Air Lift 75557 User manual

INSTALLATION GUIDE
Kit 75557
Subaru BRZ, Scion FR-S
and Toyota GT86
Front Application
For maximum effectiveness and safety,
please read these instructions completely
before proceeding with installation.
Failure to read these instructions can result in an
incorrect installation.
MN-870 • (031603) • ECR 8369

2MN-870
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TABLE OF CONTENTS
Introduction ................................... 2
Notation Explanation ...............................................2
Important Safety Notices .............................................2
Installation Diagram ............................ 3
Hardware List .....................................................3
Installing the Air Suspension..................... 4
Preparing the Vehicle ...............................................4
Stock Strut Removal ................................................4
Air Suspension Installation ...........................................5
Aligning the Vehicle.................................................6
Damping Adjustment ................................................6
Adjusting Extended or Drop Height Using Lower Mount .....................7
Before Operating ............................... 9
Installation Checklist ................................................10
Product Use, Maintenance and Servicing...........11
Suggested Driving and Maximum Air Pressures...........................11
Maintaining and Operating ...........................................11
Troubleshooting Guide..........................11
Frequently Asked Questions .....................11
Tuning the Air Pressure .........................12
Checking for Leaks .............................12
Fixing Leaks...................................12
Limited Warranty and Return Policy ...............16
Replacement Information ........................17
Contact Information ............................17

2MN-870
Air Lift Performance
Introduction
The purpose of this publication is to assist with the installation, maintenance and
troubleshooting of this Subaru BRZ/Scion FR-S/Toyota GT86 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,
tool list, step-by-step installation information, maintenance tips, safety information and a
troubleshooting guide.
Air Lift Company reserves the right to make changes and improvements to its products and
publications at any time. For the latest version of this manual, contact Air Lift Company at
[phone] or visit our website at www.airliftcompany.com.
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

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HARDWARE LIST
Item Part # Description ......................................................Qty
A 35230 Strut assembly, BRZ/FRS/GT86 Front Right................ 1
B 35231 Strut assembly, BRZ/FRS/GT86 Front Left .................. 1
C 20997 Leader Hose, 1/4” ID..................................................... 2
D 21810 Union, 1/4”FNPT X 1/4” PTC, DOT............................... 2
E 21987 Union, 1/4”FNPT X 3/8” PTC, DOT............................... 2
F Spanner Wrench........................................................... 1
G Adjustable Sway Bar End Link...................................... 2
Installation Diagram
Missing or damaged parts? Call Air Lift customer
service at [phone] for a replacement part.
STOP!
g. 1

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Air Lift Performance
PREPARING THE VEHICLE
1. Support the vehicle with jack stands or a hoist at approved lifting points.
2. Remove the front wheels.
STOCK STRUT REMOVAL
1. Remove the bolts retaining the brake hose and unclip the ABS sensor wire (g. 2).
2. Disconnect the stabilizer bar from the strut body and the lower control arm (g. 3).
g. 2
Installing the Air Suspension
g. 3
Brake line
bolt
Stabilizer
bar
Lower strut
mount bolts
ABS sensor
wire

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Air Lift Performance
3. Support the hub then unbolt and remove the two lower strut mount bolts (g. 3).
4. Unthread the three upper bracket nuts within the engine compartment and remove the
strut from the vehicle (g. 4).
AIR SUSPENSION INSTALLATION
1. Begin by installing the leader line (C) into the air spring (g. 5). Wrap the threads of the
leader hose with Teon tape or thread sealant. Tighten the appropriate tting (D or E)
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.
g. 4
g. 5
2. Align the strut assembly with the upper bracket holes in the strut tower. Thread the
nuts onto the camber plate studs. Lift the hub assembly into the strut lower mount and
reinstall bolts. See Torque Specications (Table 1).
3. Reinstall the brake hose bracket and ABS sensor wire clips. See Torque Specications
(Table 1).
4. Install the supplied stabilizer bar endlink into strut body and lower control arm. See
Torque Specications (Table 1).
INSTALLER MUST USE SUPPLIED, SHORTER, SWAYBAR ENDLINK OR POSSIBLE
DAMAGE TO COMPONENTS MAY OCCUR.
Upper
bracket
nuts
CAUTION

