Hellwig 6019 User manual

INSTALLATION INSTRUCTIONS
6019 Air Spring Kit
2001-2010Chevrolet/G C 2500/3500 HD
Thank you for purchasing a quality Hellwig Product.
PLEASE READ THIS INSTRUCTION SHEET CO PLETELY BEFORE STARTING
YOUR INSTALLATION
I PORTANT NOTES
DO NOT INFLATE AIR SPRING ASSE BLY UNLESS IT HAS BEEN
PROPERLY INSTALLED ON VEHICLE.
DO NOT INFLATE AIR SPRINGS OVER 100 PSI
A INI U OF 5-10 PSI UST BE AINTAINED IN AIR SPRINGS
AFTER INSTALLATION FOR WARRANTY TO BE VALID. FAILURE TO
KEEP INI U PRESSURE IN AIR SPRINGS WILL VOID WARRANTY.
THIS UNIT IS DESIGNED TO INCREASE THE LEVEL LOAD CARRYING
CAPACITY OF YOUR VEHICLE. NEVER LOAD THE VEHICLE THIS
UNIT IS INSTALLED ON BEYOND THE ANUFACTURER’S AXI U
GROSS VEHICLE WEIGHT RATING.
OVERINFLATION AND I PROPER USE AY RESULT IN PERSONAL
INJURY AND/OR DA AGE TO YOUR VEHICLE AND PROPERTY.

BEFORE STARTING YOUR PROJECT
WHEN LIFTING A VEHICLE WITH A JACK, BE SURE TO SET THE PARKING BRAKE AND USE
SAFETY STANDS.
ENSURE THAT THE INSTALLATION OF CO PONENTS WILL NOT CRUSH OR DA AGE
FUEL AND BRAKE LINES OR ELECTRICAL HARNESSES.
BEFORE DRILLING ANY HOLES, ENSURE THAT ALL ELECTRICAL WIRES, FUEL LINES,
BRAKE LINES, BRAKE HOSES AND ANY OTHER CO PONENTS ARE OVED OR
PROTECTED TO AVOID DA AGE FRO DRILLING ANY HOLES .
DO NOT ATTE PT ANY ODIFICATIONS TO THE VEHICLE OTHER THAN THOSE
OUTLINED IN THIS INSTRUCTION SHEET. IF ANY INTERFERENCE WITH THE GAS TANK,
FUEL LINES, BRAKE LINES, EXHAUST PIPE, ETC. EXISTS, STOP YOUR INSTALLATION AND
CALL HELLWIG PRODUCTS FOR TECHNICAL HELP.
IF WHEELS ARE RE OVED FOR INSTALLATION OF KIT, CHECK ANUFACTURERS
SPECIFICATIONS FOR PROPER LUG NUT TORQUE BEFORE REINSTALLING WHEELS.
WHEN CUTTING AIR BRAKE TUBING A SQUARE CUT IS REQUIRED OR LEAKAGE AY
RESULT.
2. Install elbow fitting in port of air spring. Torque fitting to approxi ately 20 ft-lb.
1
1. Park vehicle securely and set parking brake and
chock wheels. Re ove factory bu p stops fro ve-
hicle by re oving nuts fro studs using a 15
wrench or socket

3. Place heat shield on top of
air spring before upper plate
as shown in photo. Apply
loctite to threads of 3/8 x 1”
studs and insert into threaded
holes in plate. Attach air
spring to plate with 3/8 x 3/4”
flat head cap screw. Torque
to 20-25 ft-lb.
3/8 x 3/4 Flat Head
Cap Screw
3/8 x 1” Studs. Apply
locktite to threads
before installation
Heat Shield.
4. Insert a carriage bolt in the square hole into the short leg of the lower plate as
shown and attach air spring to plate using the 3/8 x 3/4” flat head cap screw as
shown. Torque to 20-25 ft-lb. The short leg of the lower plate will be oriented
forward.
Insert Carriage bolt into short leg of
lower plate. Short leg is oriented
forward.
Passenger Side

5. Place air spring asse bly be-
tween the axle and the fra e rail
as shown and insert threaded
studs on upper plate through the
holes in the fra e used to attach
the bu p stops. Attach to fra e
using 3/8” locknuts and washers.
Torque to 20-25 ft-lb.
6. Place lower bracket
squarely on top of axle pad.
Install carriage bolts into lower
plate on air spring asse bly
and attach strap with locknuts
and washers. Tighten strap
until ears on strap bend
slightly.
5
6
Passenger Side
Place lower bracket
on axle pad
Axle strap
Driver Side Heat Shield
Heat Shield

7. Co plete passenger and driver’s side installation of air spring asse bly.
8. Select a location for the air inflation valves. The location can be on the
bu per or body of the vehicle where an air chuck can be used to inflate the air
springs. Select a location where the valve will not be da aged or interfere
with the operation of other co ponents.
9. Cut air brake lines to length and connect air lines to fittings by pushing the air
line into the air fittings as far as possible. WHEN CUTTING AIR BRAKE
TUBING, A SQUARE CUT IS REQUIRED AND THE HOSE END
UST NOT BE DEFOR ED OR LEAKAGE AY RESULT. IF DE-
FOR ATION OF THE HOSE END OCCURS, THE HOSE END UST
BE REWORKED SO THAT IT IS ROUND. Engage ent of the sealing O
-ring will be felt when the air line has been inserted properly into the fitting.
Fittings ay be disconnected if required by pushing down on the outer ring
while pulling fir ly on the air line. Route air lines away fro exhaust pipes
or any other sources of heat and ensure that the air lines are protected fro
sharp edges. A length of heat shielding is provided to protect the air line as it
exits the passenger side air spring.
10. Inflate air springs to 40 psi and check for leaks. A soapy water solution can be
used to find slow leaks.
11. When satisfied with integrity of the syste , adjust air pressure to desired level.
The air springs can be inflated to any level between 10 and 100 psi. DO NOT
run the air springs e pty or warranty will be void. MINIMUM air spring pres-
sure is 10 psi. Failure to keep air in the air springs will void the warranty. For
best RIDE use only enough air pressure as required to level the vehicle. If a
fir er ride is desired, ore pressure can be used.
12. Check air pressure in the syste regularly to ensure syste perfor ance and
aintenance of warranty. Just like tires, the air pressure in the syste will
vary due to te perature changes. For your air spring syste to function prop-
erly it ust be checked on a regular basis.
SUSPENSION SYSTEMS
HELLWIG SUSPENSION