EV Highbeam Hack Question

[bobfrapples]

Hi, all. I've finally decided to go through with this simplest of install methods for the EV hack, but I'm stuck at a point that I didn't think would be that difficult. I've posted the question to Evan, since I was following his very detailed PDF, but I figured I'd reach out to the community at large for others who've also done this.

The problem I'm having is matching the photo of the connector pin in the PDF to the live pin in my hand in order to determine orientation for insertion into the ECU plug. The photo shows what appears to be the pin going in with the open side (the side where you would insert the wire) pointing away from the white retainer clip. The pin in the photo does not have nearly the same lateral shape as my pin (which was removed from the steering column per the instructions). When I tried this orientation, the pin jammed with over 2mms sticking out and I mangled it trying to force it in with a jeweler's screwdriver. A second pin inserted the other way around slid in almost smoothly by comparison, but then the retainer clip would not press all the way in.

Which is the proper orientation?

Any advice is appreciated.

--Bob

[efusco]

You should be able to tell the orientation from the photos, but it sounds like you're doing it right. I'm not sure I ever got the retainer clip to close all the way back down either. Just get it in there as far as you can, those pins are not perfect fits.

[bobfrapples]

Hey, Evan! Thanks for the reply. The thing was that with the retainer clip not closing back in, I couldn't stick the plug back in. But I'll give it another swing this weekend when the weather is better.

Thanks again!

[hobbit]

The white plastic retainer piece is supposed to drop down into
the open area of the pins, so it's gotta be facing up toward it.
The "wrong" pins you harvest from elsewhere may have a couple
of extra bits of metal sticking up that could be shaved off
with a file. Get the whole thing in a good light with magnification
if possible, and it should be doable.
.
The white plastic retainer is actually a grid, and the pins go
through the holes in same when it's raised and get blocked when
the horizontal elements drop down into the pin cavity.
.
_H*

[bobfrapples]

Done!! Guys, thanks for the input.

Evan, I found a guide by Tom Stangl (EV Button Installation with Y harness) which has an actual photo of the pin orientation. In his orientation, the side in which the wire is inserted faces the retainer clip. It still did not allow the retainer to close all the way, as you said, and it was still an effort to stick the plug back into the ECU socket as a result. But with a little careful pressure and some wiggling, it clicked into place. The rest was cake.

Again, thanks!!

[efusco]

Congrats...I always like to hear the success stories...those early instructions have stood the test of time for over 5 years now!