AccuAir AA-4397 User manual

AA-4397
2007-2017
AIR SUSPENSION SYSTEM
JEEP WRANGLER (JK)
INSTALLATION GUIDE

The suspension of this vehicle has been optimized for off road utility through installation of an AccuAir®system allowing
control/adjustment of ride height to accommodate challenging terrain & obstacles. The suspension feel and handling maybe
different than an unmodified Jeep.
To reduce risk of roll-over other accident & serious injury always:
• Inspect components including bags, lines, valves & compressor before use, followed by system self-test. Maintain & repair
as indicated. On road height limited to approx. 3.0” by system speed & ride height sensors. REPLACE & DO NOT USE ON
ROAD IF SPEED SENSOR DAMAGED/INOPERATIVE.
• DO NOT modify or substitute AccuAir®components of this system. Use of oversize tire/wheel combinations may increase
stopping distances, ride height and/or compromise performance of vehicle stability control and other systems.
CONGRATULATIONS!
A FEW WORDS ABOUT PRODUCT SAFETY
Your AccuAir®Jeep JK Air Suspension system reflects a unique solution to balancing enhanced off road terrain and
obstacle clearance with everyday drivability and ride quality. The AccuAir®JK system features remote mounted seamless
air tank, a quality compressor, mounts and all fittings necessary to replace your coil springs with ruggedly designed four
corner air bags allowing you to select a ride height tailored to your off road adventures. Back on the road, a unique speed
sensing value presets ride height to a maximum of 3.0” of lift (approx.), helping to preserve familiar ride comfort. Enjoy
your AccuAir®JK system by Treading Lightly©and following all instructions and product safety messaging below. If you
have further questions contact us at: [e-mail]. Our team is here to help.
• The drag link must be adjusted to center the steering wheel before the vehicle is driven. Failure to do so will cause
computer errors, odd handling characteristics, and poor performance.
• If larger tires (10% more than the OEM diameter) are installed, speedometer recalibration will be necessary.
Contact your local Jeep dealer.
• After installation, a qualified alignment facility is required to align the vehicle to the OEM specification.
• Avoid excessive speeds, abrupt maneuvers, surfaces/obstacles
which may induce a tripping moment. All occupants BUCKLE UP &
USE supplemental restraints.
• Consult the AccuAir®installation manual
([e-mail]) & OEM off road supplement 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 by one of three signal words indicating the relative risk of injury.
The signal words mean:
If you have any questions or reservations about installing this product, contact AccuAir Customer Service.
WARNING:
A hazardous situation which, if not avoided, could result in death or serious injury. You CAN be killed or seriously
hurt if you don’t follow instructions.
WARNING:
This advanced AccuAir®JK kit requires professional installation, with access to vehicle lift and experience with
Jeep JK suspension, electrical wiring, Jeep maintenance recommendations, safety messaging, torque & other
specifications, general repair safety including personal protection, vehicle rack safety, isolation and containment of
OEM spring assemblies during removal.
WARNING:
Wheel setup with a minimum of 4.5” of back spacing is
required with a maximum 9” wide wheel.
WARNING:
Incorrect shock length will distort air bag placement and lead to burst or reduced service life. USE front and rear
shock absorbers included with this kit.
Replacement shocks must be FRONT: 26.125” (allowed variance .125”); REAR: 27.72” (allowed variance .125”).
CAUTION:
A hazardous situation which, if not avoided, could result in minor or moderate injury. You CAN be moderately hurt
and may also suffer property damage if you do not follow instructions.
CAUTION:
Risk of Eye Injury. Safety glasses, gloves & other personnel protection should be worn when working with this product.
NOTICE:
Careful attention is required to this instruction or operation but does generally not relate to personal injury. Damage to
your AccuAir®product or other property may result if you don’t follow instructions.
NOTICE:
Never lower vehicle from rack or following inspection/
repair without air bags being fully inflated. CANCER AND REPRODUCTIVE HARM
WWW.P65WARNING.CA.GOV
WARNING
WARNING:SUSPENSION MODIFIED WITH VARIABLE
HEIGHT AIRBAGS - HIGHER ROLLOVER RISK
Inspect Components Followed by
System Self-test.
DO NOT Modify or Substitue AccuAir®
Components of This System.
Avoid Excessive Speeds, Abrupt
Maneuvers, Surfaces/Obstacles
Which May Induce a Tipping Moment.
Always Buckle Up.
See AccuAir® Installation
Manual & OEM Off Road
Supplement for Additional
Safety Information
Affix warning decal on driver’s side visor in clear view
of all occupants.
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PRODUCT & INSTALLATION OVERVIEW

