Kit 75576

Air Lift
™

Volkswagen
PERFORMANCE MKV & MKVI Platform
Front Application
(for vehicles with 55mm lower strut diameter)

INSTALLATION GUIDE
MN-868 • (011301) • ERN 7470

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.
 Air Lift Performance

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TABLE OF CONTENTS
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Notation Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Important Safety Notices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Installation Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hardware List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Tools List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installing the Air Suspension. . . . . . . . . . . . . . . . . . . . . . 4

Preparing the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removing the Strut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installing the New Strut Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Aligning the Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Damping Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Before Operating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Product Use, Maintenance and Servicing. . . . . . . . . . . . 9

Suggested Driving and Maximum Air Pressures. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Maintaining and Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Frequently Asked Questions . . . . . . . . . . . . . . . . . . . . . . 9
Tuning the Air Pressure . . . . . . . . . . . . . . . . . . . . . . . . . 10
Checking for Leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fixing Leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Warranty & Return Policy. . . . . . . . . . . . . . . . . . . . . . . . 11
Replacement Information. . . . . . . . . . . . . . . . . . . . . . . . 11
Contact Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

This application is designed for previously modified vehicles where the

DANGER frame has been notched for axle clearance. Air Lift Company does not
recommend frame modification and any modifications previously done
are at the owner’s risk. Air Lift Company is not liable for vehicle or
personal damage due to modifications performed.
MN-868 1
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Introduction
The purpose of this publication is to assist with the installation, maintenance and
troubleshooting of this Volkswagen MKV & MKVI 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
(800) 248-0892 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
definitions explain the use of these notations as they appear throughout this guide.

INDICATES IMMEDIATE HAZARDS WHICH WILL RESULT IN SEVERE PERSONAL

DANGER INJURY OR DEATH.
INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN SEVERE
WARNING PERSONAL INJURY OR DEATH.
INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN DAMAGE
CAUTION TO THE MACHINE OR MINOR PERSONAL INJURY.

NOTE 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 inflation pressure data — is shown on the vehicle’s Safety Compliance
Certification 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
WARNING MAY RESULT AND VOID WARRANTY.

DO NOT WELD TO, OR MODIFY PERFORMANCE STRUTS/SHOCKS IN ANY WAY.

CAUTION DAMAGE TO UNIT MAY OCCUR AND WILL VOID WARRANTY.

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Installation Diagram

G
B
C

D OR E
H
fig. 1

TOOLS LIST HARDWARE LIST

Description Item Part # Description.......................................................Qty

Jack A 35234 Strut assembly, MKV/VI Front (55mm) R....................... 1
Jack stands or hoist B 35235 Strut assembly, MKV/VI Front (55mm) L....................... 1
Torque wrench C 20997 Leader Hose, 1/4” ID..................................................... 2
Metric Wrenches D 21987 Union, 1/4”FNPT X 3/8” PTC, DOT................................ 2
Standard Wrenches E 21810 Union, 1/4”FNPT X 1/4” PTC, DOT................................ 2
VW Spreader 3424 F Collar Wrench................................................................ 1
G End Link - 260mm RIGHT.............................................. 1
H End Link - 260mm LEFT................................................ 1

Missing or damaged parts? Call Air Lift customer

STOP! service at (800) 248-0892 for a replacement part.

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Installing the Air Suspension

PREPARING THE VEHICLE
1. Elevate the vehicle and support the body with a hoist or jack stands.
2. Remove the front wheels.

NOTE If the vehicle is equipped with Automatic Headlight Vertical Aim Control, detach the unit from
the lower control arm (fig. 2 - part 1 pictured) to prevent overextension.

fig. 2

REMOVING THE STRUT

1. Unbolt the sway bar from the tab (fig. 3). Sway Bar removal, see factory repair manual
for instructions.
2. Unthread and remove the axle bolt from the hub assembly (fig. 3a).

fig. 3 fig. 3a

3. Remove the three lower nuts from the lower ball joint and control arm (fig. 4). Detach
the ball joint and hub assembly from the control arm.

fig. 4

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4. Pull drive axle out of the hub assembly and secure the axle to the body with wire.

TO PREVENT DAMAGE TO THE INNER AXLE JOINT, DO NOT ALLOW THE AXLE TO
CAUTION HANG FREE.
5. Reattach the lower ball joint to the lower control arm.
6. Support the hub assembly.
7. Remove the bolt at the back of the hub assembly to the strut.
8. Spread the hub assembly slot and push down on the hub to release the strut from its’
lower mount (fig. 5). (Volkswagen specific tool is spreader 3424).

fig. 5

9. Pull weather-stripping away from the plenum chamber cover within the engine bay and
pull cover up. Removing the wiper arms and completely removing the cover will gain
more access.
10. Remove the three bolts from the upper strut mount (fig. 6) and remove the strut assembly
from the vehicle.

fig. 6

INSTALLING THE NEW STRUT ASSEMBLY

1. Prior to installing the strut, attach the braided line provided to the threaded port at the
bottom of the air spring (fig. 7). Seal with Teflon tape or thread sealant. Seal and thread
supplied fitting to the end of braided hose.

fig. 7

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2. Insert strut into the hub assembly. Reinstall the lower mounting bolt and torque to 70
Nm (52 ft/lbs).
3. Lift assembly into strut pocket and align upper mounting bolts with three holes. Using
the supplied nuts and washers, tighten the upper mount to 37 Nm (27 ft/lbs).
4. Remove the lower ball joint bolts again and separate the control arm from the joint.
Reinsert the axle.
5. Reinstall the ball joint nuts and torque to 60 Nm (44 ft/lbs).
6. Torque the hex head drive axle to 200 NM (148 ft/lbs). If the bolt is a 12 point, torque to
70 NM (52 ft/lbs).
7. Reinstall the plenum chamber cover and wiper arms if previously removed.

Torque Specifications
Location Nm ft. lbs.
Strut Lower Mount Pinch Bolt 70 52
Strut Upper Mount Nuts 37 27
Ball Joint Nuts 60 44
Hex Head Drive Axle Bolt 200 148
Table 1
12 Point Drive Axle Bolt 70 52
Wheels 120 89

8. 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
(fig. 8). This position gives 50% stroke in either direction and is a great starting point for
ride height. At this position torque the lower clevis bolt and lower control arm bolts to
manufacturer’s specifications (Table 1).

Formula for calculating ride height:

Step 1: Step 2: Step 3: Answer:
fig. 8

ME Y
- MC X + MC Z = DESIGN HEIGHT
=Y
X 2 Z
9.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. Enjoy the new look and handling! Please make sure to get an alignment
at the preferred drive height.

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 specifications.
It may be necessary to cycle the suspension to loosen the bushing up from its mount. This
NOTE
will help unload the bushing to make it last longer at its new position based on the custom
ride height.

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DAMPING ADJUSTMENT
The shocks 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 shock
rod. Turn the adjuster clockwise and the damping settings are hardened. Turn the adjuster
counterclockwise and the damping is softened. Each rear 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/setting of damping. This setting was developed
on a 2008 Volkswagen Jetta and may need to be adjusted to different vehicles and driving
characteristics.

fig. 9 fig. 10

Before Operating
1. Next, completely deflate and reinflate 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, Lifestyle recommends setting the strut dial (if equipped) to position
6 or higher.
MAKE SURE THE FRONT WHEELS ARE STRAIGHT WHEN DEFLATING AND
CAUTION REINFLATING AIR BAGS.
2. Inflate and deflate the system (do not exceed 125 PSI) to check for clearance or binding
issues. With the air springs deflated, check clearances on everything so as not to pinch
brake lines, vent tubes, etc. Clear lines if necessary.
3. Inflate the air springs to 75PSI - 90PSI and check all connections for leaks.
4. Air Lift part #27669 or #27671, AutoPilot V2 Air Management System, is highly
recommended for this product.
5. Please continue by reading the Product Use, Maintenance and Servicing section.

