Audi A2 Conversion: Difference between revisions
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The ECU has two connector slots, a smaller one with pins 82-121 and a larger one with pins 1-81. Here we map out pins useful to us | The ECU has two connector slots, a smaller one with pins 82-121 and a larger one with pins 1-81. Here we map out pins useful to us | ||
[[File:VAG wire color codes.png|thumb]] | Connector numbering scheme: all start with part number 1J09737. The last two digits define pin count, arrangement and size. Examples: | ||
* 1J0973702 - 2 pins, small | |||
* 1J0973733 - 2x3 pins, large | |||
* 1J0973703 - 3 pins, small. | |||
* 1J0973723 - 3 pins, large | |||
* 1J0973713 - 2x3 pins, small | |||
So the last digits is the number of pins per row, second to last encodes number of rows and pin size. 0=1 row, small; 1=2 rows, small; 2=1 row large, 3=2 rows, large. The matching counterparts have an 8 in place of 7, e.g. 1J09738xx. When the part number ends in a G, the casing is keyed.[[File:VAG wire color codes.png|thumb]] | |||
{| class="wikitable" | {| class="wikitable" | ||
|+ECU pinout 1.4i (AUA, BBY) | |+ECU pinout 1.4i (AUA, BBY) | ||
Line 19: | Line 27: | ||
!our function | !our function | ||
!wire color | !wire color | ||
!Engine connector | |||
|- | |- | ||
|1,2 | |1,2 | ||
Line 24: | Line 33: | ||
|as is | |as is | ||
|br | |br | ||
| | |||
|- | |- | ||
|3 | |3 | ||
Line 29: | Line 39: | ||
| | | | ||
|ro | |ro | ||
| | |||
|- | |- | ||
|4 | |4 | ||
Line 34: | Line 45: | ||
|as is | |as is | ||
|ro/sw | |ro/sw | ||
| | |||
|- | |- | ||
|5 | |5 | ||
|Lambda (first) heater | |Lambda (first) heater | ||
|Reverse light | |Reverse light loopback | ||
|gr | |gr | ||
|733 1 | |||
|- | |- | ||
|28 | |28 | ||
Line 44: | Line 57: | ||
| | | | ||
|li/bl | |li/bl | ||
| | |||
|- | |- | ||
|33 | |33 | ||
Line 49: | Line 63: | ||
|as is | |as is | ||
|gr/ge | |gr/ge | ||
| | |||
|- | |- | ||
|34 | |34 | ||
Line 54: | Line 69: | ||
|as is | |as is | ||
|br/gn | |br/gn | ||
| | |||
|- | |- | ||
|35 | |35 | ||
Line 59: | Line 75: | ||
|as is | |as is | ||
|ge/bl | |ge/bl | ||
| | |||
|- | |- | ||
|36 | |36 | ||
Line 64: | Line 81: | ||
|as is | |as is | ||
|br/ro | |br/ro | ||
| | |||
|- | |- | ||
|38 | |38 | ||
Line 69: | Line 87: | ||
| | | | ||
|ws | |ws | ||
| | |||
|- | |- | ||
|39 | |39 | ||
Line 74: | Line 93: | ||
| | | | ||
|ro/ge | |ro/ge | ||
| | |||
|- | |- | ||
|40/41 | |40/41 | ||
Line 79: | Line 99: | ||
| | | | ||
|sw/ge sw/gr | |sw/ge sw/gr | ||
| | |||
|- | |- | ||
|43/54 | |43/54 | ||
Line 84: | Line 105: | ||
| | | | ||
|gn/sw bl/ws | |gn/sw bl/ws | ||
| | |||
|- | |- | ||
|51/52 | |51/52 | ||
Line 89: | Line 111: | ||
|CAN for Prius | |CAN for Prius | ||
|bl/ws ge | |bl/ws ge | ||
|733 6/3 | |||
|- | |- | ||
|55/56 | |55/56 | ||
Line 94: | Line 117: | ||
| | | | ||
|ws/ro ro/sw | |ws/ro ro/sw | ||
| | |||
|- | |- | ||
|57 | |57 | ||
Line 99: | Line 123: | ||
| | | | ||
|bl/ro | |bl/ro | ||
| | |||
