, liquid contact, fire, earthquake or other external cause; operating the product outside Air Lift Company’s instructions, specifications or guidelines; or service, alteration, maintenance or repairs performed by anyone other than Air Lift Company to the product from its purchased condition.

This warranty also does not apply to: Universal Air (Fabricator Kits), consumable parts, such as batteries; cosmetic damage, including but not limited to scratches or dents; defects caused by normal wear and tear or otherwise due to the normal aging of the product, or if any serial or identification number has been removed or defaced from the product. Air Lift Company reserves the right to change the design of any product without assuming any obligation to modify any product previously manufactured.

LIMITATION OF LIABILITY

TO THE EXTENT PERMITTED BY LAW, THIS WARRANTY AND THE REMEDIES SET FORTH HEREIN ARE

EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, REMEDIES AND CONDITIONS, WHETHER ORAL,

WRITTEN, STATUTORY, EXPRESS OR IMPLIED. AIR LIFT COMPANY DISCLAIMS ALL STATUTORY AND

IMPLIED WARRANTIES, INCLUDING WITHOUT LIMITATION, WARRANTIES OF MERCHANTABILITY AND

FITNESS FOR A PARTICULAR PURPOSE AND WARRANTIES AGAINST HIDDEN OR LATENT DEFECTS TO

THE EXTENT PERMITTED BY LAW. TO THE EXTENT SUCH WARRANTIES CANNOT BE DISCLAIMED, SUCH

IMPLIED WARRANTIES SHALL APPLY ONLY FOR THE WARRANTY PERIOD SPECIFIED ABOVE. PLEASE

NOTE THAT SOME STATES DO NOT ALLOW LIMITATION ON HOW LONG AN IMPLIED WARRANTY (OR

CONDITION) LASTS. SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU.

EXCEPT AS PROVIDED IN THIS WARRANTY AND TO THE EXTENT PERMITTED BY LAW, AIR LIFT COMPANY

SHALL NOT BE LIABLE FOR ANY DIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES RESULTING

FROM ANY BREACH OF WARRANTY OR CONDITION, OR ARISING IN CONNECTION WITH THE SALE, USE

OR REPAIR OF AIR LIFT PERFORMANCE PRODUCTS, OR UNDER ANY OTHER LEGAL THEORY, INCLUDING

BUT NOT LIMITED TO LOSS OF USE, LOSS OF REVENUE, LOSS OF ACTUAL OR ANTICIPATED PROFITS,

LOSS OF THE USE OF MONEY, LOSS OF BUSINESS, LOSS OF OPPORTUNITY, LOSS OF GOODWILL, AND

LOSS OF REPUTATION. AIR LIFT COMPANY’S MAXIMUM LIABILITY SHALL NOT IN ANY CASE EXCEED

THE PURCHASE PRICE PAID BY YOU FOR THE AIR LIFT PERFORMANCE PRODUCT. PLEASE NOTE THAT

SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL

DAMAGES, SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU.

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Limited Warranty and Returns Policy cont’d

HOW TO GET SERVICE

If a defect in workmanship or materials causes your Air Lift Performance product to become inoperable within the warranty period, before returning any defective product, call Air Lift Company at (800) 248-0892 in the U.S. and

Canada (elsewhere, (517) 322-2144) to obtain a Returned Materials Authorization (RMA) number. The consumer shall be responsible for removing (labor charges) the defective product from the vehicle and returning it, shipping costs prepaid, to Air Lift Company for verification. Returns to Air Lift Company must be postage prepaid and sent to:

Air Lift Company • 2727 Snow Road • Lansing, MI • 48917. You must prove to the satisfaction of Air Lift Company the date of original purchase of your Air Lift Performance product. You must also enclose the RMA number and a return address. A minimum $10 shipping and handling charge will apply to all warranty claims. You must also pack the product to minimize the risk of it being damaged in transit. If we receive a product in damaged condition as the result of shipping, we will notify you and you must seek a claim with the shipper.

WHAT AIR LIFT COMPANY WILL DO

If you submit a valid claim to Air Lift Company during the warranty period, Air Lift Company will, at its option, repair your Air Lift Performance product or furnish you with a new or rebuilt product. Air Lift Company will not reimburse you for repairs or replacement parts provided by other parties. Your repaired or replacement Air Lift Performance product will be returned to you (subject to payment of the required warranty claim shipping and handling charge) and it will be covered under the warranty for the balance of the warranty period, if any. When a product or part is replaced, any replacement item becomes your property and the replaced item becomes property of Air Lift Company.

You are responsible for installation/reinstallation (labor charges) of the product.

HOW THE LAW RELATES TO THIS WARRANTY

THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH

VARY FROM STATE TO STATE. BY THIS WARRANTY, AIR LIFT COMPANY DOES NOT LIMIT OR EXCLUDE

YOUR RIGHTS EXCEPT AS ALLOWED BY LAW. TO FULLY UNDERSTAND YOUR RIGHTS, YOU SHOULD

CONSULT THE LAWS OF YOUR STATE.

Replacement Information

If you need replacement parts, contact the local dealer or call Air Lift customer service at (800) 248-0892. Most parts are immediately available and can be shipped the same day.

Contact Air Lift Company customer service at (800) 248-0892 first if:

• Parts are missing from the kit.

• Need technical assistance on installation or operation.

• Broken or defective parts in the kit.

• Wrong parts in the kit.

• Have a warranty claim or question.

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) 248-0892, Monday through Friday. For calls from outside the USA or

Canada, our local number is (517) 322-2144. You may also contact customer service anytime by e-mail at [email protected]. For inquiries by mail, our address is PO Box 80167, Lansing, MI 48908-0167.

Our shipping address for returns is 2727 Snow Road, Lansing, MI 48917.

You may also contact our sales team anytime by e-mail at [email protected] or on the web at www.airliftperformance.com.

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Need Help?

Contact our customer service department by calling

(800) 248-0892, Monday through Friday. For calls from outside the USA or Canada, our local number is (517) 322-2144.

Thank you for purchasing Air Lift Performance products!