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INSTALLATION CHECKLIST
 Clearance test — Inflate 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 55PSI - 90PSI 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 (800) 248-0892.

 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.

Technician’s Signature__________________________________

Date__________________

POST-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 fixed. Either fix the leak yourself or return to the installer for service.

 Air pressure requirements — I understand the air pressure requirements of my air spring
system. 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 — I understand that I must 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.

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Product Use, Maintenance and Servicing

Suggested Driving Air Pressure Maximum Air Pressure
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.

MAINTENANCE GUIDELINES
NOTE 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 inflate 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 deflating 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
CAUTION 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 inflate quickly.
6. Should it become necessary to raise the vehicle by the frame, make sure the control system
is turned off before lifting.

Troubleshooting Guide
1. Leak test the air line connections, the threaded connection into the air spring, and all fittings
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 (800) 248-0892 for assistance.

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 indefinitely.

MN-868 9
 Air Lift Performance
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

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 sacrifice 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.

Checking for leaks

1. Inflate the air spring to 80 PSI.
2. Spray all connections and the inflation 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, deflate 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 lbs.

Fixing Leaks
1. If there is a problem with a swivel fitting:
a. Check the air line connection by deflating the
spring and removing the line by pulling the collar
against the fitting and pulling firmly on the air line.
Trim 1” off the end of the air line. Be sure the cut
is clean and square (see fig. 11). Reinsert the air
line into the push-to-connect fitting.
b. Check the threaded connection by tightening the fig. 11
swivel fitting another ½ turn. If it still leaks, deflate
the air spring, remove the fitting, 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 (800) 248-0892.

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Warranty and Returns Policy

Air Lift Company warrants its performance products for one year to the original purchaser against manufacturing
defects one year from the date of purchase when used on cars and trucks as specified under normal operating
conditions. 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. The consumer will
be responsible for removing (labor charges) the defective product from the vehicle and returning it, transportation
costs prepaid, to the dealer from which it was purchased or to Air Lift Company for verification.

Air Lift will repair or replace, at its option, defective products or components. A minimum $10.00 shipping and handling
charge will apply to all warranty claims. Before returning any defective product, you must call Air Lift at (800) 248-
0892 in the U.S. and Canada (elsewhere, (517) 322-2144) for a Returned Materials Authorization (RMA) number.
Returns to Air Lift can be sent to: Air Lift Company • 2727 Snow Road • Lansing, MI • 48917.

Product failures resulting from abnormal use or misuse are excluded from this warranty. The loss of use of the product,
loss of time, inconvenience, commercial loss or consequential damages is not covered. The consumer is responsible
for installation/reinstallation (labor charges) of 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.

This warranty gives you specific legal rights and you may also have other rights that may vary from state-to-state.
Some states do not allow limitations on how long an implied warranty lasts or allow the exclusion or limitation of
incidental or consequential damages. The above limitation or exclusion may not apply to you. There are no warranties,
expressed or implied including any implied warranties of merchantability and fitness, which extend beyond this
warranty period. There are no warranties that extend beyond the description on the face hereof. Seller disclaims
the implied warranty of merchantability. (Dated proof of purchase required.)

Replacement Information
If you need replacement parts, contact the local dealer or call Air Lift customer service at (800) 248-0892. Most parts
are immediately available and can be shipped the same day.

Contact Air Lift Company customer service at (800) 248-0892 first if:

• Parts are missing from the kit. • Broken or defective parts in the kit.
• Need technical assistance on installation or • Wrong parts in the kit.
operation. • 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
If you have any questions, comments or need technical assistance contact our customer service department by
calling (800) 248-0892, Monday through Friday, 8 a.m. to 8 p.m. Eastern Time. For calls from outside the USA
or Canada, our local number is (517) 322-2144. You may also contact customer service anytime by e-mail at
techsupport@airliftperformance.com.

For inquiries by mail, our address is PO Box 80167, Lansing, MI 48908-0167. Our shipping address for returns is
2727 Snow Road, Lansing, MI 48917.

You may also contact our sales team anytime by e-mail at sales@airliftperformance.com or on the web at
www.airliftperformance.com.

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Notes

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Notes

MN-868 13
 Need Help?
Contact our customer service department by calling
(800) 248-0892, Monday through Friday, 8 a.m. to
8 p.m. Eastern Time. For calls from outside the USA
or Canada, our local number is (517) 322-2144.

Thank you for purchasing Air Lift Performance products!

Air Lift Company • 2727 Snow Road • Lansing, MI 48917 or PO Box 80167 • Lansing, MI 48908-0167
Toll Free (800) 248-0892 • Local (517) 322-2144 • Fax (517) 322-0240 • www.airliftperformance.com

Printed in
the USA
 Kit 75676
Air Lift
™

Volkswagen
PERFORMANCE MKV & MKVI Platform
Independent Rear Application

INSTALLATION GUIDE
MN-869 • (011301) • ERN 7470

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.
 Air Lift Performance

2 MN-869
Air Lift Performance

TABLE OF CONTENTS

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Notation Explanation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Important Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Installation Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hardware List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installing the Rear Shock. . . . . . . . . . . . . . . . . . . . . . . . . 4

Preparing the Stock Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installing the Air Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Aligning the Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Damping Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Before Operating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Post-Installation Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Product Use, Maintenance and Servicing. . . . . . . . . . . 11

Suggested Driving Air Pressure and Maximum Air Pressure . . . . . . . . . . . . . . . . . 11
Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Frequently Asked Questions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Tuning the Air Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Checking for Leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Fixing Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Warranty and Returns Policy. . . . . . . . . . . . . . . . . . . . . 13

Replacement Information. . . . . . . . . . . . . . . . . . . . . . . . 13
Contact Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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Introduction
The purpose of this publication is to assist with the installation, maintenance and
troubleshooting of this Volkswagen MKV & MKVI 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
(800) 248-0892 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
definitions explain the use of these notations as they appear throughout this guide.

INDICATES IMMEDIATE HAZARDS WHICH WILL RESULT IN SEVERE PERSONAL

DANGER INJURY OR DEATH.
INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN SEVERE
WARNING PERSONAL INJURY OR DEATH.
INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN DAMAGE
CAUTION TO THE MACHINE OR MINOR PERSONAL INJURY.

NOTE 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 inflation pressure data — is shown on the vehicle’s Safety Compliance
Certification 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
WARNING MAY RESULT AND VOID WARRANTY.

DO NOT WELD TO, OR MODIFY PERFORMANCE STRUTS/SHOCKS IN ANY WAY.

CAUTION DAMAGE TO UNIT MAY OCCUR AND WILL VOID WARRANTY.

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Air Lift Performance

Installation Diagram
HARDWARE LIST

Item Part # Description............................................Qty

A
A 18585 3/8”-16 Nutsert................................................. 2
B 18436 3/8”-16 Nut....................................................... 4 B
C 17463 3/8”-16 X 2.0” Threaded Rod........................... 2
D 17447 3/8”-16 X 1.25” Threaded Rod......................... 2
E 58531 Air Spring 2B6 Regular (Recess Mount).......... 2 C
F 21779 1/4” MNPT X 1/4” PTC Elbow (DOT)............... 2
G 21851 1/4” MNPT X 3/8” PTC 90° (DOT)................... 2
H 11801 Roll Plate.......................................................... 2
I 03992 Lower Bracket, MKV Rear............................... 2 D
J 18427 3/8” Lock Washer............................................. 4
K 17101 3/8”-16 X 3/4” Hex Bolt.................................... 4
L 13980 Spring Seat Centering Spacer......................... 2
M 17109 3/8”-16 X 3.5” Hex Cap Screw......................... 2
N 17442 3/8”-16 X 3.0” Hex Cap Screw......................... 2

F OR G

J
K

L fig. 1

M OR N

Missing or damaged parts? Call Air Lift customer

STOP! service at (800) 248-0892 for a replacement part.

