Shock Absorber for MINI COUNTRYMAN S2000 TPX44 MNRXL0X Owner s and Service Manual
Öhlins Racing AB - The Story World Championships and other major world titles are definitive proof that Öhlins shock absorbers offer outstanding performance and reliability. Every product has gone through rigorous testing and engineers have spent thousands of hours, doing their very best to use every possible experience from our 30 years within the racing sport. By installing this shock absorber on your vehicle you have made a clear statement you are a serious driver with a focus on getting the maximal handling ability and outstanding feedback from your vehicle. Along comes the fact that your shock absorber will be a long lasting friend, delivering the very best of comfort and performance every time you go for a drive. Go explore! It was the 1970 s, a young man named Kenth Öhlin spent most of his spare time pursuing his favourite sport: motocross. A careful observer, Kenth s attention was continually drawn to one specific detail - motocross bikes had more engine power than their suspension could handle. It was not long before Kenth realised that better performance could be achieved by improved wheel suspension. Öhlins Racing was established in 1976, and just two years later the company won its first World Championship title. Despite being in the business for 30 years, the search for perfection and new functions is still the main focus of the company. Congratulations! You are now the owner of an Öhlins Shock Absorber. More than three hundred In This Manual Safety Precautions Design and Functioning Compression and Rebound Adjust Rebound Adjust Compression Adjustment and Setting Up Inspection and Maintenance General Service - McPherson Strut Tools Workshop Service Interval Page 2 3 4 5 5 6 7 8 8 9 14 1
Safety Precautions Safety Symbols The shock absorber is a very important part of the vehicle and will affect the stability. In this manual, mounting instructions and other technical documents, important information concerning safety is distinguished by the following symbols: Read and make sure that you understand the information in this manual before you use this product. If you have any questions regarding installation or maintenance please contact an authorized Öhlins Service Centre. The Safety Alert Symbol means: Warning! Your safety is involved. Warning! Warning! The Warning Symbol means: Failure to follow warning instructions can result in severe or fatal injury to anyone working with, inspecting or using the shock absorber, or to bystanders. Öhlins Racing AB can not be held responsible for any damage to the shock absorber, vehicle, other property or injury to persons, if the instructions for maintenance are not followed exactly. Warning! Caution! This product was developed and designed exclusively for a specific vehicle model and shall only be installed on the intended vehicle model in its original condition as delivered from the vehicle manufacturer. The Caution Symbol means: Special precautions must be taken to avoid damage to the shock absorber. The Note Symbol indicates information that is important regarding procedures. Warning! This product contains pressurized nitrogen gas (N2). Do not open, service or modify this product without proper education (authorized Öhlins dealer/distributor) and proper tools. When working on this product, always consult your Vehicle Service Manual. Warning! After installing this product, take a test drive at low speed to make sure that your vehicle has maintained its stability. This Manual shall be considered a part of the product and shall therefore accompany the product throughout its life cycle. Warning! If the suspension makes an abnormal noise, or the function is irregular, or if you notice any leakage from the product, stop the vehicle immediately and return the product to an Öhlins Service Centre. Öhlins Racing AB. All rights reserved. Any reprinting or unauthorized use without the written permission of Öhlins Racing AB is prohibited. Printed in Sweden. 2
Design and Functioning Congratulations on choosing the Öhlins TPX44 Rally shock absorber - the most unique and powerful shock absorber available today. The TPX44 is a three way adjusted; high and low speed compression adjuster and a rebound adjuster, twin piston type shock absorber. It is equipped with the new updated Progressive Damping System (PDS). The TPX44 shock absorber design is the culmination of two decades of Öhlins successful participation in World Championship events. The TPX44 shock absorber is designed to handle the demanding damping characteristics needed for all types of roads on which the car is aimed to compete on. The TPX44 for the MINI is designed in cooperation with Prodrive and the result is probably the lightest but strongest Mcpherson strut ever made for a rally application. For best performance, the shock absorber must be adjusted to different conditions; from the smooth and fast roads seen in some rallies to the more bumpy and rocky seen in others. The Öhlins TPX44 features patent pending concept with a unique design, that allows for the gas pressure to always back-up the low-pressure side of the piston to keep pressure at a controlled level. This concept enables totally separated adjusters for compression and rebound damping. The temperature stability is maintained with a flow restriction design in the bleed valves that creates a turbulent flow at very low piston velocities. Also, materials with different thermal expansion rates are used to compensate for the viscosity change of the fluid caused by changes in temperature. The Öhlins shim system offers infinite combinations of shim stacks with a wide spectrum of different character using only one piston. The whole system is pressurized by nitrogen gas behind a floating piston to ensure separation of gas and fluid. The Öhlins TPX44 shock absorber is a racer friendly shock absorber, easy to set up, dial in and rebuild. Support is always available from Prodrive and the Öhlins distributors worldwide. 3
