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Frustrated, need help with EV mod installation

Discussion in 'Gen 2 Prius Main Forum' started by adamtraidman, Jan 13, 2005.

  1. adamtraidman

    adamtraidman New Member

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    Got Dave's EV mod today. Spent literally 3 HOURS messing with this thing, and I haven't gotten any results! Very frustrating! Here's the situation. Got into the access area of the car pretty easily. Pulled out the correct connector, and started attempting to put on the wire clips. Those weren't a cake walk, it was difficult getting them to close. Got that done. Then spent 45 minutes trying to decipher what the heck it meant to "pull the white strip out". Once I found a tiny screwdriver, I got that nudged out, stuck the yellow wire in, and proceeded to put everything back together.

    Turned on the car, hit the stalk for 2 seconds, nothing. The car is acting exactly like it used to, doesn't even see the EV modification. So.. I pulled it apart again. My "yellow" wire is flush with the switch. Is that ok? If not, how should I get it in further? I even took off the wire taps, the wires are seated pretty deep in the metal clips, they _should_ be getting contact.

    I just can't believe how frustrating this has been. I've spent easily over 4 hours with the bugger. Any suggestions would be VERY welcome.

    Thanks..
    Adam
     
    #1 adamtraidman, Jan 13, 2005
  2. daniel

    daniel Cat Lovers Against the Bomb

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    Phone Costal Tech. They will talk you through it.
     
    #2 daniel, Jan 13, 2005
  3. DanMan32

    DanMan32 Senior Member

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    flush with the switch? Do you mean plug? Make sure you have the pin in the right slot in the right plug.

    If you happen to be local to the Tampa Bay area (your PM doesn't indicate where you are), I might be able to help.
     
    #3 DanMan32, Jan 13, 2005
  4. bruceha_2000

    bruceha_2000 Senior Member

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    What switch?? You mean the connector?
    • The white retaining bar is 'pulled out' by pushing on the little bumps on it (both ends of the bar) on the sides of the connector. It doesn't come out very far, hardly noticable. You push it back in by pushing on the front of it.
    • Per the instructions, you want the 'fold' where the pin connects to the wire to be in the proper orientation. I didn't try it the 'wrong' way so I don't know how much harder it is to get the pin in that way. :)
    • I bet the pin isn't all the way in. In my case, and others here, if you can see ANY metal once the pin is pushed in, it isn't all the way in.
    • As Dan said, make sure you have it in the proper hole. I have no idea what happens if it isn't.

      • There are other recent threads regarding the CT EV mod.
        Also, Evan's install doc in the knowledge base has some great pictures.
     
    #4 bruceha_2000, Jan 13, 2005
  5. adamtraidman

    adamtraidman New Member

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    Thanks for the replies. Sorry for the confusion, yes I meant "connector" not "switch". I can't see any metal protruding from the connector, and I have the pin orientation correct per the instructions.

    What I'm trying to understand is, under what conditions would one see no functionality? Other than all the connections being bad, if the two wire taps are in and the "pin" isn't seated fully, what would you expect? Versus the pin being in and one or two of the wire taps being somehow not making contact. This will help me narrow down the source of the problem.

    I'll try calling CT, every time I've called thus far, no answer.

    Adam
     
    #5 adamtraidman, Jan 13, 2005
  6. DanMan32

    DanMan32 Senior Member

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    The basic function of the mod is to momentarily ground out that pin. The CC mod taps into the CC cancel switch and probably ground, possibly B+ (or Ig On +), and provides the momentary grounding of the pin to facilitate EV.

    So, if the taps aren't righ, or the pin isn't right, you won't get EV. If you can get a separate wire touching the pin from the back, and try grounding it in ready mode, it should go into EV mode or indicate a denial with three beeps. If that works, the pin is in far enough, or the wire is helping make the connection, the former state indicating the taps are wrong, or the module is defective.
    If it doesn't work, either the temp wire isn't touching the added pin, or the pin isn't really in all the way.

    To check the module, I think you could connect a voltmeter between the pin and 12V source. You may also be able to connect an ohm meter between the pin and ground, but I would imagine it isn't normall a complete open circuit so there may be some voltage to give bad readings on the ohm meter.
     
    #6 DanMan32, Jan 13, 2005
  7. adamtraidman

    adamtraidman New Member

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    Ok, folks.. Good news, got it working! Just a reference, here's the info.

    So I called Coastal Tech. Summary of points:

    - If the yellow wire pin isn't inserted fully into the plug, you will see behavior as I described - i.e. the car acts as though the EV mod isn't installed. No "switch to energy screen", no extra beeps, nothing.

    - If your wire taps made a "click" when they went on, they should be making a good connection. Do not unhook them, this may risk damage or breaking the wire if not done carefully.

    - When the yellow wire pin is inserted fully into the plug, it should "click". Also, once inserted correctly, it will be difficult or impossible to pull it back out, even with the white bar pulled out.

    - If the metal on the pin is flush with the plug, it isn't in far enough.

    So, bottom line, I used a paper clip (unfolded) and a small screwdriver to press the yellow wire and pin further into the plug. I was getting a bit scared b/c the yellow wire was bent, cut, and damn near broken due to all the abuse I had put it through. When I finally got the pin in "below flush", it clicked slightly, became very difficult to pull out, and I knew it was in. Threw the plug back into the ECU, turned on the car, and voila, EV mode.

    Now, to try and get some better mileage from it.. :)

    Thanks for all the suggestions, folks.
     
    #7 adamtraidman, Jan 14, 2005
  8. Tideland Prius

    Tideland Prius Moderator of the North
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    <sigh> I'm at your (old) situation. My wire's bent and soft and I can't get it in. I've tried the pin idea and it wouldn't budge.
     
    #8 Tideland Prius, Jul 13, 2005
  9. Frank Hudon

    Frank Hudon Senior Member

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    Tideland see PM
     
    #9 Frank Hudon, Jul 13, 2005
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