Air Suspension Valve Block

Remove and replace the air suspension valve block assembly on a 1966 Chevrolet Corvette, including disconnecting air lines, electrical connections, and mounting hardware.

Warnings

Tools required

Parts

• Air suspension valve block assembly × 1 — Use OEM specification
• Air line O-rings or seals × 1 — Use OEM specification
• Valve block mounting gasket × 1 — Use OEM specification

Preparation

1. Park vehicle on level, solid surface and engage parking brake.
2. Place wheel chocks behind rear wheels.
3. Turn air suspension system switch to OFF position if equipped with a dash-mounted control switch.
4. Disconnect negative battery cable to prevent electrical shorts.
5. Locate the air suspension compressor and manually exhaust all system pressure using the pressure relief valve or by carefully loosening a line connection after ensuring proper eye protection.
6. Raise front of vehicle and support securely on jack stands under frame rails.
7. Allow adequate access to front suspension area and valve block location.

Procedure

1. 1

   Locate valve block assembly
   Because this is a custom aftermarket installation with no standard location, the air suspension valve block could be mounted anywhere the installer chose — frame rail, inner fender, firewall, or trunk area. Trace air lines from the front air springs back to the central distribution point to locate it. Identify the valve block by tracing air lines from the front air springs back to the central distribution point. Clean the area around the valve block with a wire brush and shop rags to prevent contamination during disassembly.
2. 2

   Label and photograph connections
   Before disconnecting anything, carefully label each air line connection with wire ties or tape noting its position (e.g., left front, right front, supply, exhaust). Take photographs from multiple angles showing all line routing and electrical connections. The valve block typically has 4 air line connections: supply from compressor, exhaust to atmosphere, left front air spring, and right front air spring.
3. 3

   Disconnect electrical connector
   Locate the electrical connector attached to the valve block solenoid assembly. Press the locking tab and carefully pull the connector straight off the solenoid terminals. Inspect connector terminals for corrosion and clean if necessary. Wrap connector end with a shop rag or plastic bag to prevent contamination.
4. 4

   Disconnect supply air line
   Identify the main supply line from the compressor (typically the largest diameter line). Using the appropriate air line disconnect tool, depress the internal collar while pulling the line straight out from the valve block fitting. You should hear a slight hiss as any residual pressure escapes. Immediately cap or plug the open line and valve block port with plastic caps to prevent contamination.
   ⚠Even after exhausting system pressure, some residual air may remain. Wear safety glasses and keep face away from connection point.
5. 5

   Disconnect left front air spring line
   Locate the air line running to the left front air spring. Use the air line disconnect tool to release the quick-connect fitting at the valve block. Pull the line straight out and cap both the line end and valve block port. Note the line routing for reinstallation.
6. 6

   Disconnect right front air spring line
   Locate the air line running to the right front air spring. Use the air line disconnect tool to release the quick-connect fitting at the valve block. Pull the line straight out and cap both the line end and valve block port. Ensure this line is clearly distinguished from the left side line.
7. 7

   Disconnect exhaust line or filter
   The exhaust port may have a muffler, filter assembly, or direct vent line. Disconnect this line or remove the filter assembly using the air line tool or by removing the threaded filter housing. Cap the valve block exhaust port to prevent dirt entry.
8. 8

   Remove valve block mounting hardware
   Locate the mounting bolts or bracket securing the valve block to the frame or firewall. Mounting bolt count and size depend on the specific aftermarket bracket used; inspect the installation to determine the actual fastener count before removal. Apply penetrating oil if fasteners show corrosion. Using appropriate wrenches or sockets, remove the mounting bolts while supporting the valve block with your other hand. Set hardware aside for reuse or replacement.
9. 9

   Remove valve block assembly
   Carefully withdraw the valve block from its mounting location, ensuring no air lines or wires are still attached. Inspect the mounting bracket and frame mounting surface for corrosion or damage. Clean mounting surfaces with wire brush if corrosion is present.
10. 10

    Inspect and prepare new valve block
    Unpack the new valve block assembly and verify it matches the original configuration. Install new O-rings or seals on all air line ports using a small amount of petroleum jelly for lubrication. If a mounting gasket is required between the valve block and bracket, position it now. Verify all solenoid ports are properly threaded and undamaged.
11. 11

    Install new valve block
    Position the new valve block assembly into the mounting location, aligning mounting holes with frame or bracket. Insert mounting bolts and hand-tighten. Ensure the valve block is oriented correctly with ports facing their respective line connections. Tighten mounting bolts securely, but do not overtighten to avoid cracking the valve block housing.
12. 12

    Reconnect air lines
    Remove caps from air lines and valve block ports. Starting with the supply line from compressor, push each line firmly into its respective quick-connect fitting until you hear or feel a positive click. Verify connection by gently pulling on each line - it should not release. Connect all four lines: compressor supply, left front spring, right front spring, and exhaust, following your labels and photographs.
    ⚠Ensure air lines are fully seated in quick-connect fittings. Partial connection will cause air leaks and system failure.
13. 13

    Reconnect electrical connector
    Remove protective covering from electrical connector. Align connector with solenoid terminals and push firmly until the locking tab clicks into place. Gently tug on connector to verify secure connection.
14. 14

    Reconnect battery and test system
    Lower vehicle from jack stands. Reconnect negative battery cable. Activate the air suspension system per the installed aftermarket kit's instructions. Allow the compressor to charge the system. Listen for air leaks at all connections while system pressurizes. Charge time varies by kit and compressor capacity. Verify both front air springs inflate evenly and vehicle rises to the ride height set for the installation.
    ⚠If system does not charge or air leaks are detected, immediately turn system OFF and recheck all connections.

Reassembly

1. Ensure all air line connections are fully seated and secure before pressurizing system.
2. Verify electrical connector is properly locked onto solenoid terminals.
3. Double-check mounting bolts are tight and valve block is securely mounted.
4. Confirm all caps and plugs have been removed from air lines before system activation.

Verification

• With engine running and air suspension system ON, verify compressor cycles and shuts off after reaching system pressure (typically 90-120 psi).
• Inspect all valve block connections for air leaks by listening closely and applying soapy water solution to each fitting - bubbles indicate leaks.
• Verify both front air springs are inflated equally and vehicle sits at correct ride height with no sagging.
• Turn air suspension switch OFF and ON several times, verifying system responds by exhausting and re-inflating.
• Test drive vehicle at low speed in safe area to confirm proper suspension operation and handling.
• Recheck all connections after test drive for any signs of leakage or loosening.

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