compression and rebound Rebound Damping Adjuster Rebound adjuster affects chassis movement in a similar way as the low speed compression but has even more influence on traction. Use this adjuster to control chassis movements over crests or after jumps. More rebound gives less movement and better stability but too much will cause a loss of traction. It is therefore a powerful balance tool together with the low speed compression adjuster. For slippery conditions when grip levels are low, a softer set up on both rebound and low speed compression is a way to gain more traction. Compression damping controls the energy absorption when the shock absorber is being compressed, thus controls how easy the shock absorber compresses when you hit a bump. Rebound damping controls the energy absorption when the shock absorber is being extended and controls how fast the shock absorber returns to its normal position after being compressed. Compression Damping Adjuster Low speed compression is mainly used to control chassis movements and response but it also affects the traction. It affects how the car behaves during breaking, turn in and acceleration. Less low speed compression gives more chassis movement but in many cases it can improve traction and grip. Therefore it is possible to balance the car by adjusting the low speed compression. High speed compression mainly affects how the car absorbs bumps and jumps. In rougher conditions or with a lot of jumps more high speed damping is often necessary to control the big chassis movements. 4
Compression and Rebound Adjust Rebound To adjust: Use 01822-03 adjustment tool delivered with the product. 1. Turn the adjuster clockwise to fully closed position (position zero [0]). 2. Turn counter clockwise to set the adjuster to recommended number of clicks. If you want to change setting, adjust in steps of 2-3 clicks at a time. Useful adjustment range 2 5-45 clicks Caution! 1 Do not use force, delicate sealing surfaces can be damaged. Handtighten only. Adjust Compression To adjust: High speed compression adjuster; Use a 12 mm wrench Low speed compression adjuster; Use a 3 mm Allen key 1. Turn the adjuster clockwise to fully closed position (position zero [0]). 2. Turn counter clockwise to set the adjuster to recommended number of clicks. High speed compression adjuster 1 2 If you want to change setting, High speed compression; adjust in steps of 3-5 clicks to fine tune the set up. Low speed compression; adjust in steps of 2-3 clicks at a time. Useful adjustment range Low speed High speed Low speed compression adjuster 2-40 clicks 0-50 clicks 1 Caution! Do not use force, delicate sealing surfaces can be damaged. Handtighten only. 2 5
adjustment and setting up Making adjustments Suspension settings depend on your vehicle s weight, your driving style, road conditions etc. If you are not happy with our recommended settings, here are a few guidelines and ground rules how to make adjustments. To make improvements, it is important to understand the function of the shock absorbers and through testing learn how they affect the handling of your vehicle. We recommend to try keeping damper clicks around the recommended set up. If you need to make changes, we recommend to explore the alternative set up options as well as keeping damping levels low to gain maximum grip. For example; bottoming problems, a couple of clicks stiffer high speed compression together with 5mm higher ride height probably gives a better end result compared to solving everything by changing damper clicks. Always start with the settings recommended by Prodrive. There are different settings available to suit all different conditions. If you need support to find your own optimal set-up, please contact Prodrive or an authorized Öhlins Service Centre. Setting up your vehicle After installing the dampers, do a complete set up check of the car according to Prodrive set up recommendations. Perform the following steps and always take notes before using the shock absorber; 1. Check ride height, front and rear. Adjust if necessary. 2. Check corner weight, front and rear (if scales are available). Adjust if necessary. Higher click numbers give less damping force. Always consult Prodrive or Öhlins Service Centre if you have any questions regarding settings of the shock absorber/strut. When making adjustments Take notes, make the adjustments in small steps (2-3 at a time) and stay within the recommended adjustment range. When you think you have made an improvement, go back to what you started with and double check to be sure. Pay attention to changes in conditions like tires or temperature, etc. In general, compression damping changes should be used to influence the vehicle s response and balance while rebound damping changes should be used to influence traction and stability. 6
