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

[johu]

Anyone have Nissan tap wires left? https://openinverter.org/forum/viewtopi ... =12&t=2246

[geduxaz]

Anyone have Nissan tap wires left? https://openinverter.org/forum/viewtopi ... =12&t=2246

In what state is Leaf BMS? Can it be used for cell balancing?
I can buy 24kWh pack with 50soh for 1k. Is it good price?

[johu]

The Leaf BMS can be used with just CAN connection. It will automatically balance without any interaction.

I started a wiki page for the conversion: https://openinverter.org/wiki/Audi_A2_Conversion

Encouraging everyone to do the same

[johu]

Now, I could use your input again, to have to do less "ringing". On what pins is the throttle pedal and what what pins is the CAN bus?

Should I even try to run the inverter via the unshielded motor harness (including the resolver)? Or is it wasted time?

[geduxaz]

Now, I could use your input again, to have to do less "ringing". On what pins is the throttle pedal and what what pins is the CAN bus?

Should I even try to run the inverter via the unshielded motor harness (including the resolver)? Or is it wasted time?

I did run VCU from original ECU location by 20 wire cable BUT got bad behavior. Now moved VCU near inverter and it works.
i think you can run VCU with original AUDI wiring if you find 3 or more shielded cables. AUDI has some shielded wires, but i do not know how many are in your 1.4i version. At least one shielded is for knock sensor.

Changed laptop and installing ELSA at the moment. Will take some pinouts to Wiki.
I believe we need to make different Wiki topics for different A2s versions (1.4TDI, 1.4i, 1.6FSI, 1.2TDI) and i will put at least all engine wirrings.

Which engine do you have? 1.4i were two types AUA or BBY?

[johu]

I think AUA motor

Thanks for adding to the wiki!
Maybe we can just outline the differences between variants?

[geduxaz]

I think AUA motor

Thanks for adding to the wiki!
Maybe we can just outline the differences between variants?

i took a quick look vs mine 1.6fsi and it is totally different pinout.
Never edited a Wiki, now do not know how it is better to add all this info.
For me it is easy to read stock wiring diagrams (even better vs table). but it can be copyrighted by Audi and i do not know if we can put it to this Wiki.
i can make it as pictures or PDF.

also i didnt use any of original wiring loom that went to engine bay. i took it all out and put new cables for my needs. i only use many wires that come from 4 color plugs in the ECU footwell area. These plugs have connections to brake pedal/clutch pedal (if with cruise control)/ dashboard, canbus, etc.

[johu]

[johu]

Did a test run of the VCU today. Will be in the next video.
But one detail puzzled me: throttle runs backwards
The plot goes from 0 to fully pressed. In voltage primary goes from 4V to 1V and secondary from 4.4V to 2.9V . Is it like that or have I reversed polarity? I connected it like written in the wiki

[johu]

Oh, and another question: I noticed that my diagnosis tool no longer works since I removed the ECU. Is it possible that ECU loops through the K-Line?

[geduxaz]

Oh, and another question: I noticed that my diagnosis tool no longer works since I removed the ECU. Is it possible that ECU loops through the K-Line?

In wirring there was no direct conection to OBD port. Only two wires to instrument cluster (that i do not know, maybe k line) and Canbus.
Will check again. Also will test my A2. Didnt try to plug VCDS.

[geduxaz]

Did a test run of the VCU today. Will be in the next video.
But one detail puzzled me: throttle runs backwards
The plot goes from 0 to fully pressed. In voltage primary goes from 4V to 1V and secondary from 4.4V to 2.9V . Is it like that or have I reversed polarity? I connected it like written in the wiki

I think you can try to reverse +5 vs Gnd. In 1.6 wiring diagram it is stated what pin is +5, in 1.4 wiring there are no markings.

[Martin1775]

Hello Johannes,
My experience with my Think City is that the normal diagnostic devices do not find anything, because certain exhaust-relevant components (engine control unit) are queried first and only then the remaining components on the bus. The devices are intended for use on the defined OBD interface.
If I inserted a Ford petrol engine control unit into the CAN bus in parallel, I could address the remaining devices with the diagnostic device.
As far as I know, certain fixed addresses are queried to determine which vehicle it is.
If you know the address of the components, you can also address them directly via the CAN bus.
It may be that VCDS also provides results without the engine control unit, as it can be used to query specific components, but since the electronics in the Think are based on Ford, I have not tested it with VCDS.
Martin

[johu]

Ok, that makes sense. Then I was too quick to destroy ECU
In fact one OBD tool can connect to the instrument cluster (old version of K CAN Commander) but it cannot do anything. The other one (VW Tool) cannot connect to anything.
Anyway, someone on the Audi Forum said it's probably not possible to disable the oil sensor on this unit anyway, so I might have to fake one. It's a sort of PWM signal: https://wiki.a2-freun.de/wiki/index.php ... temperatur

Lastly, I'm not even 100% sure that the remaing beep error is caused by that.

