Air Lift 75524 Installation Manual
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Air Lift 75524 Installation Manual

Kit, volkswagen mkiv threaded body, front application
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PERFORMANCE SUSPENSION PARTS

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Summary of Contents for Air Lift 75524

  • Page 1 PERFORMANCE SUSPENSION PARTS...

  • Page 2: Notation Explanation

    Air Lift Performance Introduction The purpose of this publication is to assist with the installation, maintenance and troubleshooting of this Volkswagen MKIV Threaded Body Performance kit . It is important to read and understand the entire installation guide before beginning installation or performing any maintenance, service or repair .

  • Page 3: Installation Diagram

    Air Lift Performance Installation Diagram fig. 1 C or D HARDWARE LIST Item Part # Description ........Qty 35237 Strut, Volkswagen MKIV Front .

  • Page 4: Stock Strut Removal

    Air Lift Performance Installing the Air Suspension 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.
  • Page 5 Air Lift Performance fig. 5 2 . Disconnect the stabilizer bar from the lower control arm (fig. 6). 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.
  • Page 6 Air Lift Performance fig. 8 fig. 9 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 7 Air Lift Performance fig. 11 fig. 12 PREPARING FOR THE AIR SUSPENSION 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 .
  • Page 8 Air Lift Performance 2 . Cut out the template supplied in the back of this manual and place it over the coned strut tower as shown (figs. 14 & 19). One hole is to face outboard the vehicle with the other holes inboard .
  • Page 9 Air Lift Performance fig. 17 fig. 18 fig. 19...

  • Page 10: Air Suspension Installation

    Air Lift Performance AIR SUSPENSION INSTALLATION 1 . Insert 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 (15lb-ft). fig. 20 2 . Install the strut into the hub (fig. 21). Torque the pinch bolt to 70Nm + 90˚ (52lb-ft + 90˚).
  • Page 11 Air Lift Performance 4 . Reinstall the stabilizer end link to the control arm (fig. 23). Torque to 30Nm (22 lb-ft). fig. 23 5 . 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 .

  • Page 12: Damping Adjustment

    Air Lift Performance DAMPING ADJUSTMENT The struts in this kit have 30 settings, or “clicks”, of adjustable compression and rebound damping characteristics . Damping is changed through the strut rod using the supplied adjuster (figs. 25 & 26) or a 3mm allen wrench.

  • Page 13: Adjusting Extended Or Drop Height Using Lower Mount

    Air Lift Performance ADJUSTING EXTENDED OR DROP HEIGHT USING LOWER MOUNT Your struts 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),...
  • Page 14 Air Lift Performance WHEN ADJUSTING HEIGHT UPWARDS, MAKE SURE THAT THE STRUT BODY CAUTION ENGAGES ALL THE THREADS OF THE LOWER MOUNT (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 .
  • Page 15 Template...

  • Page 17: Notation Explanation

    Air Lift Performance Introduction The purpose of this publication is to assist with the installation, maintenance and troubleshooting of this Volkswagen MKIV Threaded Body Performance kit . It is important to read and understand the entire installation guide before beginning installation or performing any maintenance, service or repair .
  • Page 18 Air Lift Performance Installation Diagram HARDWARE LIST Item Part # Description ......Qty 58130 Tapered Sleeve .

  • Page 19: Installing The Air Suspension

    Air Lift Performance Installing the Air Suspension PREPARING THE VEHICLE 1 . Elevate the vehicle and support the body with a hoist or jack stands . 2 . Remove the rear wheels . REMOVING THE REAR SUSPENSION COIL SPRINGS UNDER TENSION, PROCEED WITH EXTREME CARE! CAUTION 1 .
  • Page 20 Air Lift Performance fig. 5 3 . At the lower spring perch, lightly grind the center hole larger so that the air spring can sit flush in the lower coil spring perch. 4 . Apply thread sealant to the threads of the air fitting and thread into the air spring 1 3/4 turns beyond hand tight (fig.
  • Page 21 Air Lift Performance 8 . Apply the factory upper shock mount to the new shock (fig. 8). Torque to 25Nm (18lb-ft). Reinstall the plastic cover on the upper mount (fig. 9). fig. 8 fig. 9 9 . Install the upper mount with shock to the chassis (fig. 10). Torque the bolts to 75Nm (55lb-ft) .
  • Page 22 Air Lift Performance 11 . Fully compress the suspension using a jack . With the suspension compressed, review the best routing for the air line that is clear of all suspension components and axle . Routing should also allow for the suspension to extend without kinking the line or rubbing on other components .
  • Page 23 Air Lift Performance DAMPING ADJUSTMENT The shocks in this kit have 30 settings, or “clicks”, of adjustable compression and rebound damping characteristics . Damping is changed using the adjuster knob integrated into the upper shock rod . Turn the adjuster clockwise and the damping settings are hardened . Turn the adjuster counterclockwise and the damping is softened .
  • Page 24 Air Lift Performance ADJUSTING EXTENDED OR DROP HEIGHT USING LOWER MOUNT Your struts 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),...
  • Page 25 Air Lift Performance 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 CAUTION CAUSE AN AIR LEAK AND COMPROMISE THE ASSEMBLY .
  • Page 26 Air Lift Performance Kit Details 27671 HARDWARE LIST Part # Description ......Qty Part # Description 72605 4pt Fast Air Manifold - 1/4”” ....1 21773 3/8” MNPT X 1/8” MNPT Adapter ..1 21999 1/8” MNPT X 1/4” PTC Elbow ..... 2 27042 Gen 3 Display ........

  • Page 27: P A T E N T P E N D I N G

    Air Lift ™ AutoPilot V2 ™ P A T E N T P E N D I N G PERFORMANCE 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...
  • Page 28 Air Lift Performance Air Lift Performance 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.

  • Page 29: Install Components

    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.
  • Page 30 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) NOTE or razorblade.
  • Page 31 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 NOTE square and as smoothly as possible.

  • Page 32: Setup And Calibration

    Air Lift Performance Torque Specifications Table 1 Fitting Size Turns Past Torque Finger Tight lb/ft 1/8” NPT 1.5 - 3.0 1/4” NPT 1.5 - 3.0 3/8” NPT 1.5 - 3.0 1/2” NPT 1.5 - 3.0 3/4” NPT 1.5 - 3.0 1”...
  • Page 33 Air Lift Performance SYSTEM CALIBRATION AND fig. 2 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”...
  • Page 34 Air Lift Performance Automatic Preset Maintenance Press button 4 (fig. 3) to enter PRESET fig. 7 MAINTAIN. Press button 8 to turn ON or OFF (fig. 7). When ON, this function actively PRESET MAINTAIN ? monitors air spring pressure and fills to...

  • Page 35: Program Presets

    Air Lift Performance Program Presets fig. 2 Program Preset 1 Preset 1 should always be entered as the desired NOTE 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”...
  • Page 36 Air Lift Performance fig. 15...
  • Page 37 Air Lift Performance...

  • Page 38: Operating The System

    Air Lift Performance 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.
  • Page 39 Air Lift Performance 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.

  • Page 40: Electrical Schematic

    Air Lift Performance Electrical Schematic * Sold separately Air Lift Part Number 27679 fig. 18...
  • Page 41 Air Lift Performance AutoPilot V2 Remote Control Unit Dimensions 2.875” Top View .75”...
  • Page 42 Air Lift Performance Manifold Template 6.35”...
  • Page 43 Air Lift Performance 16380 Compressor Template HOLE PATTERN FOR BOTTOM OF 16380 COMPRESSOR 6.6900 3.3100...

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