[DRIVING] VW Touran powered by Nissan Leaf [FINISHED]

[johu]

Yes maybe the basics could be explained... in the wiki
It's fairly simple as I installed the grapical editor.
So to start, enter a URL like so https://openinverter.org/wiki/My_Page_Title
Replace My_Page_Title by something meaningful
It will take you to a new empty page. If you press "Create" it will change to edit mode and you can start to type freely.

[Jack Bauer]

Cool thanks:)

[johu]

Some progress today:

• Removed the main connector from the ECU
• Traced out a few signals on the ECU connector: https://openinverter.org/wiki/Touran_Co ... _connector
• Successfully told a BeagleBone to do CAN
• Ordered parts for motor and transmission mating
• Taking delivery of the shaft coupler maybe tomorrow

So I'm planning to put either a BeagleBone or a small embedded MCU into the original ECUs case. That way I have access to quite a few relevant signals and a nice waterproof case.
Hmm, to be honest maybe it's a bad idea to have throttle processed by a Linux machine?
EDIT: just thought about it further, I think I'll just use an Olimex STM32-H103. I have a good code base for it.

[Jack Bauer]

I've been eyeing up a few bmw ecu's with very similar ideas. Open Ecu time ?

[johu]

Well, here's an open ECU Seen that board before ?
So far I've hooked up throttle, vacuum sensor and CAN bus. It runs almost stock inverter firmware I can play around with the rev counter and more importantly I can put throttle on CAN bus.

Now I have to find out why it throws a low oil pressure error as soon as revs exceed 1000rpm or so.
I'm thinking it's either a bit on the CAN bus or the oil pressure switch is looped through to the display unit. Anyone?

[zippy500]

Some progress today:

• Removed the main connector from the ECU
• Traced out a few signals on the ECU connector: https://openinverter.org/wiki/Touran_Co ... _connector
• Successfully told a BeagleBone to do CAN
• Ordered parts for motor and transmission mating
• Taking delivery of the shaft coupler maybe tomorrow

What are doing for a leaf coupler ?

[D@F]

Yes the Dashboard receve the oil pressure information as on the old vw.
I think if there is no information you may have an alarm over 1000 rpm.

[johu]

Yes, found it today
The alarm indeed starts only above some rpm. But there is also a reverse alarm: if you pull the signal to ground (=oil pressure ok) at 0 rpm you get a STOP! message also. So I either have to live with this or pull the signal to ground selectively with my custom "ECU"

[johu]

What are doing for a leaf coupler ?

Finally I can answer that, bottom to top

• Custom fitting that adapts the VW spline that I cut out out of the clutch to the KTR coupler
• KTR Rotex 38 GS
• Adapter ring that adapts the KTR coupler to the next piece
• Nissan Leaf spline from New Electric

[mleebert]

I too would like to get more details on the source of the Leaf spline part.

Also would it be possible to get another picture of every component separated? This is by far the cleanest example of a Leaf motor adapter I've seen (Excluding Damien's of course). Bravo.

[Jack Bauer]

Yeah much better than my ham fisted version

[johu]

Would you please expand on the source of the Nissan Leaf spline.

Sure, let me google that for you http://www.newelectric.nl/
Just inquire for a Leaf spline adapter.
I think they are here on the forum as well.

Yeah much better than my ham fisted version

Yes, but also ten times the price

[Kevin Sharpe]

I think they are here on the forum as well.

I'm co-owner of New Electric Ireland and can answer questions relating to the group which has now grown to five companies

In Ireland we focus on vehicle RND and support numerous Open Source projects. I won't necessarily have at my finger tips answers relating to products or conversions from elsewhere in the group but I can get answers with a short delay

[zippy500]

that is a very nice coupler

[kiwifiat]

Hi Kevin, The question I have for you is what is the cost of the Nissan Leaf spline adapter?

[zippy500]

I think they are here on the forum as well.

I'm co-owner of New Electric Ireland and can answer questions relating to the group which has now grown to five companies

In Ireland we focus on vehicle RND and support numerous Open Source projects. I won't necessarily have at my finger tips answers relating to products or conversions from elsewhere in the group but I can get answers with a short delay

what is the cost of the coupler ?

[Kevin Sharpe]

Hi Kevin, The question I have for you is what is the cost of the Nissan Leaf spline adapter?

what is the cost of the coupler ?

225-250 Euros... for full details follow this link -> New Electric Couplers and Adaptor Plates

[johu]

So this weekend was great. I had both Arber and his family and my father over to help me get back on track with the Touran conversion.

We test-mounted one battery brick (1/2 Leaf pack) under the car with no greater problems. The other half is residing in the boot right now. My dad could not stop working until we had this done at 23:00

The adapter plates between motor and transmission are pretty much sorted. I use two 300x80x40x4 profiles to cover most of the distance. They are connected by U-profiles mainly for water proofing. Then comes the actual transmission plates which we made with the jigsaw It is only 15mm and we found out the hard way that it better be 25mm - the shaft coupler is about 5-8mm too long. So I went to a random steel working company today and found a 100x460x8 aluminum plate in the scrap. Will saw it in half and thereby add the extra distance.

Mechanically I just need to make a motor mount and the drive drain is in, yay

EDIT: maybe I should mention that Arber came from Slovenia which is 900km away - so: thank you very much

[johu]

Wedding successful

[arber333]

Nicely done!

I guess that means you can just put cells in the back for now. To simplify the build.
I just cant wait for results.

A

[johu]

Vacuum pump is in Used the original rubber mounts

[johu]

And transmission is in.
Now need to make a motor mount, connect up the drive shafts, make some temporary DC cables and off we go

[arber333]

You can cut that mount near the hole and make a hole higher up. As long as mount is flat under. Then buy one 6mm flat piece of steel cca 100mm x [whatever vertical] and get it bent under bottom. Fit one end in the mount and another down at the motor mount in such a way it will carry motor even if a bolt falls off.
Side mounts are only to stasbilize motor. Real bi*$#h it to fit the rear mount in. Does your rear mount come with transmission?

A

[johu]

Well I believe I've sorta done just that, see below He who can't weld uses profiles and screws
Yes the rear mount is attached to the transmission, easy peasy.

I've installed the Leaf wire harness and connected it up to switched 12V and GND. Only CAN missing. I might tap into it at the power steering. Inverter is powered, I can connect to the wifi.
Also installed a coolant pump from Mercedes, it starts to run with the key switch. Haven't decided on what radiator to use yet.
Also rigged up the vacuum pump to be controlled by the new "ECU", works beautifully.

More annoyingly the car has developed and airbag fault. I wonder if my messing around caused it

Tomorrow I should be ready to spin some wheels.

[zippy500]

very nice work, I hope going to YouTube your great work