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HELP!! Installing Coastal EV Mod!

Discussion in 'Gen 2 Prius Main Forum' started by Kev1000000, Apr 13, 2006.

  1. Kev1000000

    Kev1000000 New Member

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    Ok, i was putting in the orange wire and i wanted to retry it because i couldnt get it all the way in...

    So i used a pair of pliers and tried to get it out but i tore the wire from the crimp.

    Now the crimp is lodged into the plug and the wire is broken.

    Im trying not to panick, is there anything i can do? Im trying to get the pin out of the plug, but its VERY hard to get it out of there.

    Please, anyone, can you help me? Can i save the EV mod? Please!
     
  2. Kev1000000

    Kev1000000 New Member

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    There is about a cm of pin sticking out...

    could i solder the orange wire back onto it? Is that safe?
     
  3. TonyPSchaefer

    TonyPSchaefer Your Friendly Moderator
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    Ya know, Kev, I was thinking about that when I was installing mine.

    The HV ECU is way too difficult to get at to be too creative. And it's way too complicated to even consider taking it apart to fish out the part.

    I'm sorry man. My experience was just to shove mine in and be done with it. I have no usable input.
     
  4. Kev1000000

    Kev1000000 New Member

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    you broke your wire as well?

    I think i could solder the exposed wire and pin back together, but would that work and be safe?

    I have been trying to pull it out, it wont budge. Is it ok to drive if i take everything out but leave the wiretaps and pin in #27 in?
     
  5. TonyPSchaefer

    TonyPSchaefer Your Friendly Moderator
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    No. Mine did not break.

    I would suggest that you carefully pull out the pin since some of it's exposed. From there you can simply start the process over.
     
  6. Kev1000000

    Kev1000000 New Member

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    i wish i could.. the pin seems to be stuck. Not enough of the pin is exposed to get a good grip on it.


    What happened in your experience?
     
  7. TonyPSchaefer

    TonyPSchaefer Your Friendly Moderator
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    In my experience, the pin I was supplied by the manufacturer was the wrong size for the application. The real pins are located in the area under the steering wheel and described in HTMLSpinner's document. After we pretty much hacked up the over-sized pin, we used one that's the correct size and everything worked perfectly. Of course, several hours and much mental anguish went into the whole process.

    When trying to remove the pin, is the ECU "lock" popped up ensuring that it's not holding it in?
     
  8. Kev1000000

    Kev1000000 New Member

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    yea, but it has trouble staying up
     
  9. abas

    abas New Member

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    I haven't seen the connector that you are referrring to, but most of those kind of connectors have a slightly raised piece of metal on one side that lets it snap into the socket. Usually have to take something thin to push on the retaining part in order for the pin to come out.
     
  10. TonyPSchaefer

    TonyPSchaefer Your Friendly Moderator
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    <div class='quotetop'>QUOTE(Kev1000000 @ Apr 13 2006, 01:33 PM) [snapback]239256[/snapback]</div>
    I'm not even going there. STAY FOCUSSED!! :D

    It only stands up about a milimeter or two. Barely enough to notice that it's up.
     
  11. Kev1000000

    Kev1000000 New Member

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    <div class='quotetop'>QUOTE(abas @ Apr 13 2006, 02:34 PM) [snapback]239258[/snapback]</div>
    yea, i think thats what the problem is, i think the pin is actually in place, it barely sticks out at the top. If i use a very small soldering iron, would it work if i solder the exposed wire onto the exposed pin?
     
  12. TonyPSchaefer

    TonyPSchaefer Your Friendly Moderator
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    That might work, Kev. Since it's not my car, I won't try to talk you out of it. It'll be a tight operation given the limited space of that juunction. It won't be pretty. When you're done, be sure to tape it well to protect the union from shorting out against something else.
     
  13. Kev1000000

    Kev1000000 New Member

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    well, the soldering should be hidden inside the plug, right?
     
  14. TonyPSchaefer

    TonyPSchaefer Your Friendly Moderator
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    is the pin in the EV ECU or in the button?
    Now I'm confused.
     
  15. Kev1000000

    Kev1000000 New Member

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    its in the plug that goes into the EV ECU
     
  16. TonyPSchaefer

    TonyPSchaefer Your Friendly Moderator
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    Can you take/post pictures? Do you have the time?

    http://www.priuschat.com/forums/album_pic.php?pic_id=222

    This is a picture of the ECU plug. Is this where it's sticking out of?

    just occured to me: Is there anything thin enough that you can shove up through the bottom and push it out? I'm concerned that anything that thin might not be sturdy enough.
     
  17. Kev1000000

    Kev1000000 New Member

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    ive been trying to shove a paper clip up through the bottom. It does hit the pin, but the pin keeps stopping on something. I have the white bar raised as high as it can go.

    I have no Digi cam here.

    If if leave the pin and the wire taps in, but take off the EV mod circuit board thing, can i still run the car?

    Yes, its slighty sticking out of that plug.
     
  18. TonyPSchaefer

    TonyPSchaefer Your Friendly Moderator
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    NNNNNNOOOOOOOO

    "I'm sorry Dave, I'm afraid I can't do that."

    Wait a minute: Are you saying leaving the pin in place and shoving the ECU back into the housing? Or are you saying drive the car without the ECU seated into the housing? You can have a non-functioning pin in slot 27 - which is pretty much where you stand right now.
     
  19. Kev1000000

    Kev1000000 New Member

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    Yea, plug everything back in and just leave the unused plug in 27
     
  20. TonyPSchaefer

    TonyPSchaefer Your Friendly Moderator
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    Oh well that shouldn't cause a huge problem.
    But understand, my good man, that I am not an electrician nor am I a car tech nor am I in any way considered an expert. I just remember doing my own mod.

    PM Galaxee