|- | |- | ||
|58/60 | |58/60 | ||
Line 104: | Line 129: | ||
|as is | |as is | ||
|or/br or/sw | |or/br or/sw | ||
| | |||
|- | |- | ||
|63 | |63 | ||
Line 109: | Line 135: | ||
| | | | ||
|li/ro | |li/ro | ||
| | |||
|- | |- | ||
|64 | |64 | ||
Line 114: | Line 141: | ||
|vacuum pump GND | |vacuum pump GND | ||
|bl/ge | |bl/ge | ||
|722G moved to 722 | |||
|- | |- | ||
|65 | |65 | ||
Line 119: | Line 147: | ||
| | | | ||
|ro/br | |ro/br | ||
| | |||
|- | |- | ||
|68/69 | |68/69 | ||
Line 124: | Line 153: | ||
| | | | ||
|bl/br ro/li | |bl/br ro/li | ||
| | |||
|- | |- | ||
|70/71 | |70/71 | ||
Line 129: | Line 159: | ||
|LIN for A/C, fake oil pressure | |LIN for A/C, fake oil pressure | ||
|bl sw | |bl sw | ||
|733 5/4 | |||
|- | |- | ||
|72 | |72 | ||
Line 134: | Line 165: | ||
|as is | |as is | ||
|gr | |gr | ||
| | |||
|- | |- | ||
|73 | |73 | ||
Line 139: | Line 171: | ||
| | | | ||
|ge/li | |ge/li | ||
| | |||
|- | |- | ||
|75/76 | |75/76 | ||
Line 144: | Line 177: | ||
| | | | ||
|bl/sw sw/ro | |bl/sw sw/ro | ||
| | |||
|- | |- | ||
|82 | |82 | ||
Line 149: | Line 183: | ||
| | | | ||
|gr/br | |gr/br | ||
| | |||
|- | |- | ||
|85 | |85 | ||
Line 154: | Line 189: | ||
|brake vacuum | |brake vacuum | ||
|gr | |gr | ||
|704 | |||
|- | |- | ||
|86 | |86 | ||
Line 159: | Line 195: | ||
| | | | ||
|ro/sw | |ro/sw | ||
| | |||
|- | |- | ||
|87 | |87 | ||
Line 164: | Line 201: | ||
| | | | ||
|gn/sw | |gn/sw | ||
| | |||
|- | |- | ||
|88/89 | |88/89 | ||
Line 171: | Line 209: | ||
|sw/li li/sw | |sw/li li/sw | ||
br/bl sw/gn | br/bl sw/gn | ||
| | |||
|- | |- | ||
|83/84 | |83/84 | ||
Line 180: | Line 219: | ||
Throttle body motor | Throttle body motor | ||
| | |dcsw (83), prec (84), charge(91) | ||
|ro/gn gn/bl | |ro/gn gn/bl | ||
ro/bl li/ro | ro/bl li/ro | ||
gn br/sw | gn br/sw | ||
|713 | |||
2/4, 6/1, 3/5 | |||
|- | |- | ||
|93 | |93 | ||
Line 190: | Line 231: | ||
| | | | ||
|gr/ws | |gr/ws | ||
| | |||
|- | |- | ||
|98 | |98 | ||
Line 195: | Line 237: | ||
|as is | |as is | ||
|gn/li | |gn/li | ||
|704 | |||
|- | |- | ||
|99 | |99 | ||
Line 200: | Line 243: | ||
| | | | ||
|ws | |ws | ||
| | |||
|- | |- | ||
|100 | |100 | ||
Line 205: | Line 249: | ||
|EGR pot | |EGR pot | ||
EGR mot | EGR mot | ||
| | |Fake engine oil | ||
|br/li | |br/li | ||
li/ge | li/ge | ||
|1J0973713G | |||
6/5 | |||
|- | |- | ||
|102/103 | |102/103 | ||
|Ignition coil bank 1/2 | |Ignition coil bank 1/2 | ||
| | | | ||
|gn/ws gn/ro | |gn/ws gn/ro | ||
| | |||
|- | |- | ||
|106 | |106 | ||
Line 218: | Line 265: | ||
| | | | ||
|br | |br | ||
| | |||
|- | |- | ||
|108 | |108 | ||
Line 223: | Line 271: | ||
|as is | |as is | ||
|gr/ro | |gr/ro | ||
| | |||
|- | |- | ||
|109 | |109 | ||
Line 228: | Line 277: | ||
| | | | ||
|bl/gn | |bl/gn | ||
| | |||
|} | |} | ||
{| class="wikitable" | {| class="wikitable" |
Revision as of 16:21, 15 February 2022
On this page we describe the conversion of an Audi A2 1.4i petrol to electric propulsion. We will use the following components:
