That Pesky Rear Liftgate Latch…

I’m not surprised anymore when a Think arrives at the shop and the rear liftgate is released. Often the latch position switch (that should turn on the “Door Ajar” light on the center console) is not adjusted correctly. And I’ve seen plenty of liftgate latches slowly get further and further out of adjustment until you really have to slam it to get it to shut. So here’s what you can do about it: Continue reading That Pesky Rear Liftgate Latch…

Using CommTool

CommTool is Enerdel’s proprietary software for communicating with the traction battery.

Think’s TechCentre diagnostic software will retrieve diagnostic trouble codes and display them in a format that is much easier to interpret than CommTool. However, TechCentre’s interface will tell you that you can clear those battery DTCs; then it will tell you that the codes cleared but that they already reset, but that’s a big fat lie!

And that is the Number One reason that CommTool is essential for Think Technicians: Some DTCs that are set by the battery are stored in non-voltile memory (which means they can’t be cleared just by disconnecting the 12V battery) and will inhibit any further battery operation until they are cleared.
Continue reading Using CommTool

Updating PCU firmware

There have been several revisions to the program running in the Think Power Conversion Unit (PCU).  Most of these changes fixed bugs or accommodated the retrofit to a PTC heater.  In this post I might throw around various terms that all essentially mean the same thing: firmware/software, release/version, update/flash/re-flash.

The latest firmware release changed the driving characteristics of the car quite significantly.  Continue reading Updating PCU firmware

Removing the headliner

The headliners, that is, the interior roof linings of Thinks have been know to sag.  I am thrillingly close to having a retrofit designed to fix this defect properly.  Some of my previous attempts at reinforcing the headliner failed in precisely the same was as they did without the reinforcement.  Once I verify that my new design is reliable, my boss and I will decide how much it will cost to do the retrofit and publish that cost.  I’ll also publish the design and instructions for doing the retrofit yourself if you are so inclined or you can try to get someone else to do it for you.  This post will be the first and last parts of the instructions: removing and re-installing the headliner.

Continue reading Removing the headliner