DIY air bag repair

In detail: do-it-yourself air bag repair from a real master for the site my.housecope.com.

The main element of the air suspension can be safely considered the air cushion of the cab. More recently, this car accessory was quite a rarity, even exotic, but today it can no longer surprise absolutely anyone.

The main function of the air suspension is to ensure smooth movement of the car, which in the most favorable way affects its safety and comfort of movement. So, air bags perform the following role:

dampen shocks and vibrations that occur during movement;
significantly increase the controllability of the car;
convert mechanical energy into heat;
the level of comfort becomes an order of magnitude higher.

When purchasing this element, do not forget that both comfort and the service life of the pillows and the entire cabin depend on its quality and correct selection. Air springs for cars, vans, trucks have completely replaced outdated steel springs. Their design is a "pillow" of the correct geometric shape, inside which is compressed air.

Thanks to this air, there is a counteraction to all vibrations that appear during movement. The redistribution of the pressure of the mass of the vehicle and the load occurs evenly along the axes, while it takes several minutes, and the pressure of the air inside the cushion changes due to the compressor, which is included in the basic configuration of absolutely any car.

As mentioned above, air bags are the main elements of air suspension, and their quantity and quality have a direct impact on the properties of the latter. In this case, the more air in them, the higher the landing of the car will be, in addition, due to this, its center of gravity also rises. And with independent pressure control, it becomes possible to increase the compression stroke, which will make it possible to lower the desired wheel.

Video (click to play).

From all of the above, it follows: the main sign that the repair of air springs is necessary is a decrease in the center of gravity of the car, in other words, the car "sits down" and does not rise even when the engine is running. But since they rarely fail all at once, the car can "sit" on only one wheel, and when the engine is running, a characteristic whistle is heard from it. Let's figure out what to do in such a situation.

Most often, it is almost impossible to repair this element at home, and for this you need to contact a specialized center. However, replacing an air bag on a car with your own hands is a completely ordinary task, which almost everyone can cope with. But before proceeding with the replacement, you should choose the right element. To do this, it is necessary to calculate the diameter: it depends on the load on the airbag and its working pressure. Image - DIY air bag repair

To determine the load, you should divide the maximum permissible car mass by 4 and add 25% to this number. However, some amendments must also be taken into account, because the load is not always distributed evenly to all wheels. And in the case of passenger cars with an engine in the front, it will be larger on the front axle. As for trucks with a full load, their rear axle will experience more pressure than the front. If the spring also works together with the airbag, then it will take on part of the load.

It is also important to calculate the amount of travel, for this it is necessary to subtract the height of its compressed state from the value of the maximum height of the bellows (another name for the air bag).

It should be borne in mind that the value obtained should not be less than the stroke of the shock absorbers, otherwise the pillow will fail very quickly. Air bags are installed in the rear springs. In this case, a corner (5 mm) is placed on the spar, it will serve as a support, while the lower mount consists of plates that are located between the spacers and the springs. Installing them on the front axle, we mount the lower mount to the lower arm, and the upper mount to the crossbeam.

Air suspension makes driving easier and smoother when compared to shock absorbers. How does this element of the car work and does it have any drawbacks? DIY air suspension: how to do it, what is the difference between the installation of the front and rear suspension.The pneumatic suspension allows you to adjust the ground clearance semi-automatically or completely without the use of physical effort. We are talking about replacing springs, springs and torsion bars with pneumatic bellows, in which the compressed air injected from the system acts as an elastic element. Despite all the advantages of this element, a do-it-yourself air suspension can be created only if you have basic car repair skills. The process is fraught with certain difficulties and a beginner clearly cannot cope with this.The design of each air suspension is represented by a receiver, a control unit, an air distribution system and a compressor. To increase driver comfort, the suspensions can be automatic or manual.

Automatic air suspension assumes independent selection of the height of the ground clearance by electronics, taking into account such factors as acceleration, speed, incline. The benchmark in this case is aimed at high aerodynamic performance. The center of gravity is lowered, therefore the machine's controllability is significantly increased.

