The emergence of more and more innovative technologies means that systems are no longer so inaccurate, slow and clunky. Instead, more precise technologies are used, based on modern electronics that control everything from ride height to precise air suspension pressure, in turn offering a smooth, controlled drive. But the most important thing is that the car suspension system is often underestimated. And the most important thing is that this car unit is often underestimated. If we consider a car from the point of view of safe and comfortable movement, then the car suspension is as integral a part as the wheels of the vehicle. Shock absorbers and springs absorb the shock from potholes and bumps that the wheel hits. But know that every time you load or unload the car, speed it up or slow it down, turn it in different directions, you throw a “challenge” at the abilities of the shock absorbers and springs.
Nevertheless, for all its relevance and necessity, spring suspensions are already a very conservative option for softening road irregularities. The set of their functions is constant and does not include various types of adjustments and add-ons.
How does air suspension work?
Air suspension is a conventional spring car suspension in which the springs are replaced by air springs. Air springs are hard rubber or plastic cylinders that are inflated to a certain height and pressure. This is all done to imitate the same spring mechanisms in suspensions. But that’s where all the common signs end. When you add an on-board air compressor, sensors and electronic control systems to air springs, today's air suspension systems provide a huge number of benefits over the all-metal suspension of conventional springs. The air suspension adjusts instantly, can adapt to handle different types of irregularities in different situations and change load capabilities.
But the main feature of the air suspension is not its ability to expand its settings and functionality. Whether a manual or electronic air suspension adjustment system is installed, whether it was done by a garage “Kulibin” or by professionals from a large concern of experienced technologies of a world-famous popular brand, the air suspension both lowers and raises the car, increasing or decreasing its ground clearance. Air suspension is especially relevant among young car owners who use it in domestically produced cars.
The main advantages of air suspension
This mechanism installed on your car will perfectly cope with the task of absorbing unevenness and potholes while the car is moving along the road, and it will become much more dynamic and stable. By installing your own pneumatic system on your car, you will get a lot of advantages:
- the lateral roll of the car will become much less if the car is unevenly loaded;
The load on the suspension will be reduced as much as possible, and its service life will increase proportionally;
Your car will become much more comfortable than it was before with stock springs;
The stability of the car will increase when it is introduced into sharp turns;
The negative consequences of vehicle overload will be reduced to a minimum;
The longitudinal roll will disappear.
At the same time, the driver gets the opportunity to independently adjust the vehicle’s ground clearance, depending on the quality of the road surface and the degree of vehicle load.
Materials for creating your own air suspension
To make and install an air suspension on your car yourself, you should study some of the intricacies of this procedure and, of course, purchase the necessary parts for assembly. The first element you will need is air cushion. This is the most expensive part in the entire structure, which will be installed on your car instead of metal shock absorber springs. By pumping or deflating air into or from this air spring, you can adjust the ground clearance of your car. By inflating it, you will accordingly increase the ground clearance; by lowering it, you will decrease it. The air suspension works exactly according to this principle.
You will also need a compressor, which is the main element of the entire pneumatic system. It is necessary in order to pump air into the installed air bags. Braces and fastening elements. They are necessary for attaching the air spring to the body of your car. It’s not at all difficult to build these elements yourself, having first drawn up a drawing of the mounting location and ordered components from a turner or welder.
Pneumatic valves. One of them is designed to pump air masses, and the second is to release them. Pressure gauge. It can be applied to any that is used in various pneumatic systems.
Start button. Any button that works on the on-of-on principle will be an ideal option in this case. With its help, it will be very convenient for you to adjust the level of the air suspension directly from the inside of the car.
Air line. This is a device consisting of tubes connecting the pillows to each other, which are the basis of the air line of the entire system.
Pressure meter. It is provided in the form of a sensor located anywhere in the air line and used to monitor the overall pressure in the system directly from the vehicle interior.
Relay. It is necessary in order to start the injection compressor and open the exhaust valve.