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Air Lift Performance
5. Route the braided air line in a manner where the line will not be kinked or rubbed by
anything. Cycle the suspension up and down and turn the wheel lock-to-lock to verify
the air line is protected from damage. Generally, routing the air line along with the brake
line is a good place to start.
6. With the suspension fully compressed, take a measurement from the fender to some
reference point, typically the center of the axle. Record this as Max Compression (MC).
Cycle the suspension to Max Extension (ME) and record the measurement from the
same reference points. Take the difference between the two numbers and divide by
two. Add that value to the Max Compression number and then set the suspension to
that point (g. 6). This position gives 50% stroke in either direction and is a great starting
point for ride height. At this position torque the lower control arm bolts to manufacturer’s
specications (Table 1).
Formula for calculating ride height:
7. Reinstall wheels; retake the Max Compression and Extension measurements from the
fender to lower wheel lip. Recalculate the ride height at 50% stroke and set the vehicle
to that height. Make sure to get an alignment at the preferred drive height. Enjoy the new
look and handling!
ALIGNING THE VEHICLE
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 unload the bushing to make it last longer at its new position based on the custom
ride height.
DAMPING ADJUSTMENT
The struts in this kit have 30 settings or “clicks” of adjustable compression and rebound
damping characteristics. Damping is changed through the adjuster at the top of the strut.
Turn the adjuster clockwise and the damping settings are hardened. Turn the adjuster
counterclockwise and the damping is softened. Each front strut is preset to “-15 clicks”. This
means that the strut is adjusted 15 clicks away from full stiff. Counting down from full stiff
is the preferred method of keeping track/setting of damping. (Figs. 7, 8)
Table 1
Torque Specications
Location Nm Lb-ft
Camber plate to chassis 20 15
Camber plate adjustment bolts 15 11
Strut lower mount bolts 175 129
Brake hose bolt 32 24
Stabilizer bar to transverse link 30 22
Wheel bolts 120 89
g. 6
ME
- MC
X
X= Y
2
Step 1:
+ MC
Z
Y
Z = DESIGN HEIGHT
Step 3: Answer:Step 2:
NOTE

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g. 7 g. 8
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:
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. 9)
g. 9

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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.
WHEN ADJUSTING HEIGHT UPWARDS, MAKE SURE THAT THAT THE STRUT BODY
ENGAGES ALL THE THREADS OF THE LOWER MOUNT. (FIG. 10) 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.
g. 10
Thread
MUST be
showing in
window.
OK, no threads
showing.
FOR STRUTS: FOR SHOCKS:
Not OK, threads
are showing.
NOTE
CAUTION
CAUTION

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Before Operating
1. Next, completely deate and reinate the air bags 2-3 times. This procedure will purge any
trapped air in the dampers and allow for maximum performance. For ride performance and
the most versatility, Air Lift Performance recommends setting the strut dial (if equipped)
to position 6 or higher.
MAKE SURE THE FRONT WHEELS ARE STRAIGHT WHEN DEFLATING AND
REINFLATING AIR BAGS.
2. Inate and deate the system (do not exceed 125 PSI) to check for clearance or binding
issues. With the air springs deated, check clearances on everything so as not to pinch
brake lines, vent tubes, etc. Clear lines if necessary.
3. Inate the air springs to 75 PSI - 90 PSI and check all connections for leaks.
4. An air management system such as Air Lift 3H/P is highly recommended for this product.
5. Please familiarize yourself further with this product by reading the Product Use,
Maintenance and Servicing section.
CAUTION

