Air Lift 75524, Installation Manual

Page 1: ...read these instructions completely before proceeding with installation Failure to read these instructions can result in an incorrect installation INSTALLATION GUIDE Kit 75524 Volkswagen MKIV Threaded Body Front Application MN 912 011401 ERN 7537 ...

Page 2: ...2 MN 912 Air Lift Performance ...

Page 3: ...n 7 Damping Adjustment 12 Aligning the Vehicle 12 Adjusting Extended or Drop Height Using Lower Mount 13 Before Operating 15 Installation Checklist 15 Product Use Maintenance and Servicing 16 Suggested Driving and Maximum Air Pressures 16 Maintaining and Operating 16 Troubleshooting Guide 16 Frequently Asked Questions 16 Tuning the Air Pressure 17 Checking for Leaks 17 Fixing Leaks 17 Limited Warr...

Page 4: ...s explain the use of these notations as they appear throughout this guide INDICATES IMMEDIATE HAZARDS WHICH WILL RESULT IN SEVERE PERSONAL INJURY OR DEATH INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN SEVERE PERSONAL INJURY OR DEATH INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN DAMAGE TO THE MACHINE OR MINOR PERSONAL INJURY Indicates a procedure practice or hint which i...

Page 5: ...lkswagen MKIV Front 2 B 20997 Leader Hose 1 4 ID 2 C 21987 Union 1 4 FNPT X 3 8 PTC DOT 2 D 21810 Union 1 4 FNPT X 1 4 PTC DOT 2 E Spanner Wrench 1 Installation Diagram Missing or damaged parts Call Air Lift customer service at 800 248 0892 for a replacement part STOP fig 1 C or D B A E ...

Page 6: ...sion fig 2 fig 3 fig 4 PREPARING THE VEHICLE 1 Elevate the vehicle and support the body with a hoist or jack stands 2 Remove the front wheels STOCK STRUT REMOVAL 1 Unthread the sensor wire support bracket Figs 2 4 Unclip the sensor wire from the strut Fig 5 ...

Page 7: ...rol arm Fig 6 3 Support the hub assembly to prevent over extension Remove the lower pinch bolt from the hub Fig 7 Spread the hub assembly slot and push down on the hub to release the strut from the hub Fig 8 With the hub free of the strut do not allow to hang freely by the axle or sensor wires Fig 9 ...

Page 8: ...912 Air Lift Performance fig 8 fig 9 fig 10 4 Remove the cover from the strut rebound washer Fig 10 Support the strut and remove the rod nut and rebound washer Fig 11 Remove the strut from the vehicle Fig 12 ...

Page 9: ...NSION 1 Install the leader line into the air spring Fig 13 Seal the threads of the leader hose with Teflon tape or thread sealant Tighten the appropriate fitting to the airline 1 3 4 turns beyond hand tight Tighten the leader line into the air spring 1 3 4 turns beyond hand tight ...

Page 10: ...e it over the coned strut tower as shown Figs 14 19 One hole is to face outboard the vehicle with the other holes inboard Taping a string across the strut tower centers can be a useful way to ensure the centerline of the outboard stud hole Figs 15 16 Center punch and drill an 11 32 hole at each center punch Figs 17 18 ...

Page 11: ...9 MN 912 Air Lift Performance fig 17 fig 18 fig 19 ...

Page 12: ... the strut assembly into the strut pocket and attach the camber plate to the previously drilled holes Fig 20 Torque camber plate nuts to 20Nm 15 lb ft 2 Install the strut into the hub Fig 21 Torque the pinch bolt to 70Nm 90 52 lb ft 90 3 Reattach the sensor wire tab and sensor wires Fig 22 ...

Page 13: ...ponents 6 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 7 Cycle the suspension to Max Extension and record the measurement from the same reference points 8 Add ME and MC then divide by 2 Set the suspension to this point This position will give 50 stroke in either direction ...

Page 14: ... vehicles and driving characteristics ALIGNING THE VEHICLE WHEN MAKING CAMBER ADJUSTMENTS TO THE NEGATIVE SIDE FOR ALIGNMENT OR WHEEL FITMENT IT IS VERY IMPORTANT TO MAKE SURE THAT AFTER THE ADJUSTMENT THE AIR SPRING HAS ADEQUATE WORKING CLEARANCE ON THE INNER STRUT TOWER SIDE ANY RUBBING OR CONTACT WITH THE AIR SPRING WILL CAUSE A FAILURE AND WILL NOT BE COVERED UNDER WARRANTY 1 Using the control...

Page 15: ...al The result is an uncomfortable ride and potentially a knocking noise when going over bumps as your damper runs out of travel If your wheel tire combination requires greater clearance or you need a taller ride height you can eliminate topping by adjusting your damper to a longer length overall as detailed below A good rule of thumb is to have at least 1 3 of the available wheel travel available ...

Page 16: ...T FIG 28 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 STRUT DOING SO MAY C...

Page 17: ...d 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 ins...

Page 18: ...come necessary to raise the vehicle by the frame make sure the control system is turned off before lifting NOTE CAUTION 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...

Page 19: ...e again after 24 hours A 2 4 PSI loss after initial installation is normal Retest for leaks if the loss is more than 5 PSI Checking for leaks 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 ...

Page 20: ...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 products or under any other legal theory including but not limited...

Page 21: ...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 Mailing address P O Box 80167 Lansing MI 48908 0167 Shippi...

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Page 23: ...21 MN 912 Air Lift Performance Notes ...

Page 24: ...m outside the USA or Canada our local number is 517 322 2144 Air Lift Performance 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 Thank you for purchasing Air Lift Performance products Printed in the USA ...