Air Lift 1000 User manual

For maximum effectiveness and safety,
pleasereadtheseinstructionscompletely
before proceeding with installation.
Failure to read these instructions can result in an
incorrect installation.

INSTALLATION GUIDE
Cover illustration
may not depict
actual kit.
Cover illustrationCover illustrationCover illustration
may not depictmay not depictmay not depict
actual kit.actual kit.actual kit.
Kit 60814
Dodge Caravan & Grand
Caravan, Chrysler Town
& Country, Volkswagon
Routan

Air Lift 1000
Introduction
The purpose of this publication is to assist with the installation, maintenance and

Itisimportanttoreadandunderstandtheentireinstallationguidebeforebeginninginstallation
orperforming any maintenance,serviceorrepair. The informationhereincludesa hardware
list, tools list, step-by-step installation information, maintenance guidelines and operating
tips.
IMPORTANT SAFETY NOTICE

of the vehicle. Check your vehicle’s owner’s manual and do not exceed the maximum load
listed for your vehicle.
Gross Vehicle Weight Rating: The maximum allowable weight of the fully loaded vehicle



Payload: The combined, maximum allowable weight of cargo and pasengers that the truck

NOTATION EXPLANATION
Hazard notations appear in various locations in this publication. Information which is
highlightedbyoneofthesenotationsmustbeobservedtohelpminimizeriskofpersonal injury
orpossible improper installationwhichmay render thevehicleunsafe.Notesare used tohelp
emphasize areas of procedural importance and provide helpful suggestions. The following

        





Indicates a procedure, practice or hint which is important to highlight.
DANGER
NOTE
WARNING
CAUTION

Air Lift 1000
Item Part # Description.....................................Qty
   .................................................... 2
   ..................................................... 
    ..................................................... 
    ................................................... 2
    ............................................. 
   ........................................... 2
   ................................................ 2
    ....................................... 2
   ............................................................. 
    .......................................................... 
    ............................................ 
HARDWARE LIST TOOLS LIST
Description...................................................... Qty
.......................................................... 2
Safety stands.................................................................. 
Safety glasses................................................................ 
 ....... 
Drill, drill bits................................................................... 
Grinder or dremel tool..................................................... 
Pliers............................................................................... 
Air compressor or compressed air source...................... 
 ..................... 
Installing the Air Lift 1000 System
g. 1
Safety stand
Frame
Axle Jack
PREPARING THE VEHICLE




suspension cross member.
g. 2




Air Lift 1000


3. The coil spring will have to be removed to prep the vehicle for the air spring. Mark the coil
spring, upper spring damper and upper spring seat with a marker so that the assembly can



Pull sideways on the jounce bumper while twisting and remove the jounce bumper from the

6. It will be necessary to enlarge the center hole in the upper jounce bumper bracket. Drill the

It may be necessary to clean the loose plastic out with a knife or a le. The hole must be
open and not restrictive so the hose can ow freely in and out.
g. 3
g. 4
g. 5
Coil spring
Mark all three
Jounce bumper
strike plate
Jounce bumper
bracket Jounce bumper
Jounce bumper
bracket
Drill existing hole with
a 1/2” drill bit.
NOTE

Air Lift 1000
 

 
to gain access to the cylinder for the hose. Measure up from the bottom edge of the

Error to the rear of the center if needed. Mark and drill a ½” hole through the reinforcement only.
 
opposite side.
INSTALLING THE AIR SPRING
 

just enough to hold the spring in place.
2. When installing the hose it may be necessary to insert the hose through the bottom
of the jounce bumper bracket, up through the hole in the grommet that was installed
previously.
If you nd it hard to get the hose through the grommet it may be helpful to use a stiff wire
to guide the hose up through the hole. Attach the hose to the barbed end of the cylinder
using the hose clamp provided.
g. 6
g. 7
Drill existing hole with
a 1/2” drill bit.


