Air Lift 1000 User manual

Customer Service
1-800-248-0892
1
MN-439
(04606)
ECR 5715
Kit No. 60740
by
Please read these instructions completely before proceeding with the installation.
Air Spring Kit Parts List
Item Part number Description Quantity
A 46160 Air Spring 2
B 34365 Heat Shield Kit 1
A
B
Air Line Assembly Parts List
Item Part number Description Quantity
AA 20315 Air Line Assembly 15'
BB 10466 Tie Strap 6
CC 21230 Valve Caps 2
DD 18405 5/16" Flat Washer 2
EE 21234 Rubber Washer 2
FF 18411 Star Washer 2
GG 21233 5/16" Hex Nut 4
HH 21236 Plastic Tee 1
JJ 10638 Line Clips 6
KK 21455 Inflation Valve 2
CC DD EE FF GG HH JJ KK
AA
BB

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Cut Here
Open-end or box wrenches
Pliers
Drill and 5/16", 1/2", and 3/4" bit
Sharp Knife
Aluminum Shears
File, Air Grinder, Dremmel Tool
Tools Needed
Hoist or Floor Jacks
Safety Stands
Safety Glasses
Air Compressor, or Compressed Air Source
Spray Bottle with Dish Soap/Water Solution
I. Removing the Jounce Bumper
1. Jack up the rear of the vehicle. Put safety stands under
the frame so wheels hang. Removing bottom shock bolt
may aid in lowering suspension. Caution: Observe brake
line, do not over extend.
2. Cut jounce bumper off 1/8" under the steel cup where the
rubber jounce bumper is attached. See illustration and
Figure 1.
CAUTION: Be extremely careful cutting jounce bumper
off. A screw driver may aid in opening the jounce bumper
up while cutting it off (Figure 2).
3. Oncethejouncebumperiscutoff,itisnecessarytoremove
it. Use a spring spreader or cut the jounce bumper in two
with shears or bandcutters (Figures 3 and 4).
Figure 1
Figure 2
Figure 3 Figure 4

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II. Installing the Air Bag
1. Cutout the templateprovided, and stickit to theunderside
of the lower control arm, aligning the template so that the
hole to be drilled is towards the inside of the vehicle. See
Figure 5. (The template is on page 9 at the end of this
manual.)
2. Center punch and drill a 3/4" hole to provide valve stem
clearance (Figure 6).
NOTE: As an option, to a
3
/ 4 " bit, the picture shows a
1
/ 2 "
bit. Hole can be ground out to
3
/ 4 " by using an air grinder
or dremmel tool.
3. Remove cap from valve stem, and step on cylinder to
remove air. With cylinder flat, replace cap and fold like a
hot dog bun (Figure 7).
4. Insert into spring with stem pointing downward (Figure 8).
5. Aflat,bluntinstrumentmayaidinpositioningcylinderinside
the coil spring. Remove cap and let cylinder resume its
molded shape. Push the cylinder down so the barbed
stem protrudes through the hold drilled previously (Figure
9).
Figure 5
Figure 6
Figure 7
Figure 8
Figure 9

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III. Installing the Air Lines
1. Slide one line clip (JJ) over one end of the hose. Insert
hose onto barbed end of the cylinder. Using pliers, slide
line clip over barbs (Figure 10).
2. Route hose up to cross member.Tie off with tie strap (BB)
to existing hole forward of lower control arm (Figure 11).
3. Routeline across todriverside,abovecrossmember.Use
hoseheat shield (B) where linegoes over exhaust (Figure
12).
4. Find a location on driver side for a tee. Route hose from
passenger side to this location. Cut hose and install a line
clip (JJ). Insert hose into one leg of tee (HH) and slide line
clip over barbs. Repeat for driver side and attach to other
side of tee (Figure 13).
Note:You can opt to use a single line per bag,
skip step 4 and, proceed to step 5.
5. Determinealocationfortheinflationvalve,(orvalves)such
as under the bumper (Figure 14). Route the remaining
hose from this spot to the last leg of the tee and attach in
the same manner.
Figure 10
Figure11
Figure 12
Figure 13
Figure 14