inspection and maintenance Preventive maintenance and regular inspection reduces the risk of functional disturbance. If there is any need for additional service, please contact Prodrive or an authorized Öhlins Service Centre. Cleaning Clean the shock absorber externally with a soft detergent. Use compressed air. Be careful that all dirt is removed. Keep the shock absorber clean and spray it with oil (WD40, CRC 5-56 or equivalent) after washing. Wipe off excessive oil with a cloth. For top mount or spring seat service please contact Prodrive. Caution! Never spray water directly into the adjuster knobs and/or seals and scraper. Inspection points TPX - Normal use Check that the scraper sits in its position, has the pre load spring around the scraper lip and that it is not damaged. Check the external reservoir for damage that can restrict the floating piston from moving freely. Check the shock absorber body for external damage. Check the attachment of the shock absorber to the vehicle. 7
service - mcpherson strut Inspection points TPX44 - Every 400 km (McPherson Strut) We recommend to change the bushing lubrication oil in the strut casings and clean the scraper/seal every 400km. This will ensure that the friction levels are kept at a minimum and will also prolong the lives of the bushings and the strut casing. Tools Part No Tool Description 00146-01 Assembly lubricant - Red grease 01804-23 Mounting sleeve 01804-24 Seal remover tool 01804-21 Bushing removal tool 01804-22 Bushing removal tool 01804-20 Seal mount tool Vice with soft jaws Heat gun Loctite Although this manual includes the most up-to-date information available at the time of printing, minor updates may occur. To find the latest information regarding wear parts and part numbers please contact Prodrive. 8
service - mcpherson strut 1 - Cleaning 1 1.1 Remove the Nuts (8x) 1.2 Pour out all oil. 2 1. 3 Remove the Strut casing. 1. 4 Clean the Damper and Lower bushing from oil. Use soft detergent. Inspect the Lower bushing for wear or damages, replace if necessary. 1. 5 Clean the Strut casing. Use soft detergent. Be careful around the Scraper and Seal. Inspect the Upper bushing. If the Bushing, Scraper or Seal are worn, replace. To replace Bushing, Scraper and/or Seal. Go to Chapter 2. 3 1. 6 Check the O-ring on the Reservoir bracket. Replace if damaged. 5 1. 7 Use tool 01804-23. Mount the Strut casing on the Damper. 4 1. 8 Pour 40ml oil in the Strut casing. 7 6 Only use Öhlins High Performance fluid. 1. 9 Tighten the 8 Nuts. Tightening torque 10Nm Tighten in cross pattern. 8 9 9
service - mcpherson strut 2 - Replace Upper Bushing, Scraper and/or Seal 2.1 Remove the Scraper. First use a large screwdriver to loosen the Scraper from the Strut casing. Then, use a small screwdriver to remove the Scraper. 1 2.2 Remove the Circlip. 2.3 Mount tool 01804-24 around the Strut casing. We recommend to grind off the sharp edges of the screwdriver. Use a large screwdriver and pull out the Seal. 2 2.4 Remove the Bushing holder. If you can not remove the bushing holder by hand, use appropriate tool and gently tap it out from the bottom of the strut casing. 2.5 Use a heat gun. Heat the Bushing holder. 3 2.6 Mount tool 01804-21 on top of the Bushing holder. Mount tool 01804-21 with the Bushing holder on tool 01804-22. 4 6 10 5
service - mcpherson strut 2.7 Mount the whole unit in a vice. Press until the Bushing comes out. 7 2.8 Replace the Bushing. 2.9 Put tool 01804-21 on the Bushing. Put the tool and the Bushing on top of the Bushing holder. 2.10 Mount the whole unit in a vice. Press the Bushing into the Bushing holder. 2.11 Mount the Bushing holder into the Strut casing. If you notice any play between the Bushing holder and the Strut casing, use Loctite 603. 9 10 2.12 Use tool 01804-23. Mount the Strut casing on the Damper. Tighten two [2] of the lower Nuts. 11 12 11
service - mcpherson strut 2.13 Mount the Seal. Use tool 01804-20. Use assembly lubricant on the outer diameter of the Seal and a layer between the Seal lips. Mount the Seal by hitting it hard with the tool until the groove for the Circlip is visible. 13 14 2.14 Mount the Circlip. 2.15 Use tool 01840-23. Mount the Scraper. Put a layer of assembly lubricant below the Scraper lip and on the upper part (ca 50mm) of the Chrome tube. Use tool 01804-20 to hit the Scraper in place. 2.16 Remove the two [2] lower Nuts. 15 12
service - mcpherson strut 2.17 Check the O-ring on the Reservoir bracket. Replace if damaged. 2.18 Pour 40ml oil in the Strut casing. 17 Only use Öhlins High Performance fluid. 2.19 Tighten the 8 Nuts. Tightening torque 10Nm Tighten in cross pattern. 18 19 13
inspection and maintenance Service Interval Every 800-1000km Service your damper(s) at an authorized Öhlins Service Centre. If the dampers are used under rough conditions, maintenance is required more frequently. Warning! Never alter the gas pressure. Special purpose charging equipment and access to nitrogen is required. The gas pressure should normally never be altered. 14
Öhlins Owner s Manual MNRXL0X Part No. 07440-05_0 Issued 2011-05-17 2011 Öhlins Racing AB Your Öhlins retailer: Öhlins Racing AB Box 722 SE-194 27, Upplands Väsby Sweden Phone: +46 (0)8 590 025 00 Fax: +46 (0)8 590 025 80 www.ohlins.com