Drill hole here and
install supplied
grommet.
Hose

NOTE
NOTE

Air Lift 1000
INSTALLING THE AIR LINE
A tee air line installation is recommended. If the weight in the vehicle varies from one side
to the other and unequal pressures are needed to level the load or compensate for axle

TEE AIR LINE ROUTING
            

 
adequate length of air line to reach from the tee to the left and right side air springs.


2. Slide an air line clamp onto the air line.
3. Push the air line over one side of the tee until all the barbs are covered. With a pair of


 
spring seat to the air spring.
CAUTION
CAUTION
A
CUse this procedure for all air
line connections:
a. Slide the air line clamp onto
the air line.
b. Push the air line over the
barbed stem.
c. Compress the ears on the
air line clamp with pliers and
slide it forward to fully cover
the barbed section.
g. 8
 
 
air line clamp upward until it fully covers the barbed section.
g. 9
Stem Air line

Air Lift 1000
 
serves as an outside weather seal.



g. 12
Be sure to fully cover
the barbed section.
g. 11
Vehicle body
or bumper
Air line
clamp
Hex nut 
washer
Lock
washer

valve
Flat washer Air line
Hex nut
Option 1
Option 2
 

 


g. 10

spring seat and lower spacers.

If necessary, loosen the clamps and rotate or move to obtain additional clearance.

   


CAUTION

Air Lift 1000
DUAL AIR LINE ROUTING
     

           
assuring that each valve will be protected and accessible with an air hose.
2. Determine and cut an adequate length of air line to reach from the valve location to the
left side air spring.


3. Insert the air line through the spring seat and spacer.
 
 
slide the air line clamp forward until it fully covers the barbed section.
 
 

 
off the excess.
 



lower spacers.

Ifnecessary, loosen theclampsand rotate ormovetoobtain additional clearance.Ifyou
are installing this kit on a Honda Odyssey see page 6 for instruction on how to install

  

COMPLETING THE INSTALLATION
 
line into the clamp on the side of the frame and reattach the shocks.
Be sure that the hose does not kink during this process.
2. Leave slack at the top for the hose to move in and out freely during normal driving and

Loosely attach the hose to the brake line using a wire tie.
 dish
soap to 
 
your air springs.
 

CAUTION
CAUTION
CAUTION
NOTE
NOTE

Air Lift 1000
Minimum Air Pressure Maximum Air Pressure
5 PSI 35 PSI



Maintenance and Servicing
MAINTENANCE GUIDELINES

their air springs.
 
2. Always maintain at least the recommended minimum air pressure to prevent the air

 


 

OPERATING TIPS
 
toproperly mesh withthecoil spring. Afterthevehicle is loaded,adjustyour air pressure
down to level the vehicle and for ride comfort.
               
proportion to any overload condition. We recommend a 2 PSI increase above normal

  
 
CAUTION

Air Lift 1000
Product Use
FREQUENTLY ASKED QUESTIONS
Q. Will installing air springs increase the weight ratings of a vehicle?


Q. Is it necessary to keep air in the air springs at all times and how much pressure
will they need?
The minimum air pressure should be maintained at all times. The minimum air pressure
keeps the air spring in shape, ensuring that it will move throughout its travel without
rubbing or wearing on itself.
Q. Is it necessary to add a compressor system to the air springs?
No. Air pressure can be adjusted with any type of compressor as long as it can produce

a lot of work.
Q. How long should air springs last?
 
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,
support the axle with jack stands in order to take the tension off of the air springs.
TUNING THE AIR PRESSURE
            
stability.
1. Level vehicle
If the vehicle’s headlights are shining into the trees or the vehicle is leaning to one side,

and level the vehicle.
2. Ride comfort
If the vehicle has a rough or harsh ride it may be due to either too much pressure or not

3. Stability
Stability translates into safety and should be the priority, meaning the driver may need


requires an increase in pressure.
g. 13 g. 14
 
Sway and body roll
g. 15

Air Lift 1000
GUIDELINES FOR ADDING AIR
 
2. When in doubt, always add air.
 
that it is heavily loaded.

if equipped.

 
 
 


g. 16 g. 17
  Level
AIR LIFT SYSTEMS SUSPENSION SYSTEMS