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Air Lift 78604 Installation Manual

Mini cooper r50/52/53, rear application
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Kit 78604
MINI Cooper R50/52/53
Rear Application
INSTALLATION GUIDE
SEE PAGE 12 FOR IMPORTANT
INFORMATION ABOUT SLEEVE-STYLE
INSTALLATION GUIDE
DAMPERS BEFORE INSTALLATION.
For maximum effectiveness and safety,
please read these instructions completely
before proceeding with installation.
Failure to read these instructions can result in an
incorrect installation.

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Summary of Contents for Air Lift 78604

  • Page 1 Kit 78604 MINI Cooper R50/52/53 Rear Application INSTALLATION GUIDE SEE PAGE 12 FOR IMPORTANT INFORMATION ABOUT SLEEVE-STYLE INSTALLATION GUIDE DAMPERS BEFORE INSTALLATION. For maximum effectiveness and safety, please read these instructions completely before proceeding with installation. Failure to read these instructions can result in an...
  • Page 2 Air Lift Performance MN-895...

  • Page 3: Table Of Contents

    Air Lift Performance TABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Notation Explanation .

  • Page 4: Introduction

    Air Lift Performance reserves the right to make changes and improvements to its products and publications at any time . For the latest version of this manual, contact Air Lift Performance at (800) 248-0892 or visit our website at www .airliftperformance .com .

  • Page 5: Installation Diagram

    Spanner Wrench ......... 1 Missing or damaged parts? Call Air Lift customer STOP! service at (800) 248-0892 for a replacement part .

  • Page 6: Installing The Air Suspension

    Air Lift Performance Installing the Air Suspension PREPARING THE VEHICLE 1 . Elevate and support the vehicle from approved lifting points . 2 . Remove the rear wheels (Fig . 2) . fig. 2 REMOVING THE STOCK SUSPENSION 1 . Unclip the sensor wire and brake line from the shock . (Fig . 3) .

  • Page 7: Air Suspension Installation

    Air Lift Performance 3 . Remove the two upper mount bolts and remove the shock assembly from the vehicle . (Figs . 5-7) . fig. 5 fig. 6 fig. 7 AIR SUSPENSION INSTALLATION 1 . To add the flexible damping adjuster extension (required to adjust damping without removing shocks), place the extension over the adjuster knob and lock in place by tightening the side set screw with a 2mm hex key (Fig .
  • Page 8 Air Lift Performance 2 . If running the flexible damping adjusters, remove the plastic side walls within the storage compartment and move the electrical wires away from the chassis rail (Figs . 9 and 10) . Drill a 5/16” hole toward the front of the vehicle, 1/2” off center from the upper mount pocket (Figs .
  • Page 9 Air Lift Performance 4 . Remove flexible adjuster knob and route flexible adjuster extension through the previously drilled hole and attach the upper mount bracket to the chassis with the previously removed bolts (Figs. 14-16). Torque to 56 Nm (41 ft-lbs.).
  • Page 10 Air Lift Performance 6 . Spin the red locking collar against the lower eye mount . Tighten collar 1/4 turn beyond hand tight (Fig . 19) . fig. 19 Clip the sensor wire and brake line back into the attaching points on the shock (Fig . 20) .

  • Page 11: Damping Adjustment

    Air Lift Performance 11 . Cycle the suspension to Max Extension and record the measurement from the same reference points . 12 . Add ME and MC then divide by 2 . Set the suspension to this point . This position will give 50% stroke in either direction and is a starting point for ride height (Fig .

  • Page 12: Adjusting Extended Or Drop Height Using Lower Mount

    Air Lift Performance ADJUSTING EXTENDED OR DROP HEIGHT USING LOWER MOUNT Your struts have been pre-set at the factory to provide maximum drop height while maintaining adequate tire clearance to the air spring. If you wish to gain more extended height (lift),...
  • Page 13 Air Lift Performance WHEN ADJUSTING HEIGHT UPWARDS, MAKE SURE THAT THE STRUT BODY CAUTION ENGAGES ALL THE THREADS OF THE LOWER MOUNT (FIG . 27) . WHEN ADJUSTING DOWNWARDS, MAKE SURE THERE IS ADEQUATE AIR SPRING CLEARANCE TO THE TIRE/WHEEL ASSEMBLY . CLEARANCE MUST BE CHECKED WITH SYSTEM FULLY DEFLATED AS WELL AS FULLY INFLATED TO ENSURE THAT NO RUBBING OCCURS .
  • Page 14 Air Lift Performance AFTER INITIAL INSTALLATION OF YOUR STRUTS/SHOCKS: CAUTION • DO NOT CYCLE THE SUSPENSION WITH THE AIR-LINE CONNECTED TO THE LEADER HOSE WITHOUT FIRST ADDING AIR SPRING PRESSURE. DOING SO MAY CAUSE THE AIR SPRING TO IMPROPERLY INFLATE (FIG. 20). IT IS SAFE TO CYCLE THE SUSPENSION TO CHECK FOR CLEARANCES ETC.

  • Page 15: Before Operating

    2. Inflate the air springs to 75-90 PSI and check all connections for leaks. 3 . An Air Lift air management system such as 3H/3P is highly recommended for this product . 4 . Please familiarize yourself further with this product by reading the Product Use, Maintenance and Servicing section .

  • Page 16: Product Use, Maintenance And Servicing

    If the preceding steps do not solve the problem, it is possibly caused by a failed air spring — either a factory defect or an operating problem . Please call Air Lift at (800) 248-0892 for assistance . Frequently Asked Questions Q .

  • Page 17: Tuning The Air Pressure

    If the vehicle has a rough or harsh ride it may be due to either too much pressure or not enough . Try different pressures to determine the best ride comfort . See Air Lift suggested driving air pressure .

  • Page 18: Limited Warranty And Return Policy

    . Air Lift Company’s maximum liability shall not in any case exceed the purchase price paid by you for the Air Lift product . Please note that some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you.

  • Page 19: Replacement Part Information

    Air Lift Performance Replacement Part Information If replacement parts are needed, contact the local dealer or call Air Lift customer service at (800) 248-0892 . Most parts are immediately available and can be shipped the same day . Contact Air Lift Company customer service at (800) 248-0892 first if: •...
  • Page 20 Thank you for purchasing Air Lift Performance products! Air Lift Performance • 2727 Snow Road • Lansing, MI 48917 or PO Box 80167 • Lansing, MI 48908-0167 Toll Free (800) 248-0892 • Local (517) 322-2144 • Fax (517) 322-0240 • www .airliftperformance .com...

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78641

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