AIR LIFT 1000 Kit 60857 GM Midsize SUV Installation Guide
- June 3, 2024
- Air Lift
Table of Contents
AIR LIFT 1000 Kit 60857 GM Midsize SUV
Hardware and Tools Lists
HARDWARE LIST
Item
A
| Part#
46136
| | Description ………………………………………………………………. Qty
Pliers, needle nose and regular……………………………………………….. 1
---|---|---|---
B| 20937| 5/16″ and 9/16″ Drill bit…………………………………………………………. 1
C| 10466| Drill……………………………………………………………………………….. 1
D| 21230| Hose cutter, razor blade or sharp knife………………………………………. 1
E| 21233| Hoist or floor jack……………………………………………………………….. 1
F| 21234| Safety stands………………………………………………………………….. 2
G| 18411| Safety glasses…………………………………………………………………. 1
H| 18501| Air compressor or compressed air source…………………………………… 1
I| 21236| Spray bottle with dish soap/water solution………………………………….. 1
J| 21455| Tire spoon or blunt instrument………………………………………………… 1
K| 10638| Hammer…………………………………………………………………………. 1
| | Center punch…………………………………………………………………… 1
| | File or sandpaper………………………………………………………………… 1
TOOLS LIST
| Description ………………………………………………………………. Qty
Pliers, needle nose and regular……………………………………………….. 1
---|---
5/16″ and 9/16″ Drill bit…………………………………………………………. 1
Drill……………………………………………………………………………….. 1
Hose cutter, razor blade or sharp knife………………………………………. 1
Hoist or floor jack……………………………………………………………….. 1
Safety stands………………………………………………………………….. 2
Safety glasses…………………………………………………………………. 1
Air compressor or compressed air source…………………………………… 1
Spray bottle with dish soap/water solution………………………………….. 1
Tire spoon or blunt instrument………………………………………………… 1
Hammer…………………………………………………………………………. 1
Center punch…………………………………………………………………… 1
File or sandpaper………………………………………………………………… 1
Introduction
The purpose of this publication is to assist with the installation and maintenance of the Air Lift 1000 air spring kit. Air Lift 1000 kits utilize a cylinder-style air bag that provides up to 1,000 pounds (454kg) of load- leveling support when installed into the vehicle’s coil springs. Each cylinder is rated at a maximum of 35 PSI (2.4BAR). It is important to read and understand the entire installation guide before beginning installation or performing any maintenance, service or repair.
NOTATION EXPLANATION
Hazard notations appear in various locations in this publication. The
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.
DANGER
INDICATES IMMEDIATE HAZARDS WHICH WILL RESULT IN SEVERE PERSONAL INJURY OR
DEATH.
WARNING
INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN SEVERE PERSONAL
INJURY OR DEATH.
CAUTION
INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN DAMAGE TO THE
MACHINE OR MINOR PERSONAL INJURY.
Installing the System
PREPARING THE VEHICLE
- Jack up the rear of the vehicle or raise on the hoist. Support the frame with safety stands (Fig. 1).
- Lower the axle or raise the body until the coil springs are completely extended (wheels hanging).
CAUTION
OBSERVE TENSION ON BRAKE LINES. DO NOT STRAIN OR OVEREXTEND.
INSTALLING THE AIR LIFT 1000 SYSTEM
- Remove the plastic cap from the barbed stem on the end of the air spring (A). Exhaust the air from the air spring by rolling it up toward the barbed stem. Replace the cap on the stem to hold its flat shape (Fig. 2). Fold the air spring into a “hot dog bun shape.”
FOR TRAILBLAZER AND ENCORE GX INSTALLS
NOTE
These models do not have an access hole for the airline to go through,
therefore a hole will need to be drilled through the lower control arm as
follows. Some models may have an existing small hole. This hole can be
enlarged to 9/16″ (no center punching will be necessary).
-
Mark and center punch the middle of the lower control arm in the recessed pocket as shown (Fig. 3). Drill a 9/16″ hole through the control arm.
TECH TIP
If a 9/16″ drill bit is unavailable, drill the hole with a 1/2″ drill bit and then enlarge the hole up to the 9/16″ size using a file or die grinder. -
Use a file or sandpaper and smooth out the burrs and the rough edges of the hole as much as possible (Fig. 4). Repeat for both sides.
-
Insert the flattened end of the air spring (A) into the top opening of the coil spring (with the stem at the bottom) (Fig. 5). Push the air spring down into the cylinder by hand or with a blunt instrument such as a spoon-type tire iron.
-
When the air spring is completely in the coil, remove the cap and allow the air spring to assume its “as molded” shape.
-
Push the air spring to the bottom of the coil spring. Using a pair of pliers, slide an air line clamp (K) onto the air line (B). Push the air line completely over the barbed stem of the air spring and slide the clamp over the barbed stem area (Fig. 6).
-
Route the air line (B) through the lower control arm and up to the crossmember on the underside of the unibody. Leave sufficient slack for suspension articulation. Install a tee (I) (if single fill is desired) or route the airlines along the brake lines under the crossmember (Fig. 7) to the area you have chosen for the Schrader valves (J). Secure airlines with zip ties (C) provided. Keep the airline away from any heat source. Proceed to the air line installation instructions.
FOR BLAZER, ACADIA AND XT5 INSTALLS
NOTE
These models have to access holes in the lower control arm for the airline,
but not all the way through. Hose routing will be different because of this.
- Route the air line (B) into the coil spring, down through the hole in the lower control arm and, while feeding it through, direct the air line toward the center of the vehicle (Fig. 8). Route the air line out the front of the large rectangle hole in the lower control arm.
- Using a pair of pliers, slide an airline clamp (K) over the airline (Fig. 9).
