Over the winter I decided to change my management system over to Accuair’s E-Level and finally had a minute to throw together a little install guide. I started this journey by calling my buddy Andrew over at Open Road , ordering the E-level, VU4, Dakota Digital Gauge, Wireless Key Fobs, Stinger Solenoid Relay, Accuair’s New 5-Gal Aluminum Tank, and a bunch of fittings of course.
The new components:
After everything arrived, I cut a cardboard template of the trunk as I usually do to figure out how it would all fit. I decided to keep a similar layout as my Autopilot install, where everything is along the outside of the spare tire with the tank up against the rear seat. Using ¼” plywood as a base and 1x5 for the outer rails, I built a box to mount all the components. * Viair compressors are not really supposed to be sideways as it can cause uneven wear on the piston seals, just something to keep in mind if you decide to lay them sideways like I did*
While planning the trunk, I was also polishing the tank and that took a while seeing as how I was also polishing my wheels. So I took a break from polishing for a day or two and continued on with some wiring. I started by removing the driver and passenger kick plates as well as the rear seat. I made a wiring harness for the Dakota module, I used a different color wire for each bag to make it easier to connect everything once it was in.
I also decided to run the sensor wires at this point. I ran the front sensor wires along the kick plates. I chose to drill a 3/8” hole in the wheel well and install some ¼” rubber grommets. I put a dab of super glue on each one to hopefully keep them from coming out. To get the sensors outside the car you will need to cut the wires. Make a careful slit in the gray housing exposing enough of the wires that they can easily be worked with. You can either solder them back together or use good crimp connections. All of the connections should be covered in shrink tubing with either method.
Passenger side path:
I ran the rear sensor wires in the same manner by drilling holes in the corners in the rear of the hatch area. I forgot to take photos and they are now covered back up by the carpet. I also previously had a compressor power wire, and 12V accessory wire ran from my previous install.
Once I finished the tank, I started hooking all the components up. I installed the stinger 40A relay, running the 4 gauge wire to the input side, and then running a 4 gauge wire from the output to a distribution block splitting into 8 gauge wire for each compressor. I also attached all the signal wires to the pressure senders using ring terminals for easy removal. I ran all my compressor, ecu, manifold, and sender grounds along the outside of the box to a single grounding block.
I then mounted the tank and manifold running the fill lines to 3/8” bulkhead fittings underneath the tank. One of the water traps is directly mounted to the tank and copper hard lined to the manifold. The second water trap has hardline from both the tank to the trap and trap to manifold.
This is the finished setup with the polished tank, hardlined manifold and false floor. I hinged the false floor so I can get to anything I may need out of the bag I keep the jack, lug wrench, some tools and my most important BBS wrench in.
After everything was function/ leak tested, it was time for the most important part of any E-Level install, the leveling sensors. I started by taking max and min measurements to determine the overall length of travel and midpoint of travel. Measures from the center of the axle to the fender all the way out and filled, then find the midpoint of the distance traveled.
With the front of the car jacked up and resting on jack stands, you can now determine you desired location for the sensors. I chose to mount them directly over the control arm. I started by using the jack to place the center of the axle at the midpoint of the travel. I mounted the sensor behind the strut using two self tapping screws. Using some 1” galvanized brackets I had laying around, I trimmed up some brackets to attach the arm to. *You want the arm of the sensor to be at the midpoint of its allowable range of motion when the suspension is at the midpoint of travel.* Then move the suspension through its range of motion while holding the bracket in place. You want to verify that the sensor does not bottom out prematurely and that the sensor arm is vertically level, or as close as possible. This will help to prevent premature failure of the sensors.
I followed the same process for the passenger side verifying no interference during the process.
The rear was the next and a little bit trickier. I decided to use drive on ramps instead of jack stands, it helps with visualizing the travel of the rear control arms. I decided on mounting the sensor to the lower control arm. I started by mounting the fixed mount for the arm, first trimming about 1/8” off the hex coupling. This allowed me to make the leveling arm more vertically level and less susceptible to damage. The location I chose for the top mount was approximately 3” from the outside edge of the upper stress bar. This location had enough range of travel without over extending the sensor. The sensor body was mounted using the supplied hardware, although I did put some washers behind the body to help shim it out. Then move the car to the middle of the range of travel and trim the arm so that the sensor is again at the midpoint of travel while suspension as the middle of its travel. For the rear, the drivers and passenger side are as close to identical as they can be.
Once everything is plugged in and connected , take the car out for some photos and enjoy your work:
All done and at SoWo
After a year of having the e-level, I decided I wanted to try the sway bar in there. My bombers came without sway bar mounts so I pulled them out and sent the to Mr. Drew Dorbritz to have some oem tabs welded on and a fresh coat of candy white applied. After getting everything back in and working it was time for a sensor reposition. This was the third time I was doing them with a sway bar so I took some photos and finally have the time to upload them. Both sides are essentially in the same location with the arms rotated toward the rear of the car as opposed to the front as they were previously. When doing the lower mounts you can either use the angle bracket or weld some tabs on. I've done both ways but decided to bolt for my car to get done as quick as possible.
The key when installing with the sway is to place the car at your desired ride height with a jack on the control arm and turn the wheels back and forth to ensure that the endlink will not contact the sensor.
Feel free to ask me any questions, I don’t mind helping out.