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AccuAir AA-4397 Installation Manual

2007-2017 jeep wrangler (jk) air suspension system
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AA-4397
2007-2017
JEEP WRANGLER (JK)
AIR SUSPENSION SYSTEM

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Summary of Contents for AccuAir AA-4397

  • Page 1 AA-4397 2007-2017 JEEP WRANGLER (JK) AIR SUSPENSION SYSTEM...
  • Page 2 WARNING NOTICE: The suspension of this vehicle has been optimized for off road utility through installation of an AccuAir ® system allowing Never lower vehicle from rack or following inspection/ CANCER AND REPRODUCTIVE HARM control/adjustment of ride height to accommodate challenging terrain &...
  • Page 3 Any claim to enforce an arbitration award or for other breach or damages under this Limited to the initial retail purchaser of a AccuAir Jeep JK suspension kit that AccuAir will according to terms herein, repair Warranty can only be brought in a court of competent jurisdiction closest to Brevard County, Florida.

  • Page 4: Included Parts

    9/16”, 3/4”, 13/16”, 7/8” & 1-1/8”) 18mm, 19mm, 21mm, 22mm & 24mm) Ball Peen Hammer Floor Jack Drill Bits (1/8”, 3/8”, 15/32”) Wheel Chock Torque Wrench Measuring Tape Jack Stands Blue Loctite Wire Wheel Safety Glasses Pliers AA-4397 Installation Manual REV 01 | 05/25/2023...