Air Lift Company • 2727 Snow Road • Lansing, MI 48917 or PO Box 80167 • Lansing, MI 48908-0167

Toll Free (800) 248-0892 • Local (517) 322-2144 • Fax (517) 322-0240 • www.airliftperformance.com

Printed in the USA

Air Lift

™

PERFORMANCE

Kits

78646/78643

Ford Focus (MK3)

Ford Focus ST

Rear Application

(With and Without Shocks)





2

MN-975



Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2


Important Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Installation Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Hardware List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installing the Air Suspension . . . . . . . . . . . . . . . . . . . . . 4

Preparing the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Stock Suspension Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Air Suspension Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Damping Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Aligning the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Adjusting Extended or Drop Height Using Lower Mount . . . . . . . . . . . . . . . . . . . . .10

Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Post-Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Product Use, Maintenance and Servicing . . . . . . . . . . . 13

Suggested Driving and Maximum Air Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13


Frequently Asked Questions . . . . . . . . . . . . . . . . . . . . . 13

Tuning the Air Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Fixing Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Limited Warranty and Returns Policy . . . . . . . . . . . . . . 15



MN-975

1

2


Introduction

The purpose of this publication is to assist with the installation, maintenance and troubleshooting of this Ford Focus Performance 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, step-by-step installation information, maintenance tips, safety information and a troubleshooting guide.

Air Lift 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 Lift Company at

(800) 248-0892 or visit our website at www.airliftcompany.com.



DANGER

WARNING

CAUTION


INJURY OR DEATH.





NOTE


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 PERFORMANCE STRUTS/SHOCKS IN ANY WAY.

DAMAGE TO UNIT MAY OCCUR AND WILL VOID WARRANTY.

MN-781


Installation Diagram

HARDWARE LIST

Item Part # Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Qty

A 07038

B 58531

Upper Spring Seat ....................................... 2

Air Spring, 2B6 REG (Recess Mount).......... 2

C 11115

D 13979

E 13990

F 17101

G 21779

H 21851

I

J

26794

Control Arm (C1 Rear) ................................. 2

Bushing Spacer............................................ 4

Bushing Spacer............................................ 4

3/8-16 X 3/4” Hex Bolt.................................. 4

1/4MNPT X 1/4PTC Elbow “DOT” ............... 2

1/4MNPT X 3/8PTC 90° “DOT” .................... 2

Ford Focus ST Rear Shock ......................... 2

Spanner Wrench .......................................... 1

I

fig. 1

A

E

B

G OR H

F

STOP!


MN-975

J

C

D

3


Installing the Air Suspension

PREPARING THE VEHICLE


2. Remove the rear wheels (fig. 2). Support the hub assembly before beginning work (fig. 3).

fig. 2 fig. 3

STOCK SUSPENSION REMOVAL

1. Disconnect the stabilizer bar end link from the lower control arm (fig. 4). You may also remove the end links from the stabilizer bar for easier installation covered later in this manual (fig. 5).

4

CAUTION

fig. 4 fig. 5

THE FOLLOWING STEPS COVER HOW TO REMOVE THE COIL SPRING WITHOUT

A SPRING COMPRESSOR. CARE MUST BE TAKEN TO ENSURE THE SAFETY OF

YOURSELF AND OTHERS WHEN REMOVING THE COIL SPRINGS.

2. Unbolt the outer lower control arm from the wheel bearing housing (fig. 6). Carefully lower the control arm down until coil spring tension is released (fig. 7). You may need to pull the control arm farther down to unseat the control arm from the upper spring perch

(fig. 8). Remove the coil spring and rubber isolators.

fig. 6 fig. 7 fig. 8

MN-975


3. Remove the inner control arm cam bolts and remove the lower control arms (fig. 9).

There is a connector on one side that will need some coaxing to clear the cam bolt upon removal (figs. 10 and 11).

fig. 9

Make sure connector is clear of bolt head upon removal of bolt fig. 10

Bolt head clear of connector fig. 11

4. If retaining the factory shocks, continue to next step. Unbolt the upper and lower shock mount bolts and remove the shock from the vehicle (figs. 12 and 13).

fig. 12 fig. 13

MN-975

5


AIR SUSPENSION INSTALLATION

1. Remove the subframe bolt from the upper coil spring perch (fig. 14). Place the bolt and washer through the supplied upper air spring mount and bolt into place (figs. 15-17).

fig. 14 fig. 15

6

fig. 16 fig. 17

2. Clip the zip tie off the end farthest from the large round spring seat (end with thick bushing spacers) and install into the cross member at the inner control arm pivot point.

Reinstall the cam bolts. Do not torque at this time. (Figs. 18-21) a) Install the stabilizer bar end link onto the newly supplied control arm.

Torque to 55 Nm (40 lbs.-ft.).

fig. 18 fig. 19 fig. 20 fig. 21

MN-975


3. Attach the air spring to the control arm using the supplied washers and bolts (fig. 22).

Torque to 27 Nm (20 lbs.-ft.). Once the air spring is attached to the control arm, wrap the fitting threads with Teflon tape or thread sealant and thread into the air spring 1 and

3/4 turns beyond hand tight.

MN-975

fig. 22 fig. 23

4. Clip zip tie from the other end and attach the control arm to the wheel bearing housing

(fig. 24). Do not torque at this time.

fig. 24

5. Reattach the stabilizer end link to the stabilizer bar (figs. 25 and 26). Torque nuts to

55 Nm (40 lbs.-ft.).

fig. 25 fig. 26

6. If retaining the factory shocks, continue to the next step. Install the new shock (figs. 27 and 28). Torque the lower shock mount bolt to 102 Nm (76 lbs.-ft.). Toque the upper shock mount bolts to 29 Nm (21 lbs.-ft.). At this time, make sure the air spring is seated against the new upper spring perch as shown in fig. 24.

fig. 27 fig. 28

7

8


7. Fully compress the suspension using a jack. With the suspension compressed, review the best routing for the leader hose that is clear of all suspension components. Routing should also allow for the suspension to extend without kinking or pulling the line tight or rubbing on other components. Following the brake line routing is often a good place to start. Check clearances to all other components.

8. With the suspension fully compressed, take a measurement from the fender to some reference point – typically the center of the axle. Record this measurement as Max

Compression.