[Doig5710]

I would be pretty sure that a vcds tool could disable the oil level sensor in either coding, adaptions or basic setting menus, I have done this on all sorts of VAG stuff over the years. Sometimes some Google searching helps with a answer in that department as vcds doesn't always have help sections on every menu.
Output is usually a duty cycle and variable frequency, 1 for oil temp, 1 for oil level, can't remember which way round though.

[geduxaz]

I would be pretty sure that a vcds tool could disable the oil level sensor in either coding, adaptions or basic setting menus, I have done this on all sorts of VAG stuff over the years. Sometimes some Google searching helps with a answer in that department as vcds doesn't always have help sections on every menu.
Output is usually a duty cycle and variable frequency, 1 for oil temp, 1 for oil level, can't remember which way round though.

1.Only some instrument clusters allow to disable oil sensor.
I will try to emulate this sensor.

2. As per wiring diagram, your ECU has no Kline, only CanBus diagnostics. So removing it from the system should not change how diagnostic to Kline works...

[geduxaz]

Hi, Johu. Just checked on my other A2. Unplugged engine ECU and was able to scan all other ECUs by VCDS successfully. I do not see any issues why you cant scan other ECUs without engine ECU. Maybe you unplugged something too much

And you cant disable oil sensor in instrument cluster. channel 38 is not active in it. I think all A2s are with oil sensor so engineers didn't enable this option. maybe we need to edit eeprom in the cluster. i will try to read it, but still cant think of any ways to find a location for oil sensor bits.

[geduxaz]

We should put Color MFD to have all the power info in the dash:
https://www.a2oc.net/community/index.ph ... ost-289150

[johu]

Cool, thanks for checking that!
A guy on A2 forum just made a little fake device: https://a2-freun.de/forum/forums/topic/ ... ent-622906
Apparently you can also buy the actual sensor and leave it dangling somewhere.

Did some CAD today:

[ZooKeeper]

Maybe substitute a vacuum sensor for oil?

[RetroZero]

Nice CAD drawing.

[geduxaz]

Cool, thanks for checking that!
A guy on A2 forum just made a little fake device: https://a2-freun.de/forum/forums/topic/ ... ent-622906
Apparently you can also buy the actual sensor and leave it dangling somewhere.

Did some CAD today:

Why you do not use original audi mount? will you have a rubber bushing there? or EV motors are so vibration free that you can mount it directly to frame?

[arber333]

Why you do not use original audi mount? will you have a rubber bushing there? or EV motors are so vibration free that you can mount it directly to frame?

Argh! NO dont bolt your motor directly to frame!
Seriously, electric motors need separators as well. It is just that they can use full rubber mounts (higher order damping) versus various engines that need spaced rubber because of lower frequency vibration and larger offsets in movement.

I think original Audi rubber mount would be OK with it. I assume it has some oil inside? You would just had to remodel the boltup interface.

[SuperV8]

Cool, thanks for checking that!
A guy on A2 forum just made a little fake device: https://a2-freun.de/forum/forums/topic/ ... ent-622906
Apparently you can also buy the actual sensor and leave it dangling somewhere.

Did some CAD today:

Regarding Audi A2 oil level sensors;

There are two versions for Petrol A2's with a VIN change
Petrol eng.+ AUA,BBY,BAD
1J0907660B VIN >> 8Z-2-070 000
1J0907660C superseded by 1J0907660F VIN 8Z-3-000 001>>

There are two versions for diesel A2's depending on engine PR code:
045907660D = AMF,BHC,ATL
045907660B = ANY

They are quite expensive sensors, OE priced around £100 for the petrols and £200 for the diesels, all used across many VAG models (except 045907660B which only fits A2 & Lupo!), Hella aftermarket versions look like about 50% the cost of the OE parts.

[johu]

Very good, thanks. I actually found one on ebay for 15€ or so.

I removed the fuel tank and remaining exhaust parts today and am again delighted by the very boxy space that makes. So I will be able to easily fit 24 Leaf modules (i.e. half of them) where the tank used to be.

We will cut out the floor and place a plastic box (800x330x230) into the void for weather protection. The actual battery brick will then be mounted with a set of angles into the longitudinal carriers. So the battery box has no structural task. The other brick will life directly on top of that, so the rear seats are gone. The owner prefers it that way. But we might also put them into the compartment below the boot. Time will tell