"How To" Broken DSI Clip Fix - Ford Focus Forum, Ford Focus ST Forum, Ford Focus RS Forum
Ford Focus Forum
HomeContact UsAbout UsGalleryDiscussion ForumsMarketplace


Go Back   Ford Focus Forum, Ford Focus ST Forum, Ford Focus RS Forum > Ford Focus SVT > SVT Performance (2002-2004)

SVT Performance (2002-2004) The place to chat about any 2.0L SVT DOHC Zetec engine performance, tuning and exhaust related upgrades.

Search This Forum | Image Search | Advanced Search    
Ford Focus Tire & Wheels FocusFanatics Merchandise

Reply
 
Thread Tools Display Modes
Old 08-13-2005, 10:33 PM   #1
..:: sleestak ::..
on thin air
 
..:: sleestak ::..'s Avatar
 
Join Date: Apr 2005
Fan#: 22528
Location: The Lou, MO
What I Drive: 04 Forester XTi

Posts: 3,612
Points 14,456, Level 78
Points: 14,456, Level: 78 Points: 14,456, Level: 78 Points: 14,456, Level: 78
Level Up 2% Completed
Level up: 2% Level up: 2% Level up: 2%
Forum Activity 0%
Activity: 0% Activity: 0% Activity: 0%
FF Reputation: 80 ..:: sleestak ::.. Excellent Standing Member
Buy-Sell-Trade Rating: (15)
Post :: Fix Dat Busted DSI Clip ::

Introduction:
Okay, so I have just fallen victim to the infamous busted DSI Clip. The part costs $9 bucks and wont be available till Sept...mine is on order. Other than that, you can buy a whole new $260 manifold to get the $9 part. Ummm...no.

Thanks to a post from FORDSVTPARTS, I got some direction on how to fix this...but it had no pics. So with camera in hand I did the job to keep me happy till the new part shows up. (oh yeah, this is my first post of a new thread, and a how-to...go easy on me)..oh yeah, and my server is seeing a lot of traffic these days...so if all 7 img's dont show up, refresh.


Lets Go!

First thing is first....grab your tools and take out your intake. If it is stock, you will need to take the entire box out...open it up, take out the filter, unbolt it from the car and pull it up out. You may also want to take the MAF off the side of the box as well to help keep it out of your way.

Amongst a set of sockets and a screw driver or two, you will also need a dremmel or drill, a set of pliers/vice grips/vice.....I used a pair of needle nose pliers.



Once you have that outta the way, stand on the drivers side and look down in at the side of your manifold, right around where the Throttle Body sits...you should see the DSI "Actuator" and a dangling cable w/clip.

See how that cheap crap broke?
You should see a dot at the top of the actuator, where the post once was....the clip snaps onto the actuator right there.

Here is a pic of the broken post...I popped this out of the clip on the end of the cable using a flathead screwdriver:


and this little gem will be it's replacement:

check that it is the same thickness on the post.

Now grab that screw with a pair of pliers/vice grips/vice and grind it down with a dremmel so that the head of the screw matches the same diameter and thickness of the posts head....go a little at a time and check to make sure it fits snug, not loosely, into the clip.

Here is my grind on the screw head...I also cut it shorter so it didnt hang out too far from the side of the actuator:


If you dont have a dremmel, you should really buy one..they rule. But you can put the screw into a drill chuck and use a file to "lathe" it down.


Almost there, can you feel the suspense?!

Aight, now you gotta go back to the actuator and pilot a hole for that screw...and make sure its not a bigger hole than the the screw with wide...duh. I used a dremmel cause it fit nicely in there and I didnt have to try to wiggle that actuator out of its home.

Lol, here's a picture of my hole...



I am sure you can see where this is going....screw + hole =



If you did it right, the screw should go in snug. You can reinforce it with some epoxy if you like. But now all you have to do is rock the actuator forward a little and snap the clip over the head of the screw and you are done! Drive your car around and enjoy the satisfying sound of your dsi switching over again.

Hopefully this helps ease your frustrations while waiting for those parts to become available. Hell, you could also use this as a guide when you go to replace the part!