9. Cycle the suspension to Max Extension and record the measurement from the same reference points.

10. Add ME and MC then divide by 2. Set the suspension to this point. This position will give

50% stroke in either direction and is a starting point for ride height (fig. 29).

Formula for Calculating Ride Height

(ME+MC)÷2=MID STROKE

fig. 29

11. With the suspension at this position, loosen, then re-torque the lower control arm bolts to manufacturer’s specifications (Table 1).

Location

Fitting to air spring

Upper shock mount to chassis

Lower shock mount bolt

Stabilizer end link nuts

Wheel lugs

Air spring bolt to control arm

Control arm cam bolt

Control arm outer bolt


Nm Lbs.-ft.

1 and 3/4 turns beyond hand tight

29 21

102 76

55

135

27

100

102

40

99

20

73

75

Table 1

MN-975


DAMPING ADJUSTMENT

The dampers in this kit have 30 settings, or “clicks,” of adjustable compression and rebound damping characteristics. Damping is changed through the damper rod using the supplied adjuster (figs. 30 & 31) or a 3 mm allen wrench.

Turn the adjuster clockwise and the damping settings are hardened. Turn the adjuster counterclockwise and the damping is softened.

Each damper is preset to “-17 clicks.” This means that the damper is adjusted 17 clicks away from full stiff. Counting down from full stiff is the preferred method of keeping track of, or setting, damping. This setting was developed on a 2014 Ford Focus ST and may need to be adjusted to different vehicles and driving characteristics.

NOTE

fig. 30 fig. 31

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.

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 and increase life of the bushings based on the custom ride height.

MN-975

9


ADJUSTING EXTENDED OR DROP HEIGHT

USING LOWER MOUNT

Your dampers have been pre-set at the factory to provide maximum drop height while maintaining adequate tire clearance to the air spring. If you wish to gain more extended height (lift), which is the same as reducing drop height, or want to lower the chassis further and there is still adjustment available at the lower mount, please use the following procedure:


2. Remove the wheel.

3. Using the supplied spanner wrench, loosen the lower locking collar (fig. 32).

NOTE

10

fig. 32

4. Deflate the air spring to 0 PSI on the corner you are adjusting.

5. Disconnect lower mount from suspension.

6. Spin the lower mount to the desired location.

Not all models will have further drop height available.

7. Re-install lower mount to suspension and torque fasteners.

8. Tighten the lower locking collar to the lower mount using significant force.

MN-975


CAUTION

CAUTION

WHEN ADJUSTING HEIGHT UPWARDS, MAKE SURE THAT THE DAMPER BODY

ENGAGES ALL THE THREADS OF THE LOWER MOUNT (FIG. 33). WHEN ADJUSTING

DOWNWARDS, MAKE SURE THERE IS ADEQUATE AIR SPRING CLEARANCE TO THE

TIRE/WHEEL ASSEMBLY. CLEARANCE MUST BE CHECKED WITH SYSTEM FULLY

DEFLATED AS WELL AS FULLY INFLATED TO ENSURE THAT NO RUBBING OCCURS.

FAILURE TO MAINTAIN ADEQUATE CLEARANCE CAN RESULT IN AIR SPRING FAILURE

AND WILL NOT BE COVERED UNDER WARRANTY.

DO NOT ADJUST HEIGHT BY SPINNING AIR SPRING ON DAMPER! DOING SO MAY

CAUSE AN AIR LEAK AND COMPROMISE THE ASSEMBLY.

FOR STRUTS: FOR SHOCKS:

OK, no threads showing.

Not OK, threads are showing.

Thread

MUST be showing in window.

fig. 33

MN-975

11


Before Operating

CAUTION

MAKE SURE THE FRONT WHEELS ARE STRAIGHT WHEN DEFLATING AND

REINFLATING AIR BAGS.

1. Inflate and deflate the system (do not exceed 125 PSI) to check for clearance or binding issues. With the air springs deflated, check clearances on everything so as not to pinch brake lines, vent tubes, etc. Clear lines if necessary.

2. Inflate the air springs to 75 PSI - 90 PSI and check all connections for leaks.

3. Air Lift Performance offers a complete line of air suspension control systems which are highly recommended for use with this product. Visit www.airliftperformance.com for more details.

4. Please continue by reading the Product Use, Maintenance and Servicing section.

INSTALLATION CHECKLIST



Clearance test — Inflate the air springs to 75-90 PSI and make sure there is at least ½” clearance from anything that might rub against each sleeve. Be sure to check the tire, brake drum, frame, shock absorbers and brake cables.



Leak test before road test — Inflate the air springs to 75 PSI - 90 PSI and check all connections for leaks. All leaks must be eliminated before the vehicle is road tested.



Heat test — Be sure there is sufficient clearance from heat sources, at least 6” for air springs and air lines. If a heat shield was included in the kit, install it. If there is no heat shield, but one is required, call Air Lift customer service at (800) 248-0892.



Fastener test — Recheck all bolts for proper torque.



Road test — The vehicle should be road tested after the preceding tests. Inflate the springs to recommended driving pressures. Drive the vehicle 10 miles and recheck for clearance, loose fasteners and air leaks.



Operating instructions — If professionally installed, the installer should review the operating instructions with the owner. Be sure to provide the owner with all of the paperwork that came with the kit.

Technician’s Signature Date

POST-INSTALLATION CHECKLIST



Overnight leak down test — Recheck air pressure after the vehicle has been used for 24 hours.

If the pressure has dropped more than 5 PSI, then there is a leak that must be fixed. Either fix the leak yourself or return to the installer for service.



Air pressure requirements — Regardless of load, the air pressure should always be adjusted to maintain adequate ride height at all times while driving.



Thirty day or 500 mile test — Recheck the air spring system after 30 days or 500 miles, whichever comes first. If any part shows signs of rubbing or abrasion, the source should be identified and moved, if possible. If it is not possible to relocate the cause of the abrasion, the air spring may need to be remounted. If professionally installed, the installer should be consulted. Check all fasteners for tightness.

12

MN-975


Product Use, Maintenance and Servicing

NOTE

CAUTION

Suggested Driving Air Pressure Maximum Air Pressure

35-45 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

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.


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.

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 Lift at (800) 248-0892 for assistance.

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.