Technician’s Signature_________________________________________
Date ____________________
Clearance test — Inate the air springs to 55-90 PSI and make sure there is at least ½”
clearance from anything that might rub against each sleeve. Be sure to check the tire,
brake drum, frame, shock absorbers and brake cables.
Leak test before road test — Inflate the air springs to 55 PSI - 90 PSI and check all
connections for leaks. All leaks must be eliminated before the vehicle is road tested.
Heat test — Be sure there is sufficient clearance from heat sources, at least 6” for air
springs and air lines. If a heat shield was included in the kit, install it. If there is no heat
shield, but one is required, call Air Lift customer service at [phone].
Fastener test — Recheck all bolts for proper torque.
Road test — The vehicle should be road tested after the preceding tests. Inflate the
springs to recommended driving pressures. Drive the vehicle 10 miles and recheck for
clearance, loose fasteners and air leaks.
Operating instructions — If professionally installed, the installer should review the
operating instructions with the owner. Be sure to provide the owner with all of the
paperwork that came with the kit.
INSTALLATION CHECKLIST
Overnight leak down test — Recheck air pressure after the vehicle has been used for
24 hours. If the pressure has dropped more than 5 PSI, then there is a leak that must
be xed. Either x the leak yourself or return to the installer for service.
Air pressure requirements — Regardless of load, the air pressure should always be
adjusted to maintain adequate ride height at all times while driving.
Thirty day or 500 mile test —Recheck the air spring system after 30 days or 500
miles, whichever comes first. If any part shows signs of rubbing or abrasion, the source
should be identified and moved, if possible. If it is not possible to relocate the cause of
the abrasion, the air spring may need to be remounted. If professionally installed, the
installer should be consulted. Check all fasteners for tightness.
POST-INSTALLATION CHECKLIST
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MAINTENANCE GUIDELINES
By following these steps, vehicle owners will obtain the longest life and best results from their
air spring.
1. Check the air pressure before driving.
2. Never inate beyond 125 PSI.
3. If you develop an air leak in the system, use a soapy water solution to check all air line
connections, before deating and removing the spring.
4. When increasing load, always adjust the air pressure to maintain normal ride height.
Increase or decrease pressure from the system as necessary to attain normal ride height
for optimal ride and handling. Remember that loads carried behind the axle (including
tongue loads) require more leveling force (pressure) than those carried directly over the
axle.
FOR YOUR SAFETY AND TO PREVENT DAMAGE TO YOUR VEHICLE, DO NOT EXCEED
MAXIMUM GROSS VEHICLE WEIGHT RATING (GVWR), AS INDICATED BY THE VEHICLE
MANUFACTURER. ALTHOUGH YOUR AIR SPRINGS ARE RATED AT A MAXIMUM
INFLATION PRESSURE OF 125 PSI, THE AIR PRESSURE ACTUALLY NEEDED IS
DEPENDENT ON YOUR LOAD.
5. Always add air to the springs in small quantities, checking the pressure frequently. Sleeves
require less air volume than a tire and inate quickly.
6. Should it become necessary to raise the vehicle by the frame, make sure the control system
is turned off before lifting.
NOTE
Troubleshooting Guide
1. Leak test the air line connections, the threaded connection into the air spring, and all ttings
in the control system.
2. Inspect the air lines to be sure none are pinched. Tie straps may be too tight. Loosen or
replace the strap and replace leaking components.
3. Inspect the air line for holes and cracks. Replace as needed.
4. Look for a kink or fold in the air line. Reroute as needed.
If the preceding steps do not solve the problem, it is possibly caused by a failed air spring — either
a factory defect or an operating problem. Please call Air Lift at [phone] for assistance.
Product Use, Maintenance and Servicing
45 PSI 125 PSI
FAILURE TO MAINTAIN ADEQUATE MINIMUM PRESSURE (OR PRESSURE
PROPORTIONAL TO LOAD) WILL RESULT IN BOTTOMING OUT, OVER-EXTENSION
OR RUBBING AGAINST ANOTHER COMPONENT AND WILL VOID THE WARRANTY.
Maximum Air PressureSuggested Driving Air Pressure
Frequently Asked Questions
Q. Will installing air springs increase the weight ratings of a vehicle?
No. Adding air springs will not change the weight ratings (GAWR, GCWR and/or GVWR)
of a vehicle. Exceeding the GVWR is dangerous and voids the Air Lift warranty.
Q. How long should air springs last?
If the air springs are properly installed and maintained they can last indenitely.
CAUTION