- Insert the flattened end of the air spring (A) into the top opening in the coil spring, with the stem at the bottom (Fig. 10). Push the spring down into the cylinder by hand or with a blunt instrument such as a spoon-type tire iron.
- When the air spring is completely in the coil, remove the cap and allow the air spring to assume its “as molded” shape.
- Push the air spring to the top of the coil spring and completely slide the airline over the barbed stem of the air spring (Fig. 11). Using a pair of pliers, slide the airline clamp (K) over the barbed stem of the air spring.
- Once the airline is attached to the air spring, push the air spring down to the bottom of the coil spring. Leaving sufficient slack for suspension articulation, attach the airline to the sway bar with a supplied zip tie (C) and route the airline up to the top of the crossmember (Fig. 12).
- Install a tee (I) (if single fill is desired) or route the airlines across the crossmember (Fig. 13) to the chosen area for the Schrader valves (J). Secure airlines with zip ties (C) provided. Keep the airline away from any heat source. Proceed to the air line installation instructions.
Installing the Air Lines
-
A single-path air line installation is recommended for vehicles that typically have even weight distribution (Fig. 14). If weight in the vehicle varies from side to side and unequal pressures are needed to level the load, use a dual-path installation. For dual-path air line installations, eliminate the tee fitting (I) and route separate air lines for both air springs (Fig. 15).
CAUTION
TO PREVENT THE AIRLINE FROM MELTING, MAINTAIN AT LEAST 6″ (152MM) FROM THE EXHAUST SYSTEM TO THE AIRLINE. -
If installing a single-path airline, choose a location for the tee fitting (I) on the wheel well or rear bumper. Determine and cut an adequate length of airline (B) to reach to the tee from the left and right side air springs. Make clean, square cuts with a razor blade or hose cutter (Fig. 16). Do not use scissors or wire cutters.
-
Leave sufficient airline slack to prevent any strain on the fitting during axle motions.
-
Use this procedure (Fig. 17) for all airline connections:
- Slide the airline clamp (K) onto the airline (B).
- Push the airline and airline clamp over the barbed stem so that the airline covers all the barbs.
- Compress the ears on the airline clamp with pliers and slide it forward to fully cover the barbs.
-
Select a location for the Schrader valve (J), ensuring that the valve will be protected and accessible with an air hose (Fig. 18). Drill a 5/16″ (8mm) hole, if necessary. Determine and cut an adequate length of the airline (B) to reach from the tee to the Schrader valve or from the air springs to the valve if using a dual-path installation.
-
Drill a 5/16″ (8mm) hole for the Schrader valve (J) and mount as shown (Fig. 19). Install the airline on the Schrader valve first. The rubber washer (F) serves as an outside weather seal.
CAUTION
DO NOT INFLATE THE AIR SPRINGS BEFORE READING THE MAINTENANCE AND USE
GUIDELINES IN THIS INSTALLATION GUIDE AS WELL AS THE USER GUIDE INCLUDED WITH
THIS KIT.
COMPLETE THE INSTALLATION
- Once the airline has been installed, raise the suspension or lower the body completely and remove the safety stands. Inflate the air springs as stated in the next section and check for leaks.
Finished Installation
INSTALLATION CHECKLIST
- Clearance test — Inflate the air springs to 30 PSI (2BAR) and make sure there is at least 1/2″ (13mm) clearance from anything that might rub against each air spring. Be sure to check the tire, brakes, frame, shock absorbers and brake cables.
- Leak test before road test — Inflate the air springs to 30 PSI (2BAR) 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″ (152mm) 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 — After 500 miles (800km), recheck all bolts for proper torque.
- Road test — The vehicle should be road tested after the preceding tests. Inflate the air springs to recommended driving pressures. Drive the vehicle 10 miles (16km) 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.
MAINTENANCE AND USE GUIDELINES
- Check air pressure weekly.
- Always maintain normal ride height. Never inflate beyond 35 PSI (2.4BAR).
- If the system develops an air leak, use a soapy water solution to check all air line connections and the inflation valve core before deflating and removing the air spring.
Minimum Recommended Pressure
- 5 PSI (.34BAR)
Maximum Air Pressure
- 35 PSI (2.4BAR)
CAUTION
FOR SAFETY AND TO PREVENT POSSIBLE DAMAGE TO THE VEHICLE, DO NOT EXCEED THE
MAXIMUM GROSS VEHICLE WEIGHT RATING (GVWR) OR PAYLOAD RATING, AS INDICATED BY
THE VEHICLE MANUFACTURER. ALTHOUGH THE AIR SPRINGS ARE RATED AT A MAXIMUM
INFLATION PRESSURE OF 35 PSI (2.4BAR), THE AIR PRESSURE ACTUALLY NEEDED IS
DEPENDENT ON LOAD AND GROSS VEHICLE WEIGHT RATING.
LIMITED WARRANTY AND RETURN POLICY
Air Lift Company provides a limited lifetime warranty to the original purchaser of its load support products, that the products will be free from defects in workmanship and materials 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 in the full Limited Warranty and Return Policy that is available at www.airliftcompany.com/warranty.
For additional warranty information contact Air Lift Company customer service.
Thank you for purchasing Air Lift Products — the Authorized Installer’s choice!
Need Help?
Contact Air Lift Company Customer Service at
800-248-0892 or email
[email protected]. For calls
outside the U.S. or Canada, dial
517-322-2144.
Air Lift Company • 2727 Snow Road • Lansing, MI 48917 or P.O. Box 80167 • Lansing, MI 48908-0167
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 airliftcompany.com.
California:
WARNING: Cancer and Reproductive Harm –
www.P65Warnings.ca.gov.