[DRIVING] Audi A2 /w Prius Gen2 Transaxle & Inverter  [FINISHED]

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Re: Audi A2 /w Prius Gen2 Transaxle & Inverter

Post by arber333 »

Well not only, but since electric motors dont have compression to hold them in place you need something to hold the car parked on an incline. It is as well practical as legislative requirement.

I would say if the car had a handbrake you can just use it as parking brake.
It would also be terribly embarrasing if one would slip his car down the slope unattended...
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Re: Audi A2 /w Prius Gen2 Transaxle & Inverter

Post by johu »

First task done ;) Crimped the resolver wire. Used geduxaz pinout.
Orange pair (pin 1 and 2): excitation R1/R2
Green pair (pin 3 and 4): sine S2/S1
Blue pair (pin 5 and 6): cosine S3/S4

Spliced off the brown pair to reach the temperature sensor. It seems both MG1 and MG2 temp sensors end up on the same connector, does anyone know which one is which?

Also tested it with my old test inverter and it runs nicely.
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Re: Audi A2 /w Prius Gen2 Transaxle & Inverter

Post by johu »

I got cracking


Today I fully removed the bumper, undid most connectors and removed aircon. Might be able to pull the engine tomorrow.
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Re: Audi A2 /w Prius Gen2 Transaxle & Inverter

Post by RetroZero »

Can't wait to see your progress 💪👍
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Re: Audi A2 /w Prius Gen2 Transaxle & Inverter

Post by johu »

Early forum release then :)

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Re: Audi A2 /w Prius Gen2 Transaxle & Inverter

Post by johu »

Suspended the transmission from the crane yesterday.

It lines up quite nicely. On the right side (seen from the front) the Audi driveshaft gets very close to the Prius drive shaft cup that Damien thankfully included when he sent me the transmission. So plan is to attach the driveshaft cup from the Audi transmission to the cup from the Prius transmission and then bolt on the original driveshaft as before.

The left side has a hollow shaft that can be widened on the lathe so that the Prius shaft slides right in.

The right transmission mount sort of lines up and today I found the torque arm isn't too hard to adapt as well. Only on the left side there is quite some distance to cover, obviously.
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Re: Audi A2 /w Prius Gen2 Transaxle & Inverter

Post by RetroZero »

Loads of place to make a battery box that doubles as frame to hold up transaxle. Much easier too for using original supports. How does it fit with the inverter on top (I'm sure you checked that already) 👍
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Re: Audi A2 /w Prius Gen2 Transaxle & Inverter

Post by arber333 »

You will probably make a plate on the transmission bell to fix MG1 shaft so you will be able to run both motors. You can use that plate as a fixing plain for your left mount. If you are carefull you could mount inverter or other electronics on the left side which would leave more space on the top for other things.
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Re: Audi A2 /w Prius Gen2 Transaxle & Inverter

Post by johu »

RetroZero wrote: Thu Feb 03, 2022 8:58 pm Loads of place to make a battery box that doubles as frame to hold up transaxle. Much easier too for using original supports. How does it fit with the inverter on top (I'm sure you checked that already) 👍
Hard to test, as the straps are in the way. But it seems like plenty of space left.
arber333 wrote: Fri Feb 04, 2022 7:54 am You will probably make a plate on the transmission bell to fix MG1 shaft so you will be able to run both motors. You can use that plate as a fixing plain for your left mount. If you are carefull you could mount inverter or other electronics on the left side which would leave more space on the top for other things.
I will not use MG1. Damien said he welded something inside the transmission, not sure what it means though? Inverter side mount is hard for a pretty silly reason: the cable from MG2 is not long enough and I have to stick with the original cable for approval. But good news is: what other things? No separate DC/DC converter and charger needed :) Maybe not even a DC junction box. Only other HV component will be A/C compressor.
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Re: Audi A2 /w Prius Gen2 Transaxle & Inverter

Post by Bigpie »

Looks like he welded the use both MG1 and MG2 to output power.
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Re: Audi A2 /w Prius Gen2 Transaxle & Inverter

Post by geduxaz »

Nice progress! i have studied all the Audi wiring if you need any help. i have quite a long history with VAG group and Elsa etc.
i use original wiring from four plugs under drivers feet.
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Re: Audi A2 /w Prius Gen2 Transaxle & Inverter

