Do-it-yourself air suspension installation. DIY air suspension DIY air springs

The presence of air suspension in a car provides smoother and easier control compared to shock absorbers, but in order install air suspension yourself you need to know how the depreciation system in a car works and how it works. You also need to have basic car repair skills.

What is air suspension?

Air suspension - what does it look like? Photo of air suspension.

These properties include:

• Ability to control ride height. This function allows you to improve ride quality in any road conditions for its class, without changing the springs to stiffer and shorter ones or longer and softer ones. The air suspension can be adjusted for any of these options.
• Smoothing out body vibrations on rough roads. Spring shock absorbers are more sensitive to uneven road surfaces, which in turn requires more careful driving on damaged roads. The air suspension compensates for these vibrations, thereby reducing vehicle vibration.
• Excellent handling. Again, it is worth noting the fact that with different springs, different controllability. Stiffer springs give good handling on paved roads, but poor handling on rough roads. On soft springs it’s the opposite. The air suspension compensates for these differences by simply adjusting the pressure.
• Preventing subsidence under heavy load. The air suspension makes it possible to adjust the stiffness and height at which the ride quality is constant, regardless of the amount of cargo or passengers in the car.

Also, the above properties can be considered the main advantages of the suspension, for which most car enthusiasts purchase them.

Disadvantages of air suspension

Air spring photo.

The second factor is the almost complete lack of maintainability. This means that if any part of the system fails, it will only need to be replaced, which entails additional costs.

Air suspension operation diagram

Another important factor is poor resistance to frost and road agents, because of which the service life of the air suspension is significantly reduced. If in case of frost, it will be enough to pour a little alcohol or a composition used in pneumotomosis into the pillow, then only branded and high-quality pneumatic pillows have protection against reagents.

Instructions for installing air suspension with your own hands

• A compressor that will pump air into the air bag;
• receiver, adjusts the clearance height without the participation of a compressor;
• air bags, which, in fact, act as shock absorbers;
• lines that combine all components into a single pneumatic system;
• sensors that allow you to control the tilt of the body and its position, pressure in the system;
• the suspension control unit automatically controls the entire installation and processes the signal coming from the sensors;
• fastening parts.

It is advisable to order a turner in advance for fastenings. To avoid unreliability of the design, it is advisable not to touch the factory mounting grooves that are already in the car, but to adjust the installation to them. In the future, this will make it possible, if necessary, to replace them back with springs without much difficulty.

Photo of installing air suspension with your own hands

To install the suspension, you need to put the car on jacks, then remove the wheels and springs.
Further actions depend on the type of installation: you can install a combined suspension, where the cushions are installed directly into the spring or a separate air cushion, which is structurally more complicated. In general, the installation consists of the following steps:

1. removal of racks;
2. preparing a site for installing fasteners;
3. installation of pillows with valves in mountings;
4. racks with installed air bags are secured in place;
5. at the next stage, the main air supply system, sensors, control unit, compressor and receiver are installed.

It is worth mentioning separately the backbone system. If you plan to install air shock absorbers on both axles, then it is advisable to use a four-circuit suspension instead of a dual-circuit one. It includes four valves, while controlling each of them separately. This will allow you to more flexibly regulate the roll of the car, since each airbag will maintain a given pressure. The compressor and receiver are usually installed in the luggage compartment.

Air suspension air bags photo

After installing and connecting the system to the compressor and receiver, it is necessary to display the control panel with sensor readings and suspension adjustment buttons.

The last step is to calibrate the pneumatic system by pumping a small amount of air into the system and checking the clearance and pressure when the vehicle is fully loaded. We also immediately diagnose possible leaks by hearing or using a soap solution. It is important to ensure that all airbags are inflated evenly and that the ground clearance is the same in both the front and rear of the car. The camber will also need to be re-adjusted.

Air suspension price

Based on the above, it is advisable to install air suspension only on foreign cars or in warmer climates. Installation, for example, on a VAZ is not cost-effective. If you purchase cheaper components, they will quickly fail. It can justify itself only if the air bags are made of frost-resistant rubber and are not exposed to chemicals, but these are quite expensive.