MN-869 3
 Air Lift Performance

Installing the Air Suspension

PREPARING THE STOCK VEHICLE
1. Elevate the vehicle and support the body with a hoist or jack stands.
2. Remove the rear wheels.

NOTE If the vehicle is equipped with automatic vertical headlight control, disconnect the coupling
rod from the lower transverse link (fig. 2).

fig. 2

3. To remove the coil spring, it is recommended that you use a spring compressor.

COIL SPRING UNDER COMPRESSION: THE COIL SPRING CAN BE REMOVED BY

CAUTION SECURELY SUPPORTING THE LOWER TRANSVERSE LINK WITH A JACK AND
REMOVING THE LOWER MOUNTING BOLT FROM THE WHEEL BEARING HOUSING.
SLOWLY LOWER THE TRANSVERSE LINK UNTIL THE SPRING IS LOOSE AND FREE
FROM TENSION.
4. Remove the rubber isolator in the lower transverse link.
5. Disconnect the lower transverse link from the hub.
6. Support the axle carrier and remove the lower shock mount.
7. Unbolt the upper shock bracket and remove the shock from the vehicle.
8. Remove the upper bracket plastic cap and remove the nut shock rod nut. Retain the
upper shock bracket and plastic cap for later use.

INSTALLING THE REAR SHOCK

1. The rear shocks supplied in this kit are height adjustable through the use of the threaded
lower mount. The shocks are threaded all the way down for maximum drop height. To
adjust the height, loosen the locking collar and thread the shock cartridge in or out of
the lower mount. Lock the shock cartridge in-place by torqueing the collar against the
lower mount 45 degrees beyond hand tight.
a. Thread the out to 300mm to match the compressed height of Bilstein Sport shocks
(ideal height for Golf R). Figure 3

fig. 3
300mm Damping
Adjuster

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Air Lift Performance
2. Attach the factory upper shock mount to the shock using the supplied nut and torque
to 25NM (18ft-lbs).
3. Reattach the shock upper bracket to the chassis and toque bolts to 45Nm (33ft-lbs).
4. Align the lower shock eye with the axle carrier and reinstall the lower shock bolt. Do
not torque at this time.
5. Use a 17/32” drill bit to enlarge the hole in the upper coil spring perch. If the upper coil
spring perch has been removed, drill in the center of where the perch used to be.
6. The hole must be 17/32” for the nutsert to be effective (figs 3-6).
Factory / OEM Upper Spring Perch

fig. 4 fig. 5

Previously Cut Spring Perch with Aftermarket Shock

fig. 6 fig. 7

7. Assemble the nutsert and nutsert tool together and insert into the 17/32” hole. Review
diagram below on how to attach the nutsert to the vehicle. (fig. 8).

fig. 8

8. Two lengths of threaded studs are included with the kit (C or D, fig. 1). The shorter stud
is for vehicles that retain the coil spring perch bump. The longer threaded stud is for
vehicles without the spring perch bump. Apply Loctite to the threads of the upper end
cap and thread in the appropriate stud. Take the supplied nuts and thread both onto
one stud (fig. 9, 10). Using the nuts jammed together, tighten the stud into the end cap
until it bottoms (fig. 11). Remove both nuts (fig. 12).

MN-869 5
 Air Lift Performance

fig. 9 fig. 10

fig. 11 fig. 12

9. Wrap the threads of the fitting with Teflon tape or thread sealant. Tighten the fitting 1
¾ turns beyond hand tight.
10. Thread the air spring into the lower end cap of the air spring. Tighten by hand (figs. 13,
14 for a factory shock, figs. 15, 16 for an aftermarket shock).

Installation With Factory Shock

fig. 13 fig. 14

Previously Cut Spring Perch with Aftermarket Shock

fig. 15 fig. 16

6 MN-869
Air Lift Performance

11. Orient the air fitting inline with lower transverse link toward the center of the vehicle.
12. The lower bracket in this kit has a scribe line. This indicates the height the bracket should
be if using Air Lift rear shocks or shocks that allow for more drop than the factory shock
absorbers with half cut jounce bumpers.

IF RUNNING A SHORTER-THAN-FACTORY SHOCK, THE BRACKET MUST BE TRIMMED

CAUTION DOWN TO PREVENT THE AIR SPRING FROM BEING OVER COMPRESSED AND
POTENTIALLY CAUSING A RUPTURE.
13. Attach the lower bracket and roll plate with the lock washer and bolts provided. The
roll plate is used with the full length lower bracket. Roll plates are not used with a cut
bracket. (See figs. 17-19 for installation with a factory shock, figs. 19-22 for aftermarket
shock.)

fig. 17 fig. 18

fig. 19

Installation with factory shock, roll plate and un-cut lower bracket

SCRIBE LINE

fig. 20 fig. 21

MN-869 7
 Air Lift Performance
Installation with aftermarket shock, no roll plate and cut bracket (cont’d)

fig. 22 fig. 23

14. Route the air line from the center of the cross-member, through the lower transverse
link and attach insert into the air fitting (fig. 24).

fig. 24

15. Reattach the lower transverse link to the hub. Do not torque at this time (fig. 25).

NOTE If the lower bracket has been cut, the shorter length bolt should be used to secure the
assembly to the lower transverse link with the centering washer and lock washer. Uncut
brackets use the longer bolt (C or D, fig. 1) (fig. 26).

fig. 25 fig. 26

16. 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 (fig. 27). This position gives 50% stroke in either direction and is a great starting
point for ride height. At this position torque the lower clevis bolt, upper and lower control
arm bolts to manufacturer’s specifications (Table 1).

8 MN-869
Air Lift Performance

Formula for calculating ride height

fig. 27
Step 1 Step 2 Step 3 Answer
ME Y
- MC X + MC Z = DESIGN HEIGHT
=Y
X 2 Z
Table 1
Torque Specifications
Location Nm ft. lbs.
Upper bracket to chassis 64 47
Upper shock mount cap 25 18
Axle carrier to shock eye 70 52
Axle carrier to upper control arm ball joint 70 52
Camber adjustment bolt 50 37˚
Upper control arm to subframe 90 67
Rear suspension arm to subframe 90 67
Headlight alignment link 5.4 48 in/lbs
Wheels 103 76

17. Reinstall wheels and 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. Enjoy the new look and handling! Please make sure to get an
alignment at the preferred drive height.

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 (figs. 4 &
5). Once they have been loosened, re-torque to stock specifications (Table 1).

NOTE 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.

DAMPING ADJUSTMENT
The shocks 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 shock
rod. Turn the adjuster clockwise and the damping settings are hardened. Turn the adjuster
counterclockwise and the damping is softened. Each rear 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/setting of damping. This setting was developed
on a 2008 Volkswagen Jetta and may need to be adjusted to different vehicles and driving
characteristics.