Installing a homemade air suspension
In order to install air suspension on a car, the car should be placed and secured on a flat surface. Then, using jacks or a lift, you should hang one of the parts of the car - this will all depend on the place where the air spring is installed. Next, remove the factory springs and then prepare the installation site for the air spring mounting brackets. Afterwards, the prepared braces must be secured on pads with already installed valves. Then attach the cushions in place of the old shock absorbers.
The next stage of work will be the creation of an air line, thanks to which the functions of the air suspension will be carried out. To do this, it will be necessary to connect them together using tubes previously connected to the compressor. Then install the pressure gauge along with the sensors. Then place the start button inside the car and remove the sensor sensor.
After installing the air suspension, you can begin adjusting the entire system. To do this, pump some air into it and check what ground clearance corresponds to a certain pressure on a fully loaded car. When making adjustments, make sure that both sides of your vehicle have identical ground clearance. When the car is leveled on the site, feel free to get behind the wheel and conquer the road.
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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Air suspension for a car is a suspension with which body height can be adjusted relative to the road, change the ground clearance for off-road travel.
What is air suspension?
Air suspension is used for trucks and various trailers. This suspension is also used on business class cars. It can be the basis of existing similar pendants.
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The main purpose of this device is ensuring higher road safety and comfort when moving. Some business class cars are equipped with pneumatic elements at the base of the adaptive suspension.
Air suspensions can be divided into three main types. This single-circuit, double-circuit and quadruple-circuit suspensions. Air suspension is often included in a ready-made vehicle package, and can also be installed independently. If you install the suspension yourself, you will have the ability to manually adjust the body height. What is the difference between all three types:
1. Single-circuit suspension is designed for one axis car (rear or front). Single-circuit suspension is often installed on trucks, where the emphasis is on adjusting the rear axle of the vehicle, depending on the load on the body.
2. Double-circuit air suspension can be installed on two axles or on one. This allows adjustment of two axes. But if a dual-circuit suspension is installed on only one axle, then each wheel can be adjusted independently.
3. Four-circuit air suspension is a complex system. In this mode All four wheels can be adjusted, a support system is provided. This pneumatic system is controlled using an electronic unit. The support pressure is regulated with the assistance of special sensors.
The basis of the air suspension design consists of a control unit, special sensors, a compressor for air supply, a receiver, pneumatic elements for each wheel and a control unit. When the suspension is operating automatically, body height is adjustable depending on speed, inclination etc. The operation of automatic and manual adjustment is somewhat different. But in general, the principle and purpose have the same meaning.
On what cars does it come from the factory?
It’s interesting to know that one of the first cars to be equipped with air suspension was Citroen DS in 1955. And imagine, in the very first days, this car model received a huge number of applications, a third of which were made literally within the first hour.
The serial production of the Citroen DS was the first to include air suspension. Today, the production of cars of this brand with this configuration also continues, as well as cars such as Toyota, Mercedes, etc. It is better to use air suspension together with the standard suspension. It will, as it were, take on part of the load, working as an auxiliary element.
To be able to adjust the height of the body relative to the road strip, you can install air suspension and use it together with the standard suspension. Vehicles that are designed to transport various loads, with large bodies and medium-sized trailers, are produced with an already built-in pneumatic system. For example, such as Mercedes, Renault Master, etc. Also various models of dump trucks, large-sized trucks for transporting large loads. In these types of vehicles, a pneumatic system is mandatory. It facilitates the movement of the car and makes driving easier and more comfortable.
On which machines can I install it myself?
How to make air suspension yourself and what car models can you install it on? In practice, manufacturing is not particularly difficult. Contrary to the popular belief that such an installation is unreliable, this process is quite effective and feasible.
You can design and install yourself air suspension for VAZ car. There are some important points to consider. The most difficult moment in the manufacture of suspension for a VAZ is replacing shock absorbers with air springs. It is better to use the original housing of the racks for support. It is necessary to take into account the features of a specific VAZ model and the type of pneumatic cylinders used.
To design an air suspension for a VAZ car, you will need a set of certain parts and mechanisms. No worries. There are no difficulties in this process.
