Page 1
INSTALLATION INSTRUCTIONS
6019 Air Spring Kit
2001-2010Chevrolet/GMC 2500/3500 HD
Thank you for purchasing a quality Hellwig Product.
PLEASE READ THIS INSTRUCTION SHEET COMPLETELY BEFORE STARTING
YOUR INSTALLATION
IMPORTANT NOTES
DO NOT INFLATE AIR SPRING ASSEMBLY UNLESS IT HAS BEEN
PROPERLY INSTALLED ON VEHICLE.
DO NOT INFLATE AIR SPRINGS OVER 100 PSI
A MINIMUM OF 5-10 PSI MUST BE MAINTAINED IN AIR SPRINGS
AFTER INSTALLATION FOR WARRANTY TO BE VALID. FAILURE TO
KEEP MINIMUM PRESSURE IN AIR SPRINGS WILL VOID WARRANTY.
THIS UNIT IS DESIGNED TO INCREASE THE LEVEL LOAD CARRYING
CAPACITY OF YOUR VEHICLE. NEVER LOAD THE VEHICLE THIS
UNIT IS INSTALLED ON BEYOND THE MANUFACTURER’S MAXIMUM
GROSS VEHICLE WEIGHT RATING.
OVERINFLATION AND IMPROPER USE MAY RESULT IN PERSONAL
INJURY AND/OR DAMAGE TO YOUR VEHICLE AND PROPERTY.
Page 2
BEFORE STARTING YOUR PROJECT
WHEN LIFTING A VEHICLE WITH A JACK, BE SURE TO SET THE PARKING BRAKE AND USE
SAFETY STANDS.
ENSURE THAT THE INSTALLATION OF COMPONENTS WILL NOT CRUSH OR DAMAGE
FUEL AND BRAKE LINES OR ELECTRICAL HARNESSES.
BEFORE DRILLING ANY HOLES, ENSURE THAT ALL ELECTRICAL WIRES, FUEL LINES,
BRAKE LINES, BRAKE HOSES AND ANY OTHER COMPONENTS ARE MOVED OR
PROTECTED TO AVOID DAMAGE FROM DRILLING ANY HOLES .
DO NOT ATTEMPT ANY MODIFICATIONS TO THE VEHICLE OTHER THAN THOSE
OUTLINED IN THIS INSTRUCTION SHEET. IF ANY INTERFERENCE WITH THE GAS TANK,
FUEL LINES, BRAKE LINES, EXHAUST PIPE, ETC. EXISTS, STOP YOUR INSTALLATION AND
CALL HELLWIG PRODUCTS FOR TECHNICAL HELP.
IF WHEELS ARE REMOVED FOR INSTALLATION OF KIT, CHECK MANUFACTURERS
SPECIFICATIONS FOR PROPER LUG NUT TORQUE BEFORE REINSTALLING WHEELS.
WHEN CUTTING AIR BRAKE TUBING A SQUARE CUT IS REQUIRED OR LEAKAGE MAY
RESULT.
1. Park vehicle securely and set parking brake and
chock wheels. Remove factory bump stops from vehicle by removing nuts from studs using a 15mm
wrench or socket
1
2. Install elbow fitting in port of air spring. Torque fitting to approximately 20 ft-lb.
Page 3
3/8 x 3/4 Flat Head
Cap Screw
3/8 x 1” Studs. Apply
locktite to threads
before installation
Heat Shield.
3. Place heat shield on top of
air spring before upper plate
as shown in photo. Apply
loctite to threads of 3/8 x 1”
studs and insert into threaded
holes in plate. Attach air
spring to plate with 3/8 x 3/4”
flat head cap screw. Torque
to 20-25 ft-lb.
Insert Carriage bolt into short leg of
lower plate. Short leg is oriented
forward.
4. Insert a carriage bolt in the square hole into the short leg of the lower plate as
shown and attach air spring to plate using the 3/8 x 3/4” flat head cap screw as
shown. Torque to 20-25 ft-lb. The short leg of the lower plate will be oriented
forward.
Passenger Side
Page 4
5
Passenger Side
Heat Shield
5. Place air spring assembly between the axle and the frame rail
as shown and insert threaded
studs on upper plate through the
holes in the frame used to attach
the bump stops. Attach to frame
using 3/8” locknuts and washers.
Torque to 20-25 ft-lb.
6
Driver Side Heat Shield
Place lower bracket
on axle pad
6. Place lower bracket
squarely on top of axle pad.
Install carriage bolts into lower
plate on air spring assembly
and attach strap with locknuts
and washers. Tighten strap
until ears on strap bend
slightly.
Axle strap
Page 5
7. Complete passenger and driver’s side installation of air spring assembly.
8. Select a location for the air inflation valves. The location can be on the
bumper or body of the vehicle where an air chuck can be used to inflate the air
springs. Select a location where the valve will not be damaged or interfere
with the operation of other components.
9. Cut air brake lines to length and connect air lines to fittings by pushing the air
line into the air fittings as far as possible. WHEN CUTTING AIR BRAKE
TUBING, A SQUARE CUT IS REQUIRED AND THE HOSE END
MUST NOT BE DEFORMED OR LEAKAGE MAY RESULT. IF DE-
FORMATION OF THE HOSE END OCCURS, THE HOSE END MUST
BE REWORKED SO THAT IT IS ROUND. Engagement of the sealing O
-ring will be felt when the air line has been inserted properly into the fitting.
Fittings may be disconnected if required by pushing down on the outer ring
while pulling firmly on the air line. Route air lines away from exhaust pipes
or any other sources of heat and ensure that the air lines are protected from
sharp edges. A length of heat shielding is provided to protect the air line as it
exits the passenger side air spring.
10. Inflate air springs to 40 psi and check for leaks. A soapy water solution can be
used to find slow leaks.
11. When satisfied with integrity of the system, adjust air pressure to desired level.
The air springs can be inflated to any level between 10 and 100 psi. DO NOT
run the air springs empty or warranty will be void. MINIMUM air spring pressure is 10 psi. Failure to keep air in the air springs will void the warranty. For
best RIDE use only enough air pressure as required to level the vehicle. If a
firmer ride is desired, more pressure can be used.
12. Check air pressure in the system regularly to ensure system performance and
maintenance of warranty. Just like tires, the air pressure in the system will
vary due to temperature changes. For your air spring system to function properly it must be checked on a regular basis.
HELLWIG SUSPENSION
SUSPENSION SYSTEMS
Loading...