Damping
fig. 28 Adjuster

MN-869 9
 Air Lift Performance

Before Operating
MAKE SURE THE FRONT WHEELS ARE STRAIGHT WHEN DEFLATING AND
CAUTION REINFLATING AIR BAGS.
1. Inflate and deflate the system (do not exceed 125 PSI) to check for clearance or binding
issues. With the air springs deflated, check clearances on everything so as not to pinch
brake lines, vent tubes, etc. Clear lines if necessary.
2. Inflate the air springs to 75 PSI - 90 PSI and check all connections for leaks.
3. Air Lift part #27669 or #27671, AutoPilot V2 Air Management System, is highly
recommended for this product.
4. Please continue by reading the Product Use, Maintenance and Servicing section.

INSTALLATION CHECKLIST

 Clearance test — Inflate the air springs to 75-90 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 75 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 (800) 248-0892.

 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.

Technician’s Signature__________________________________

Date__________________

POST-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 fixed. Either fix 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.

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Air Lift Performance

Product Use, Maintenance and Servicing

Suggested Driving Air Pressure Maximum Air Pressure

40-70 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.

MAINTENANCE GUIDELINES
NOTE 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 inflate 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 deflating 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
CAUTION 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 inflate quickly.
6. Should it become necessary to raise the vehicle by the frame, make sure the control system
is turned off before lifting.

TROUBLESHOOTING GUIDE
1. Leak test the air line connections, the threaded connection into the air spring, and all fittings
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 (800) 248-0892 for assistance.

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 indefinitely.

MN-869 11
 Air Lift Performance

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

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 sacrifice 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.

CHECKING FOR LEAKS

1. Inflate the air spring to 80 PSI.
2. Spray all connections and the inflation 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, deflate 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 lbs.

FIXING LEAKS
1. If there is a problem with a swivel fitting:
a. Check the air line connection by deflating the spring and removing the line by pulling
the collar against the fitting and pulling firmly on the air line. Trim 1” off the end of
the air line. Be sure the cut is clean and square (see fig. 29). Reinsert the air line
into the push-to-connect fitting.
b. Check the threaded connection by tightening the swivel fitting another ½ turn. If it still
leaks, deflate the air spring, remove the fitting, 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
(800) 248-0892.

fig. 29

12 MN-869
Air Lift Performance

Warranty and Returns Policy

Air Lift Company warrants its performance products for one year to the original purchaser against manufacturing
defects one year from the date of purchase when used on cars and trucks as specified under normal operating
conditions. 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. The consumer will
be responsible for removing (labor charges) the defective product from the vehicle and returning it, transportation
costs prepaid, to the dealer from which it was purchased or to Air Lift Company for verification.
Air Lift will repair or replace, at its option, defective products or components. A minimum $10.00 shipping and handling
charge will apply to all warranty claims. Before returning any defective product, you must call Air Lift at (800) 248-
0892 in the U.S. and Canada (elsewhere, (517) 322-2144) for a Returned Materials Authorization (RMA) number.
Returns to Air Lift can be sent to: Air Lift Company • 2727 Snow Road • Lansing, MI • 48917.
Product failures resulting from abnormal use or misuse are excluded from this warranty. The loss of use of the product,
loss of time, inconvenience, commercial loss or consequential damages is not covered. The consumer is responsible
for installation/reinstallation (labor charges) of 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.
This warranty gives you specific legal rights and you may also have other rights that may vary from state-to-state.
Some states do not allow limitations on how long an implied warranty lasts or allow the exclusion or limitation of
incidental or consequential damages. The above limitation or exclusion may not apply to you. There are no warranties,
expressed or implied including any implied warranties of merchantability and fitness, which extend beyond this
warranty period. There are no warranties that extend beyond the description on the face hereof. Seller disclaims
the implied warranty of merchantability. (Dated proof of purchase required.)

Replacement Information
If you need replacement parts, contact the local dealer or call Air Lift customer service at (800) 248-0892. Most parts
are immediately available and can be shipped the same day.

Contact Air Lift Company customer service at (800) 248-0892 first if:

• Parts are missing from the kit. • Broken or defective parts in the kit.
• Need technical assistance on installation or • Wrong parts in the kit.
operation. • 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
If you have any questions, comments or need technical assistance contact our customer service department by
calling (800) 248-0892, Monday through Friday, 8 a.m. to 8 p.m. Eastern Time. For calls from outside the USA
or Canada, our local number is (517) 322-2144. You may also contact customer service anytime by e-mail at
techsupport@airliftperformance.com.

For inquiries by mail, our address is PO Box 80167, Lansing, MI 48908-0167. Our shipping address for returns is
2727 Snow Road, Lansing, MI 48917.

You may also contact our sales team anytime by e-mail at sales@airliftperformance.com or on the web at
www.airliftperformance.com.

MN-869 13
 Need Help?
Contact our customer service department by calling
(800) 248-0892, Monday through Friday, 8 a.m. to
8 p.m. Eastern Time. For calls from outside the USA
or Canada, our local number is (517) 322-2144.

Thank you for purchasing Air Lift Performance products!

Air Lift Company • 2727 Snow Road • Lansing, MI 48917 or PO Box 80167 • Lansing, MI 48908-0167
Toll Free (800) 248-0892 • Local (517) 322-2144 • Fax (517) 322-0240 • www.airliftperformance.com

Printed in
the USA
Air Lift Performance

Kit Details
27671

HARDWARE LIST

Part # Description Qty Part # Description...............................Qty

72605 4pt Fast Air Manifold - 1/4””................. 1 21773 3/8” MNPT X 1/8” MNPT Adapter........ 1
27042 Gen 3 Display...................................... 1 21999 1/8” MNPT X 1/4” PTC Elbow.............. 2
26498-002 Electrical Harness - FastAir................. 1 21633 Push Lock Valve.................................. 1
24672 Fuse, spade 3amp.............................. 1 21585 1/4” Pipe Plug...................................... 1
24547 Fuse, spade, 30amp............................ 1 20937 Polyurethane Filter Drain Hose.......... 5ft
24500 ATC Fuse holder w/ cap...................... 2 20946 DOT 1/4” Air Line............................. 60ft
24645 16GA Butt Connector........................... 1 17263 1/4-14 x 1 Self Tapping Screw............. 3
24752 12-10GA Butt Connector..................... 3 18444 3/8” Flat Washer.................................. 8
24748 12GA Ring Terminal 3/8”..................... 2 17188 3/8-16 x 1.25 Hex Cap Screw.............. 4
24524 Female Spade Terminal...................... 1 18435 3/8-16 Nyloc Nut.................................. 4
24595 12GA Female Spade Terminal ........... 1 11517 Miniature Filter.....................................1
24561 Adaptor, Mini Fuse............................... 1 11217 P Clamp...............................................1
24542 ATC/ATO Fuse Adaptor....................... 1 17173 1/4”-14 X 3/4” Self Tapping Screw....... 1
23586 Thread Sealant....................................1 16380 VIAIR 380C Compressor (200 psi)...... 1
21043 1/4” MNPT X 1/4” PTC Elbow.............. 1 11955 4 Gallon Aluminum Air Tank................ 1
21847 3/8” MNPT X 1/4” PTC Elbow.............. 1 10466 8” Zip Tie............................................10
21737 3/8” Pipe Plug......................................1 10530 Air Line Cutter...................................... 1

Missing or damaged parts? Call Air Lift customer

STOP!
service at (800) 248-0892 for a replacement part.