MN-975

13


Q . Will raising the vehicle on a hoist for service work damage the air springs?

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.

Tuning the Air Pressure

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.

Checking for Leaks

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.

Fixing Leaks

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. 34). Reinsert the air line into the push-to-connect fitting.

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.

2. If the preceding steps have not resolved the problem, call Air Lift customer service at (800) 248-0892.

fig. 34

14

MN-975


Limited Warranty and Returns Policy

WHAT THIS WARRANTY COVERS

Air Lift Company provides a Limited Lifetime Warranty to the original purchaser of its Air Lift Performance 3H™ and

3P™ Control/Air Management Systems, that the Air Lift Performance products will be free from defects in workmanship and materials for the normal expected life of the part when used on cars and trucks as specified by Air Lift Company and under normal operating conditions, subject to the requirements and exclusions set forth below.

For all other Air Lift Performance products, Air Lift Company warrants to the original purchaser for a period of one year from the date of original purchase, that the Air Lift Performance products will be free from defects in workmanship and materials when used on cars and trucks as specified by Air Lift Company and under normal operating conditions, subject to the requirements and exclusions set forth below.

WHAT THIS WARRANTY DOES NOT COVER

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. This warranty does not apply and is void if damage or failure is caused by: accident, abuse, misuse (including but not limited to racing or off-road activities or commercial use), abnormal use, faulty installation, liquid contact, fire, earthquake or other external cause; operating the product outside Air Lift Company’s instructions, specifications or guidelines; or service, alteration, maintenance or repairs performed by anyone other than Air Lift Company to the product from its purchased condition.

This warranty also does not apply to: Universal Air (Fabricator Kits), consumable parts, such as batteries; cosmetic damage, including but not limited to scratches or dents; defects caused by normal wear and tear or otherwise due to the normal aging of the product, or if any serial or identification number has been removed or defaced from the product. Air Lift Company reserves the right to change the design of any product without assuming any obligation to modify any product previously manufactured.

LIMITATION OF LIABILITY

TO THE EXTENT PERMITTED BY LAW, THIS WARRANTY AND THE REMEDIES SET FORTH HEREIN ARE

EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, REMEDIES AND CONDITIONS, WHETHER ORAL,

WRITTEN, STATUTORY, EXPRESS OR IMPLIED. AIR LIFT COMPANY DISCLAIMS ALL STATUTORY AND

IMPLIED WARRANTIES, INCLUDING WITHOUT LIMITATION, WARRANTIES OF MERCHANTABILITY AND

FITNESS FOR A PARTICULAR PURPOSE AND WARRANTIES AGAINST HIDDEN OR LATENT DEFECTS TO

THE EXTENT PERMITTED BY LAW. TO THE EXTENT SUCH WARRANTIES CANNOT BE DISCLAIMED, SUCH

IMPLIED WARRANTIES SHALL APPLY ONLY FOR THE WARRANTY PERIOD SPECIFIED ABOVE. PLEASE

NOTE THAT SOME STATES DO NOT ALLOW LIMITATION ON HOW LONG AN IMPLIED WARRANTY (OR

CONDITION) LASTS. SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU.

EXCEPT AS PROVIDED IN THIS WARRANTY AND TO THE EXTENT PERMITTED BY LAW, AIR LIFT COMPANY

SHALL NOT BE LIABLE FOR ANY DIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES RESULTING

FROM ANY BREACH OF WARRANTY OR CONDITION, OR ARISING IN CONNECTION WITH THE SALE, USE

OR REPAIR OF AIR LIFT PERFORMANCE PRODUCTS, OR UNDER ANY OTHER LEGAL THEORY, INCLUDING

BUT NOT LIMITED TO LOSS OF USE, LOSS OF REVENUE, LOSS OF ACTUAL OR ANTICIPATED PROFITS,

LOSS OF THE USE OF MONEY, LOSS OF BUSINESS, LOSS OF OPPORTUNITY, LOSS OF GOODWILL, AND

LOSS OF REPUTATION. AIR LIFT COMPANY’S MAXIMUM LIABILITY SHALL NOT IN ANY CASE EXCEED

THE PURCHASE PRICE PAID BY YOU FOR THE AIR LIFT PERFORMANCE PRODUCT. PLEASE NOTE THAT

SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL

DAMAGES, SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU.

MN-975

15


Limited Warranty and Returns Policy cont’d

HOW TO GET SERVICE

If a defect in workmanship or materials causes your Air Lift Performance product to become inoperable within the warranty period, before returning any defective product, call Air Lift Company at (800) 248-0892 in the U.S. and

Canada (elsewhere, (517) 322-2144) to obtain a Returned Materials Authorization (RMA) number. The consumer shall be responsible for removing (labor charges) the defective product from the vehicle and returning it, shipping costs prepaid, to Air Lift Company for verification. Returns to Air Lift Company must be postage prepaid and sent to:

Air Lift Company • 2727 Snow Road • Lansing, MI • 48917. You must prove to the satisfaction of Air Lift Company the date of original purchase of your Air Lift Performance product. You must also enclose the RMA number and a return address. A minimum $10 shipping and handling charge will apply to all warranty claims. You must also pack the product to minimize the risk of it being damaged in transit. If we receive a product in damaged condition as the result of shipping, we will notify you and you must seek a claim with the shipper.

WHAT AIR LIFT COMPANY WILL DO

If you submit a valid claim to Air Lift Company during the warranty period, Air Lift Company will, at its option, repair your Air Lift Performance product or furnish you with a new or rebuilt product. Air Lift Company will not reimburse you for repairs or replacement parts provided by other parties. Your repaired or replacement Air Lift Performance product will be returned to you (subject to payment of the required warranty claim shipping and handling charge) and it will be covered under the warranty for the balance of the warranty period, if any. When a product or part is replaced, any replacement item becomes your property and the replaced item becomes property of Air Lift Company.

You are responsible for installation/reinstallation (labor charges) of the product.

HOW THE LAW RELATES TO THIS WARRANTY

THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH

VARY FROM STATE TO STATE. BY THIS WARRANTY, AIR LIFT COMPANY DOES NOT LIMIT OR EXCLUDE

YOUR RIGHTS EXCEPT AS ALLOWED BY LAW. TO FULLY UNDERSTAND YOUR RIGHTS, YOU SHOULD

CONSULT THE LAWS OF YOUR STATE.















