AccuAir AA-4397, Installation Manual

Page 1: ...AA 4397 2007 2017 AIR SUSPENSION SYSTEM JEEP WRANGLER JK INSTALLATION GUIDE...

Page 2: ...for additional safety information Before installation please take a moment to review the following safety information and installation instructions Important safety information is generally preceded...

Page 3: ...component to AccuAir for inspection repair or replacement OBTAINING WARRANTY CUSTOMER SERVICE Register your AccuAir Purchase For questions or claims contact AccuAir Customer Service 100 Sea Ray Drive...

Page 4: ...ront and Rear Sway Bar End Links Height Sensor Brackets Front and Rear Brake Line Extension Brackets VU4 4 Corner Manifold Install Kit for ECU Air Tank Compressor 3 Gallon Seamless Tank Air Compressor...

Page 5: ...fold ECU Purge Valve Battery ECU Chassis Ground ECU Compressor Output Compressor Input to Headlight Optional Relay Touchpad Route to Vehicle Cabin Fuse 70 AMP Ride Height Sensor 4 Rear Right Ride Heig...

Page 6: ...11 J7 J20 J21 J9 J17 J18 J12 FP CB1 J15 J19 J2 J14 J10 J6 J1 J3 J4 J5 M5 M6 M29 M36 M25 M24 M17 M23 M18 M38 M33 M15 M3 M22 M31 M26 M28 M21 M19 K9 K4 K1 K2 K6 K3 K5 K10 K11 K7 J13 M32 M16 TAP INTO TAP...

Page 7: ...CB1 J15 J19 J2 J14 J10 J6 J1 J3 J4 J5 M5 M6 M29 M36 M25 M24 M17 M23 M18 M38 M33 M15 M3 M22 M31 M26 M28 M21 M19 K9 K4 K1 K2 K6 K3 K5 K10 K11 K7 J13 M32 M16 ECU Relay Fuse Box Ignition Fuse Tap M4 Igni...

Page 8: ...t Right ViAIR Compressor Intake Filter Air Spring 3 Rear Left Air Spring 4 Rear Right Manifold Regulator Air Line Union Air Line Union Residual Pressure Union Residual Pressure Union 13 14 AA 4397 Ins...

Page 9: ...r pan of the vehicle Install supplied grommet Figure 2 FIGURE 2 3 Pull the ECU main harness plug valve harness plug compressor power cable batter power cable and height sensor harness plug into the ca...

Page 10: ...end all three grounds Figure 6 FIGURE 6 7 Using the supplied butt connector connect the three grounds to one side and the length of wire with ring terminal to the other Figure 7 FIGURE 7 8 Along the h...

Page 11: ...ke relay connections Figure 11 FIGURE 11 Front Rear M20 M27 M1 M34 M37 M10 M35 M30 M12 M11 M8 M14 M9 M13 M2 M4 M7 J8 J22 J11 J7 J20 J21 J9 J17 J18 J12 FP CB1 J15 J19 J2 J14 J10 J6 J1 J3 J4 J5 M5 M6 M2...

Page 12: ...rewdriver loosen but do not remove the bolts on the tank strap to relieve tension on the tank allowing tank to be repositioned during installation to allow access to mounting hardware Figure 14 FIGURE...

Page 13: ...member and the EVAP cannister using the hardware removed in Step 15 The tank will face forward toward the engine bay while the compressor and VU4 valve block will face the rear of the vehicle Use Blu...

Page 14: ...elow will go over top of the cross member at the front of the tank bracket Using the supplied carriage bolt and flange nut through the top of the bracket tighten to clamp bracket to the cross member T...

Page 15: ...t hole locations and the 19mm bolts removed earlier This will allow access to reconnect tubing to its original location Route the compressor wires and purge solenoid wires to the rear of the bracket F...

Page 16: ...e 28 FIGURE 28 23 Slide the VU4 mounting bracket between the cross member and EVAP Reinstall bolt Figures 29 30 FIGURE 29 FIGURE 30 24 Above VU4 remove this bracket holding the e brake cables Save har...

Page 17: ...4 from the e brake bracket that was removed Do not tighten at this time Figure 32 FIGURE 32 26 Make connection for compressor harness and route the grounds from the harness to the stud above the VU4 T...

Page 18: ...ap provided Extract 20 AMP fuse from M6 and place on bottom position of the fuse tap Install the 5 AMP fuse supplied and position in top slot of the fuse tap Reinsert into the fuse box location M6 Fig...

Page 19: ...e the GPS antenna cable through the carpet along the ignition and power cables Attach GPS antenna to the top of the ECU bracket Figure 40 FIGURE 40 33 Connect 12 pin Molex connector to GPS Speed modul...