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ACCUAIR®SUSPENSION LIMITED WARRANTY
WHAT IS COVERED?:
Subject to the terms, exclusions and limitations herein, Arnott, LLC. (“Warrantor” or “AccuAir”) exclusively warrants
to the initial retail purchaser of a AccuAir Jeep JK suspension kit that AccuAir will according to terms herein, repair
defects in or replace AccuAir supplied components which, upon AccuAir inspection are determined to have defects
in materials or workmanship existing as of the date of sale to the initial retail customer (hereafter “Customer”). This
Limited Warranty is the sole and exclusive warranty made or authorized by Warrantor. This Limited Warranty is not a
warranty or promise of any particular future performance.
The term of this Limited Warranty shall be three years as measured from the date of sale to initial Customer (the
warranty “TERM”). Any claim under this limited warranty must be made within six months of the last day of the
warranty TERM or will be forever waived. The duration of any implied warranty shall be limited to the three year term
of express limited warranty above.
WHAT IS NOT COVERED?:
Your AccuAir Limited Warranty does not cover: (1) defect in a AccuAir air suspension kit or component causing or
contributing to damage or defect, of any type whatsoever, to the vehicle it is installed upon or any electrical system
or other vehicle system or component separately warranted or supplied by a manufacturer other than AccuAir, (2)
damage to AccuAir components or your vehicle from altering or disabling any component of your vehicle or AccuAir
product; additions, alterations, or other products or components not supplied by AccuAir, (3) installation or use
contrary to professional installation recommendations, or other installation/use contrary to instructions and safety
messaging included within your AccuAir product, (4) expected wear and tear on airbags and other components
considering vehicle use, damage related to failure to adequately, install, inspect, maintain, adjust or service as
recommended or required, damage resulting from improper suspension set-up, loading, accident, collision, vandalism,
abuse, misuse, neglect, fire, flood, normal wear, defects in or degradation of finishes, reflecting corrosion, UV or
other environmental influences (5), AccuAir, components used in competition, other off road use or events which
may involve unforeseen vehicle components, suspension set ups, contact between vehicles, rocks or obstacles, other
components of your vehicle and your AccuAir components, damage or degradation of performance, (6) labor, lost time,
lost use or opportunities, reasonable delays in remedies hereunder, other consequential, incidental, punitive or other
damages or costs, including those incurred in removing, reinstalling or delivering your AccuAir 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,
Merritt Island, FL 32953. You will be asked to advise AccuAir in writing of your understanding of all defects and
provide AccuAir an opportunity to repair or replace the affected component(s) subject to the terms of this Limited
Warranty. Please have proof of purchase available.
REMEDY LIMITED TO REPAIR/REPLACEMENT BY ACCUAIR. BINDING, SINGLE CLAIM ARBITRATION-VENUE:
Upon Customer’s removal and delivery to AccuAir for inspection and AccuAir determination of a covered defect,
the exclusive remedy provided hereunder shall at AccuAir’s option be repair or replacement of the defective AccuAir
component(s). Your sole and exclusive remedy for breach of this Limited Warranty or any implied warranty imposed
by law, is the reasonable costs for replacement parts necessary to correct the defect(s) upon which the finding of
breach is based. For separate, valuable consideration received; all claims arising from or related to purchase or use of
AccuAir components shall exclusively be maintained as a separate action by each Customer applying Florida state law
(without reference to treaties or conflict of law provisions) through binding arbitration before a neutral selected by
Customer from the JAMS® panel closest to Merritt Island, Florida. To the extent permitted by law, each party shall bear
its own costs and fees. Any claim to enforce an arbitration award or for other breach or damages under this Limited
Warranty can only be brought in a court of competent jurisdiction closest to Brevard County, Florida.
OTHER EXCLUSIONS –LIMITATION OF DAMAGES - YOUR RIGHTS UNDER STATE LAW.
No employee, other agent of AccuAir or authorized reseller may, amend or waive this written Limited Warranty
or make additional representations or warranties regarding any AccuAir features, performance, workmanship or
materials. AccuAir reserves the right to make changes in design and changes or improvements upon its products
without imposing any obligation on itself to install or upgrade the same upon products previously manufactured.
By installation and use of your AccuAir product, and/or submitting a claim under this Limited Warranty, you
acknowledge that you have received and understand all product instructions, warnings and this Limited Warranty
and agree to be bound by all terms therein, reflecting the exclusive terms and remedies of the parties bargain.
This Limited Warranty gives you specific rights. You may also have other rights that vary from state to state. For
example, some states do not allow limitations of how long an implied warranty lasts and/or do not allow the exclusion
or limitation of incidental or consequential damages, so the limitations and exclusions herein may not apply to you. All
other warranties are hereby disclaimed, except to the extent prohibited by applicable law.