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Dead Air Space
Exhaust
Pipe
6. Drill a 5/16"holeforinflation valve, (orvalves) and mountas
illustrated(rubberwasherisforoutside weather seal). See
Figure 15. Slide hose clip onto free end of remaining line,
pushlineontoinflation valve and put on hosecliptosecure
line.
7. Bend heat shield tabs out at a 90° angle.Then bend again
half the distance up at 90° angle to form an “L” shape.
Position heat shield between spring and pipe. Clamp to
pipe using radiator clamps (Figure 16).
NOTE: Thereshouldbe a deadairspacebetween exhaust
pipe and heat shield (Figure 17).
8. Inflate air springs to 10 p.s.i. Spray all connections and
the inflation valves with a solution of 1/5dish soap and 4/5
water to check for leaks. You should be able to spot leaks
easily by looking for bubbles in the soapy water. Now
adjust air pressure for optimal comfort and performance
(minimum 5 p.s.i and maximum 35 p.s.i.).
9. Check the air pressure again after 24 hours. A 2–4 p.s.i.
loss after initial installation is normal. Retest for leaks if
the loss is more than 5 p.s.i.
Figure 15
Figure 16
Figure 17
Hex Nut
Inflation Valve
Star Washer
Rubber Washer
Body Sheet
Metal
Flat
Washer
Hex Nut

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IV. Troubleshooting Guide
1. Leak test all the air line connections (Figure 18). Repair
or replace as needed.
2. Inspect air line for holes and cracks (Figure 19). Replace
as needed.
3. Inspect air lines to be sure it is not pinched. Tie straps
may be too tight (Figure 20). Replace strap.
4. A kink or fold in theairline(Figure21). Rerouteasneeded.
5. Leak test the inflation valve for leaks at the air line
connection or dirt or debris in the valve core (Figure 22).
Youhavenowtested forallof themost probableleak conditions
that can be easily fixed. At this point the problem is most likely
a failed air spring - either a factory defect or an operating
problem. Please call Air Lift at 1-800-248-0892 for assistance
or a replacement air spring.
Figure 18
Figure 19
Figure 20
Figure 21
Figure 22

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V. Post Installation Checklist (to be completed by owner)
1. Overnight Leakdown Test: Recheck air pressure after vehicle has been used for 24 hours. If
pressure has dropped more than 5 p.s.i., there is a leak that must be fixed. Either fix the leak
yourself or return to the installer for service.
2. Air Pressure Requirements: I understand that the air pressure requirements of my air spring
system are as follows:
Minimum ___________ Maximum ___________
Exceedingthemaximumrecommendedairpressurewillresultintheairspring“bulgingout”between
the coils of the spring which may cause the air spring to be pinched or may rub a hole into the
cylinder.
VI. Maintenance and Operations
By following these steps, vehicle owners should obtain the longest life and best results from
their air springs.
1. Check the air pressure in the air springs weekly.
2. Always maintain at least the recommended minimum air pressure to prevent the air spring from being
pinched. Never inflate beyond the recommended maximum air pressure.
3. If you develop a leak in the system, use a soapy water solution to check all air line connections and the
inflation valve core before deflating and removing the air spring.
4. Always add air to springs in small quantities, checking the pressure frequently. Air springs require less
air volume than a tire and inflate quickly.
MINIMUM AIR PRESSURE
5 p.s.i.
MAXIMUM AIR PRESSURE
35 p.s.i.
View of the Final Installation

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3.75"
2.35"
1.88"
Hole
Location
'99 - '00 Honda Odyssey
Template

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“The Choice of the Professional Installer”
For Technical Assistance call 1-800-248-0892
Thank you for purchasing Air Lift Products
Mailing Address: Street Address:
AIR LIFT COMPANY AIR LIFT COMPANY
P.O. Box 80167 2710 Snow Rd.
Lansing, MI 48908-0167 Lansing, MI 48917
Local Phone: [phone]
Fax: [phone]
Printed in the USA