Page 20: ...34 Connect the 3 wire pressure sensor Figure 42 FIGURE 42 35 When installed this is what the assembly will look like Figure 43 FIGURE 43 37 38 AA 4397 Installation Manual REV 01 05 25 2023 WIRING...

Page 21: ...on Residual Pressure Union Residual Pressure Union 2 Make VU4 connections as shown Note the port to corner association with Figure 22 and plumbing diagram Figure 44 1 1 2 2 3 3 4 4 FIGURE 44 3 Connect...

Page 22: ...M19 K9 K4 K1 K2 K6 K3 K5 K10 K11 K7 J13 M32 M16 Manifold ECU Purge Valve Battery ECU Chassis Ground ECU Compressor Output Compressor Input to Headlight Optional Relay Touchpad Route to Vehicle Cabin...

Page 23: ...the ECU bracket insert clamp and hardware behind the lip of the Jeep s body and tighten to secure ECU bracket ensuring the tab is in the slot Figure 52 FIGURE 52 4 When completed ECU bracket should l...

Page 24: ...rails using jack stands at indicated lift points in OEM service manual 3 Remove the front tires wheels using a 22mm socket 4 Park the vehicle on a level concrete or asphalt surface set the emergency...

Page 25: ...ew longer exhaust spacer is to be installed on the passenger side FIGURE 58 6 Remove the index stop on the OEM Y pipe using an air chisel grinder or similar tool Figure 56 NOTE This will allow the OEM...

Page 26: ...heck all of the hardware for the proper torque periodically thereafter TORQUE SPECIFICATIONS INCH SYSTEM METRIC SYSTEM Bolt Size Grade 5 Grade 8 Bolt Size Class 8 8 Class 10 9 5 16 15 ft lbs 20 ft lbs...

Page 27: ...rackets from OEM front lower control arms using a 15mm socket wrench 16 While checking for appropriate slack in ABS lines brake lines differential vent hose etc lower front differential remove OEM fro...

Page 28: ...new monotube shocks Figure 67 FIGURE 67 20 Using a 21mm socket and wrench remove the OEM lower control arm Figures 68 69 FIGURE 68 FIGURE 69 53 54 AA 4397 Installation Manual REV 01 05 25 2023 FRONT I...

Page 29: ...t Figure 70 FIGURE 70 22 Ensure that the locating tab is contacting the bracket during and after tightening Figure 71 FIGURE 71 23 When installed it should look as shown Mount link to lower control ar...

Page 30: ...nut to secure drill guide template Shift the bracket to center on spring perch Figure 74 FIGURE 74 25 Using a 1 8 drill bit drill through the spring perch Figure 75 FIGURE 75 26 Using a step bit or 3...

Page 31: ...ring studs Tighten to 17 ft lbs Figures 82 83 FIGURE 82 FIGURE 83 30 Install top cap with the air line passing through the center Seat the cap on the top mount Figures 84 85 FIGURE 84 FIGURE 85 NOTE I...

Page 32: ...ST be inflated Failure to inflate will cause air spring damage 33 Connect OEM vent hose to front differential using pliers 34 Install front tires wheels using a 22mm socket Lower vehicle to ground Tor...

Page 33: ...8 wrench turn rod end to adjust in or out Once body is properly aligned over front tires wheels tighten OEM hardware using a 21mm socket wrench Fully tighten all OEM hardware at upper frame mount axl...

Page 34: ...xle remove OEM rear coil springs and isolator bushings Figure 93 FIGURE 93 4 Disconnect OEM rear track bar from the axle using a 21mm socket wrench Figure 90 FIGURE 90 5 Install supplied brake line re...

Page 35: ...is will allow you to position the track bar relocation brackets for drilling Figure 96 FIGURE 96 10 Install and snug supplied bolt and spacer where the OEM track bar location checking to ensure the ho...

Page 36: ...13 One at a time remove the OEM rear lower control arms install the new rear lower control arms using the OEM hardware a 21mm socket wrench Note the location of the height sensor mounting tab on the u...

Page 37: ...6 Install air spring on OE spring perch with retaining clips facing the front of the vehicle and tighten Figure 104 FIGURE 104 17 Slowly pull the air springs up and install the air spring retaining cl...

Page 38: ...utside of vehicle inward through sway bar with a 7 16 USS Washer 12mm Nylon Insert Lock Nut on inside using a 5 16 hex key socket a 18mm socket wrench Figure 106 FIGURE 106 Attach upper end link with...

Page 39: ...nt Tighten Torque Sequence Track bar at frame using a 21mm wrench Torque 52 ft lbs Track bar at axle using a 21mm wrench Torque 52 ft lbs Front shock absorber upper mount using a 18mm wrench Torque 81...

Page 40: ...www AccuAir com 833 247 3696 200 Sea Ray Drive Merritt Island FL 32953...