Mazda Protege

Mazda Protege T EE

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Rear Kit Part No. 75689

MN-560 (01305) NPR 4184

www.airliftcompany.com

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Please read these instructions completely before proceeding with installation

Hardware Item A B C D E

P/N 18523 18207 10466 17132 10467

Description 1/2” - 20 Nylock Nut 1/2” Flat Washer Black Zip Tie 1/2” #8-18 Phillips Screw Plastic Line Clamp

Item P/N 09333 F G 35006

Qty. 2 2 2 2 2

Description Rubber Spacer Rear Strut Assembly

Qty. 2 2

Technical Support Support

1-800-248-0892 Ext. 2

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IMPORTANT: Always keep safety in mind when working on your vehicle. Completely read these instructions before installing the kit. I. Preparing the Vehicle 1. Raise the vehicle and support the body on jack stands. 2. Remove the rear wheels (Figure 1).

II. Strut Removal Figure 1

1. Remove the sway bar by removing the four inner sway bar bolts and sway bar link on each side of the vehicle (Figure 2, Figure 3). 2. In the trunk compartment on one side of the vehicle, remove the trim panel (Figure 4). 3. Using a wrench, remove the seat belt bolt (Figure 5). 4. Remove the three nuts securing the seat belt retainer and remove the retainer and seat belt apparatus (Figure 6). 5. Underneath where the seat belt retainer was located, remove the three nuts securing the upper strut mount and retain for later use.

Figure 2

6. Remove the ABS brake line bolt and discard (Figure 7). 7. Remove the clamp from the brake line and discard (Figure 8). 8. Remove the two lower strut mounting bolts and retain for later use (Figure 9). 9. Remove the O.E.M. strut from the vehicle (Figure 10). 10. Repeat steps 1-9 for the other side of the vehicle.

Figure 3

III. Preparing the Upper Strut Mounting Bracket 1. Using a spring compressor, remove the nut and washer from the upper strut mounting bracket and discard (Figure 11). 2. Remove the upper strut mounting bracket from the strut and retain for later use.

Figure 4 Technical Support

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IV. Installing the Air Line NOTE: If you will be installing an air management system with this kit, follow the instructions on the next page. If you will not be installing an air management system at this time, continue to section V. 1. Refer to the air management system instruction manual for directions on how to install your particular system. 2. If possible at this time, secure the air lines under the vehicle AWAY FROM HEAT SOURCES.

NOTE: It may be helpful to install the strut before securing the air lines. Refer to section V for strut installation instructions.

Figure 5

NOTE: You may need to drill a hole in the inner fenderwell. If so, follow steps 3-5 below. If no drilling is needed, proceed to section V after the air management system is installed. 3. If a hole needs to be drilled to secure your air line, hold the strut up to the vehicle where it will be in place and make a mark on the inner fenderwell where the air fitting and air hose will pass through it.

NOTE: The air fitting should point toward the rear of the vehicle. 4. Remove the strut and drill at least a 3/4” hole.

NOTE: Drilling the hole at least 1/4” larger than the size of the air line prevents the air line from rubbing on the fenderwell. Figure 6

5. After running the air line through the previously drilled hole, use a rubber grommet or silicone caulk to prevent the air line from rubbing on or against the hole in the inner fenderwell.

Figure 7

Figure 8 Technical Support Support

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V. Installing the Strut 1. Grind off the excess bolt sticking out from inside the strut tower to allow for strut clearance (Figure 12). 2. Drill the center hole of the O.E.M. upper strut mount out to 9/16” and attach the supplied rubber spacer (F) and O.E.M. upper strut mount to the new strut (G) using the supplied washer (B) and nylock nut (A) (Figures 13, 14, and 15). 3. Place the assembled strut into the strut tower, making sure to line up the upper and lower mounting brackets with their corresponding mounting holes (Figure 16). 4. Reattach the two previously removed lower strut mounting bolts (Figure 17).

