Air Lift 75524 User manual

PERFORMANCE SUSPENSION PARTS

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. The information includes a
hardware list, step-by-step installation information, maintenance tips, safety information
and a troubleshooting guide.
NOTATION EXPLANATION
Hazard notations appear in various locations in this publication. Information which is
highlighted by one of these notations must be observed to help minimize risk of personal
injury or possible improper installation which may render the vehicle unsafe. Notes are used
to help emphasize areas of procedural importance and provide helpful suggestions. The
following denitions explain the use of these notations as they appear throughout this guide.
INDICATES IMMEDIATE HAZARDS WHICH WILL RESULT IN SEVERE PERSONAL
INJURY OR DEATH.
INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN SEVERE
PERSONAL INJURY OR DEATH.
INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN DAMAGE
TO THE MACHINE OR MINOR PERSONAL INJURY.
Indicates a procedure, practice or hint which is important to highlight.
IMPORTANT SAFETY NOTICES
The installation of this kit does not alter the Gross Vehicle Weight Rating (GVWR) or payload
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
(including passengers and cargo). This number — along with other weight limits, as well
as tire, rim size and ination pressure data — is shown on the vehicle’s Safety Compliance
Certication Label.
Payload: The combined, maximum allowable weight of cargo and passengers that the
vehicle is designed to carry. Payload is GVWR minus the Base Curb Weight.
DO NOT INFLATE AIR SPRINGS WHILE OFF OF THE VEHICLE. DAMAGE TO ASSEMBLY
MAY RESULT AND VOID WARRANTY.
DO NOT WELD TO, OR MODIFY PERFORMANCE STRUTS/SHOCKS IN ANY WAY.
DAMAGE TO UNIT MAY OCCUR AND WILL VOID WARRANTY.
DANGER
NOTE
WARNING
CAUTION
WARNING
CAUTION

Air Lift Performance
HARDWARE LIST
Item Part # Description................................... Qty
A 35237 Strut, Volkswagen MKIV Front...............2
B 20997 Leader Hose, 1/4” ID..............................2
C 21987 Union, 1/4”FNPT X 3/8” PTC, DOT........2
D 21810 Union, 1/4”FNPT X 1/4” PTC, DOT .......2
E Spanner Wrench ....................................1
Installation Diagram
g. 1
C or D
B
A
E

Air Lift Performance
Installing the Air Suspension
g. 2
g. 3
g. 4
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 (gs. 2-4). Unclip the sensor wire from the
strut (g. 5).

Air Lift Performance
g. 5
g. 6
g. 7
2. Disconnect the stabilizer bar from the lower control arm (g. 6).
3. Support the hub assembly to prevent over extension. Remove the lower pinch bolt from
the hub (g. 7). Spread the hub assembly slot and push down on the hub to release the
strut from the hub (g. 8). With the hub free of the strut, do not allow to hang freely by
the axle or sensor wires (g. 9).

Air Lift Performance
g. 8
g. 9
g. 10
4. Remove the cover from the strut rebound washer (g. 10). Support the strut and remove
the rod nut and rebound washer (g. 11). Remove the strut from the vehicle (g. 12).

Air Lift Performance
g. 11
g. 12
g. 13
PREPARING FOR THE AIR SUSPENSION
1. Install the leader line into the air spring (g. 13). Seal the threads of the leader hose
with Teon tape or thread sealant. Tighten the appropriate tting to the airline 1 3/4
turns beyond hand tight. Tighten the leader line into the air spring 1 3/4 turns beyond
hand tight.

Air Lift Performance
g. 14
g. 15
g. 16
2. Cut out the template supplied in the back of this manual and place it over the coned
strut tower as shown (gs. 14 & 19). One hole is to face outboard the vehicle with the
other holes inboard. Taping a string across the strut tower centers can be a useful way
to ensure the centerline of the outboard stud hole (gs. 15 & 16). Center punch and drill
an 11/32” hole at each center punch (gs. 17 & 18).

Air Lift Performance
g. 17
g. 18
g. 19

Air Lift Performance
g. 20
g. 21
g. 22
AIR SUSPENSION INSTALLATION
1. Insert the strut assembly into the strut pocket and attach the camber plate to the
previously drilled holes (g. 20). Torque camber plate nuts to 20Nm (15lb-ft).
2. Install the strut into the hub (g. 21). Torque the pinch bolt to 70Nm + 90˚ (52lb-ft + 90˚).
3. Reattach the sensor wire tab and sensor wires (g. 22).