Manual control requires the initiative of the driver 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 assumes the presence of air shock absorber struts.

There are three modifications of pneumatic suspensions:

Single-circuit options are designed to be installed on one axle and provide the same pressure in both cushions on it, since the compressor and cylinders are located on the same circuit.

Dual-circuit modifications are also installed on one axle, but in fact they 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 machine, since there is a pressure difference between the two wheels that run along the outer radius.

Four-circuit options are considered the best because four separate valves for each wheel, pressure sensors and a microcomputer are used for control. Therefore, the problem with the roll in this case is excluded, since the pillow stably holds the required pressure.

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There were micro cracks on the puff, letting it go down by itself. I poured the Amurukan bodyagu ... traveled ... traveled for a long time ... 5 months, not less ... I made a hole with a wire, thick ... a millimeter. kill the compressor or blow up like a German tank on this mine from the allies .. replaced the nafik pillows with new ones ..
Something like this..

How to disassemble and then correctly assemble the pneumoposhka, watch the video. how to install it correctly and without hemorrhoids in place, we read in the commentary to the video. the sound is bad, so I described everything in detail there, on YouTube ..

... Do not be afraid of perfection, you will never achieve it.
... Salvador Dali

but since it helps, you need to go to the knowledge base

everything is bullshit, except for gifts, but if the gift is bullshit.

The fact that the plate helps to put the pillow in place is a fact, but it seems to me that it also supports the pillow itself. Indeed, most of the time, the pillow is in tension, under load, so the upper pin will not fall out of the frame, but sometimes it happens that the wheel hangs out completely and this is where this plate helps.

everything is bullshit, except for gifts, but if the gift is bullshit.

Paying tribute to fashion, air suspension is becoming one of the attributes of the car. The direction of stance is becoming more and more developed, in which, not having an air suspension, but letting you use a helical suspension, using a car in everyday mode becomes more difficult and uncomfortable.

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

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

The ability to adjust the ground clearance (you can improve the permeability of your car despite its lower class)
Controllability and roll (it is worth noting that despite the smoothness of the ride, unlike springs, you can change the behavior of your car in a matter of seconds by regulating the pressure)
Drawdown when loaded (you can adjust the height of the car regardless of its load)

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

To the main cons can be attributed:

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

Basic types air suspension:

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

As for the airbags, they also exist. several types:

A more expensive option is bagel type pillows as they are the most resistant to loads and provide better handling (suspension travel is stiffer)

The most common ones consist of two and three links. The three links have a correspondingly longer stroke, which will allow the vehicle to be lifted higher.
The "sleeve" type is the cheapest option, the suspension travel is softer, less resistant to loads and the environment.

Air bags(bagels or sleeves)
Receiver(optimal is 12 liters)
Compressor(based on the many reviews, the Berkut r20 model is considered optimal today)
Remote Control - a device with which you can raise and lower the vehicle's ground clearance, in other words, this is a head unit that is responsible for the functions of distributing signals to the valves. Today, there are many choices of ready-made consoles for both two and four-circuit suspension, with various functions from the simplest to the more complex wireless
Valve block - is responsible for the supply and release of pressure in the system. You can make it yourself or buy a ready-made kit.
Pressure gauges - are necessary to regulate the pressure in the system. There are one-arrow and two-arrow ones, there are also electronic ones.
Dehumidifier - is necessary so that additional moisture in the system is not collected.
Pressure switch
Connectors and fittings
Check valve
Connecting tubes +Reinforced hose (for compressor)- there are 6, 8 and 10 mm.
The larger the tube diameter, the faster the inflation of the pillows is. The optimal tube is 0.8mm.

Before making pneumatic 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(separate from the shock absorber, or the shock absorber in the springs).

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

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

For the manufacture of pneumatic struts, we need turned flanges and braces, for fastening the pneumatic cushion.

Welding flange (for strut, shock absorber).

On sale on the sites there are ready-made flanges for the diameter of the air bag, as well as ready-made semi-sets. Flanges for the diameter of your pillow and stand can be ordered from the dealer.