Figure 9

5. Secure the upper strut mount with the three previously removed mounting nuts and tighten (Figure 18). 6. Reinstall the previously removed seat belt retainer, seat belt, O.E.M. seat belt bolt, and plastic trim (Figures 4, 5, and 6). 7. Using a pair of pliers, remove the bracket from the ABS line and tie the ABS line to the brake line using a supplied zip tie (C) (Figure 19, Figure 20). 8. Fasten the brake line behind the strut as shown in Figure 21 using a supplied clamp (E) and screw (D). 9. Tighten any loose hardware at this time. Finished installation should look like Figure 22.

Figure 10

10. Repeat steps 1-9 for the other side of the vehicle.

VI. Before Operating 1. Tighten and visually inspect all hardware after 100 miles. 2. Our BigBore control kit is highly recommended for this product. 3. Please continue by reading the Maintenance and Operation section.

Figure 11

Figure 12 Technical Support

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VII. Fixing Leaks 1. If there is a problem with any of the air fittings: a. Check the air line connection by deflating the spring and removing the line by pulling the collar against the fitting and pulling firmly on the air line. Trim 1" off the end of the air line. Be sure the cut is clean and square. Reinsert the air line into the push-to-connect fitting. b. Check the threaded connection by tightening the fitting another 1/2 turn. If it still leaks, deflate the air spring, remove the fitting, and re-coat the threads with thread sealant. Reinstall by hand tightening as much as possible, then use a wrench for an additional two turns.

Figure 13

2. If the preceding steps have not resolved the problem, call Air Lift Technical Service at 1-800-248-0892 for assistance.

Figure 14

Figure 15

Figure 16 Technical Support

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VIII. Troubleshooting Guide Problems maintaining air pressure, without on-board compressor. 1. Leak test the air line connections and threaded connection of the fitting into the air-strut. See Section VII to repair. 2. Inspect air lines to be sure they are not pinched. Tie straps may be too tight. Loosen or replace straps as needed. Replace leaking components. 3. Inspect air line for holes and cracks. Replace as needed. 4. If there is a kink or fold in the air line, reroute as needed.

Figure 17

If the above steps have not solved your problem, please call Air Lift at 1-800-248-0892 for assistance.

Figure 18

Figure 19

Figure 20 Technical Support

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Figure 21

Figure 22: Finished Installation

IX. Maintenance and Operation: Minimum Pressure

Maximum Pressure

10 p.s.i.

175 p.s.i.

Failure to maintain correct minimum pressure (or pressure proportional to load) or to avoid bottoming out, overextension, or rubbing against another component will void the warranty. By following these steps, vehicle owners should obtain the longest life and best results from their air springs: 1. Check the air pressure in the air springs weekly. 2. Always maintain Ride Height. Never inflate beyond 175 p.s.i. 3. If you develop an air leak in the system, use a soapy water solution to check all air line connections and the inflation valve core before deflating and removing the air spring. 4. Always adjust the air pressure to maintain Ride Height. Increase or decrease pressure from the system as necessary to attain Ride Height for optimal ride and handling. 5. IMPORTANT: For your safety and to prevent possible damage to your vehicle, do not exceed Maximum Gross Vehicle Weight Rating (GVWR), as indicated by the vehicle manufacturer. Although your air springs are rated at a maximum inflation pressure of 175 p.s.i., the air pressure actually needed is dependant on your load and GVWR, which may be less than 175 p.s.i. Check your vehicle owners manual and do not exceed the maximum load listed for your vehicle. 6. Always add air to springs in small quantities, checking the pressure frequently. Air springs require less air volume than a tire and inflate quickly. 7. Should it become necessary to raise the vehicle by the frame or do any service work, make sure the system is at minimum pressure (10 p.s.i.) for safety and to reduce the tension on the suspension/brake components. Check that the front lower brackets nest properly in the lower A-arm when servicing is complete. Do this before operating the vehicle.

Thank you for purchasing Air Lift Products Mailing Address: AIR LIFT COMPANY P.O. Box 80167 Lansing, MI 48908-0167

Street Address: AIR LIFT COMPANY 2727 Snow Rd. Lansing, MI 48917

Local Phone: (517) 322-2144 Fax: (517) 322-0240

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For Technical Assistance call 1-800-248-0892 Technical Support

1-800-248-0892 10 “The Choice of the Professional Installer” 10 7 Printed in the USA Ext. 2