  • Page 5: Wire Routing

    Valve (Route to Vehicle Cabin) Relay Bolt Ground lug (under vehicle) Ground Lug (in vehicle) Input to Ride Height Headlight Sensor - 1 (Optional) Front Left Ride Height Sensor - 3 Rear Left AA-4397 Installation Manual REV 01 | 05/25/2023...
  • Page 6 FUSE BOX TAP INTO TAP INTO M4 AA-4397 Installation Manual REV 01 | 05/25/2023...
  • Page 7 SPEED MODULE ROUTING Fuse Box (Ignition Fuse Tap - M4) Relay Speed Module Ignition Wire Tap Antenna AA-4397 Installation Manual REV 01 | 05/25/2023...
  • Page 8 Front Right Rear Right ViAIR Residual Air Line Compressor Pressure Union Intake Filter Union Manifold Residual Air Line Regulator Union Pressure Union Air Spring - 1 Air Spring - 3 Front Left Rear Left AA-4397 Installation Manual REV 01 | 05/25/2023...
  • Page 9 FIGURE 2 3. Pull the ECU main harness plug, valve harness plug, compressor power cable, batter power cable, and height sensor AA-4397 Installation Manual REV 01 | 05/25/2023 harness plug into the cab via the grommeted floor pan hole. Run an end of the 1/4” air line for the pressure regulator...
  • Page 10 (Figure 6) supplied M6 nut. (Figure 8) FIGURE 6 FIGURE 8 AA-4397 Installation Manual REV 01 | 05/25/2023...
  • Page 11 Compressor Sensor - 2 Compressor Front Right Output Fuse (70 AMP) Manifold Pressure Sensor Fuse Box Battery FIGURE 10 (Ignition Fuse Tap Comp - M4) Purge Touchpad Valve (Route to Vehicle Cabin) Relay AA-4397 Installation Manual REV 01 | 05/25/2023...
  • Page 12 (Figure 14) FIGURE 12 FIGURE 14 14. After loosening straps, slide the tank forward to allow access to mounting holes. (Figures 15, 16) LOWER UPPER FIGURE 13 FIGURE 15 AA-4397 Installation Manual REV 01 | 05/25/2023...
  • Page 13 15. Remove the two bolts holding the front of the EVAP cannister with 16mm socket/wrench. (Figure 17) With the brackets lined up, reinsert the 16mm bolts and tighten. Ensure clearance of muffler to bracket. (Figure 19) FIGURE 17 FIGURE 19 AA-4397 Installation Manual REV 01 | 05/25/2023...
  • Page 14 Then insert the hex bolt and washer into the front. (Figures 22, 23) FIGURE 20 FIGURE 22 FIGURE 21 FIGURE 13 AA-4397 Installation Manual REV 01 | 05/25/2023...
  • Page 15 (Figure 26) FIGURE 24 FIGURE 26 21. After making tubing connections, finish installing the lower bracket to the upper using the rest of the 19mm hardware removed earlier. (Figure 27) FIGURE 25 FIGURE 27 AA-4397 Installation Manual REV 01 | 05/25/2023...
  • Page 16 24. Above VU4, remove this bracket holding the e-brake cables. Save hardware. (Figure 31) 23. Slide the VU4 mounting bracket between the cross member and EVAP. Reinstall bolt. (Figures 29, 30) FIGURE 31 FIGURE 29 AA-4397 Installation Manual REV 01 | 05/25/2023...
  • Page 17 26. Make connection for compressor harness and route the grounds from the harness to the stud above the VU4. VU4 from the e-brake bracket that was removed. Do not tighten at this time. (Figure 32) Tighten the ground stud. (Figures 33, 34) FIGURE 33 FIGURE 34 FIGURE 32 AA-4397 Installation Manual REV 01 | 05/25/2023...
  • Page 18 29. Crimp the orange ignition wire to the fuse tap 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. (Figures 36, 37) FIGURE 38 FIGURE 36 AA-4397 Installation Manual REV 01 | 05/25/2023...
  • Page 19 FIGURE 39 FIGURE 41 32. Route 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 AA-4397 Installation Manual REV 01 | 05/25/2023...
  • Page 20 WIRING 34. Connect the 3-wire pressure sensor. (Figure 42) 35. When installed, this is what the assembly will look like. (Figure 43) FIGURE 43 FIGURE 42 AA-4397 Installation Manual REV 01 | 05/25/2023...
  • Page 21 4. Trim and attach 1/4” air line to regulator. (Figure 46) 2. Make VU4 connections as shown. Note the port to corner association with Figure 22 and plumbing diagram. (Figure 44) FIGURE 46 FIGURE 44 AA-4397 Installation Manual REV 01 | 05/25/2023...
  • Page 22 8. Next, locate the TouchPad user interface where you want it to be in the vehicle (typically near center console). Ensure the cable is routed appropriately for your chosen location. (Figure 49) FIGURE 48 FIGURE 49 AA-4397 Installation Manual REV 01 | 05/25/2023...
  • Page 23 ECU bracket, ensuring the tab is in the slot. (Figure 52) FIGURE 50 FIGURE 52 2. Tighten forward hex. (Figure 51) 4. When completed, ECU bracket should look as shown. (Figure 53) FIGURE 51 FIGURE 53 AA-4397 Installation Manual REV 01 | 05/25/2023...

