Another Coastal EV question

This is the 2nd Coastal EV mod I've installed on a 2006 and it's got me confused (the 1st one went great). I never could get the socket (plug position 27) in far enough so that the white bar would depress again. In my (many) attempts I eventually screwed up the wire on the Coastal mod just above the crimp, and now the Coastal wire is partially severed so that about half of the strands are cut. I'll have to get another socket crimped on there before I go at it again. BTW - All of the taps are correct, the right wires were tapped, etc.

Anyway, after my first attempt I just plugged the gray plug it back in and tried it out. The car warmed up for a few minutes in the driveway - the ambient air temp was in the 80s and the car had been sitting for over an hour - and there were six bars on the MFD. After the ICE warmed up and shut off, I tried to go into EV mode and I got the three beeps and the message about not being able to go into EV mode. I was guessing that since I got this message that the install went okay. However, I could never get the car to go into EV mode. I tried about a dozen times with the same result each time.

I went back in to check everything over and saw that the gray plug's white bar wasn't in all the way. After that, I tried to get the socket in far enough to get the bar back down. I never succeeded and my efforts resulted in the Coastal mod's wire strands getting mangled.

My questions are:
1) Is the wire insulation on the Coastal mod so thick that the bar won't go back down?
2) Is the install correct if I get the three beeps and the message?
3) What would prevent the car from going into EV mode, but giving the beeps and message, given the vehicle circumstances I described above?

Lastly, before any of this happened ... when I had the gray plug out but before the install began, I noticed some chaffing on the red wire (gray plug pin 26). I could seen bare wire through the insulation where it comes in contact with the back of the plastic plug. Anything need to be done here?

 

<div class='quotetop'>QUOTE(ken1784 @ Sep 4 2006, 09:38 PM) [snapback]314322[/snapback]</div>

I think the installation was right, and I hosed the wire for naught. With the conditions I described, I'd be hard pressed to believe the batt temp was too high to go into EV mode (without CAN-view I'm in the dark though).

My main concern in the re-try will be getting the bar on the plug locked down again.