The bracket can be of a deaf type (photo # 1) (if the shock absorber is located separately from the air cushion), or with a hole in the center (photo # 2) for the shock absorber shank (if the shock absorber is inside the cushion).

photo # 1

photo # 2

A platform for the spring is cut off from the rack and a flange is welded on for fastening the pillow.

A brace is put on the pillow.

And it is tightened to the welded flange on the rack using bolts. From the top to the pillow, a bracket is also put on and bolted to the flange, a rubber seal is put on the top of the stem.

Ready air suspension.

If the rear shock absorbers are fitted with springs, the manufacturing process is the same.

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

Ready-made rear airbag (provided the shock absorber is located separately).

Once the air struts have been manufactured, they must be checked for air leaks prior to installation. After checking, it remains to remove the old suspension and install a new one, stretch the hoses, wires, and connect to the control unit.

Installing an air suspension in specialized centers will not cost a small amount of money, ready-made pneumatic kits or accessories, and installing it yourself will save you at least half of the budget.

Repair of air suspension and conversion to manual control of air bags. Why do this? Especially if the sensors, electronics are working properly ... What can not suit the driver? Image - DIY air bag repair

Isuzu Forward. Air suspension repair. Car service First. Vladivostok

This question arises for many. Let's ask the drivers themselves, why guess?

- Tell me, why did you decide to transfer the pillows to manual control?

- Well ... They just live their own lives, They pump themselves, they let them down. And the most important thing

Isuzu Giga cargo van. Carrying capacity - 10 tons. In the Far East, such trucks, with the sides opening upward, are called "butterfly".

Rear axle air suspension - 8 airbags (4 pcs per axle). Spring front suspension. The wheel arrangement is 8 * 4, so trucks with 4 axles are also called "centipede".

Why did the Isuzu Giga truck come to be repaired? The client had a problem - the air bags of the middle axle were constantly being lowered. The driver found an interesting solution ... He fed the air suspension of the middle axle from the air springs of the rear axle cross to cross. The problem was solved for a while, but ... Recently, an Isuzu Giga truck arrived at our Pervy car service. The cab airbags did not work on the tractor. Image - DIY air bag repair

Isuzu Giga. Car service "First" Vladivostok. Truck repair seven days a week.

Our auto electrician examined the cab carefully, then made diagnostics of the Isuzu Giga truck electrician.

Isuzu Giga cabin air springs. Car service "First" Vladivostok.

It turned out that the pillows were not inflated with air. constantly play off

Japanese truck air suspension not working? Are the sensors and computer burned out?

Usually there are no such spare parts in car dealerships. Must be ordered from Japan. A set of spare parts for a truck's air suspension costs from 25 to 120 thousand rubles.

Plus, you will need to wait for the delivery of spare parts from Japan from two to four weeks ... 🙁

Really, there are no other options? Yes, you can save time and money. For instance,Refrigerated van 2005 Isuzu Forward. It has a rear axle air suspension, i.e. on the rear axle, instead of springs, air bags are installed. Image - DIY air bag repair

Isuzu Forward Air suspension repair Car service "First" Vladivostok

On the Vladivostok - Khabarovsk highway, a tube supplying air from the compressor to the air bags came off ...

One pillow immediately lowered, a little later, and the second also lowered due to a strong air leak. To Vladivostok to go more than 700 km. How to be?

Thought, thought the driver. There is nothing to do, you have to go ... 🙁

The loaded truck Isuzu Forward had to continue to run. True, not on air cushions, but on their aluminum cups. So a refrigerator with a deflated air suspension drove from Khabarovsk to Vladivostok (more than 700 km) ...

He arrived, unloaded, and then went straight to our car service "First" to repair the air suspension.

We removed the air bags in half a day. It turned out that the air bags needed to be replaced. They chewed hard.

Isuzu Forward Repair of pneumatic cushions Car service "First" Vladivostok

But the cups of the pillows are also badly damaged. There are no new or contract pillows in auto dealerships and auto dismantling sites. It is possible to order from Japan, but it will need to wait 2-3 weeks.

