I finally got around to pulling my Accuair ENDO air suspension tank apart the other day and took some photos to show the process.
I’ve talked about why I am running one of Accuair’s compressor-in-tank, all-in-one ENDO-CVT set-ups elsewhere on Barge Garage, so this post will cover the process of converting an ENDO-VT into a burger-with-the-lot CVT. If you’d like to know more about the CVT system you can read about it HERE
Here are a couple of photos of the complete ENDO-CVT set-up from the 2017 SEMA Show. You can see the WABCO compressor in the centre hooked to the valve blocks on each end of the tank. The compressor is fed by an external air source, while the valves provide metered amounts of air to each bag.
My CVT upgrade turned up a few months ago from Air Ride Suspension Supplies in Victoria, neatly packaged. It is sold as a complete DIY kit with everything you need, although you will need to also have a roll of thread tape, some Loctite sealant, and a selection of T-handle Allen key wrenches (including an adapter to use socket/Allen key drivers on your torque-wrench).
To start with I removed my ENDO-VT from the Bonneville and took it to my parent’s house where I had all my tools and a good work bench.
The upgrade kit is comprehensive, but not well labelled. Accuair are meant to supply a link to a YouTube video on how to install the compressor to make your ENDO-T or VT into a fully-fledged ENDO-CVT but my upgrade kit didn’t provide that URL. This made it exceptionally difficult to start with, but I eventually found the video – HERE
I start by removing the 4.5mm socket-head bolts holding both end caps to the cylinder, then removing one of the ports on the other end of the tank to thread some plastic rod in to so I can hammer the end cap off (as it is retained by a rubber O-ring). Note to self, find my set of T-handle Allen key wrenches, damnit!
The port with the blue tape is the feed line from the old twin Viair 480C compressors I had been using to pressurise the tank. This was no longer required, though it provided a perfect spot to feed in some plastic rod which I could hammer the opposite end cap off.
The WABCO compressor slides into the ENDO tank oriented so the blue wiring plug leads, and with the base of the compressor slides along the bottom of the tank. You pull out one of the plugs in the bottom of the tank and look through those ports to see when the compressor is properly lined up in the middle of the tank. You then screw in the alignment pin and the compressor is held in place until you fully secure it.
There are five socket-headed bolts on each end of the compressor bracket which also secure the WABCO to the tank in its proper location. Tightening down the two outer clamp bolts per-side can be a little tricky. There are also three socket-headed bolts on the plastic outriggers on each side to tighten so the compressor unit is locked in place.
With the WABCO compressor locked in place I was able to then start securing these wiring plugs and air lines to the end cap. You know which is which as the end cap plugs are colour-coded (red & blue) to which side they’re meant to run to, and only one side (the red) has the two air lines.
The red plug goes to this cap which houses the air fitting (not fully oriented in this point).
The other side of this cap. The gold fitting is the back of the air inlet fitting above. Accuair supply a feed line with an external filter on it to plug into this fitting.
The rest of the install proved fairly boring. The kit came with new end cap O-rings and bolts, and once I worked out the orientation of the various wiring clips and holders it all snapped together easily.
It is important to note you’ll need an adapter for your torque-wrench so you can use socket-head drivers with it. All the mounting bolts need to be torqued down, and most will require a dab of Loctite thread glue. Sockets and plugs which run through the pressurised section of the tank also need to be wrapped in thread tape (3.5 times).
With some basic wiring taken care of the system runs almost silently and fills within a couple of minutes. This changes the game for air suspension and is definitely worth the purchase price! The next job is to program the Accuair E-level height management software…