Canada, our local number is (517) 322-2144. You may also contact customer service anytime by e-mail at [email protected]. For inquiries by mail, our address is PO Box 80167, Lansing, MI 48908-0167.

Our shipping address for returns is 2727 Snow Road, Lansing, MI 48917.


16

MN-975

Need Help?






Printed in the USA


Kit Details

27671

HARDWARE LIST

Part # Description Qty

72605

27042

4pt Fast Air Manifold - 1/4”” ................ 1

Gen 3 Display ..................................... 1

26498-002 Electrical Harness - FastAir ................ 1

24672 Fuse, spade 3amp .............................1

24547

24500

24645

24752

24748

24524

24595

24561

24542

Fuse, spade, 30amp ...........................1

ATC Fuse holder w/ cap .....................2

16GA Butt Connector ..........................1

12-10GA Butt Connector.....................3

12GA Ring Terminal 3/8” ....................2

Female Spade Terminal......................1

12GA Female Spade Terminal ..........1

Adaptor, Mini Fuse ..............................1

ATC/ATO Fuse Adaptor ......................1

23586

21043

21847

21737

Thread Sealant ...................................1

1/4” MNPT X 1/4” PTC Elbow .............1

3/8” MNPT X 1/4” PTC Elbow .............1

3/8” Pipe Plug .....................................1

Part #

21773

21999

21633

21585

20937

20946

17263

18444

17188

18435

11517

11217

17173

16380

11955

10466

10530

Description ..............................Qty

3/8” MNPT X 1/8” MNPT Adapter .......1

1/8” MNPT X 1/4” PTC Elbow .............2

Push Lock Valve .................................1

1/4” Pipe Plug .....................................1

Polyurethane Filter Drain Hose .........5ft

DOT 1/4” Air Line ............................60ft

1/4-14 x 1 Self Tapping Screw ............3

3/8” Flat Washer .................................8

3/8-16 x 1.25 Hex Cap Screw .............4

3/8-16 Nyloc Nut .................................4

Miniature Filter ....................................1

P Clamp ..............................................1

1/4”-14 X 3/4” Self Tapping Screw ......1

VIAIR 380C Compressor (200 psi) .....1

4 Gallon Aluminum Air Tank ...............1

8” Zip Tie ...........................................10

Air Line Cutter .....................................1

MN-784 • (021503) • ECR 7999

STOP!


Air Lift

™

PERFORMANCE

AutoPilot V2

P A T E N T P E N D I N G

™





Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2


Installing the AutoPilot V2 Kit . . . . . . . . . . . . . . . . . . . . 3

Install Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Install Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Install Air Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

NPT Assembly Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Helpful Tips: Air Line and Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Setup and Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

System Calibration and Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Program Presets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Operating the System . . . . . . . . . . . . . . . . . . . . . . . . . . . 12


Leak Testing and Detection . . . . . . . . . . . . . . . . . . . . . . 13

Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

AutoPilot V2 Remote Control Unit Dimensions . . . . . . 15

Manifold Template . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

16380 Compressor Template . . . . . . . . . . . . . . . . . . . . . 19

Warranty and Returns Policy . . . . . . . . . . . . . . . . . . . . . 21



2

Introduction

The purpose of this publication is to assist with the installation, operation and troubleshooting of the AutoPilot V2 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 step-by-step installation information, installation templates and a troubleshooting guide.

Air Lift 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 Lift Performance at (800) 248-0892 or visit our website at www.airliftperformance.com.



DANGER

WARNING

CAUTION


INJURY OR DEATH.





NOTE



MN-754

Air Lift Performance Air Lift Performance

Installing the AutoPilot V2 Kit

NOTE

CAUTION

INSTALL COMPONENTS

For a complete schematic, please see fig. 15. (pages 10-11)

BEST PRACTICE IS TO LOCATE THE MANIFOLD UNIT INSIDE THE VEHICLE. IF

EXTERNAL MOUNTING IS DESIRED, THE MANIFOLD MUST BE LOCATED IN AN

AREA SHIELDED FROM DIRECT WATER SPRAY FROM TIRES OR CAR WASHES. THE

MANIFOLD SHOULD BE CONSIDERED “WATER RESISTANT” NOT “WATERPROOF”.

NOTE

Layout

1. Plan component location first. Ideally, the manifold should be located above the compressor and tank if possible to avoid compressor ingested water from gathering in the manifold. This is most important for vehicles operated in below freezing climates.

2. 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.

• the air lines will route cleanly through the vehicle without kinking or bending.

Be sure to install all components as far as possible from any heat sources. Plan and prepare harness and air line routing thru the vehicle. Eliminate all sharp edges that could chafe. Use grommets when passing through compartment walls.

NOTE

NOTE

Prepare and install the compressor

1. Prepare the compressor intake. If the compressor body is mounted inside the vehicle, attach filter to port on end of compressor (fig. 15). If compressor is located outside the vehicle, snorkel inlet filter to dry location inside vehicle using components supplied with compressor.

2. Center punch and drill four holes using the template on page 19.

3. Attach using the hardware supplied with the compressor.

If the harness must be lengthened, use properly sized butt connectors and wire. If extending the power/ground wires, use 8AWG wire minimum or contact Air Lift for more information.

The supplied harness is only capable of powering a single compressor. If installing dual compressors, a second dedicated power wire is required. Consult the Electrical Schematic section for proper wiring, and contact Air Lift for an optional second compressor harness

(part number: 27679).

Manifold

1. Position the manifold in a desired location. Make sure the manifold mounting surface is flat.

Mount the manifold to the body either horizontally (fig. 1a) or vertically with the ports facing toward the ground (fig. 1b). Do not mount the manifold upside down (fig. 1c). Proper manifold

mounting will help prevent water from settling in areas sensitive to freezing.

2. Fasten the manifold using the two self-tapping screws.

If the mounting surface is not flat, add washers to space the manifold up over surface irregularities.