MN-784 • (021503) • ECR 7999

 Air Lift
™

AutoPilot V2
™

P A T E N T P E N D I N G
PERFORMANCE

INSTALLATION GUIDE
MN-754 • 071411 • ECR 7999

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.
TABLE OF CONTENTS

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Notation Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Installing the AutoPilot V2 Kit . . . . . . . . . . . . . . . . . . . . . 3

Install Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install Air Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
NPT Assembly Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Helpful Tips: Air Line and Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Setup and Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

System Calibration and Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Program Presets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Operating the System. . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . 13
Leak Testing and Detection . . . . . . . . . . . . . . . . . . . . . . 13
Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
AutoPilot V2 Remote Control Unit Dimensions . . . . . . 15
Manifold Template. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
16380 Compressor Template . . . . . . . . . . . . . . . . . . . . . 19
Warranty and Returns Policy. . . . . . . . . . . . . . . . . . . . . 21
Replacement Information. . . . . . . . . . . . . . . . . . . . . . . . 21
Contact Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
 Air Lift Performance

Introduction
The purpose of this publication is to assist with the installation, operation and troubleshooting
of the AutoPilot V2 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 step-by-step installation
information, installation templates 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 Performance
at (800) 248-0892 or visit our website at www.airliftperformance.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 definitions
explain the use of these notations as they appear throughout this guide.

INDICATES IMMEDIATE HAZARDS WHICH WILL RESULT IN SEVERE PERSONAL

DANGER INJURY OR DEATH.
INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN SEVERE
WARNING PERSONAL INJURY OR DEATH.
INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN DAMAGE
CAUTION TO THE MACHINE OR MINOR PERSONAL INJURY.

NOTE Indicates a procedure, practice or hint which is important to highlight.

2 MN-754
Air Lift Performance

Installing the AutoPilot V2 Kit

INSTALL COMPONENTS
NOTE For a complete schematic, please see fig. 15. (pages 10-11)

BEST PRACTICE IS TO LOCATE THE MANIFOLD UNIT INSIDE THE VEHICLE. IF

CAUTION EXTERNAL MOUNTING IS DESIRED, THE MANIFOLD MUST BE LOCATED IN AN
AREA SHIELDED FROM DIRECT WATER SPRAY FROM TIRES OR CAR WASHES. THE
MANIFOLD SHOULD BE CONSIDERED “WATER RESISTANT” NOT “WATERPROOF”.

Layout
1. Plan component location first. Ideally, the manifold should be located above the
compressor and tank if possible to avoid compressor ingested water from gathering in
the manifold. This is most important for vehicles operated in below freezing climates.
2. Prior to mounting components, check to make sure:
• the electrical harness connections will reach the manifold and compressor.
• the compressor leader hose will reach the tank.
• the air lines will route cleanly through the vehicle without kinking or bending.

NOTE Be sure to install all components as far as possible from any heat sources. Plan and prepare
harness and air line routing thru the vehicle. Eliminate all sharp edges that could chafe. Use
grommets when passing through compartment walls.

Prepare and install the compressor

1. Prepare the compressor intake. If the compressor body is mounted inside the vehicle,
attach filter to port on end of compressor (fig. 15). If compressor is located outside the
vehicle, snorkel inlet filter to dry location inside vehicle using components supplied with
compressor.
2. Center punch and drill four holes using the template on page 19.
3. Attach using the hardware supplied with the compressor.

NOTE If the harness must be lengthened, use properly sized butt connectors and wire. If extending
the power/ground wires, use 8AWG wire minimum or contact Air Lift for more information.

The supplied harness is only capable of powering a single compressor. If installing dual
compressors, a second dedicated power wire is required. Consult the Electrical Schematic
section for proper wiring, and contact Air Lift for an optional second compressor harness
(part number: 27679).

Manifold
1. Position the manifold in a desired location. Make sure the manifold mounting surface
is flat.

NOTE Mount the manifold to the body either horizontally (fig. 1a) or vertically with the ports facing
toward the ground (fig. 1b). Do not mount the manifold upside down (fig. 1c). Proper manifold
mounting will help prevent water from settling in areas sensitive to freezing.
2. Fasten the manifold using the two self-tapping screws. If the mounting surface is not
flat, add washers to space the manifold up over surface irregularities.
3. If needed, a manifold mounting template can be found on page 17.

MN-754 3
 Air Lift Performance
This represents the top of the vehicle frame or any custom setup (and is the same for figures 1b and 1c).

fig. 1a fig. 1b fig. 1c

PREFERRED ACCEPTABLE ABSOLUTELY NOT!

NOTE Air compressors intake moisture (humidity) from the outside air source and will deposit
water in the air tank. The AutoPilot V2 system includes a filter that will greatly reduce the
potential for moisture to enter the manifold, however, tanks must be regularly purged to
eliminate the possibility of water entering the manifold. Be sure to provide easy access to
tank drain/fill valve (preferably outside the vehicle). This is an automatic draining filter and
does not need servicing. If you find this filter to be plugged, it will need to be replaced. If
using an engine driven compressor, the life of the provided filter may be reduced due to the
increased potential for oil being introduced into the system.

Tank pre-assembly (see fig. 15)

1. Per the diagram on pages 10 and 11, install the filter to the tank with supplied fittings/
adapters or remotely mount the filter using the supplied fittings, P-clamp and self tapping
screw. Be sure to mount the filter in the correct orientation.

NOTE This is a one-way filter. The arrow at the top should be pointing in the direction of the air
flow from the tank to the manifold (fig. 15b).

This is an automatic draining filter that does not require servicing. If you find this filter to be
plugged, it will need to be replaced. The tank will need to be purged periodically to reduce/
eliminate the potential of moisture entering the manifold.

Tank install (see fig. 15)

1. Using the tank feet as a template, drill holes for hardware assembly.
2. Attach the tank using the supplied hardware.
3. Cut an appropriate length of hose from the manifold port T, to the PTC fitting on the filter.
4. Route the drain/fill air line with a schrader valve (preferably outside the vehicle).
5. Install the supplied drain tube (soft hose) to the bottom of the filter and route to a location
outside of the vehicle.

NOTE When cutting plastic air line, only use a standard hose cutter like (Air Lift part number 10530)
or razorblade. Cut all hose ends square and as smoothly as possible. See hose cutting tips
on page 6.

INSTALL HARNESS
1. Disconnect the battery ground while installing the system.
2. Compressor / manifold connections (see fig. 15)
• Attach the manifold connector, it will “click” into place once fully seated.
• Mount the compressor relay in a preferred location using a self-tapping screw.
• Cut off the spade and eyelet from the compressor power and ground wires.
• Strip 1/4” of wire casing from the compressor wires.
• Strip 1/4” of wire casing from the black and pink harness wires.
• NOTE: Use an appropriate terminal crimp tool to ensure a good connection.

4 MN-754
Air Lift Performance
• Using a butt connector attach the RED compressor wire to the PINK harness wire.
• Using a butt connector attach the BLACK compressor wire to the BLACK harness wire.
• Carefully apply heat (preferably with a heat gun) to seal these connections.

3. Battery / ignition connections (see fig. 15)

• Identify the power, ground, + ignition leg of the harness.
• Ground: 10AWG black wire; Power: 10AWG red wire; Ignition: 18AWG pink wire.
• Route power and ground leg of the harness free from any heat source to the battery.
• Using a butt connector attach the red wire to a fuse holder.
• Attach an 3/8” eyelet to the other end of the fuse holder and attach to the positive
battery (+) terminal.
• Attach an 3/8” eyelet to the black wire and attach to the battery ground.
• Route the 18AWG pink wire to a key switched IGNITION source that remains on
during cranking. Examples include: ECU, fuel pump.
Do not select an accessory source. If the AutoPilot V2 display shuts off while starting the
NOTE
vehicle, this is not a true ignition source.
• Using a butt connector attach the pink ignition wire to a fuse holder.
• Select ignition source and attach the fused ignition wire.
• Use fuse adaptors as necessary.
4. Display
• Route the display cable as desired to the preferred operating location.
• Attach the display cable to the main harness cable (small white 3 cavity connector).
5. Reconnect the battery.

