DIY Network

Suspension-Damping Controller: Rear Servos and Control Module From "Tricked Out" episode DTRK-205

NOTE: Images on this page may be enlarged for enhanced viewing simply by clicking on them.

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 second phase of the project, Andrew installs the rear servo motors, the control unit in the 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
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. For the initial steps in this project, however, you'll need to leave the battery connected to locate the proper circuits using a volt-meter. The instructions below indicate when the battery cable should be disconnected.

advertisement

	Figure A
	Figure B

Now that the front motors of the EDFC have been installed, it’s time to move to the rear of the car. Once the rear motors are in place, wiring of the system can begin. Andrew also installs the control unit inside the car, underneath the dash, using hook-and-loop tape.

Installing the Rear Servo Motors

In the previous phase of this project, Andrew installed the EDFC servo motors on the front shocks. The installation of the rear servo motors is essentially the same as. The only difference is that the rear strut adjustment knobs are underneath some trim.

• Pull the panels loose from each side of the cargo compartment to access the adjusters on top of the damper shafts. In the Focus, you’ll also have to pop out the cargo area light from the driver’s side to get the panel out of the way.

• Once you get to the struts, the procedure is the same as the front. Remove the manual adjustment knob (figure A).

• Replace the inner screw,.

• Secure the motor to the piston shaft (figure B).

Figure C

Mounting the Control Module

When installing the control panel in your car, be careful not to mount it in direct sunlight, in a heater vent or anywhere it will be exposed to extreme heat or moisture. A good place for installation might be at the bottom of the center console. Since the bottom of the dash on the Focus is curved and the bracket is flat, we simply popped the mounting bracket off the control unit and did a little creative bending to ensure a good fit.

• Clean both surfaces thoroughly with rubbing alcohol and attach a strip of industrial strength hook-and-loop tape to the bracket.

• Peel off the other backing and stick the controller to the dash in the desired position (figure C).
  

  Figure D

There are only a few wires that supply power to the unit. The yellow wire is a constant power line. Maintaining constant power to the unit ensures that it retains its memory when the car's power is turned off. The yellow wire gets attached to a circuit that stays on when the ignition switch is off. The red wire gets connected to a switched 12-volt line that only gets power when the key is on. The green wire is hooked into the parking-light wiring so that, when you turn your lights on at night, the controller’s display lights up with your dash. The black wire is the ground. You’ll find all the circuitry you need to connect the unit under the driver’s side dash.

• Remove the four bolts that hold the access panel under the steering column.
  

• Connect a 12-volt multi-meter to a ground point and locate a fuse that shows power with the ignition key turned off (figure D).
  

  	Figure E
  	Figure F

• Attach the yellow wire to a quality fuse tap, being sure to crimp the connection securely.

• Remove the old fuse, then insert the fuses into the tap, and plug the new fuse tap into the panel (figure E).

• Next, find a fuse that only shows power when the ignition switch is on.

• Attach a fuse tap to the red lead from the controller harness and install that into the panel as well (figure F).

• For the last tap, the parking light fuse is usually a good match for the illumination lead. If it’s not labeled, you can turn the parking lights on and off to find it.

  Important: Once all of the proper electrical connections have been identified, disconnect the vehicle's negative battery cable before going further with this project.
  

  	Figure G
  	Figure H

• To complete the power harness connections, find a good ground screw and attach the black wire to it using the eyelet terminal on the end.

• Once all the wires are connected use wire ties to route the new harness over to the control panel, then tuck it away neatly (figure G).

• Reinstall the access panel.

• Since hook-and-loop tape was used to attach the control panel, it’s easy to pop it off and get a good look at the connections at the rear of the unit. The power harness plugs into the center port, and the module extensions go into either side (figure H). Go ahead and connect the extensions to the control unit and route them to the area behind the glove compartment where they can meet up with the individual wires from the dampers later.

• Remove the three bolts from under the glove compartment and work it free. Route the two extensions together to the side panel, and the control unit is ready to go.
  

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 similar 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