A refrigerator Isuzu Forward should work, earn money, and not stand and wait for spare parts! 🙂

We thought, consulted and decided to restore the cups. First they welded on, then grinded. Then they welded on and grinded again. Etc…

- Hello. We have a one-legged Isuzu Giga tractor with air suspension. So, the pillows are not lowered, which are instead of springs.

- It's clear.Pull up, we'll figure it out!

Isuzu Giga truck repair seven days a week Car service "First" Vladivostok

We didn’t figure it out right away with the air travel cushions ... We suffered, thought, tested, but coped.

The Isuzu Giga has a series of solenoids in the back that control the inflation and deflation of the cushions under different conditions.

Diagnostics of solenoids Isuzu Giga Auto electrician 12 - 24V Car service First Vladivostok

So, one of them, simply, got clogged with mud and soured. It was not possible to repair it

Paying tribute to fashion, air suspension is becoming one of the additional options and tuning elements of the car. The stance direction is becoming more and more developed, in which, not owning an air suspension, but letting us say a helical suspension, using a car in everyday mode becomes more difficult and uncomfortable.

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

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

The ability to adjust the ground clearance (you can improve the permeability of your car despite its lower class)
Controllability and roll (It is worth noting that despite the smoothness of the ride, unlike springs, you can change the behavior of your car in a matter of seconds by regulating the pressure)
Drawdown when loaded (you can adjust the height of the car regardless of its load)

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

To the main cons air suspension can be attributed:

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

Basic types air suspension :

Dual-circuit - the ability to separately adjust the height of the front and rear of the car.

Four-circuit - control of each air bag separately, while they are connected to each other through an electronic controller for dynamic and static control. (is a more expensive option)

As for the airbags, they also exist. several types :

A more expensive option is bagel type pillows as they are the most resistant to loads and provide better handling (suspension travel is stiffer)

The most common ones consist of two and three links. The three links have a correspondingly longer stroke, which will allow the vehicle to be lifted higher.

2. Type " Sleeves " - The cheapest option, the suspension travel is softer, less resistant to loads and the environment.

Air suspension accessories:

Air bags (bagels or sleeves)
Receiver (optimal is 12 liters)
Compressor (based on the many reviews, the Berkut r20 model is considered optimal today)

Remote Control - a device with which you can raise and lower the vehicle's ground clearance, in other words, this is a head unit that is responsible for the functions of distributing signals to the valves. Today, there are many choices of ready-made consoles for both two and four-circuit suspension, with various functions from the simplest to the more complex wireless

Valve block - is responsible for the supply and release of pressure in the system. You can make it yourself or buy a ready-made kit.

Pressure gauges - are necessary to regulate the pressure in the system. There are one-arrow and two-arrow ones, there are also electronic ones.

7. Dehumidifier - is necessary so that additional moisture in the system is not collected.

8. Pressure switch

9. Connectors and fittings

10. Check valve

11. Connecting tubes +Reinforced hose (for compressor)- there are 0.6mm, 0.8mm, 10mm
The larger the tube diameter, the faster the inflation of the pillows is. The optimal tube is 0.8mm.

Manufacturing of pneumatic struts.

Before making pneumatic 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 (separate from the shock absorber, or the shock absorber in the springs)

For passenger car Rubena airbags 114x2, 114x3, 130x2, 130x3 are considered the most widespread and universal

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

For the manufacture of pneumatic struts, we need turned flanges and braces, for fastening the pneumatic bag

flange for welding (for rack, shock absorber)

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On sale on the sites there are ready-made flanges for the diameter of the air bag, as well as ready-made semi-sets. Flanges for the diameter of your pillow and stand can be ordered from a turner.

photo # 1

photo # 2

A platform for the spring is cut off from the rack and a flange is welded on for fastening the pillow.

A brace is put on the pillow

and tightened to the welded flange on the rack, using bolts. From the top to the pillow, a bracket is also put on and bolted to the flange, from the top a rubber seal is put on the stem.

finished air suspension

If the rear shock absorbers are fitted with springs, the manufacturing process is the same.

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

finished rear airbag (provided that the shock absorber is located separately)

Video (click to play).