Air Lift Performance
Torque Specications
Location Nm lb-ft
Camber plate to chassis 20 15
Strut to hub pinch bolt 70 + 90˚ 52 + 90˚
Stabilizer link to control arm 30 22
Wheels 120 89
Table 1
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.
Routing should also allow for the suspension to extend without kinking or pulling the
line tight or rubbing on other components. Check clearances to all other components.
6. With the suspension fully compressed, take a measurement from the fender to some
reference point – typically the center of the axle. Record this measurement as Max
Compression.
7. Cycle the suspension to Max Extension and record the measurement from the same
reference points.
8. Add ME and MC then divide by 2. Set the suspension to this point. This position will
give 50% stroke in either direction and is a starting point for ride height (g. 24).
9. With the suspension at this position, loosen, then re-torque the lower control arm bolts
to manufacturer’s specications (Table 1).
g. 24
g. 23
Formula for Calculating Ride Height
(ME+MC)÷2=MID STROKE
4. Reinstall the stabilizer end link to the control arm (g. 23). Torque to 30Nm (22 lb-ft).

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 (gs. 25 & 26) or a 3mm allen wrench.
Turn the adjuster clockwise and the damping settings are hardened. Turn the adjuster
counterclockwise and the damping is softened.
Each shock is preset to “-15 clicks”. This means that the shock is adjusted 15 clicks away
from full stiff. Counting down from full stiff is the preferred method of keeping track of, or
setting, damping. This setting was developed on a 2002 Volkswagen Jetta TDi and may
need to be adjusted to different vehicles and driving characteristics.
ALIGNING THE VEHICLE
WHEN MAKING CAMBER ADJUSTMENTS TO THE NEGATIVE SIDE FOR ALIGNMENT
OR WHEEL FITMENT, IT IS VERY IMPORTANT TO MAKE SURE THAT AFTER THE
ADJUSTMENT, THE AIR SPRING HAS ADEQUATE WORKING CLEARANCE ON THE
INNER STRUT TOWER SIDE. ANY RUBBING OR CONTACT WITH THE AIR SPRING
WILL CAUSE A FAILURE AND WILL NOT BE COVERED UNDER WARRANTY.
1. Using the control system, set the vehicle height to the new custom ride height.
2. If the custom ride height is lower than stock, we recommend loosening all pivot points
(bolts, nuts) on any control arm, strut arm or radius rod that contains bushings. Once
they have been loosened, re-torque to stock specications.
It may be necessary to cycle the suspension to loosen the bushing up from its mount. This
will help re-orient the bushing at its new position based on the custom ride height.
g. 25 g. 26
NOTE
CAUTION

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),
which is the same as reducing drop height, or want to lower the chassis further and there is
still adjustment available at the lower mount, please use the following procedure:
Since all kits are designed to provide maximum drop, driving regularly at a pressure/height
greater than recommended in this manual may create a situation called “topping”. This
occurs when the available wheel travel is restricted in the rebound direction by shifting the
ride height past the mid-point as described in this manual. The result is an uncomfortable
ride and, potentially, a knocking noise when going over bumps as your damper runs out of
travel. If your wheel/tire combination requires greater clearance or you need a taller ride
height, you can eliminate topping by adjusting your damper to a longer length overall as
detailed below. A good rule of thumb is to have at least 1/3 of the available wheel travel
available for rebound (extension) travel.
1. Support the vehicle with jack stands or a hoist at approved lifting points.
2. Remove the wheel.
3. Using the supplied spanner wrench, loosen the lower locking collar (g. 27).
4. Deate the air spring to 0 PSI on the corner you are adjusting.
5. Disconnect lower mount from suspension.
6. Spin the lower mount to the desired location.
Not all models will have further drop height available.
7. Re-install lower mount to suspension and torque fasteners.
8. Tighten the lower locking collar to the lower mount using signicant force.
g. 27
NOTE
NOTE

Air Lift Performance
CAUTION
FOR STRUTS: FOR SHOCKS:
Thread
MUST be
showing in
window.
OK, no threads
showing.
Not OK, threads
are showing.
g. 28
WHEN ADJUSTING HEIGHT UPWARDS, MAKE SURE THAT THE STRUT BODY
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. 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
CAUSE AN AIR LEAK AND COMPROMISE THE ASSEMBLY.
CAUTION