Air suspension is an indispensable element if the driver needs to raise or lower the car for some time. This tuning method is perfect for Russian roads, because in urban areas the vehicle’s ground clearance can be significantly reduced, and on rough terrain it can be increased.

1

Among newcomers to tuning, there is an opinion that such a complex design as is best purchased ready-made. But the cost of such an element often exceeds several tens of thousands of rubles. In this case, those who want to improve the car have no choice but to assemble the part with their own hands. First, let's decide on the spare parts that are included in the machine, and then we'll figure out the suitable parts for its manufacture. So, the set includes:

• racks;
• pillows;
• receiver;
• HBO valves;
• tubes;
• compressor;
• pressure gauges;
• control device.

The only disadvantage of spare parts from the “nine” is their large dimensions

The air suspension on a VAZ can be created from various spare parts. We will list the most suitable and reliable elements. The first part that makes up the system is the racks. It is best to buy new oil parts from a domestic manufacturer SAAZ. The racks must have 2 “donut” bumpers. The latter are designed for installation on the shock absorber rod. The average cost of a set of spare parts is approximately 7,500 rubles. Pillows will be mounted on top of the racks. Parts from the concern's trucks are highly reliable Scania. We recommend buying pillows from 4th generation models.

A gas cylinder from the model is suitable as a receiver VAZ 2109. Firstly, this element can withstand fairly high pressure, up to 21 atm. Secondly, it is initially equipped with a check valve, so you don’t need to come up with anything extra. Thirdly, the cylinder has a 45-liter volume, which guarantees a high lifting speed of the car.

The only disadvantage of spare parts from the “nine” is their large dimensions. If you want to save space in the trunk, you will have to use a 25-liter cylinder from KAMAZ. However, in this case you need to weld the fittings and install a check valve. In this regard, a spare part from the “nine” is the best option. Approximate cost – 2 thousand rubles. 4 solenoid valves are also required for operation. Two of them will work for reset, and the other 2 will work for front-to-back intake. Take valves that can easily withstand a pressure of 25 atm. Price – about 300 rubles. a piece.

2

The next essential elements are tubes. PVC pipes from the brake system of any truck are best suited for these parts. The cost of spare parts is approximately 200 rubles. The compressor is one of the most important elements of the system. Therefore, its choice must be approached with great responsibility. In many cases, drivers use a compressor Berkut R20. It has a high pumping speed and long service life. According to these parameters, analogues in this price category are noticeably inferior to this model.

The main components of the air suspension on a VAZ

The system control device consists of three toggle switches. The first three-position toggle switch should be on the left - it is responsible for turning the rear circuit on and off. The second three-position toggle switch is located on the right and is responsible for turning the front circuit on and off. The third toggle switch – the middle two-position switch – turns the compressor on and off.

When creating a system, do not forget about pressure gauges. The first of them must be located between the receiver and the compressor. In addition to the pressure gauge, a moisture-oil separator should also be located in this part. Several more pressure gauges should be located in the car interior - they are designed to monitor the pressure inside the circuits. Where exactly to install them, decide for yourself. The main thing is that they stand in a visible place, and you can easily monitor the indicators. The cost of one pressure gauge is about 100 rubles.

3

To install the system, you will need to use the services of a turner. If you have a lathe at hand and you have a little experience working with it, then you can do everything yourself. First, grind down the pillow. Initially, it has a diameter of 4.5 cm. In order for the part to fit tightly into the shock absorbers, the diameter must be reduced to 4 cm. The second option is to grind the adapter bushings. In addition to machining this part, you must also make washers of the appropriate diameter for the seal.

To install the system you will need to use the services of a specialist

In the second stage, remove the spring cups located on the front “boots” - the body of the front struts into which the shock absorbers are installed. The cups at the back must first be lowered and then cut off. There is no need to drill additional holes to install racks. To do this, use the drainage holes. Remove the rubber plugs and insert the hoses into the holes. Next, the hoses are fixed with plastic clamps. The rear contour must be placed above the beam at the rear of the car. In the same part you will need to remove the hoses from the pillows. Fix the LPG valve to release air and reduce the vehicle's ground clearance on the bracket where the gas tank is mounted.