INSTALL AIR LINES

Use a standard hose cutter (Air Lift part number 10530) or razorblade. Cut all hose ends
NOTE square and as smoothly as possible.
1. Route and attach the air lines to the air springs.
• Route air lines free from abrasive edges and heat sources.
2. Attach manifold port FL to the front, drivers side left spring.
3. Attach manifold port FR to the front, passengers side right spring.
4. Attach manifold port RL to the rear, drivers side left spring.
5. Attach manifold port RR to the rear, passengers side right spring.
6. Attach manifold port T to the PTC fitting previously installed on the filter.
7. Manifold port E is the exhaust port.
• Port E can be left open, or routed to a preferred exhaust location.

NOTE Air lines should be pushed in firmly, with a slight back and forth rotational twist – check the
connection by pulling on each line to verify a robust connection.

Release the air line from the fitting by releasing air, pushing on the line, depressing the ring
towards the fitting, and then pulling the hose out of the fitting.

NPT ASSEMBLY INSTRUCTIONS

1. Inspect the port and fitting ensuring both are free of contaminants and excessive burrs
and nicks.
2. Apply a stripe of liquid pipe sealant around the male threads leaving the first two threads
uncovered.
3. Screw finger tight into the port.
4. Wrench tighten the fitting to the correct turns past finger tight position (see table 1
located on page 6).
NEVER BACK OFF AN INSTALLED PIPE FITTING TO ACHIEVE PROPER ALIGNMENT.
CAUTION LOOSENING INSTALLED PIPE FITTINGS WILL CORRUPT THE SEAL AND CONTRIBUTE
TO LEAKAGE AND FAILURE.

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 Air Lift Performance

Torque Specifications Table 1

Fitting Size Turns Past Torque
Finger Tight lb/ft
1/8” NPT 1.5 - 3.0 12
1/4” NPT 1.5 - 3.0 25
3/8” NPT 1.5 - 3.0 40
1/2” NPT 1.5 - 3.0 54
3/4” NPT 1.5 - 3.0 78
1” NPT 1 - 2.5 112
1 1/4” NPT 1 - 2.5 154
1 1/2” NPT 1 - 2.5 211
2” NPT 1 - 2.5 300

HELPFUL TIPS: AIR LINE AND FITTINGS

1. Minimum hose bend radius
• 3/8” hose = 1.5” hose bend radius.
• 1/4” hose = 1” hose bend radius.
2. Hose to fitting
• No side loading on fitting from hose.
• Hose straight for 1” before bending.
3. Hose cutting
• Cut hose perpendicular to hose length.
• Inspect hose for scratches that run lengthwise on hose prior to insertion.
• Use proper hose cutter, cigar cutter, or razor on flat surface.
4. DOT/SAEJ844 air brake hose data
• Maximum working pressure of 175 PSI.
• Not to be used for frame (body) to un-sprung mass connection, use a braided leader
hose for this moving connection.

Compressor Tank Pressure Table 2

Viair Air Lift P/N Max. Tank Pressure
380C 16380 175
400C 16400 150
444C 16444 175
450C 16450 150
480C 16480 175

Setup and Calibration

AutoPilot V2 is an advanced pressure-based air suspension control system, that uses state-
of-the-art software algorithms to calibrate or map the control system to your vehicle. Once
the system is calibrated, the algorithm predicts required “valve open time” to move the air
suspension to achieve preset target pressures. AutoPilot V2 has 8 programmable presets,
allowing the user to input 8 different combinations of the 4 corner air spring pressures.

After installing AutoPilot V2 in your vehicle, please follow the steps below to properly setup
your new system. If changes are made after installing and calibrating the system such as
changes to air springs, lines, tank, compressor, or other vehicle modifications, the system
must be recalibrated to maintain accuracy.

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Air Lift Performance

SYSTEM CALIBRATION AND fig. 2

SETTINGS
1. Key-on/power up, and compressor should
come on to fill the tank. Check to make 1 2 3 4
sure system is triggered by IGNITION
source. While starting the engine, the
system should be ON. If not, please refer LF RF T
LR RR
back to the “Install Harness” section.
2. Press buttons 1 and 5 simultaneously
(1+5) and hold for 5-10 seconds until 5 6 7 8
settings and diagnostics mode main page
appears (fig. 3).
Button Definition
Tank Adjust (Maximum System PSI)
Press button 1 (TANK ADJUST). Set tank fig. 3
pressure preference by pressing MAX up/
down buttons simultaneously (fig. 4). The MAX 1. TANK ADJUST
value sets compressor cut-off pressure. Press 2. CALIBRATE
buttons (1+5) simultaneously to exit to settings
3. BACKLIGHT
and diagnostics mode.
4. PRESET MAIN
NOTE MIN tank pressure will follow MAX within 15
PSI to provide further accuracy. fig. 4
If tank MAX settings are changed, a system
recalibration is necessary for optimal
performance. Max tank pressures for various TANK MAX=175
compressors can be found in table 2.

Calibrate to your vehicle

fig. 5
Press button 2 to enter CALIBRATE (fig. 3).
Press button 1 SYSTEM CAL (fig. 5), follow
instructions to calibrate AutoPilot V2 system CALIBRATION MENU
to your vehicle. Once calibration is complete, 1. SYSTEM CAL
Press buttons (1+5) simultaneously to exit to 2. ADJUST SYSTEM
settings and diagnostics mode.

DURING CALIBRATION THE SYSTEM WILL AUTOMATICALLY DEFLATE TO 0 PSI AND

CAUTION RAISE TO 100 PSI ON EACH AXLE AUTOMATICALLY. IF WHEELS EXTEND BEYOND
FENDERS, VEHICLE DAMAGE MAY RESULT. CALIBRATION ON NARROW WHEELS
THAT TUCK INSIDE THE FENDERS IS RECOMMENDED. ALSO, MAKE SURE VEHICLE
BODYWORK WILL NOT BE HARMED IF ONE END IS RAISED TO 100 PSI AND THE
OTHER IS AT ZERO. IF DAMAGE IS POSSIBLE, IT MAY BE BEST TO CALIBRATE BY
SETTING VEHICLE ON BLOCKS OF WOOD (SAME HEIGHT) TO GIVE THE BODYWORK
MORE CLEARANCE.

Backlight Setting
Press button 3 to enter BACKLIGHT (fig. fig. 6
3). Set display backlight to your preference + + +
by pressing the + and – on R (Red), G
(Green), B (Blue) (fig. 6). Press buttons BACKLIGHT
(1+5) simultaneously to exit to settings and R G B
diagnostics mode. - - -

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 Air Lift Performance

Automatic Preset Maintenance

Press button 4 (fig. 3) to enter PRESET fig. 7
MAINTAIN. Press button 8 to turn ON or
OFF (fig. 7). When ON, this function actively PRESET MAINTAIN?
monitors air spring pressure and fills to
maintain active preset pressure when average
pressure drops below a threshold due to a ON
system leak.

NOTE This function will not exhaust pressure. If air spring pressure is higher than preset target,
only the operator pressing the preset button again will activate the system to exhaust air
spring pressure (for safety). Press buttons (1+5) simultaneously to exit.

PRESET MAINTAIN should be off for performance/track driving or if operating in

extremely hilly areas.