INDEX
Wire Routing, Fuse Box, Speed Module Routing & Plumbing Routing Diagrams 7
Wiring 15
Plumbing & Routing 39
Final Interior Installation 43
Front Installation 46
Rear Installation 64
Final Clearance Check & Torque Steps 75
Troubleshooting & Technical Support 76
INCLUDED PARTS
Air Suspension Conversion Kit VIAIR Inflation System
JRi Custom Tuned Shocks Front Lower Control Arms
e+ Connect Rear Upper and Lower Control Arms
TouchPad+ Upgrade Adjustable Front Track Bar
Height+ Front 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 Bracket
VIAIR 485C Compressor
REQUIRED TOOLS
SAE & SAE Hex Key Sockets/Wrenches Metric & Metric Hex Key Sockets/Wrenches
(5/32”, 7/32” & 5/16” Hex Key Sockets, 7/16”, 1/2”,
9/16”, 3/4”, 13/16”, 7/8” & 1-1/8”)
(6mm Hex Key Socket, 8mm, 10mm, 13mm, 15mm,
18mm, 19mm, 21mm, 22mm & 24mm)
Drill Bits Ball Peen Hammer Floor Jack
(1/8”, 3/8”, 15/32”) Wheel Chock Torque Wrench
Measuring Tape Jack Stands Blue Loctite Wire Wheel
Safety Glasses Pliers
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INDEXINCLUDED PARTS

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
J19J2J14
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
Manifold
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 Height
Sensor - 3
Rear Left
Ride Height
Sensor - 2
Front Right
Ride Height
Sensor - 1
Front Left
Pressure Sensor
Comp
87
86
85
30
Bolt Ground lug
(under vehicle)
Ground Lug
(in vehicle)
Battery Fuse Box
(Ignition
Fuse Tap
- M4)
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WIRE ROUTING

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
J19J2J14
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 INTOTAP INTO M4M4
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FUSE BOX

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
J19J2J14
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)
Ignition Wire Tap
Speed
Module
GPS
Antenna
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SPEED MODULE ROUTING

Front
Rear
Air Spring - 1
Front Left
Air Spring - 2
Front 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
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PLUMBING ROUTING

1. Take the 6 gauge power wire with the 70 AMP fuse installed provided. (Figure 1)
Lay the fuse beside the battery and route remaining wire along the passenger side frame rail to the floor drain
plug underneath the drivers side of the vehicle (Figure 2). Do not connect to battery at this time.
FIGURE 1
2. Remove the floor pan drain plug from underneath the rear driver side floor 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 cab via the grommeted floor pan hole. Run an end of the 1/4” air line for the pressure regulator
into the cab via the grommeted floor pan hole. (Figure 3)
FIGURE 3
4. Inside the cab, fold the rear seats forward. Gather and pull the wires, tubing, and ground connections, up from the
grommeted floor pan hole. (Figure 4)
FIGURE 4
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WIRING