Happy motorin'


__________________
..:: sleestak ::..

"Our mother of blessed accelleration, dont fail us now!" -- Elwood Blues

Last edited by ..:: sleestak ::..; 08-21-2005 at 11:46 AM.
..:: sleestak ::.. is offline  
    Reply With Quote Quick reply to this message
Sponsored Links
Advertisement
 
Old 08-14-2005, 12:15 AM   #2
Scott_SVT
Focus Addict
 
Scott_SVT's Avatar
 
Join Date: Apr 2005
Fan#: 21836
Location: Cocoa, FL.
What I Drive: 2002 Pitch Black w/Blue int SVT

Posts: 1,067
FF Reputation: 4 Scott_SVT Good Standing Member
Buy-Sell-Trade Rating: (1)
Nice write-up!

I was wondering what to expect whenever mine decides to break, I hadn't seen where it actually broke at before your pic. Now I won't worry so much about it, cause I do little "engineering upgrades" like that all the time.
Scott_SVT is offline  
    Reply With Quote Quick reply to this message
Old 08-14-2005, 02:38 AM   #3
..:: sleestak ::..
on thin air
 
..:: sleestak ::..'s Avatar
 
Join Date: Apr 2005
Fan#: 22528
Location: The Lou, MO
What I Drive: 04 Forester XTi

Posts: 3,612
Points 14,456, Level 78
Points: 14,456, Level: 78 Points: 14,456, Level: 78 Points: 14,456, Level: 78
Level Up 2% Completed
Level up: 2% Level up: 2% Level up: 2%
Forum Activity 0%
Activity: 0% Activity: 0% Activity: 0%
FF Reputation: 80 ..:: sleestak ::.. Excellent Standing Member
Buy-Sell-Trade Rating: (15)
glad I could help. I noticed a couple places where it was talked about, but never a pic.....I was kinda nervous at first until I took everything off and realized what I was up against. I damn near laughed at myself cause it was so "stupid simple"
__________________
..:: sleestak ::..

"Our mother of blessed accelleration, dont fail us now!" -- Elwood Blues
..:: sleestak ::.. is offline  
    Reply With Quote Quick reply to this message
Old 08-15-2005, 12:07 PM   #4
Hillyard
Supercharged
 
Hillyard's Avatar
 
Join Date: Jul 2004
Fan#: 10982
Location: Evansville, IN, United States
What I Drive: 2002 ZX3 SVT, 2004 Ford Ranger 4x4

Posts: 3,267
Points 13,364, Level 75
Points: 13,364, Level: 75 Points: 13,364, Level: 75 Points: 13,364, Level: 75
Level Up 29% Completed
Level up: 29% Level up: 29% Level up: 29%
Forum Activity 0%
Activity: 0% Activity: 0% Activity: 0%
FF Reputation: 2 Hillyard Good Standing Member
Buy-Sell-Trade Rating: (27)
Hey thanks for How To! Awesome Work!
__________________
#3788 InfraRed SVT
Hill <><
Hillyard is offline  
    Reply With Quote Quick reply to this message
Old 08-15-2005, 02:17 PM   #5
02SVTscreamin
Focus Enthusiast
 
Join Date: Jul 2005
Fan#: 25911
Location: Memphis Tn
What I Drive: 02 SVT focus and 96 mitsubishi eclipse

Posts: 370
FF Reputation: 2 02SVTscreamin Good Standing Member
Buy-Sell-Trade Rating: (0)
dsi

how can you tell when its not working?
02SVTscreamin is offline  
    Reply With Quote Quick reply to this message
Old 08-15-2005, 03:00 PM   #6
Hillyard
Supercharged
 
Hillyard's Avatar
 
Join Date: Jul 2004
Fan#: 10982
Location: Evansville, IN, United States
What I Drive: 2002 ZX3 SVT, 2004 Ford Ranger 4x4

Posts: 3,267
Points 13,364, Level 75
Points: 13,364, Level: 75 Points: 13,364, Level: 75 Points: 13,364, Level: 75
Level Up 29% Completed
Level up: 29% Level up: 29% Level up: 29%
Forum Activity 0%
Activity: 0% Activity: 0% Activity: 0%
FF Reputation: 2 Hillyard Good Standing Member
Buy-Sell-Trade Rating: (27)
Re: dsi

Quote:
Originally posted by 02SVTscreamin
how can you tell when its not working?
When it makes this noise..

THIS IS NOT MY VIDEO but I am hosting it on my server. If the owner dislikes please PM me.

DSI broken...

Enjoy..