Post by Jack Bauer »

It means both MG1 and MG2 are now able to turn the wheels either individually or together without the Gen 2 speed limit of 50mph due to mg1 overspeed.
I'm going to need a hacksaw
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Re: Audi A2 /w Prius Gen2 Transaxle & Inverter

Post by arber333 »

I still think it would be a good think to make a shelf over the longitudinal members in the car where you can put some of your batteries.
Also making a shelf from a motor mount to to transmission bell in L shape could be a good idea. This would make space for inverter as well as AC compressor and heater eventually. What will you do for charging? Will you use 3phase wires from MG1?
johu wrote: Fri Feb 04, 2022 9:37 am Only other HV component will be A/C compressor.
May i recommend Outlander AC compressor on the fact it is very easy to control by CAN bus.
https://leafdriveblog.wordpress.com/202 ... installed/
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Re: Audi A2 /w Prius Gen2 Transaxle & Inverter

Post by geduxaz »

johu wrote: Wed Jan 12, 2022 1:40 pm Spliced off the brown pair to reach the temperature sensor. It seems both MG1 and MG2 temp sensors end up on the same connector, does anyone know which one is which?
Here You go ;)
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Re: Audi A2 /w Prius Gen2 Transaxle & Inverter

Post by geduxaz »

arber333 wrote: Fri Feb 04, 2022 12:20 pm I still think it would be a good think to make a shelf over the longitudinal members in the car where you can put some of your batteries.
Also making a shelf from a motor mount to to transmission bell in L shape could be a good idea. This would make space for inverter as well as AC compressor and heater eventually. What will you do for charging? Will you use 3phase wires from MG1?
johu wrote: Fri Feb 04, 2022 9:37 am Only other HV component will be A/C compressor.
May i recommend Outlander AC compressor on the fact it is very easy to control by CAN bus.
https://leafdriveblog.wordpress.com/202 ... installed/
i believe we should use original Prius AC. Inverter will have original wirring.
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Re: Audi A2 /w Prius Gen2 Transaxle & Inverter

Post by johu »

Jack Bauer wrote: Fri Feb 04, 2022 11:36 am It means both MG1 and MG2 are now able to turn the wheels either individually or together without the Gen 2 speed limit of 50mph due to mg1 overspeed.
Awesome, thanks for reminding the old man :D
geduxaz wrote: Fri Feb 04, 2022 11:01 am Nice progress! i have studied all the Audi wiring if you need any help. i have quite a long history with VAG group and Elsa etc.
i use original wiring from four plugs under drivers feet.
Cool, will get back to that!
arber333 wrote: Fri Feb 04, 2022 12:20 pm I still think it would be a good think to make a shelf over the longitudinal members in the car where you can put some of your batteries.
Also making a shelf from a motor mount to to transmission bell in L shape could be a good idea. This would make space for inverter as well as AC compressor and heater eventually. What will you do for charging? Will you use 3phase wires from MG1?
Yes, L shape indeed sounds good to not block off space.
Trying to avoid batteries in the front because of using the centralized Leaf BMS.
Charging 1-phase only as requested by the owner, using the A/C inverter for rectification. Need to sneak in a current sensor somewhere along because naturally there is none.
arber333 wrote: Fri Feb 04, 2022 12:20 pm May i recommend Outlander AC compressor on the fact it is very easy to control by CAN bus.
https://leafdriveblog.wordpress.com/202 ... installed/
I have a Leaf compressor with LIN bus and want to test it. https://openinverter.org/forum/viewtopic.php?f=4&t=2136
geduxaz wrote: Fri Feb 04, 2022 12:27 pm Here You go ;)
Thanks :)
geduxaz wrote: Fri Feb 04, 2022 12:28 pm i believe we should use original Prius AC. Inverter will have original wirring.
Yes would be cool, but nobody knows how to start it up, isn't it?
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Re: Audi A2 /w Prius Gen2 Transaxle & Inverter

Post by arber333 »

johu wrote: Fri Feb 04, 2022 1:44 pm Yes would be cool, but nobody knows how to start it up, isn't it?
Well if you are for some openinverter surgery you can just use prius compressor. But then you need to control it with AC inverter inside main inverter because gen2 compressor does not have 6bridge inside. Its just the motor and scroll.
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Re: Audi A2 /w Prius Gen2 Transaxle & Inverter

