Onboard air has become an essential part of any off-road vehicle. Onboard air allows you to run air tools and more importantly, fill up your tires after an off-road trip. Some time ago, we received an OnboardAir kit from Brad Kilby at Kilby Enterprises for our Project TJ. Before installing the new kit, we first had to make a decision on where to buy a compressor. Brad sells them new on his web site (www.onboardair.com) for about $295. That was a little steep for our pocket book, so we opted for the used compressor. One bright, blissful Saturday morning, we headed down to the local Pick-a-Part in the stunning San Fernando Valley to find a donor vehicle. Once there, the search for a good compressor was on the way. There are several vehicles that carry the compressor needed for the project (visit onboardair.com for list of vehicles), but we found that Volvo's make good donors! After finding the Volvo of choice, we removed the compressor. Now, there are two choices to make at this point. Since you are removing this compressor from a used Volvo that has been sitting for who knows how long, it is important to know that it's going to work. Here are a couple of different test methods that you can utilize:
1. Find a vehicle that has a good battery and test to see if the clutch engages.
2. Pay for the compressor; take it back to the casa and pray that it works.
We opted for method #1. After testing the compressor, we purchased it for $20. All it needed now was a little time spent cleaning it up.
Installation
The first thing you need to do is to remove the factory air cleaner. Once the air cleaner has been removed, you then need to take a saw and cut the air intake pipe so you can fit a new air cleaner. (K&N air cleaners work perfectly here). We used a K&N filter that we snagged from the JeepTrix garage. Once the air cleaner is installed, you can then install the brackets from the Kilby kit.
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(For Jeeps with AC)
Remove the factory bolts from the factory air conditioning and install the Kilby brackets using the existing bolts. Once the brackets are in place, take the serpentine belt off and remove the pulley from the alternator. (If you don't have power tools or air compressor, we recommend taking it down to your local auto mechanic shop - they will usually do this for free). Then install the new pulley that comes with Kilby's kit. Reinstall the alternator and then the York compressor.
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Before you install the compressor, it is important to check the oil level in the York compressor or you will burn it up! Again, you can check out Brad's site www.onboardair.com for information about oil levels. Brad also sells a dipstick for the York compressors for $5. We grabbed our newly acquired York compressor and bolted it to the brackets, sliding the new belt onto the pulley and then tightening both the belt and the compressor. Now, it was time to see how this bad boy really worked. We started up the Jeep and hooked up the power wire to the battery. The clutch then engaged and the compressor was pumping air. The only problem that we noticed was that the compressor was very noisy! We decided to just live with it - well, that is, - until everyone started questioning why the TJ's engine sounded so bad!
Tired of the noisy compressor, we unbolted it and tossed it in the trash (hey, it only cost $20). We then had to return to our favorite treasure yard to find another donor vehicle. Once again we found a Volvo with the compressor that we needed. This time though, we opted for method #2 above! MISTAKE! We trekked the 2nd York home, and again, spent the time cleaning it up, checking the oil, and then installed it.
Plumbing for Air
Plumbing is the fun part! Not having done any air plumbing before, we knew it was going to be an adventure. We had originally purchased a small tank from Currie Enterprises because we planned on using it to just fill up tires and also because it fit so conveniently in the well right next to the brake boost. With the tank installed, we made a list of all the fittings we thought that we would need, and headed down to the local hardware store. After purchasing all the fittings, we began plumbing the vehicle and of course, didn't get all the appropriate fittings - T's, etc... So, after 4 different trips to the hardware store we finally had it all completed and it was time to test. We fired up the Jeep and powered on the compressor. At first test, the clutch engaged but the pulley did not spin (but the belt sure was screaming!). We turned the compressor off and then tampered with it a little and finally got the clutch wheel to spin while engaged. Starting up the Jeep once again, we watched the TJ's pressure gauge and noticed that the tank was not filling up very fast??? So we revved the engine slightly and noticed that the pressure began to build. It was finally working...and then...BANG, CLUNK, CLUNK, CLUNK. We shut everything down as fast as possible and then checked out the compressor. This is what we found.
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One of the pistons had seized and blown right out through the block! (And yes, there was oil in the compressor). How cool was that!! Of course, we didn't really get to test any of our fresh plumbing.
Final Touch
So, we had to run down to Pick-a-Part again. This time the wife chose the donor vehicle (another...gulp...Volvo) and yes...she removed the compressor. Of course, by this time we doubted if we should get another Volvo compressor. This time however, we purchased the 30-day warranty that they sell with their parts, and it still only cost $35. We brought the 3rd compressor home and once again, cleaned it, checked the oil, and then installed it. Once installed, we started the Jeep up and fired the York up and it worked perfectly! It's like they say, "Third times a charm". So now we are able to fill up our tires just as fast as we can air them down!
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Price List
Kilby Onboard Kit - $200
(3) York Compressors- $75
Air Fittings- $50
Air/Oil Filter- $25
8' Air Hose- $8
Air Filter (Kilby Ent.)- $20
Pressure Switch (Kilby)- $20
Rubber Cover (Kilby)- $5
Watching a compressor blow up- $ PRICELESS $
Kilby Enterprises
1847 N. Keystone St.
Burbank, Ca. 91504
Phone 818-848-2900
Fax 818-848-2974