5. Locate all three grounds coming from the ECU harness. Depending on model or year, the ground stud location can
vary. If wires will not reach available ground stud, follow the steps in the next figure. (Figure 5)
FIGURE 5
6. Cut all three grounds equal length. The excess from the long ground wire will now be used to extend 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 harness that runs down the drivers side rear wheel well, locate the plastic clip that sits over the stud. Using
a wire brush or sandpaper, remove paint from stud, and this will be where the ground will be connected, using the
supplied M6 nut. (Figure 8)
FIGURE 8
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9. Install heat shrink onto wire end and crimp copper ring terminal onto battery power cable. (Use the ring terminal with
flat sides.) (Figure 9)
10.
FIGURE 9
Gather all wire harnesses and the regulator air tubing and bundle them behind the carpet behind the drivers side rear
seat. Also add TouchPad cable (white connector). (Figure 10)
FIGURE 10
11. Grab supplied ECU bracket. Make electrical connections as shown below. Refer to relay diagram to make 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
J19J2J14
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
Manifold
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 Height
Sensor - 3
Rear Left
Ride Height
Sensor - 2
Front Right
Ride Height
Sensor - 1
Front Left
Pressure Sensor
Comp
87
86
85
30
Bolt Ground lug
(under vehicle)
Ground Lug
(in vehicle)
Battery Fuse Box
(Ignition
Fuse Tap
- M4)
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WIRING

12. Separate the upper and lower tank bracket assembly for installation using a 19mm socket/wrench. (Figures 12, 13)
FIGURE 12
UPPERLOWER
FIGURE 13
13. Using Phillips head screwdriver, 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 14
14. After loosening straps, slide the tank forward to allow access to mounting holes. (Figures 15, 16)
FIGURE 15
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WIRING

MOUNTING
HOLES
FIGURE 16
15. Remove the two bolts holding the front of the EVAP cannister with 16mm socket/wrench. (Figure 17)
FIGURE 17
16. Install the upper bracket holding the seamless tank to the frame underneath the vehicle. The tank bracket will slide
in between the cross 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 Blue
Loctite when installing the M8 fasteners to the factory cross member.) (Figure 18)
FIGURE 18
With the brackets lined up, reinsert the 16mm bolts and tighten. Ensure clearance of muffler to bracket. (Figure 19)
FIGURE 19
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17. Slide the seamless tank back into the original location and re-tighten tank straps. (Figures 20, 21)
FIGURE 20
FIGURE 21
18. The bracket shown below 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. Then
insert the hex bolt and washer into the front. (Figures 22, 23)
FIGURE 22
FIGURE 13
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19. Insert the hex head bolts and washers through the tabs located at the front and back of the upper tank bracket
through the cross member above. (Figures 24, 25)
FIGURE 24
FIGURE 25
20. Hang the lower tank bracket using the front two bolt 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. (Figure 26)
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 27
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WIRING

22. Remove this bolt at the rear of the EVAP cannister to allow mounting the VU4. (Figure 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 hardware. (Figure 31)
FIGURE 31
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WIRING

25. Route VU4 harness above EVAP cannister and connect to VU4 and route the ground wires to the stud located above
VU4 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.
Tighten the ground stud. (Figures 33, 34)
FIGURE 33
FIGURE 34
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27. Connect purge valve to plug from main harness. (Figure 35)
FIGURE 35
28. Run the orange ignition wire up to the fuse box.
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 36
FIGURE 37
30. Attach t-tap to ignition line near passenger side door. (Figure 38)
FIGURE 38
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31. Connect GPS speed module spade connector to t-tap. (Figure 39)
FIGURE 39
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
33. Connect 12-pin Molex connector to GPS Speed module. (Figure 41)
FIGURE 41
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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
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