12 MN-870
Air Lift Performance
Tuning the Air Pressure
1. If there is a problem with a swivel fitting:
a. Check the air line connection by deating the
spring and removing the line by pulling the collar
against the tting and pulling rmly on the air line.
Trim 1” off the end of the air line. Be sure the cut
is clean and square (see g. 10). Reinsert the air
line into the push-to-connect tting.
b. Check the threaded connection by tightening the
swivel tting another ½ turn. If it still leaks, deate
the air spring, remove the tting, and re-coat the
threads with thread sealant. Reinstall by hand
tightening as much as possible and then use a
wrench for an additional two turns.
2. If the preceding steps have not resolved the problem,
call Air Lift customer service at [phone].
Fixing Leaks
1. Inate the air spring to 80 PSI.
2. Spray all connections and the ination valves with a solution of 1/5 liquid dish soap and
4/5 water. Spot leaks easily by looking for bubbles in the soapy water.
3. After the test, deate the springs to the minimum pressure required to restore the system
to normal ride height.
4. Check the air pressure again after 24 hours. A 2 - 4 PSI loss after initial installation is
normal. Retest for leaks if the loss is more than 5 PSI.
Checking for leaks
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.
Pressure determination comes down to three things — level vehicle, ride comfort, and
stability.
1. Level vehicle
If the vehicle’s headlights are shining into the trees or the vehicle is leaning to one side,
then it is not level. Raise the air pressure to correct either of these problems 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
enough. Try different pressures to determine the best ride comfort. See Air Lift suggested
driving air pressure.
3. Stability
Stability translates into safety and should be the priority, meaning the driver may need
to sacrice a perfectly level and comfortable ride. Stability issues include roll control,
bounce, dive during braking and sponginess. Tuning out these problems usually requires
additional air pressure, strut damping, or both.
g. 10