Compressor Test / Run Time

fig. 8
Press button 5 to run a compressor test (fig.
8). This function will exhaust the tank to the 5. COMP TEST
specified MIN tank pressure, then turn ON 6. COMP TIME
the compressor and measure its inflate time 7. RISE ON START
to achieve MAX pressure (fig. 9). AutoPilot V2
8. PSI/BAR & SWV
will record this fill time, allowing the operator
to compare future fill times to determine
compressor performance. Press buttons (1+5) fig. 9
simultaneously to exit. Press button 6 (fig. 8)
to view the number of hours the compressor TANK PRESSURE RANGE
has been running. 135-150 PSI

Rise on Start PROCEED? YES NO

Press button 7 (fig. 8) to enter RISE ON
START (fig. 10). This function will automatically fig. 10
activate valves to achieve preset 1 target
pressures when the vehicle is keyed-on. This RISE ON START?
function allows the operator to drive away
seconds after vehicle is started. Press buttons
(1+5) simultaneously to exit. ON

This function only operates when the start-up pressures are BELOW the Preset 1 target
NOTE
pressures. The system will not deflate to achieve Preset 1 target

Set Units (PSI / BAR)

1. Press button 8 (fig. 8) to toggle between PSI and BAR pressure units and check software
version. Press buttons (1+5) simultaneously to exit.
2. Press buttons (1+5) simultaneously to exit settings and diagnostics – you are now ready
to create presets!

NOTE BAR stands for DeciBar values.

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Air Lift Performance

Program Presets
Program Preset 1 fig. 2

NOTE Preset 1 should always be entered as the desired

ride pressure for the RISE ON START function. 1 2 3 4
Determine desired ride pressures: press
buttons (1+5) simultaneously to toggle display
to MANUAL mode. Manually activate each LF RF T
LR RR
corner (see MANUAL mode section page
13) to achieve desired “normal driving” ride
pressure (fig. 11). Program preset 1: press 5 6 7 8
buttons (1+5) simultaneously to toggle display
to PRESET mode (fig. 12). Press and hold
button 1 for 3 seconds to set preset 1. Release Button Definition
button and actual air spring pressures will
appear (fig. 12). Fine-tune the pressures by
pressing up/down buttons. Press and hold to fig. 11
scroll. Press buttons (1+5) simultaneously to
save and exit.

Program Presets 2-8 64 66 82 80

You are now free to program the additional 7 150
presets to desired pressures. Typical presets
can be:
• “Low”: set pressures to the lowest fig. 12
possible pressures for extreme low
driving stance. EDIT
• “Front up”: for speed bump or driveway
clearance. 65 65 80 80
• “Rear up”: for added load of
PRESET 1
passengers, equipment.
• “Play”: for those that want to enjoy their
air suspension freedom, AutoPilot V2
has a special function that recognizes fig. 13
side-to-side presets. When left side
pressures are equal, and right side EDIT
pressures are equal but >25PSI
different than left, the algorithm will 5 100 5 100
activate side to side instead of front
PRESET 6
to back. It will also equalize all air
spring pressures when exiting the
“play” preset, conserving air by using
the high pressure side to inflate the fig. 14
low pressure side. Pairing two “play”
presets together allows side-to-side EDIT
activation that consumes far less air
than manual mode activation would
100 5 100 5
consume. PRESET 7

Sample Pressure Layouts

for Play Mode (figs. 13 & 14)

MN-754 9
 -

10
-
Connect direct to battery fig. 15
direct to battery
Connect Preferred
Butt connector 30 AMP fuse
Preferred
NOTE: If not run to battery, voltage drop
Butt connector 30 AMP fuse +
AL005 + may reduce
NOTE: If notsystem performance
run to battery, and
voltage drop
durability.
may reduce system performance and
AL005
durability.
AL002
1 2 3 4 AL002
1 2 3 4 Ignition Source (on while cranking)
LF RF LR RR Ignition Source (on while cranking)
LF RF LR RR AL004
5 6 7 8
5 6 7 8 AL004
3 AMP fuse
3 AMP fuse
Existing fuse
Examples: Existing fuse
Fuel pump � etc.
� ECU �Examples:
� ECU � Fuel pump � etc.

Relay schematic reference

Relay schematic reference
ALOO2
Pink
30 AMP ALOO2Red
To +12 Volt 20GA
Pink
Relay 30 AMP Back View 10GA
Red IGN
Battery
To +12Source
Volt 20GA
Relay 30 10GA
Back View IGN
Battery Source 85 86
30
87
85 86
Gray 87
20GA Pink
Gray 10GA
Manifold
To 20GA Pink
Compressor (OUT) (7) 10GA
To Manifold
Compressor (OUT) (7)

AL034
AL034
Second compressor signal wire
Air Lift Performance

MN-754
Second compressor signal wire
 AL005 AL007
AL005 AL007

MN-754
Attach filter
Attach filter

Exhaust
Exhaust
Air Lift Performance

DO NOT INSTALL Filter

FILTER INVERTED Drain/fill valve
Filter
*mount
Drain/fillinvalve
OR ANGLED accessible 1/4” Elbow
*mount in location Mount
*1/4” to bottom tank port
accessible location Elbow
* Mount to bottom tank port
FILTER INSTALLATION OPTIONS

OPTION #1 - INSTALL TO TANK OPTION #2 - REMOTELY MOUNT**

Tank
LEFT LEFT
LEFT LEFT Mount

Soft
drain
FRONT REAR hose * fig. 15b
FRONT REAR * Top view Manifold Tank
Manifold of filter **This option must be
used for tank P/N10995
*This is a moisture drain and must drain to the outside of the vehicle.

AIR LINE CUTTING

NOTE: Air Lift recommends
RIGHT RIGHT
using a hose cutting tool
RIGHT RIGHT to ensure a proper cut (Air
Lift part number 10530). If
a hose connection has been
For Reference Only For Reference Only disconnected the hose must
Not included in kit Not included in kit
For Reference Only For Reference Only be trimmed 1/2” back to
Not included in kit Not included in kit provide for a leak free seal. Good Cut Poor Cut

11
 Air Lift Performance

Operating the System

Now that your system is set up, it’s time to use it. If changes are made after installing and
calibrating the system such as changes to air springs, lines, tank, or compressor, the system
must be recalibrated to maintain system accuracy.

There are two operational modes: PRESET and MANUAL. Pressing buttons (1+5)
simultaneously will toggle between modes. After 10 seconds of non-use, the display enters
standby where the LCD dims. Any button hit will “wake-up” the display and allow users to
activate the system. See mode operation below for more details.

PRESET Mode
1. If display is sleeping, press any button once to “wake up” the display. If display is
illuminated, go to the next step. Press of any button will display the programmed preset
pressures for that button. Users can quickly view each preset prior to activating to make
sure they are selecting the desired preset.
2. A 2nd button press of the same preset button within 2 seconds will activate it. The system
will iterate up to 6 times to achieve the preset target pressures by +/- 3 PSI. The display
shows PLEASE WAIT as it iterates, then will flash SUCCESSFUL when achieved or
UNSUCCESSFUL if not able to achieve the target pressure window.
3. Micro adjust to ±1 PSI: If more accuracy is desired, double press the same preset and
the system will refine pressures closer to target. This is often necessary when target
preset pressures are LOWER than current pressure. Accuracy can be improved by
rolling the vehicle straight while activating the preset.

NOTE If the system indicates UNSUCCESSFUL, refer to troubleshooting guide on page 13.