What is needed for this:
1. Compressor.
2. Set of 4 air bags. When selecting pillows, specific models can be used specifically for VAZ, and there can also be others suitable from other car models.
3. Receiver for air injection. It should be cylindrical for a VAZ sedan. For hatchbacks, the receiver is shaped like a spare wheel.
4. You will need 4 pcs. solenoid valves.
5. Connecting tubes.
6. Two pressure gauges.
Directly during the manufacturing process, you may need to purchase other related parts, wires, fasteners, etc. Approximate the cost of all elements in general will be from 800 to 1200 dollars. This depends on the individual design parameters and car model.
Advantages and disadvantages
Like any device, air suspension also has advantages and disadvantages. One of the advantages of having a pneumatic system is the absence of noise and smooth running of the car. A big plus is automatic clearance adjustment and the rigidity of the racks during movement. These qualities are inherent in factory installation systems. Regarding the four-circuit pneumatic system, manual installation is not used at all with this model with automatic control. Because it is a very complex and costly process to do on your own.
The disadvantage is low probability of successful repair. For example, pneumatic struts, when they fail, are already cannot be repaired. Only parts need to be replaced.
Cost of the kit and installation itself
If we talk about the cost of a pneumatic system, it varies. Depends on the type (single-circuit, double-circuit, four-circuit). And also the price depends on the manufacturer and supplier. In the price range in Ukraine the cost of pneumatic elements and kits can be from 4,000 to 25,000 UAH. Depends again on the type of model.
Installation cost depends on needs. On average, it can be from 2,500 to 10,000 UAH. It depends on your goals and individual wishes. Before you begin installation, you need to clearly and in detail explain to the technician all the nuances. Because every modification is an additional price. It is not always necessary to buy all the parts to assemble a kit. To do this, it is advisable to seek advice from a specialist in this field. After this already sum up the entire cost of installation and related items workflow.
The topic will not contain comparisons of bagels and sleeves. High-quality Pindos air springs will not be mentioned.
Only accessibility, simplicity, cheapness.
So, we will talk about Scania cabin cushions.
Pre-made cabin cushions are definitely cool and wonderful. Finished it with a file and installed it. What could be simpler?
But what if the pillow cannot be installed in this form, if other characteristics are needed, a smaller stroke?
One of the most common problems when installing air suspension on a VAZ PP is the location of the lower bracket of the rear cushion. If you place it on a spring cup, then the plastic part of the bracket will be higher than the body of the stand and if the suspension breaks, there will be a blow to this same plastic bracket. In addition, it will not allow the car to sink lower.
Well, we saw off the cup, grind out the retaining ring and weld it 5-7 cm below the spring cup. The problem with the protruding bracket is solved, but another problem appears.
The spring cup is located at the level of the rubber profile, and by lowering the bottom point of the cushion lower, we position the bracket just opposite the wheel - accordingly, there is a chance to wipe the cushion, especially when installing wheels of larger width and diameter.
There are several options for solving the problem: installing donuts, moving the mount back up, installing spacers on the wheels, shortening the cushion and installing other braces.
Another equally common problem is the discrepancy between the inner diameter of the cushion and the diameter of the front strut housing. The same problem can be attributed to the inability to put the pillow on through the outer nut or protrusion on the stand.
This problem is also solved in different ways.
Someone sharpens plastic:
Someone makes special cases:
Well, one more option:
All of these options provide for the installation of only a full-size sleeve.
But what if you really want a short cut or need to reduce the sleeve length?
This issue cannot be resolved without solving the problem of sealing the sleeve.
In the factory version, the sleeve is crimped with a special ring. The ring has certain strength characteristics and resistance to corrosion; in addition, to crimp this ring you need a special machine (like those that crimp RVDs). All this makes the compression method almost impossible to do at home.
But there is one relatively simple way to shorten Scanian pillows.
Quote : " The process of shortening the same Scanie pillow is as follows. The elastic is cut with a knife along the edge of the metal ring. The metal ring slips out with little effort without a rubber band. Shorten the elastic band of the pillow to the required length. We put the same metal ring on the pillow and press it into place like an oil seal using a machine or press and soap solution. On Scanie pillows, it is better to shorten the pillows at the top, since they have a metal upper support.