At the same time, do not forget to leave a small part of the hose in reserve. To prevent the hose from dangling, it must be secured to the shock absorber using clamps. When working on the front circuit, you will need to run a hose through the entire body of the car, attach it to the tube, then to the stabilizer, and then to the windshield. Route the hoses of the front airbags along the steering rod, lead them into the engine compartment and install the crosspiece. Then route the hoses, install the air release valve and the HBO valve.

After this, it is necessary to assemble the control system. Connect the toggle switches via relays using fuses and wiring. After this, fill the system with air, not exceeding a pressure of 8 atm. To check for air leaks, you need to close the garage and try to hear a hissing sound. After this, dissolve a little soap in water and lubricate the joints of the system elements with the solution. If the system has passed the test, you can proceed to testing its operation.

4

The air suspension on a VAZ requires adjustment of parameters such as pressure and wheel alignment of the car. For optimal operation of the system, the pressure inside it must be within 8 atm, since the airbags in the front part can fully expand at 7.5 atm. This is mainly due to the large weight of the front of the car due to the location of the engine in it.

Air suspension requires car wheel alignment adjustment

The rear of the car is lighter - 6 atm is enough to deploy the airbags. Behind the brand compressor Golden eagle you need to constantly monitor, otherwise it can pump the system up to 10 atm, which can lead to rupture of hoses or breakage of fittings. To do this, you must constantly use a pressure gauge. The ideal operation of the system is one in which it lowers itself within a few weeks or a month.

The wheel alignment of a chassis equipped with the system must be set in the normal position. Initially, set the parameter based on the height at which your car most often resides, since in the lowest position of the car the wheel alignment will be positive, and in the highest position it will be negative. Do not forget about this while driving, since the speed and controllability of the car depend on this parameter.

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The air suspension allows you to adjust the ride height semi-automatically or completely without the use of physical effort. We are talking about replacing springs, springs and torsion bars with pneumatic cylinders, in which compressed air pumped from the system acts as an elastic element. Despite all the advantages of this element, a do-it-yourself air suspension can only be created if you have basic car repair skills. The process is fraught with certain difficulties and a beginner clearly cannot cope with it.

Air suspension device

The design of each air suspension consists of a receiver, a control unit, an air distribution system and a compressor. To improve driver comfort, the suspensions can be automatically or manually controlled.

1. Automatic air suspension involves independently selecting the ride height electronically, taking into account factors such as acceleration, speed, and inclination. The focus in this case is on high aerodynamic performance. The center of gravity is reduced, so the car's controllability is significantly increased.
2. Manual control requires the driver's initiative when choosing the height of the ground clearance relative to the road. Manual adjustment is also possible in relation to the stiffness of the suspension if its design involves the presence of shock absorber pneumatic struts.

Modifications

There are three modifications of air suspension:

1. Single-circuit options are designed for installation on one axle and provide the same pressure in both cushions on it, since the compressor and cylinders are located on the same circuit.
2. Double-circuit modifications are also installed on one axle, but in essence these are two single-circuit suspensions, thanks to which it is possible to adjust the height of the front and rear of the car relative to each other. The main disadvantage is the roll of the car, since there is a pressure difference between the two wheels that run along the outer radius.
3. Four-circuit options are considered the best because they use four separate valves for each wheel, pressure sensors and a microcomputer for control. Consequently, the problem with roll is eliminated in this case, since the pillow steadily holds the required pressure.

Advantages and disadvantages of air suspension

Due to the positive properties of air suspension, there is a tendency to install it on both trailers and trucks, as well as passenger cars. The advantages of tuning a car with air suspension are represented by the following possibilities:

1. Ride height control. This improves handling under all road conditions. In this case, the springs do not need to be changed to softer and longer ones or shorter and harder ones (read also about).
2. Under heavy loads, sagging can be avoided, as the height and stiffness adjustments ensure consistent ride quality.
3. Handling is significantly improved, and the air suspension compensates for the difference between hard and soft springs by adjusting the pressure.
4. When driving on uneven roads, body vibrations are smoothed out.
5. It is possible to install air suspension on any car.