3. If needed, a manifold mounting template can be found on page 17.

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3


This represents the top of the vehicle frame or any custom setup (and is the same for figures 1b and 1c).

fig. 1a fig. 1b fig. 1c

NOTE

NOTE

NOTE

4

PREFERRED ACCEPTABLE

ABSOLUTELY NOT!

Air compressors intake moisture (humidity) from the outside air source and will deposit water in the air tank. The AutoPilot V2 system includes a filter that will greatly reduce the

potential for moisture to enter the manifold, however, tanks must be regularly purged to eliminate the possibility of water entering the manifold. Be sure to provide easy access to

tank drain/fill valve (preferably outside the vehicle). This is an automatic draining filter and does not need servicing. If you find this filter to be plugged, it will need to be replaced. If using an engine driven compressor, the life of the provided filter may be reduced due to the

increased potential for oil being introduced into the system.

Tank pre-assembly

(see fig. 15)

1. Per the diagram on pages 10 and 11, install the filter to the tank with supplied fittings/ adapters or remotely mount the filter using the supplied fittings, P-clamp and self tapping screw. Be sure to mount the filter in the correct orientation.

This is a one-way filter. The arrow at the top should be pointing in the direction of the air flow from the tank to the manifold (fig. 15b).

This is an automatic draining filter that does not require servicing. If you find this filter to be

plugged, it will need to be replaced. The tank will need to be purged periodically to reduce/ eliminate the potential of moisture entering the manifold.

Tank install

(see fig. 15)

1. Using the tank feet as a template, drill holes for hardware assembly.

2. Attach the tank using the supplied hardware.

3. Cut an appropriate length of hose from the manifold port T, to the PTC fitting on the filter.

4. Route the drain/fill air line with a schrader valve (preferably outside the vehicle).

5. Install the supplied drain tube (soft hose) to the bottom of the filter and route to a location outside of the vehicle.

When cutting plastic air line, only use a standard hose cutter like (Air Lift part number 10530)

or razorblade. Cut all hose ends square and as smoothly as possible. See hose cutting tips

on page 6.

INSTALL HARNESS

1. Disconnect the battery ground while installing the system.

2. Compressor / manifold connections (see fig. 15)

• 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 1/4” of wire casing from the compressor wires.

• Strip 1/4” of wire casing from the black and pink harness wires.

• NOTE: Use an appropriate terminal crimp tool to ensure a good connection.

MN-754



NOTE

NOTE

NOTE

CAUTION

• Using a butt connector attach the RED compressor wire to the PINK harness wire.

• Using a butt connector attach the BLACK compressor wire to the BLACK harness wire.

• Carefully apply heat (preferably with a heat gun) to seal these connections.

3. Battery / ignition connections (see fig. 15)

• Identify the power, ground, + ignition leg of the harness.

• Ground: 10AWG black wire; Power: 10AWG red wire; Ignition: 18AWG pink wire.

• Route power and ground leg of the harness free from any heat source to the battery.

• Using a butt connector attach the red wire to a fuse holder.

• Attach an 3/8” eyelet to the other end of the fuse holder and attach to the positive battery (+) terminal.

• Attach an 3/8” eyelet to the black wire and attach to the battery ground.

• Route the 18AWG pink wire to a key switched IGNITION source that remains on during cranking. Examples include: ECU, fuel pump.

Do not select an accessory source. If the AutoPilot V2 display shuts off while starting the

vehicle, this is not a true ignition source.

• Using a 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

• Route the 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 the battery.

INSTALL AIR LINES

Use a standard hose cutter (Air Lift part number 10530) or razorblade. Cut all hose ends

square and as smoothly as possible.

1. Route and attach the air lines to the air springs.

• Route air lines free from abrasive edges and heat sources.

2. Attach manifold port

FL

to the front, drivers side left spring.


FR

to the front, passengers side right spring.


RL

to the rear, drivers side left spring.


RR

to the rear, passengers side right spring.


T

to the PTC fitting previously installed on the filter.

7. Manifold port

E

is the exhaust port.

• Port E can be left open, or routed to a preferred exhaust location.

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.

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.

NPT ASSEMBLY INSTRUCTIONS

1. Inspect the port and fitting ensuring both are free of contaminants and excessive burrs and nicks.

2. Apply a stripe of liquid pipe sealant around the male threads leaving the first two threads uncovered.

3. Screw finger tight into the port.

4. Wrench tighten the fitting to the correct turns past finger tight position (see table 1 located on page 6).

NEVER BACK OFF AN INSTALLED PIPE FITTING TO ACHIEVE PROPER ALIGNMENT.

LOOSENING INSTALLED PIPE FITTINGS WILL CORRUPT THE SEAL AND CONTRIBUTE

TO LEAKAGE AND FAILURE.

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5

1/8” NPT

1/4” NPT

3/8” NPT


Fitting Size Turns Past

Finger Tight

1.5 - 3.0

1.5 - 3.0

1.5 - 3.0

1/2” NPT

3/4” NPT

1” NPT

1.5 - 3.0

1.5 - 3.0

1 - 2.5

1 1/4” NPT

1 1/2” NPT

2” NPT

1 - 2.5

1 - 2.5

1 - 2.5

Torque lb/ft

12

25

40

54

78

112

154

211

300


Table 1

6

HELPFUL TIPS: AIR LINE AND FITTINGS

1. Minimum hose bend radius

• 3/8” hose = 1.5” hose bend radius.

• 1/4” hose = 1” hose bend radius.

2. Hose to fitting

• No side loading on fitting from hose.

• Hose straight for 1” before bending.

3. 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 razor on flat surface.

4. DOT/SAEJ844 air brake hose data

• Maximum working pressure of 175 PSI.

• Not to be used for frame (body) to un-sprung mass connection, use a braided leader hose for this moving connection.

Compressor Tank Pressure

Viair Air Lift P/N Max. Tank Pressure

380C 16380 175

400C

444C

16400

16444

150

175

450C

480C

16450

16480

150

175

Table 2

Setup and Calibration

AutoPilot V2 is an advanced pressure-based air suspension control system, that uses stateof-the-art software algorithms to calibrate or map the control system to your vehicle. Once the system is calibrated, the algorithm predicts required “valve open time” to move the air suspension to achieve preset target pressures. AutoPilot V2 has 8 programmable presets, allowing the user to input 8 different combinations of the 4 corner air spring pressures.