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Notes

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Notes

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Notes

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Limited Warranty and Return Policy
WHAT THIS WARRANTY COVERS
Air Lift Company, for all Air Lift Performance products, except its Air Lift Performance 3H™ and 3P™ systems, warrants to the original
purchaser for a period of one year from the date of original purchase that the Air Lift Performance damper kits will be free from defects in
workmanship and materials for the normal expected life of the part when used on cars and trucks as specified by Air Lift Company and
under normal operating conditions, subject to the requirements and exclusions set forth below.
Air Lift Company provides a Limited Lifetime Warranty to the original purchaser of its Air Lift Performance 3H™ and 3P™ Control/Air
Management Systems, that the Air Lift Performance products will be free from defects in workmanship and materials for the normal
expected life of the part when used on cars and trucks as specified by Air Lift Company and under normal operating conditions, subject
to the requirements and exclusions set forth below.
WHAT THIS WARRANTY DOES NOT COVER
The warranty does not apply to products that have been improperly applied, improperly installed, or which have not been maintained
in accordance with installation instructions furnished with all products. This warranty does not apply and is void if damage or failure is
caused by: accident, abuse, misuse (including but not limited to racing or off-road activities or commercial use), abnormal use, faulty
installation, liquid contact, fire, earthquake or other external cause; operating the product outside Air Lift Company’s instructions, specifi-
cations or guidelines; or service, alteration, maintenance or repairs performed by anyone other than Air Lift Company to the product from
its purchased condition. This warranty also does not apply to: Universal Air (Fabricator Kits), consumable parts, such as batteries; cos-
metic damage, including but not limited to scratches or dents; defects caused by normal wear and tear or otherwise due to the normal
aging of the product, or if any serial or identification number has been removed or defaced from the product. Air Lift Company reserves
the right to change the design of any product without assuming any obligation to modify any product previously manufactured.
LIMITATION OF LIABILITY
To the extent permitted by law, this warranty and the remedies set forth herein are exclusive and in lieu of all other warranties, remedies
and conditions, whether oral, written, statutory, express or implied. AIR LIFT COMPANY DISCLAIMS ALL STATUTORY AND IMPLIED
WARRANTIES, INCLUDING WITHOUT LIMITATION, WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PUR-
POSE AND WARRANTIES AGAINST HIDDEN OR LATENT DEFECTS TO THE EXTENT PERMITTED BY LAW. To the extent such warran-
ties cannot be disclaimed, such implied warranties shall apply only for the warranty period specified above. Please note that some states
do not allow limitation on how long an implied warranty (or condition) lasts. So the above limitation may not apply to you.
Except as provided in this warranty and to the extent permitted by law, Air Lift Company shall not be liable for any direct, special, inci-
dental or consequential damages resulting from any breach of warranty or condition, or arising in connection with the sale, use or repair
of air lift products, or under any other legal theory, including but not limited to loss of use, loss of revenue, loss of actual or anticipated
profits, loss of the use of money, loss of business, loss of opportunity, loss of goodwill, and loss of reputation. Air Lift Company’s maxi-
mum liability shall not in any case exceed the purchase price paid by you for the Air Lift product. Please note that some states do not
allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you.
HOW TO GET SERVICE
If a defect in workmanship or materials causes your Air Lift Performance product to become inoperable within the warranty period,
before returning any defective product, call Air Lift Company at [phone] in the U.S. and Canada (elsewhere, [phone]) to
obtain a Returned Materials Authorization (RMA) number. The consumer shall be responsible for removing (labor charges) the defective
product from the vehicle and returning it, shipping costs prepaid, to Air Lift Company for verification. Returns to Air Lift Company must
be postage prepaid and sent to: Air Lift Company • 2727 Snow Road • Lansing, MI • 48917. You must prove to the satisfaction of Air
Lift Company the date of original purchase of your Air Lift Performance product. You must also enclose the RMA number and a return
address. A minimum $10 shipping and handling charge will apply to all warranty claims. You must also pack the product to minimize
the risk of it being damaged in transit. If we receive a product in damaged condition as the result of shipping, we will notify you and you
must seek a claim with the shipper.
WHAT AIR LIFT COMPANY WILL DO
If you submit a valid claim to Air Lift Company during the warranty period, Air Lift Company will, at its option, repair your Air Lift Per-
formance product or furnish you with a new or rebuilt product. Air Lift Company will not reimburse you for repairs or replacement parts
provided by other parties. Your repaired or replacement Air Lift Performance product will be returned to you (subject to payment of the
required warranty claim shipping and handling charge) and it will be covered under the warranty for the balance of the warranty period,
if any. When a product or part is replaced, any replacement item becomes your property and the replaced item becomes property of Air
Lift Company. You are responsible for installation/reinstallation (labor charges) of the product.
HOW THE LAW RELATES TO THIS WARRANTY
This warranty gives you specific legal rights and you may also have other rights which vary from state to state. By this warranty, Air Lift
Company does not limit or exclude your rights except as allowed by law. To fully understand your rights, you should consult the laws of
your state.

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Replacement Part Information
If replacement parts are needed, contact the local dealer or call Air Lift customer service at
[phone]. Most parts are immediately available and can be shipped the same day.
Contact Air Lift Company customer service at [phone] first if:
• Parts are missing from the kit.
• Need technical assistance on installation or operation.
• Broken or defective parts in the kit.
• Wrong parts in the kit.
• Have a warranty claim or question.
Contact the retailer where the kit was purchased:
• If it is necessary to return or exchange the kit for any reason.
• If there is a problem with shipping if shipped from the retailer.
• If there is a problem with the price.
Contact Information
Mailing address P.O. Box 80167
Lansing, MI 48908-0167
Shipping address 2727 Snow Road
for returns Lansing, MI 48917
Phone Toll free: [phone]
International: [phone]
Email [email protected]
Web address www.airliftcompany.com

Need Help?
Contact our customer service department by calling
[phone]. For calls from outside the USA or
Canada, dial [phone].
Air Lift Performance • 2727 Snow Road • Lansing, MI 48917 or PO Box 80167 • Lansing, MI 48908-0167
Toll Free [phone] • Local [phone] • Fax [phone] • www.airliftperformance.com
Printed in
the USA
Thank you for purchasing Air Lift Performance products!