Post by geduxaz »

@Johu. I checked your images. I see resolver Sin/Cos grounds (pin 5/6 in Prius pinout) are used as signals and
Sin/Cos ( pin 2/3) you use as grounds (green blue wires are connected together in your board). why?
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Re: Audi A2 /w Prius Gen2 Transaxle & Inverter

Post by johu »

geduxaz wrote: Fri Feb 04, 2022 11:01 am Nice progress! i have studied all the Audi wiring if you need any help. i have quite a long history with VAG group and Elsa etc.
i use original wiring from four plugs under drivers feet.
can you identify that one from the image? It's in the motor loom and the only one that has 4 poles. it fits the vacuum sensor so would like to use it for that. Would be good to know where it turns up in the ECU (if at all)
geduxaz wrote: Sat Feb 05, 2022 12:23 pm @Johu. I checked your images. I see resolver Sin/Cos grounds (pin 5/6 in Prius pinout) are used as signals and
Sin/Cos ( pin 2/3) you use as grounds (green blue wires are connected together in your board). why?
you mean I swapped polarity? if so, it wasn't intentional but it doesn't really matter. The supposed grounds are tied to 1.6V and the signals are used unipolar.
arber333 wrote: Fri Feb 04, 2022 2:16 pm Well if you are for some openinverter surgery you can just use prius compressor. But then you need to control it with AC inverter inside main inverter because gen2 compressor does not have 6bridge inside. Its just the motor and scroll.
Yes I thought about patching the board that has the little A/C compressor. But then there's no feedback from the motor I suppose?
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Re: Audi A2 /w Prius Gen2 Transaxle & Inverter

Post by geduxaz »

Can you show the sensor itself? Where it was located? If it was in the vaccum pipe- yes it is vaccum sensor.
Mine 1.6FSi had vaccum sensor. On the pipe from engine to brake booster. As FSi use throttle to make more vaccum if it is not enough for brakes.

Yours looks like 1.4i (one coilpack etc) so i think it does not have brake booster vaccum sensor. You might hold a MAP sensor.
In some hours i will reach my laptop with elsa and will make a pdf for your wirring
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Re: Audi A2 /w Prius Gen2 Transaxle & Inverter

Post by geduxaz »

Ok i looked at 1.6fsi wirring i have on hand.
G294 is sensor. But it is 3 wires.
It goes to 36 ECU pin directly.
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Re: Audi A2 /w Prius Gen2 Transaxle & Inverter

Post by MattsAwesomeStuff »

arber333 wrote: Fri Feb 04, 2022 12:20 pmMay i recommend Outlander AC compressor on the fact it is very easy to control by CAN bus. https://leafdriveblog.wordpress.com/202 ... installed/
Shhh, maybe Johannes will be the one who reverse engineers the Prius A/C inverter. Then we're one step closer to an all-in-one package ;)
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Re: Audi A2 /w Prius Gen2 Transaxle & Inverter

Post by arber333 »

MattsAwesomeStuff wrote: Sat Feb 05, 2022 6:39 pm Shhh, maybe Johannes will be the one who reverse engineers the Prius A/C inverter. Then we're one step closer to an all-in-one package ;)
True, that would be the best for OI world :).
In that case for incentive I can offer my Prius AC compressor. It didnt work for me since my aux inverter blew IGBT at 25A starting current. But it may work for you J. With compressor i have original pipes with some flexible hoses attached. So you could get a shop to make you new fittings for your application.
https://leafdriveblog.wordpress.com/202 ... ompressor/
https://leafdriveblog.wordpress.com/202 ... sor-drive/
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Re: Audi A2 /w Prius Gen2 Transaxle & Inverter

Post by geduxaz »

Yours is G71 G72 intake manifold pressure sensor with temperature sensor.
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Re: Audi A2 /w Prius Gen2 Transaxle & Inverter

Post by johu »

Oh perfect, so there must be that same sensor on the engine. Will check. Although I plan to sell it and it wouldn't be a nice move to raid parts.

Re A/C: It's probably quite easy if someone with an actual Prius can sniff that 6-pin connector.
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