Mine has already been replaced once.
__________________
#3788 InfraRed SVT
Hill <><
Hillyard is offline  
    Reply With Quote Quick reply to this message
Old 08-15-2005, 03:50 PM   #7
..:: sleestak ::..
on thin air
 
..:: sleestak ::..'s Avatar
 
Join Date: Apr 2005
Fan#: 22528
Location: The Lou, MO
What I Drive: 04 Forester XTi

Posts: 3,612
Points 14,456, Level 78
Points: 14,456, Level: 78 Points: 14,456, Level: 78 Points: 14,456, Level: 78
Level Up 2% Completed
Level up: 2% Level up: 2% Level up: 2%
Forum Activity 0%
Activity: 0% Activity: 0% Activity: 0%
FF Reputation: 80 ..:: sleestak ::.. Excellent Standing Member
Buy-Sell-Trade Rating: (15)
indeed...the engine takes on a different sound when it switches over....depending on what tune you have determines what rpm...usually 5 - 6k
__________________
..:: sleestak ::..

"Our mother of blessed accelleration, dont fail us now!" -- Elwood Blues
..:: sleestak ::.. is offline  
    Reply With Quote Quick reply to this message
Old 08-15-2005, 07:26 PM   #8
WD40
The Librarian
 
WD40's Avatar
 
Join Date: Mar 2004
Fan#: 5157
Location: Helena, MT
What I Drive: '04 Sonic Blue - SVT 3Door

Posts: 13,116
FF Reputation: 138 WD40 Excellent Standing Member WD40 Excellent Standing Member
Buy-Sell-Trade Rating: (3)
This is now a "sticky".
I edited the title to be a little more PC.

Thanks, ..:: sleestak ::..
WD40 is offline  
    Reply With Quote Quick reply to this message
Old 08-15-2005, 10:00 PM   #9
bolink
Focus Enthusiast
 
bolink's Avatar
 
Join Date: Aug 2005
Fan#: 26580
Location: VA Beach, VA
What I Drive: 1995 Pimpala SS

Posts: 74
FF Reputation: 1 bolink Good Standing Member
Buy-Sell-Trade Rating: (0)
Thanks! Mine has been broken so I have just disconnected the actuating motor from the wiring harness to spare burning it out. That in turn caused my engine light to come on which has been pissing me off for the past month. Not too mention the horrible gas mileage due to the manifold automatically springing to the larger intake.

I had been planning something exactly like this in my ghetto rigging mind for a while but havnt had a chance to really tear into the engine bay being in the military and all..time is a rarity.

Also pisses me off when the car first started making that noise which turned out to me the control motor trying to switch over to the smaller intakes non stop I took it to the ford dealership...which charged me 80 bucks to tell me that the Control Motor itself was broken and caused me to buy a new 150 dollar motor...which they refuse to let me return because it was a special order. In essence I wasted 230 dollars on a solution to a non existant problem. [:)][:)][:)][:)][:)][:)]*in morons.

PS. If anyone would like to buy a brand new Control Motor (not sure what the exact part name is) Ill gladly sell it to you for 100 dollars shipped.
__________________
1995 Impala SS- Dynaflow Exhaust, K&N FPIK Air Intake, Hypertech tune, Aftermarket Sunroof.
bolink is offline  
    Reply With Quote Quick reply to this message
Old 08-16-2005, 01:07 AM   #10
S2
Retired Fanatic
 
S2's Avatar
 
Join Date: Mar 2004
Fan#: 4939
Location: Canada, Canada
What I Drive: Camaro 2SS/RS

Posts: 19,999
FF Reputation: 67 S2 Excellent Standing Member
Buy-Sell-Trade Rating: (20)
I also added this to the HOW TO ARCHIVE....
__________________
Chad (S2)
S2 is offline  
    Reply With Quote Quick reply to this message
Reply

Bookmarks & Social Networks

Quick Reply
Message:
Options

Register Now

In order to be able to post messages on the Ford Focus Forum, Ford Focus ST Forum, Ford Focus RS Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.
User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.
Password:
Confirm Password:
Email Address
Please enter a valid email address for yourself.
Email Address:

Log-in

Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.



Thread Tools
Display Modes

Posting Rules
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump


All times are GMT -5. The time now is 08:20 PM.


Copyright 2002-2014 FocusFanatics.com. All Rights Reserved : Privacy Policy : Advertise Information

Focus Fanatics Ford Focus Forum offers many fun ways for you to engage with other Ford Focus Owners from across the world. Whether it be about the aftermarket performance modifications, technical how-to's, European tuned suspension or awesome fuel economy similar to the Audi S3, Ford Fusion and Acura TLX. You can find all Ford Focus and Focus ST related information here. Join our Ford Focus discussion forums and chat with local Focus enthusiasts in your area. Challenger Hellcat - Charger Hellcat