DIY Network

Tricked-Out Suspension: Introduction and Strut Assembly, Part 1 From "Tricked Out" episode DTRK-101

	According to Tricked Out host Andrew Totolos, adding performance mods to your vehicle can be habit forming.
	Andrew's guest in this episode is Andy Williamson, editor of C-16 Magazine. With Andy's help, we add an adjustable suspension to a 1996 Honda Civic hatchback, then take it and the track to let it rip.

In this premiere episode of DIY's Tricked Out host Andrew Totolos and guest auto-expert Andy Williamson take on an automotive upgrade project "from the ground up," adding a performance-suspension package to an essentially stock 1996 Honda Civic hatchback. Andrew shows viewers how to get the horsepower to the ground by changing out the factory suspension with new parts designed for performance and adjustability. Finally, we add some new wheels and tires and put our modifications to the test at a SCCA race.

According to auto-mods specialist Andy Williamson, the suspension should be the first step you think of when deciding how to trick out your vehicle. Increasing your car's power is only advantageous if your suspension can keep pace with the horsepower boost. "If you can't get the power to the ground," says Williamson, "it's worth nothing."

In this first segment, we begin our road-handling modifications with addition of performance shocks, struts and coil-overs.

DIY Difficulty Rating for Repair: This job is fairly straightforward. We gave it a difficulty rating of 2 on a 5-point intermediate-level scale. Experienced gear-heads should have no problem installing these upgrades.

Upgrades in this episode:

Performance coil-over kit
Adjustable shocks
Strut tower bars
17-inch wheels and performance tires

Other materials:

In addition to standard auto-mechanic's tools (wrenches, ratchets, extenders, screwdrivers, nut-drivers, torque wrench, etc.), some of the specialty tools that will be needed for this project include small flat-head screwdriver, cordless drill and 2-1/8 hole saw, spring compressor, a jack and jack-stands. An air-compressor and set of pneumatic tools is optional, but may help speed the assembly process.

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Figure A

Strut Assembly, Part 1

• Before installing the new suspension, measure the height of the ground clearance at the car's factory settings (figure A) at all four corners. Record those measurements for later reference when the car is lowered.

• Before jacking the car and taking the weight off the tires, break the lug nuts loose using a hand wrench. This will make it easier to remove the wheels once the car is lifted onto the jack.

• Safety Alert: Whenever jacking a car up for service or upgrades, always use jack stands. If you're not sure on where to mount the jack stands, call your local service center for help.
  
• The heart of this suspension upgrade is the adjustable coil-over kit. This particular kit (figure B) has a spring rate specifically designed for our Civic.

• By adjusting the threaded perches (figure C), the height of the car can be raised or lowered.

  Figure B

  Figure C

  
  
• The new performance shocks are specifically designed for a lowered car. The dampening -- or resistance to free-suspension travel at each wheel -- is adjustable. On the back shock, the adjustment is made using an external knob (figure D).

• The front shock functions in a similar manner, but has an adjuster at the tip (figure E). The adjustment can be made using a small, flat-head screwdriver.

  Figure D

  Figure E

  
  

  Figure F

• Tricked Out Tip: With adjustable dampening, you can soften your ride for daily driving, then dial 'em up for enhanced performance for track use.

• Jack the car high enough so that the wheels are well clear of the ground, but make sure it's low enough so that you can easily access the strut-tower bolts (figure F)
  
• Once the front wheels are removed and the car is secured in position, you can begin work on the front strut. The first bolt removed is the one that secures the lower part of the strut to the factory suspension piece (figure G) -- a.k.a., "the dog bone."

• Use a 14-mm socket to remove the upper pinch bolt (figure H).

  Figure G

  Figure H

  
  
• Next, remove the lower securing nut and bolt to disconnect the strut from the lower control arm (figure I).

• In the engine bay, you'll next need to remove the two bolts holding the top of the factory strut (figure J).

  Important: As you loosen the bolts, it's a good idea to have an assistant holding the strut so that it doesn't fall to the ground once it's released.

  Figure I

  Figure J

  
  

  As you loosen the bolts, it's a good idea to have an assistant holding the strut so that it doesn't fall to the ground once it's released.

Important: Included in this segment 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 repair-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.

Safety Alert: Always wear eye protection, and follow proper safety precautions, when working with power tools or pneumatic tools.

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

Honda & Acura Performance Handbook (Performance Handbooks)
Author: Mike Ancas
Order this title from Amazon.com.
June, 1999
Publisher: Motorbooks International
ISBN: 0760306699

Honda/Acura Engine Performance: How to Modify D, B and H Series Honda/Acura Engines for Street and Drag Racing Performance
Author: Mike Kojima
Order this title from Amazon.com.
April 2002
Publisher: HP Books
ISBN: 155788384X

Honda/Acura Performance Handbook: High Performance Modifications for Street and Drag Racing Applications
by the editors of Sport Compact Car Magazine
Order this title from Amazon.com.
November 1999
Publisher: HP Books
ISBN: 1557883246