The advantages are significant and there are many of them, however, it is worth knowing about the disadvantages:

1. Poor resistance to road agents and frost, which significantly reduce the service life of the suspension.
2. The level of maintainability tends to zero, so failure of one of the elements requires a complete replacement of the suspension.
3. The cost is much higher compared to traditional shock absorbers.

Air suspension assembly

Since a do-it-yourself pneumatic device is only a subtype, installation is possible on an existing car suspension. The essence of the installation is to replace elastic elements with pneumatic cylinders, therefore, such a modernization scheme can be carried out on any machine. All that remains is to find out how to make an air suspension with your own hands and how to install it.

Necessary tools, materials and equipment

The equipment in this case is standard and every driver has it if he periodically encounters the need for repairs:

• sealant;
• hammer;
• metal brush;
• Bulgarian.

Do-it-yourself air suspension consists of the following components:

• a set of racks, even if the ones currently installed are reliable;
• receiver (you can make it for air suspension with your own hands and not buy it);
• air suspension cushions;
• compressor;
• several different fittings and PVC pipes with a diameter of 6 and 8 mm;
• two pairs of solenoid valves;
• Any oil and moisture separator will do;
• pressure gauge;
• Control block.

Front suspension assembly

It is worth considering separately the technology for installing the rear and front suspension, since in the case of the latter the scheme is more complex.

1. Knock the cap off the stand and clean off the paint layer using an angle grinder.
2. Press the adapter onto the post and add spacers underneath to increase the softness.
3. Select small diameter fittings or tubing and place them near the air holes in the adapter.
4. Install the air spring onto the strut. The height of the bump stop should be calculated in advance, otherwise the spring may fail after the first strong impact on the road.
5. Use caulk and a copper press washer to seal the connection.
6. Secure the support bearing to the strut so that the rod does not rotate inside the shock absorber when the steering wheel is turned.
7. Connect the air tube to the pillow socket.
8. Now you can install the finished structure.

The step-by-step procedure for assembling the rear suspension is as follows:

1. Trim the spring cup a little and remove the paint coating.
2. To the end of the rack rod it is necessary to cut a thread for pneumatics.
3. To seal, install a press washer and then put the air spring on the rod.
4. To achieve particularly smooth movement, you can not install a bump stop, which will result in a strong lowering of the rear of the car.
5. Press the air spring to the end of the shock absorber.
6. Apply air supply.

Installing air suspension on a car

Before installing the air suspension yourself, remove the struts from the car. A beginner's skills will be enough in this case - just lift the car with a jack and follow the step-by-step process.

1. Use existing holes to install the stand or make new ones if necessary.
2. Remove the rubber bands and stretch the tubes to ensure air supply; then they must be secured in relation to the body using clamps.
3. Attach the receiver to a special bracket near the gas tank.
4. Lead the tubes from the airbags along the steering rods and lead them into the engine compartment. Make the wiring in two directions - to the receiver valve and the relief valve.
5. Connect the pneumatics to the control unit toggle switches.

Functionality check

Be sure to check the system's functionality. After increasing the pressure to 8 atmospheres, check for leaks in the system by ear; there should be no hissing. Next, set the pressure in the system to 6 atmospheres for the rear suspensions and to 8 for the front ones. Do not rush when pumping air, otherwise there is a chance that the compressor will overfill the system. At the final stage, adjust the wheel alignment.

Suspension control

A control unit with 8 buttons is responsible for controlling the air suspension. Each button is responsible for a specific strut or shock absorbers in the complex. To receive data from each airbag, be sure to install the controller in the car interior. Based on the road situation, you can reduce or increase the air pressure in the airbag to reduce or, accordingly, increase ground clearance.

Paying tribute to fashion, air suspension becomes one of the attributes of the car. The direction of stance is becoming more and more developed, in which, without having air suspension, but let’s say a coil suspension, using the car in everyday use becomes more difficult and uncomfortable.

Air suspension is installed not only by connoisseurs of new tuning trends, it can also be very useful in the everyday life of the average driver.