  • Page 24: Front Installation

    Park the vehicle on a level concrete or asphalt surface, set the emergency brake & block the rear tires/wheels. With the exhaust of the vehicle cool, loosen the OEM exhaust clamp that joins the OEM Y-pipe & OEM mid-pipe using a 13mm socket/wrench. (Figure 55) FIGURE 54 FIGURE 55 AA-4397 Installation Manual REV 01 | 05/25/2023...
  • Page 25 The new shorter exhaust spacer is to be installed on the driver side & the new longer exhaust spacer is to be installed on the NOTE: passenger side. FIGURE 56 FIGURE 58 Remove the four OEM exhaust flange bolts at the driver & passenger side OEM Y-pipe collectors using a 13mm socket/wrench. (Figure 53) FIGURE 57 AA-4397 Installation Manual REV 01 | 05/25/2023...
  • Page 26 After the installation is complete, double check that all nuts & bolts are tight. Refer to the following chart for the proper torque specifications. NOTE: • Check the entire exhaust system for proper clearances. • After the first 100 miles, check all of the hardware for the proper torque & periodically thereafter. FIGURE 60 AA-4397 Installation Manual REV 01 | 05/25/2023...
  • Page 27 Disconnect OEM front shock from upper shock tower mount & lower axle mount using a 18mm socket/wrench. (Figure 62) FIGURE 63 Remove the bump stop and upper/lower spring isolators. (Figures 64, 65, 66) FIGURE 64 FIGURE 65 FIGURE 66 FIGURE 62 AA-4397 Installation Manual REV 01 | 05/25/2023...
  • Page 28 FRONT INSTALLATION Install new monotube shocks. (Figure 67) Using a 21mm socket and wrench, remove the OEM lower control arm. (Figures 68, 69) FIGURE 68 FIGURE 69 FIGURE 67 AA-4397 Installation Manual REV 01 | 05/25/2023...
  • Page 29 When installed it should look as shown. (Mount link to lower control arm.) (Figures 72, 73) (Figure 70) FIGURE 72 FIGURE 70 Ensure that the locating tab is contacting the bracket during and after tightening. (Figure 71) FIGURE 73 FIGURE 71 AA-4397 Installation Manual REV 01 | 05/25/2023...
  • Page 30 Shift the bracket to center on spring perch. (Figure 74) FIGURE 74 Using a 1/8” drill bit, drill through the spring perch. (Figure 75) FIGURE 76 FIGURE 75 FIGURE 77 AA-4397 Installation Manual REV 01 | 05/25/2023...
  • Page 31 Install the new front lower control arms with the NOTE: arms & install the new front lower control arms using offset bend toward the inside of the vehicle. the OEM hardware, a 21mm socket/wrench, & 24mm socket/wrench. AA-4397 Installation Manual REV 01 | 05/25/2023...

  • Page 32: Air Spring

    If lowering vehicle before moving onto rear installation, front air springs MUST be inflated. Failure to inflate will cause air spring damage. Connect OEM vent hose to front differential using pliers. FIGURE 88 AA-4397 Installation Manual REV 01 | 05/25/2023...

  • Page 33: Rear Installation

    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 & axle mount. Fully tighten jam nut of adjustable front track bar using a 1-1/8” wrench. FIGURE 89 AA-4397 Installation Manual REV 01 | 05/25/2023...
  • Page 34 7. While checking for appropriate slack in ABS lines, brake lines, differential vent hose & etc, lower rear axle & remove OEM rear coil springs and isolator bushings. (Figure 93) FIGURE 91 FIGURE 93 NOTE: Be very careful not to damage OEM rear hard brake lines. AA-4397 Installation Manual REV 01 | 05/25/2023...
  • Page 35 9. Install the rear track bar brace to the differential. This will allow you to position the track bar relocation brackets for drilling. (Figure 96) FIGURE 97 11. Using a centering punch, mark this location to drill for hardware. (Figure 98) FIGURE 96 FIGURE 98 AA-4397 Installation Manual REV 01 | 05/25/2023...
  • Page 36 14. Install rear ride height sensor bracket assembly to the frame using the existing hole and tighten to 17 ft-lbs. (Figures 101, 102) FIGURE 101 - RIGHT REAR FIGURE 102 - RIGHT REAR FIGURE 99 NOTE: It may be necessary to raise/lower axle to take pressure off track bar bolt. AA-4397 Installation Manual REV 01 | 05/25/2023...
  • Page 37 16. Install air spring on OE spring perch with retaining clips facing the front of the vehicle and tighten. (Figure 104) FIGURE 105 18. Install monotube rear shocks with OEM hardware using a 18mm socket/wrench. FIGURE 104 AA-4397 Installation Manual REV 01 | 05/25/2023...
  • Page 38 5/16” hex key socket & a 18mm socket/wrench. (Figure 106) FIGURE 106 Attach upper end link with OEM hardware with large washer to bushing side of end link using a 18mm socket/ wrench. Secure, but do not tighten completely at this time. AA-4397 Installation Manual REV 01 | 05/25/2023...

  • Page 39: Final Notes

    Remove all obstructions and HOURS: MONDAY - FRIDAY 8:00AM - 6:00 PM (EST) air springs from near empty. keep clear of vehicle before proceeding. weeks will but can vary. AA-4397 Installation Manual REV 01 | 05/25/2023...
  • Page 40    www.AccuAir.com 833.247.3696 200 Sea Ray Drive, Merritt Island, FL 32953...