OMG! I Installed the Hewitt Technologies Gen-II Bypass

OMG was it hard!

First, full disclosure, if a level 1 mechanic is someone who can change their own oil and filter, then I consider myself a level 2 mechanic. Not only can I change my own oil and filter, but I can change brake pads and rotors, but that is about it.

This supposed 1 hour install took me most of the day, and I almost gave up numerous times.

I would highly recommend starting the install by installing the harness first. That way, if you can't disconnect the connectors that attach to the pumps (you can't believe how difficult it is to reach back behind the engine to get to them) and you decide to give up, you don't have to go to the trouble of removing the Gen-II unit and putting the stock one back on.

The main wiring harness for the entire truck is pretty much in your way for the entire install of the AIP harness. There are three small brackets holding the main wiring harness in place. If you loosen those brackets the main wiring harness moves about a half inch (no more than that) and if you have really small hands that are as strong as a linebackers, maybe that extra half inch will allow you to get back to the connector.

That is the other thing, you never actually see either of these connectors. It is done totally by feel. I wasn't even 100% sure I was removing the correct connectors.

Moving on to the block-off plates:

Absolutely, positively go to The Home Depot and buy a wooden dowel about five feet long that you will eventually cut to size. The dowel I bought was in the gardening section and I think it was some sort of replacement handle for a shovel.

Once I got the dowel and cut it to size the plate installation was a piece of cake. The problem was, and this is on me, I tried just about everything else first, before going with the dowel.

In my opinion, all the significant difficulties I encountered were kinda sorta mentioned in the online videos and the written instructions, but, again, in my opinion, they were completely glossed over. The trick using the dowel for the plate install is mentioned in the written instructions, but I don't even think it is mentioned in the video, let alone demonstrated.

I eventually got 'er done, and as far as I know the kit is working correctly, but it was definitely a frustrating ordeal.

One last thing. I was having no problems with my AIP system and I did this install strictly on a preventative basis.

Thanks for letting me vent.

 

Nice job! You got out of your comfort zone and you got it done. I consider myself an average type mechanic so I know where you are coming from.

 

I don't know where I fall on the skill level scale, but those block off plates were a bear. I don't think that I would offer to do this portion of the install for someone else, but merely serve as an "observational consultant".

 

Nice write-up and thanks for the tips.

Not real familiar with the job so I can’t envision the purpose of the wooden dowel.

For the purposes of being prepared in the case I need to do this, would you measure the diameter of the dowel? Perhaps it is on the price label. Or provide the Home Depot product code.


Greg

 

We must have been tackling this job at the same time. To echo it is challenging. The block off plates went on relatively smooth.

Plugging in the harness the the air pumps was daunting and felt impossible at times. I almost gave up. My dad got one side and I got the other but if you don’t have slim hands I don’t know how it would be possible.

no codes and truck ran great after. This was a preventative measure as well. Good luck to all you weekend warrior mechanics.

 

The diameter of the dowel was a tad more than one inch. As mentioned above, I think it was a replacement handle for a shovel.

The written instructions are pretty clear on what to do with the dowel; it's just a matter of going to the trouble to get one and then following the instructions.

 

thanks for the tips

 

Just installed mine and it was a beast. I made the mistake of thinking the block off plates was going to be the hard part so started with that. Turned out to be the easiest by far. Getting the factory harness unplugged from the pumps was a huge challenge. I was 500 miles from home and had no tools

 

What was it about unplugging the factory harness from the pumps that made it challenging? Simply reaching the connectors, disconnecting them, both, or something else. Would a wire plug tool help? Considering buying a tool and wondering if it would help. This is what I am looking at.

$23 Lisle 37960 Electrical Disconnect Pliers

https://www.amazon.com/Lisle-37960-...hasWorkingJavascript.1|hasWorkingJavascript.1

 

When I did my Gen 2 kit the connectors were the easy part I did use a small screwdriver to release the lock on the connector, the block off plates were more challenging especially the driver side one of the nuts was pretty stripped I think the Toyota tech who replaced the system the first time they failed didn’t do the best job

When I did the block off plates I only loosened the nuts to barely slide the plate in and not to completely remove the 2 connections

 

The tool that Steve 6 linked would have helped

 

So, begs the question....how'd ya do the block off plates without tools?