Template

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. The information includes a
hardware list, step-by-step installation information, maintenance tips, safety information and
a troubleshooting guide.
NOTATION EXPLANATION
Hazard notations appear in various locations in this publication. Information which is
highlighted by one of these notations must be observed to help minimize risk of personal injury
or possible improper installation which may render the vehicle unsafe. Notes are used to help
emphasize areas of procedural importance and provide helpful suggestions. The following
denitions explain the use of these notations as they appear throughout this guide.
INDICATES IMMEDIATE HAZARDS WHICH WILL RESULT IN SEVERE PERSONAL
INJURY OR DEATH.
INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN SEVERE
PERSONAL INJURY OR DEATH.
INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN DAMAGE
TO THE MACHINE OR MINOR PERSONAL INJURY.
Indicates a procedure, practice or hint which is important to highlight.
IMPORTANT SAFETY NOTICES
The installation of this kit does not alter the Gross Vehicle Weight Rating (GVWR) or payload
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
(including passengers and cargo). This number — along with other weight limits, as well
as tire, rim size and ination pressure data — is shown on the vehicle’s Safety Compliance
Certication Label.
Payload: The combined, maximum allowable weight of cargo and passengers that the
vehicle is designed to carry. Payload is GVWR minus the Base Curb Weight.
DO NOT INFLATE AIR SPRINGS WHILE OFF OF THE VEHICLE. DAMAGE TO ASSEMBLY
MAY RESULT AND VOID WARRANTY.
DO NOT WELD TO, OR MODIFY PERFORMANCE STRUTS/SHOCKS IN ANY WAY.
DAMAGE TO UNIT MAY OCCUR AND WILL VOID WARRANTY.
DANGER
NOTE
WARNING
CAUTION
WARNING
CAUTION

Air Lift Performance
Installation Diagram
g. 1
NOTE Use of axle relocation
brackets, such as “Great Plates”
voids the warranty. We will
not warranty the air springs for
premature failure due to any
relocation of spring or axle
from factory location.
HARDWARE LIST
K
J
E
A
H
F
E
F
G
D
I
B or C
Item Part # Description .............................. Qty
A 58130 Tapered Sleeve................................. 2
B 21851 1/4” MNPT X 3/8” PTC...................... 2
C 21779 1/4” MNPT X 1/4” PTC, 90˚ Nickel.... 2
D 07324 Upper Bracket Assembly .................. 2
E 18427 3/8” Lock Washer ............................. 6
F 17187 3/8”-16 X 7/8” Hex Cap Screw .......... 6
G 18422 3/8”-16 Flange Nut............................ 2
H 18585 3/8”-16 Nutsert.................................. 2
I 10956 Washer, Plate ................................... 2
J 26700 Shock, Threaded MKIV Rear............ 2
K Spanner Wrench............................... 1

Air Lift Performance
Installing the Air Suspension
NOTE
g. 4
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!
1. Support the hub with a jack and remove the lower shock bolt. Slowly lower the axle until
the axle hangs free. Move to the other side of the vehicle and repeat this process until
the axle and springs hang freely.
2. Remove the coil springs and rubber isolators.
3. Unbolt the two shock upper bracket bolts and remove the shock from the vehicle.
4. Remove the plastic cap to reveal the shock rod nut and remove the rod nut. Remove
the upper bracket from the shock.
INSTALLING THE AIR SUSPENSION
1. Use a 17/32” (.531” diameter) drill bit to drill the hole precisely in the upper coil spring
perch (gs. 2 & 3).
The hole must be 17/32” (.531 diameter) for the nutsert to be effective.
2. Assemble the nutsert and nutsert tool (g. 4) together and insert into the drilled hole
(g. 3). While holding the nutsert spacer in place, tighten the tool bolt until the nutsert
is fully seated and locked in place.
CAUTION
g. 2 g. 3

Air Lift Performance
g. 6
3. At the lower spring perch, lightly grind the center hole larger so that the air spring can
sit ush in the lower coil spring perch.
4. Apply thread sealant to the threads of the air tting and thread into the air spring 1 3/4
turns beyond hand tight (g. 6).
5. Attach the upper bracket to the air spring using the supplied lock washers and bolts.
Torque to 27Nm (20lb-ft).
6. Thread the air spring/bracket assembly into the installed nutsert. Tighten by hand while
positioning the air tting where the air line will have maximum clearance.
7. Extend the air spring into the lower spring perch and lock in place with the large washer,
lock washer and bolt (g. 7). Torque to 7Nm (5lb-ft).
g. 5
g. 7