Let's look at the main ones pros air suspension:

1. Ability to adjust ground clearance (you can improve the cross-country ability of your car despite its lower class)
2. Handling and roll (it is worth noting that despite the smooth ride, unlike springs, you can change the behavior of your car in a matter of seconds by adjusting the pressure)
3. Drawdown when loaded (you can adjust the height of the car regardless of how loaded it is)

The advantages include many more factors that satisfy the needs of the car owner.

To the main cons can be attributed:

1. Initial installation costs (since your car was not previously equipped with this function, you will need to spend money on purchasing all the units)
2. The service life of air suspension due to external factors (frost, reagents, etc.) is significantly less than that of springs.

Main types air suspension:

1. Dual-circuit - the ability to separately adjust the height of the front and rear of the car.
2. Four-circuit - control of each air spring separately, while they are connected to each other via an electronic controller for dynamic and static control (this is a more expensive option).

As for air bags, they also exist. several types:

Air suspension components

Manufacturing of air struts

Before manufacturing air struts, it is necessary to decide on the choice of pillows, based on the weight of the vehicle and the diameter of the springs.

It is also necessary take into account the location of the spring(separately from the shock absorber, or the shock absorber in the springs).

For passenger car The most common and universal are Rubena air springs 114x2, 114x3, 130x2 and 130x3.




For heavier vehicles, the Dunlop 152x2, 152x3 and Rubena 170x2, 170x3 models are suitable.

To make air struts, we will need machined flanges and brackets to mount the air spring.


Welding flange (for strut, shock absorber).

For sale on the websites there are ready-made flanges for the diameter of the air spring, as well as ready-made semi-kits. Flanges to match the diameter of your pillow and stand can be ordered from the dealer.


The bracket can be a blind type (photo No. 1) (if the shock absorber is located separately from the air cushion), or with a hole in the center (photo No. 2) for the shock absorber shank (if the shock absorber is located inside the air cushion).

photo No. 1

photo No. 2

The platform for the spring is cut off from the rack and a flange is welded to mount the cushion.

A brace is placed on the cushion.

And it is tightened to the welded flange on the rack using bolts. A bracket is also put on the cushion from the top and bolted to the flange; a rubber seal is put on the rod from the top.

Ready air strut.

If the rear shock absorbers are installed in springs, then the manufacturing process is similar.

If the rear shock absorber is separate from the spring, the manufacturing process becomes simpler. You won't have to weld anything anymore.

Ready rear air spring (provided the shock absorber is located separately).

After air struts are manufactured, they must be checked for air leaks before installation. After checking, all that remains is to remove the old suspension and install a new one, stretch the hoses, wires, and connect the control unit.

Installing an air suspension in specialized centers will cost quite a bit of money; ready-made air suspension kits or components, and installation by yourself will save you at least half of the budget.

Air suspension is a type of automobile suspension with adjustable ground clearance; this design is often used on trucks, crossovers, and premium cars. Pneumatics in the chassis ensure a smooth ride and allow the vehicle to adapt to different road conditions. This article will discuss the design of an air suspension, the disadvantages and advantages of a chassis with pneumatic elements, as well as the possibility of installing this type of device yourself.

Although, in general, factory-made air suspension (AS) elements are not cheap, there are many car owners who want to make tuning - a do-it-yourself upgraded car suspension is much cheaper than the standard one originally installed on the car. Another big advantage of homemade assembly is that some components of the pneumatic system can be purchased quite cheaply, without having to buy a ready-made kit.

Types of air suspension, main elements

The most important elements of any automobile air suspension are pneumatic stops, which are elastic elements, often installed instead of standard shock absorbers and simultaneously perform their functions. Adjusting the position of the body above the road can be done either manually or automatically; pneumatic systems vary in complexity and design features. PP usually consists of the following components:

• elastic pneumatic elements (pneumatic struts), which are actuators;
• a compressor that supplies compressed air to the pneumatic system;
• receiver - compressed air storage;
• air lines connecting the system components into one;
• air suspension control unit;
• various sensors (acceleration and body position, wheel acceleration).

If the pneumatic elements are also shock-absorbing struts, it becomes possible to adjust not only the ground clearance, but also the stiffness of the suspension. There are three main types of PP:

On automatically controlled systems, the air suspension is adaptive, that is, it itself, without driver intervention, changes the stiffness of the shock absorbers and ground clearance depending on the condition of the road surface and speed.

