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Front Air Lines





FRONT AIR LINES

Special Tools:






WARNING: All pressurized air suspension components contain high pressure air (up to 220 psig). Use extreme caution when inspecting for leaks. Wear safety goggles and adequate protective clothing when inspecting or servicing the air suspension system. A sudden release of air under this amount of pressure can cause personal injury or death.

WARNING: Support the vehicle by supplemental means before performing any work on the air suspension system to prevent the vehicle from changing height. Before any given component is to be serviced it must be deflated. Servicing the air suspension system without supplemental support, or with pressure in the specific component, can cause personal injury or death.

CAUTION: When removing an air line from a component and the air line is to be reused, do not remove the 90° fitting or the brass fitting from the air line. If either is removed, the air line must be replaced. New components have air line fittings attached; however if the original air line is used the original fitting must also be used. Do not remove protective caps or plugs from air lines or components until ready to install the air line to prevent moisture or dirt intrusion. All air line fittings must be hand started to avoid cross threading.

CAUTION: The air lines/bundle must be routed the same when installed AND connected to all routing clips during installation or a leak may result.

NOTE: New fittings must be used with new air lines, and new air lines do not include new fittings.





1. Install the front air lines in the vehicle by feeding the LF air line (1) from the right side behind the engine/cowl heat insulator, under the AC lines (3), heater hoses (2), the steering column shaft (not shown) and up between the engine and master cylinder.
2. Move the LF air line (1) forward and to the left of the master cylinder as originally routed.
3. Connect the master cylinder fluid level switch connector (5) and brake booster vacuum switch electrical connector (4).





4. Pull the brake line (2) toward the fender enough to position the LF air line (1) under the brake line in the routing bracket (3). Make sure the brake line (2) is properly positioned after seating the air line (1).





5. Verify which air line connector (4) goes through each grommet hole for proper connection inside the vehicle.

NOTE: With the caps that come on the new air lines still on the air lines, a small amount of rose water can be applied on the tip and outside of the air line connector/tubes to make it easier to push through the grommet. If the caps are not present, do not apply rose water.

6. Position the front air line bundle and push the three air line connectors (4) through the grommet in the cowl.

NOTE: The air lines must be connected to all routing clips during installation.

7. Attach the LF air line to the three air line routing clips below and to the left of the brake booster assembly.
8. Attach the LF air line to the seven routing clips behind the engine/cowl heat insulator.
9. Attach the air suspension air line bundle to the wiring harness routing clip (1) below the battery positive cable jump post.
10. Attach the LF air line (2) to the routing clip (3) below the battery positive cable jump post.





11. Route the air suspension air line bundle (2), as removed, down through the wiring harness (1) to the compressor area.





12. Install a new air line fitting (1) on each spring and shock assembly and tighten to 5.5 Nm (49 in. lbs.).
13. Install the air lines to the two front air spring and shock assemblies by pushing the line straight into the fitting (1) until seated, then pulling to verify it is seated.





14. Position the HVAC air inlet duct (1) to the engine compartment side of the dash panel (3), install the two retaining nuts (2) and tighten to 4.5 Nm (40 in. lbs.).
15. Install the cowl extension silencer.






NOTE: The connector locking tabs under the instrument panel are color coded for identification. The reservoir locking tab is black, the RR is green, and the LR is white.

16. Inside the vehicle, remove the protective caps and connect the air lines (1, 2) under the RH side of the IP. Make sure the air lines are fully inserted, the locking tabs are seated and the lines will not pull out.
17. Position the carpet as necessary.
18. Install the RH instrument panel lower insulator.





19. Install a new air line fitting on the adapter air line (2) and each of the four air spring air lines (4) on the valve block (5) and tighten to 3.5 Nm (31 in. lbs.).

NOTE: The air lines are color coded with tape for identification. Match the tape colored tape to the color on the valve block.

NOTE: The front and rear spring air lines are removed for clarity.

20. Remove the protective caps and install the correct air lines to the adapter air line (2) and the four air spring air line positions (4) on the valve block (5) by pushing the line straight into the fitting (4) until seated, then pulling to verify it is seated.
21. Attach the routing clip (1) at the wiring harness loom near the compressor.
22. Install the RF wheelhouse splash shield Splash Shield - Installation.
23. Install the RF wheel Service and Repair.
24. Connect the negative battery cable Negative Cable.

25. With a scan tool, under the Air Suspension Control Module (ASCM), and using Air Suspension Refill Tool - , perform the Complete System Fill procedure Complete System Fill.
26. Perform the ASCM Verification Test ASCM Verification Test
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