After installing AutoPilot V2 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 to maintain accuracy.

MN-754



NOTE

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 IGNITION source. While starting the engine, the system should be ON. If not, please refer back to the “Install Harness” section.

2. Press buttons 1 and 5 simultaneously

(1+5) and hold for 5-10 seconds until settings and diagnostics mode main page appears (fig. 3).

Tank Adjust (Maximum System PSI)

Press button 1 (TANK ADJUST). Set tank pressure preference by pressing MAX up/ down buttons simultaneously (fig. 4). The MAX value sets compressor cut-off pressure. Press buttons (1+5) simultaneously to exit to settings and diagnostics mode.

MIN tank pressure will follow MAX within 15

PSI to provide further accuracy.

If tank MAX settings are changed, a system recalibration is necessary for optimal performance. Max tank pressures for various

compressors can be found in table 2.

Calibrate to your vehicle

Press button 2 to enter CALIBRATE (fig. 3).

Press button 1 SYSTEM CAL (fig. 5), follow instructions to calibrate AutoPilot V2 system to your vehicle. Once calibration is complete,

Press buttons (1+5) simultaneously to exit to settings and diagnostics mode.

fig. 2

1

LF RF

2

T

LR

3

5 6 7 8

Button Definition

RR

4

fig. 3

1. TANK ADJUST

2. CALIBRATE

3. BACKLIGHT

4. PRESET MAIN

fig. 4

TANK MAX=175

fig. 5

CALIBRATION MENU

1. SYSTEM CAL

2. ADJUST SYSTEM

CAUTION

DURING CALIBRATION THE SYSTEM WILL AUTOMATICALLY DEFLATE TO 0 PSI AND

RAISE TO 100 PSI ON EACH AXLE AUTOMATICALLY. IF WHEELS EXTEND BEYOND

FENDERS, VEHICLE DAMAGE MAY RESULT. CALIBRATION ON NARROW WHEELS

THAT TUCK INSIDE THE FENDERS IS RECOMMENDED. ALSO, MAKE SURE VEHICLE

BODYWORK WILL NOT BE HARMED IF ONE END IS RAISED TO 100 PSI AND THE

OTHER IS AT ZERO. IF DAMAGE IS POSSIBLE, IT MAY BE BEST TO CALIBRATE BY

SETTING VEHICLE ON BLOCKS OF WOOD (SAME HEIGHT) TO GIVE THE BODYWORK

MORE CLEARANCE.

Backlight Setting

Press button 3 to enter BACKLIGHT (fig.

3). Set display backlight to your preference by pressing the + and – on R (Red), G

(Green), B (Blue) (fig. 6). Press buttons

(1+5) simultaneously to exit to settings and diagnostics mode.

fig. 6

+ + +

BACKLIGHT

R G B

- - -

MN-754

7

NOTE

NOTE

NOTE


Automatic Preset Maintenance

Press button 4 (fig. 3) to enter PRESET

MAINTAIN. Press button 8 to turn ON or

OFF (fig. 7). When ON, this function actively monitors air spring pressure and fills to maintain active preset pressure when average pressure drops below a threshold due to a system leak.

fig. 7

PRESET MAINTAIN?

ON

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) simultaneously to exit.

PRESET MAINTAIN should be off for performance/track driving or if operating in extremely hilly areas.

Compressor Test / Run Time

Press button 5 to run a compressor test (fig.

8). This function will exhaust the tank to the specified MIN tank pressure, then turn ON the compressor and measure its inflate time to achieve MAX pressure (fig. 9). AutoPilot V2 will record this fill time, allowing the operator to compare future fill times to determine compressor performance. Press buttons (1+5) simultaneously to exit.

Press button 6 (fig. 8) to view the number of hours the compressor has been running.

Rise on Start

Press button 7 (fig. 8) to enter RISE ON

START (fig. 10). 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) simultaneously to exit.

fig. 8

5. COMP TEST

6. COMP TIME

7. RISE ON START

8. PSI/BAR & SWV

fig. 9

TANK PRESSURE RANGE

135-150 PSI

PROCEED? YES NO

fig. 10

RISE ON START?

ON

This function only operates when the start-up pressures are BELOW the Preset 1 target pressures. The system will not deflate to achieve Preset 1 target

Set Units (PSI / BAR)

1. Press button 8 (fig. 8) to toggle between PSI and BAR pressure units and check software version. Press buttons (1+5) simultaneously to exit.

2. Press buttons (1+5) simultaneously to exit settings and diagnostics – you are now ready to create presets!

BAR stands for DeciBar values.

8

MN-754



Program Presets

Program Preset 1

NOTE

Preset 1 should always be entered as the desired ride pressure for the RISE ON START function.

Determine desired ride pressures: press buttons (1+5) simultaneously to toggle display to MANUAL mode. Manually activate each corner (see MANUAL mode section page

13) to achieve desired “normal driving” ride pressure (fig. 11). Program preset 1: press buttons (1+5) simultaneously to toggle display to PRESET mode (fig. 12). Press and hold button 1 for 3 seconds to set preset 1. Release button and actual air spring pressures will appear (fig. 12). Fine-tune the pressures by pressing up/down buttons. Press and hold to scroll. Press buttons (1+5) simultaneously to save and exit.

Program Presets 2-8

You are now free to program the additional 7 presets to desired pressures. Typical presets can be:

• “Low”: set pressures to the lowest possible pressures for extreme low driving stance.

• “Front up”: for speed bump or driveway clearance.

• “Rear up”: for added load of passengers, equipment.

• “Play”: for those that want to enjoy their air suspension freedom, AutoPilot V2 has a special function that recognizes side-to-side presets. When left side pressures are equal, and right side pressures are equal but >25PSI different than left, the algorithm will activate side to side instead of front to back. It will also equalize all air spring 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.

fig. 2 fig. 11

1 2 3 4

LF RF

T

LR RR

5 6 7 8

Button Definition

64 66 82 80

150

fig. 12

EDIT

65 65 80 80

PRESET 1

fig. 13

EDIT

5 100 5 100

PRESET 6

fig. 14

EDIT

100 5 100 5

PRESET 7

Sample Pressure Layouts for Play Mode (figs. 13 & 14)

MN-754

9

fig. 15


10

MN-754


Soft dr

T

MN-754

11


Operating the System

Now 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 to maintain system accuracy.

