DIY Network

Suspension-Dampening Controller: Completing the Servo Wiring From "Tricked Out" episode DTRK-205

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In this episode of Tricked Out, host Andrew Totolos installs a remote suspension dampening controller (EDFC system) to upgrade the coil-over suspension on a Ford Focus SVT. In this third phase of the project, Andrew installs the rear servo motors, the control unit in passenger compartment and runs the wiring for the system.

Materials used in this project:

In addition to standard auto-mechanic's tools (wrenches, ratchets, extenders, screwdrivers, nut-drivers, torque wrench, etc.), tools and materials used in this episode include:

EDFC kit
Panel removal tool
Pliers
Allen wrench
8mm spanner wrench, from kit
Rubbing alcohol and towels
12-volt tester
Fuses and taps
Crimpers
Grabber tool
Panel removal tool
Industrial strength hook-and-loop tape
Electrical tape
Wire ties

DIY Difficulty Rating for This Project: We gave this a difficulty rating of 3 on a 5-point intermediate-level scale.

Important: As a standard safety precaution, it's a good idea to always disconnect the vehicle's negative battery cable before you begin work on any electrical or mechanical components.

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Wiring the Servo Units

With the servo units and control unit installed on the Focus, and the module wired to the appropriate fuses, it’s time to connect the wiring from the dampers at each corner of the control unit under the dash.

• To get from the strut towers to the control panel inside the car requires pulling off the front wheel and running the wires through the fender well (figure A).

• Once the wheel is off, remove the panel screws, panel clips and fender screws that secure the fender liner and carefully pull it out.

• Inside the car, use a panel tool to remove the trim piece in the passenger’s foot well. Work your fingers underneath the door sill and pop it off from front to back (figure B).

  Figure A

  Figure B

  
  

• In the fender well, pull out the large grommet between the well and the passenger compartment. Hold it with pliers, and cut a small slit in it for the EDFC wires to pass through (figure C).

• A wire grabber tool will help bring the wires through the grommet (figure D). If you’re working alone, try using this mechanic’s trick to get the job done. Once the grabber is in position, push in the plunger to open the jaws, and use vice grips to hold them open.

  Figure C

  Figure D

  
  

• Position the wires in between the jaws from inside the car, and then hop back out to release the grip. Wrap tape around the wires to tighten the loop.

• Pull the tool with the wires back through to the fender well (figure E), pulling as much slack through as possible.

• Feed the wires through the grommet one at a time, and reinsert the grommet into the fender well.

• Next, push the wiring from the fender well into the engine compartment (figure F).

  Figure E

  Figure F

  
  

• Hook up the passenger side motor (figure G), and route the driver’s side control-cable along the firewall to the other side and plug it in.

• Wire-tie the cables at each motor and at the firewall for a clean installation and added protection (figure H).

  Figure G

  Figure H

  
  

• Now it’s time to run the rear set of wires. Attach one of the rear cables to the driver’s side motor, being sure to leave plenty of slack at the motor end (figure I).

• Then run that wire down the side of the car and under the back of the rear seat to cross over to the passenger side.

• Connect the other cable to the passenger side motor in the same manner and run the wires under the back seat towards the passenger side door sill.

• Tuck the two wires together under the rear trim panel on the passenger side and under the carpet along the door sill (figure J).

  Figure I

  Figure J

  
  

• Once all the wires are routed properly, make the connections behind the glove box (figure K).

• The plugs are different for the front and rear motors, so you’ll be sure to make the right connections. Once everything is connected, use wire ties to straighten out the mess.

• Reinstall the trim panels and glove compartment to complete the project (figure L).

  Figure K

  Figure L

  
  

Important: Included in this summary are the steps in this automotive procedure as shown in the episode. These steps are general guidelines that are applicable to most vehicles. With any particular vehicle, there may be procedures, specifications, settings, tolerances, components, etc. that are specific to that vehicle. There are also variations according to the type and brand of upgrade-kit you select. Always consult your vehicle's service manual when undertaking significant automotive repairs, and read and follow the manufacturer's directions and precautions that come with your kit or replacement parts.

RESOURCES :

Sport Compact Bolt-On Performance Guide: Import Cars (Sport Compact Bolt-On Performance Guides)
Author: Joe Pettitt
Order this book from Amazon.com.
Voyageur Press (October 2000)
ISBN: 1884089526

TEIN USA, Inc.
Website: www.tein.com