PRESET Mode: Improve Accuracy

If system reads SUCCESSFUL but pressures are consistently lower or higher than target,
you can improve first attempt accuracy by going to Calibration Menu (fig. 5) and pressing
button 2. Adjust the ADJ value to a higher number if first attempt pressures are lower than
target. Adjust the value to a lower number if first attempt pressures are higher than target.
WHEN A PRESET IS ACTIVATED THAT LOWERS THE VEHICLE SIGNIFICANTLY BELOW
CAUTION DRIVING HEIGHT, BE SURE TO HAVE THE FRONT WHEELS STEERED STRAIGHT
AHEAD TO AVOID FENDER TO TIRE DAMAGE!

1 2 3 4 1 2 3 4
100
99 99100299 90
150
99
99 90 99 99 299 90
100 100
150
99
99 90
5 6 7 8 5 6 7 8
fig. 16 fig. 17
PRESET Mode MANUAL Mode

12 MN-754
Air Lift Performance

MANUAL Mode
1. MANUAL mode allows the user to fill or exhaust each spring independently. The display
will show arrows above and below the pressures to indicate manual control mode (fig. 17).
The arrow will be solid when the spring is filling/exhausting, and outlined when not active.
2. The system detects button press time. For a very short (<0.1sec) duration press, the
system will open the valves for a defined “burst”, changing pressure minimally so users
can fine-tune their pressures. For a longer than 0.1 sec duration press, the valves open
as long as you hold the button down. If a button is held active, the fill/exhaust will time
out after 10 seconds.
• Fill springs: buttons 1 - 4, Exhaust springs: buttons 5 - 8

Troubleshooting Guide
For further technical assistance please contact our customer service department by calling
(800) 248-0892, Monday through Friday. For calls from outside the USA or Canada, our
local number is (517) 322-2144.

PROBLEM CAUSE SOLUTION

Compressor doesn’t run There is a blown fuse or relay, bad ground, or poor Replace the fuse, check the ground wire, or check
electrical connections. the compressor connector

Compressor runs all the time. The compressor relay is defective or there is a leak. Replace the relay or locate the leak and repair.
Air spring or tank leak. Fitting seal or air line is compromised. Check to make sure air lines are seated in connectors.
Inspect fittings with soapy water. Trim hose or re-
seal fitting.
Nothing happens when the vehicle is key-on There is a blown fuse or a poor connection. Replace the fuses and check the electrical
ignition active connections.
The display does not light up. There is a blown fuse or a poor connection. Replace the fuses and check the electrical
connections.
Compressors runs all the time but doesn’t fill the tank. Compressor in-line check valve fitting has been Loosen fitting and check again. Replace if needed.
overtorqued.
Display shows UNSUCCESSFUL. “Double Click” for Preset not completed within 2 If display is in sleep mode, click once to “Wake Up”,
second window. then “Double Click” desired preset within 2 seconds
of each press.
Calibration may need to be adjusted or system may Adjust ADJ value or recalibrate system to reduce
need to be recalibrated. number of iterations.
Tank pressure settings changed.
Vehicle load changed significantly. Attempt recalibration.
Air springs/air lines/tank changed.
Display shows PRESSURE SENSOR FAILURE. ECU has detected a pressure sensor operating Only manual mode can be used to operate
incorrectly. suspension. Contact customer service immediately
to resolve the problem.

Leak Testing and Detection

Leak detection
1. A leak can be defined as a loss of pressure of more than 5 psi over an 8 hour period. Be
aware that ambient temperature change has an effect on pressure that may seem like
a leak. For example: a change of 10deg Fahrenheit up or down from your baseline will
have an approximate gain or loss of indicated pressure of 2 psi. If a leak is suspected
after including any temperature change, then proceed to #2.
2. Spray soapy water (1/5 Dawn brand dish soap to 4/5 water) on suspect fittings and hose
connections and look for any bubbling caused by air leakage.
3. Fix leaking connection (review pg. 6 for help on NPT fittings and air line connections).
4. Wipe down sprayed connections with rag to remove any residual soapy water.

NOTE Dawn brand dish soap will not corrode the metals (aluminum, brass, steel) with which it
comes into contact.

MN-754 13
 Air Lift Performance

Electrical Schematic

AUTOPILOT V2 SECOND COMPRESSOR HARNESS*

AUTOPILOT V2 GEN 3 PRESSURE CONTROL

* Sold separately
Air Lift Part Number 27679

fig. 18

14 MN-754
Air Lift Performance

AutoPilot V2 Remote Control Unit Dimensions

2.375”

2.875”
Top View

.75”

Side View
MN-754 15
 Air Lift Performance

Notes

16 MN-754
Air Lift Performance

Manifold Template

6.35”

MN-754 17
 Air Lift Performance

Notes

18 MN-754
Air Lift Performance

16380 Compressor Template

HOLE PATTERN FOR

BOTTOM OF 16380 COMPRESSOR
6.6900

3.3100

MN-754 19
 Air Lift Performance

Notes

20 MN-754
Air Lift Performance

Warranty and Returns Policy

Air Lift Company warrants its performance products for one year to the original purchaser against manufacturing
defects one year from the date of purchase when used on cars and trucks as specified under normal operating
conditions. 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. The consumer will
be responsible for removing (labor charges) the defective product from the vehicle and returning it, transportation
costs prepaid, to the dealer from which it was purchased or to Air Lift Company for verification.

Air Lift will repair or replace, at its option, defective products or components. A minimum $10.00 shipping and handling
charge will apply to all warranty claims. Before returning any defective product, you must call Air Lift at (800) 248-
0892 in the U.S. and Canada (elsewhere, (517) 322-2144) for a Returned Materials Authorization (RMA) number.
Returns to Air Lift can be sent to: Air Lift Company • 2727 Snow Road • Lansing, MI • 48917.

Product failures resulting from abnormal use or misuse are excluded from this warranty. The loss of use of the product,
loss of time, inconvenience, commercial loss or consequential damages is not covered. The consumer is responsible
for installation/reinstallation (labor charges) of 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.

This warranty gives you specific legal rights and you may also have other rights that may vary from state-to-state.
Some states do not allow limitations on how long an implied warranty lasts or allow the exclusion or limitation of
incidental or consequential damages. The above limitation or exclusion may not apply to you. There are no warranties,
expressed or implied including any implied warranties of merchantability and fitness, which extend beyond this
warranty period. There are no warranties that extend beyond the description on the face hereof. Seller disclaims
the implied warranty of merchantability. (Dated proof of purchase required.)

Replacement Information
If you need replacement parts, contact the local dealer or call Air Lift customer service at (800) 248-0892. Most parts
are immediately available and can be shipped the same day.

Contact Air Lift Company customer service at (800) 248-0892 first if:

• Parts are missing from the kit. • Broken or defective parts in the kit.
• Need technical assistance on installation or • Wrong parts in the kit.
operation. • 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
If you have any questions, comments or need technical assistance contact our customer service
department by calling (800) 248-0892, Monday through Friday. For calls from outside the USA or
Canada, our local number is (517) 322-2144. You may also contact customer service anytime by e-mail at
techsupport@airliftperformance.com.

For inquiries by mail, our address is PO Box 80167, Lansing, MI 48908-0167. Our shipping address for returns is
2727 Snow Road, Lansing, MI 48917.

You may also contact our sales team anytime by e-mail at sales@airliftperformance.com or on the web at
www.airliftperformance.com.

MN-754 21
 Need Help?
Contact our customer service department by calling
(800) 248-0892, Monday through Friday. For calls
from outside the USA or Canada, our local number
is (517) 322-2144.

Thank you for purchasing Air Lift Performance products!

Air Lift Company • 2727 Snow Road • Lansing, MI 48917 or PO Box 80167 • Lansing, MI 48908-0167
Toll Free (800) 248-0892 • Local (517) 322-2144 • Fax (517) 322-0240 • www.airliftperformance.com

Printed in
the USA