The pillows in this photo are shortened in this way. Although the rings are also machined differently for ease of folding the pillow. New rings can be sharpened, but the dimensions must be taken from the originals."
Knowing the general principle, you can order the necessary components for the turner:
It’s not very convenient to look for a press every time to assemble and disassemble. Therefore, sealing can be done using bolted cones:
There is another way. This method is based on the connection principle of the CAMMOZI union nut for plastic tubes.
Do-it-yourself air suspension was conceived a long time ago. The obstacles to its installation were financial difficulties and technical issues. But they were finally overcome.
The air suspension was installed with my own hands on a 1986 model, in the SL configuration.
Air suspension diagram
The air suspension on the car is built according to a four-circuit design with 8 valves, 2 valves per cushion - one valve for air supply, the second for return. The scheme will allow you to effectively control each air spring: lower the left side, raise the right side or vice versa, lower the front of the car and raise the rear, etc.
Fig.1 Moskvich-2140
Fig.2
Air suspension components
Unfortunately, they do not produce ready-made air suspension kits for domestic cars, so I assembled the air suspension with my own hands. Main components of air suspension - air springs from America. Having studied the range of produced airbags, taking measurements with a ruler so that the air pillows would fit in place of the springs and not rub against the lower arms, an order was made.
Also, solenoid valves were delivered from America. In addition to all of the above, we purchased: fittings, tees, nipples, etc., a compressor - from a car store, an oxygen hose - from the construction market.
For the front suspension, RE-5 air springs from the American company Slam Specialties were chosen. The outer diameter, depending on the load and pressure, is 130-139 mm. If the diameter was larger, the air bags rubbed against the sides of the lower arm. In addition, the RE-5 has built-in bump stops, so the car's standard bump stops are not needed. For the rear suspension, Dominator 2500 cushions were purchased.
Fig.3 PP
The electromagnetic type valves for the air suspension were controlled under a voltage of 12 volts. The valves have a flow area of 15 mm and this allows them to pass a huge amount of air through themselves, which will make it possible to very quickly pump and bleed air from the air bag. With these valves, the Mosvich will rise and fall in one second. The valves are connected with 0.5 inch plumbing threaded fittings.
Fig.4 Air suspension components
At the very beginning, the Berkut R17 compressor was used for the air suspension, but its performance was rather weak. Therefore, it was replaced by the Berkut R20 compressor, which is half the price of a similar design Viair 400P.
Fig.5 Berkut R20
The receiver for the air suspension is an air cylinder with a volume of 20 liters from the brake system of a KAMAZ vehicle. Some modifications were made: the U-shaped supports were welded, cut from a channel and painted. It has 5 holes - two at each end, and one for draining condensate.
Fig.6 Receiver
Installing air springs on the front axle
The main feature of the front axle of cars from the 60s to the 80s is the placement of shock absorbers inside the springs. Therefore, we had to place the shock absorber differently. We also had to move the brake lines. The PP fastenings were made using metal pads 3 mm thick. The upper one is attached to the cross beam and the lower one to the lower arm.
Fig.7 Front axle
Fig.8 Disassembled front suspension
Fig.9 Air bags
Fig. 10 Shock absorber on a new mount
Fig. 11 Front axle with air spring
Fig.12 Front air suspension
Installing air springs on the rear axle
A 5 mm thick corner was attached to the spar, which served as an upper support for the Dominator 2500 PP. The lower mount of the PP was made of several plates, which were secured between the springs and spacers. Spacers were needed so that in the lower position the body would lower onto the bump stops. The spring leaves were reduced to 3 pieces, and the stepladders were replaced from IZH-2715, since they are longer.
Fig.13 Details
Fig.14 Rear inflated PP
Fig.15 Rear air suspension
Air suspension control
The air suspension is controlled by yourself using a wired remote control G1910 from Gainta with 8 buttons. You can control either one airbag or separately the front or rear suspension and left or right side.
Fig.17 Remote control
Fig. 18 PD diagram