Air suspension device for a truck

Initially, pneumatic elements in the chassis were used by the Americans in aviation and on military trucks; they appeared on executive cars in the early thirties of the last century. Currently, “pneumo” is most often used on heavy-duty vehicles and truck tractors; it is not so common on passenger cars due to the high cost of parts.

On trucks, various types of air suspension can be used; most often, the air elements are placed between the frame and the axle using special brackets, and the design itself can be:

• spring;
• independent type (with springs):
• torsion bar

Mostly on trucks, single-circuit (double-circuit) PP is used, and it is installed mainly on the rear axle, although recently it is often equipped with pneumatic elements and front independent suspension, which is also found on foreign-made buses.

Freight vehicles can also be equipped with hydropneumatics; hydropneumatic struts simultaneously serve as vibration dampers (shock absorbers) and elastic elements. Hydropneumatics are successfully used on vehicles with independent suspension, and are used on all-terrain vehicles, trailers and semi-trailers.

One of the latest developments of pneumohydraulic suspension is DTS, such a system is equipped with modern electronics and has the ability to:

• stabilize rolls in any road conditions;
• withstand heavy axle loads;
• Flexibly change the stiffness of shock-absorbing elements.

In the DTS-type air-hydraulic suspension, each wheel is independently controlled; the system provides an optimal comfort/safety ratio when driving.

Advantages and disadvantages of air suspension

Like any component in a car, PP has its pros and cons; the main advantages of air suspension include:

• smooth ride;
• low noise level when driving;
• change in ground clearance depending on road conditions;
• possibility of adjusting suspension stiffness.

The adaptive air suspension is especially convenient to use; it allows you to increase rigidity when the car enters turns, thereby minimizing roll and increasing the stability of the car. When driving a car on a straight, flat road, the adaptive PP reduces the ground clearance, thereby improving aerodynamics and reducing fuel consumption.

Unfortunately, air suspension also has serious disadvantages:

• low maintainability - if the PP elements fail, almost all of them must only be replaced; it is impossible to restore the parts;
• intolerance to low temperatures; in cold weather, pneumatic struts often refuse to work;
• high cost of spare parts;
• Many car models have poor sensor and wiring protection.

As a rule, pneumatic parts fail faster than conventional suspension parts, and replacing parts requires higher qualifications from auto repairmen.

DIY air suspension

Most often, car owners independently install single-circuit or double-circuit air suspension with manual control; automatic four-circuit air suspension is too expensive, especially there is no point in installing it on budget cars. The simplest option for making your own air suspension is to buy a ready-made kit, although installation here also takes quite a bit of time, but the convenience lies in the fact that the kit contains all the necessary spare parts and instructions are included. The disadvantage of installing a ready-made kit is the relatively high cost, for example, on a Lada Priora/Grant, VAZ BAGONE parts will cost around 40 thousand rubles or more, and this is in the basic version.

You can assemble the air suspension kit for the Lada yourself; it will turn out cheaper if some parts are not only from the Lada, for example:

• air bags - from the Scania cabin;
• connecting pipes - from the truck brake system (PVC);
• receiver – gas cylinder VAZ-2109;
• solenoid valves - from gas equipment;
• compressor - type Falcon 820 or Berkut (model R17 or R20, the second option will be preferable).

Such little things as toggle switches, fittings or a pressure gauge are quite inexpensive and are sold not only in automobile stores, but also in hardware stores and on the market.

But the “prefabricated” version of installing the air suspension will take more time and will require additional adjustment of the parts in place. Most likely, the help of a turner will be required, for example, for turning spacers and accurately fitting air springs onto shock absorber struts.

Important points when installing air suspension yourself

When selecting air suspension spare parts, it is worth considering several important points; they determine how the system will function and whether everything will suit you in its operation:

Air suspension means comfort and ease of driving, but before you think about carrying out such tuning, you should first estimate your budget. Even self-installation, taking into account maximum savings, will not be cheap, you will have to spend a lot of time, but you have to pay for comfort.