There are two operational modes: PRESET and MANUAL. Pressing buttons (1+5) simultaneously will toggle between modes. After 10 seconds of non-use, the display enters standby where the LCD dims. Any button hit will “wake-up” the display and allow users to activate the system. See mode operation below for more details.

NOTE

PRESET Mode

1. If display is sleeping, press any button once to “wake up” the display. If display is illuminated, go to the next step. Press of any button will display the programmed preset pressures for that button. Users can quickly view each preset prior to activating to make sure they are selecting the desired preset.

2. A 2 nd

button press of the same preset button within 2 seconds will activate it. The system will iterate up to 6 times to achieve the preset target pressures by +/- 3 PSI. The display shows PLEASE WAIT as it iterates, then will flash SUCCESSFUL when achieved or

UNSUCCESSFUL if not able to achieve the target pressure window.

3. Micro adjust to ±1 PSI: If more accuracy is desired, double press the same preset and the system will refine pressures closer to target. This is often necessary when target preset pressures are LOWER than current pressure. Accuracy can be improved by rolling the vehicle straight while activating the preset.

If the system indicates UNSUCCESSFUL, refer to troubleshooting guide on page 13.

CAUTION

PRESET Mode: Improve Accuracy

If system reads SUCCESSFUL but pressures are consistently lower or higher than target, you can improve first attempt accuracy by going to Calibration Menu (fig. 5) and pressing button 2. Adjust the ADJ value to a higher number if first attempt pressures are lower than target. Adjust the value to a lower number if first attempt pressures are higher than target.

WHEN A PRESET IS ACTIVATED THAT LOWERS THE VEHICLE SIGNIFICANTLY BELOW

DRIVING HEIGHT, BE SURE TO HAVE THE FRONT WHEELS STEERED STRAIGHT

AHEAD TO AVOID FENDER TO TIRE DAMAGE!

1 2 3 4 1 2 3 4

fig. 16

5 6 7

PRESET Mode

8

fig. 17

5 6 7

MANUAL Mode

8

MN-754

12



MANUAL Mode

1. MANUAL mode allows the user to fill or exhaust each spring independently. The display will show arrows above and below the pressures to indicate manual control mode (fig. 17).

The arrow will be solid when the spring is filling/exhausting, and outlined when not active.

2. 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 - 4, Exhaust springs: buttons 5 - 8


For further technical assistance please contact our customer service department by calling


PROBLEM CAUSE SOLUTION

Compressor doesn’t run

There is a blown fuse or relay, bad ground, or poor electrical connections.

Replace the fuse, check the ground wire, or check the compressor connector

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.

The compressor relay is defective or there is a leak. Replace the relay or locate the leak and repair.

Fitting seal or air line is compromised.

Check to make sure air lines are seated in connectors.

Inspect fittings with soapy water. Trim hose or reseal fitting.

There is a blown fuse or a poor connection.

There is a blown fuse or a poor connection.

Replace the fuses and check the electrical connections.

Replace the fuses and check the electrical connections.

Loosen fitting and check again. Replace if needed.

Compressors runs all the time but doesn’t fill the tank. Compressor in-line check valve fitting has been overtorqued.

Display shows UNSUCCESSFUL.

“Double Click” for Preset not completed within 2 second window.

Calibration may need to be adjusted or system may need to be recalibrated.

Tank pressure settings changed.

Vehicle load changed significantly.

If display is in sleep mode, click once to “Wake Up”, then “Double Click” desired preset within 2 seconds of each press.

Adjust ADJ value or recalibrate system to reduce number of iterations.

Attempt recalibration.

Display shows PRESSURE SENSOR FAILURE.

Air springs/air lines/tank changed.

ECU has detected a pressure sensor operating incorrectly.

Only manual mode can be used to operate suspension. Contact customer service immediately to resolve the problem.

Leak Testing and Detection

NOTE

Leak detection

1. A leak can be defined as a loss of pressure of more than 5 psi over an 8 hour period. Be aware that ambient temperature change has an effect on pressure that may seem like a leak. For example: a change of 10deg Fahrenheit up or down from your baseline will have an approximate gain or loss of indicated pressure of 2 psi. If a leak is suspected after including any temperature change, then proceed to #2.

2. Spray soapy water (1/5 Dawn brand dish soap to 4/5 water) on suspect fittings and hose connections and look for any bubbling caused by air leakage.

3. Fix leaking connection (review pg. 6 for help on NPT fittings and air line connections).

4. Wipe down sprayed connections with rag to remove any residual soapy water.

Dawn brand dish soap will not corrode the metals (aluminum, brass, steel) with which it

comes into contact.

MN-754

13

Electrical Schematic


14

* Sold separately

Air Lift Part Number 27679

fig. 18

MN-754


AutoPilot V2 Remote Control Unit Dimensions

MN-754

2.875”

Top View

Side View

.75”

15

Notes


16

MN-754


Manifold Template

MN-754

6.35”

17

Notes


18

MN-754


16380 Compressor Template

MN-754

HOLE PATTERN FOR

BOTTOM OF 16380 COMPRESSOR

6.6900

3.3100

19

Notes


20

MN-754


Warranty and Returns Policy

Air Lift 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 Lift Company for verification.

Air Lift will repair or replace, at its option, defective products or components. A minimum $10.00 shipping and handling charge will apply to all warranty claims. Before returning any defective product, you must call Air Lift at (800) 248-

0892 in the U.S. and Canada (elsewhere, (517) 322-2144) for a Returned Materials Authorization (RMA) number.

Returns to Air Lift can be sent to: Air Lift Company • 2727 Snow Road • Lansing, MI • 48917.

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 Lift 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 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 required.)















Canada, our local number is (517) 322-2144. You may also contact customer service anytime by e-mail at [email protected].

For inquiries by mail, our address is PO Box 80167, Lansing, MI 48908-0167. Our shipping address for returns is

2727 Snow Road, Lansing, MI 48917.


MN-754

21

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