- Nissan Leaf 24 kWh battery pack with original BMS
- Toyota Prius Gen 2 (2004-2009) transaxle with matching inverter
- openinverter Prius Gen2 motor controller
- openinverter main board running stm32-car (VCU in ECU enclosure)
Pin mapping
We start out by mapping out useful pins of the original wire harness
ECU
The ECU has two connector slots, a smaller one with pins 82-121 and a larger one with pins 1-81. Here we map out pins useful to us
Connector numbering scheme: all start with part number 1J09737. The last two digits define pin count, arrangement and size. Examples:
- 1J0973702 - 2 pins, small
- 1J0973733 - 2x3 pins, large
- 1J0973703 - 3 pins, small.
- 1J0973723 - 3 pins, large
- 1J0973713 - 2x3 pins, small
So the last digits is the number of pins per row, second to last encodes number of rows and pin size. 0=1 row, small; 1=2 rows, small; 2=1 row large, 3=2 rows, large. The matching counterparts have an 8 in place of 7, e.g. 1J09738xx. When the part number ends in a G, the casing is keyed.
# | orig function | our function | wire color | Engine connector |
---|---|---|---|---|
1,2 | GND | as is | br | |
3 | permanent 12V | ro | ||
4 | ignition 12V | as is | ro/sw | |
5 | Lambda (first) heater | Reverse light loopback | gr | 733 1 |
28 | From generator (maybe DF) | li/bl | ||
33 | Throttle second pot +5V | as is | gr/ge | |
34 | Throttle second pot (signal) | as is | br/gn | |
35 | Throttle first pot (signal) | as is | ge/bl | |
36 | Throttle first pot +5V | as is | br/ro | |
38 | To cruise control switch * if installed | ws | ||
39 | Clutch pedal sensor * if installed | ro/ge | ||
40/41 | To Climate control display | sw/ge sw/gr | ||
43/54 | To instrument cluster (function unknown) | gn/sw bl/ws | ||
51/52 | Lambda (first) signal | CAN for Prius | bl/ws ge | 733 6/3 |
55/56 | Brake light switch NC/NO to +12V | ws/ro ro/sw | ||
57 | To cruise control switch * if installed | bl/ro | ||
58/60 | CAN-L CAN-H | as is | or/br or/sw | |
63 | Lambda (second) heater | li/ro | ||
64 | Charcoal filter solenoid | vacuum pump GND | bl/ge | 722G moved to 722 |
65 | Fuel pump relay- control | ro/br | ||
68/69 | Lambda (second) signal | bl/br ro/li | ||
70/71 | Lambda (first) signal | LIN for A/C, fake oil pressure | bl sw | 733 5/4 |
72 | Throttle second pot GND | as is | gr | |
73 | Throttle first pot GND | ge/li | ||
75/76 | To cruise control switch * | bl/sw sw/ro | ||
82 | Engine speed sensor | gr/br | ||
85 | Intake manifold Temp/Pressure | brake vacuum | gr | 704 |
86 | Hall sender G40 signal | ro/sw | ||
87 | Engine speed sensor | gn/sw | ||
88/89
96/97 |
Injector 1-4 | sw/li li/sw
br/bl sw/gn |
||
83/84
91/92 117/118 |
Throttle body senror
Throttle body sensor Throttle body motor |
dcsw (83), prec (84), charge(91) | ro/gn gn/bl
ro/bl li/ro gn br/sw |
713
2/4, 6/1, 3/5 |
93 | Coolant temp sensor | gr/ws | ||
98 | +5V wiring to engine bay | as is | gn/li | 704 |
99 | Knock sensor | ws | ||
100
114 |
EGR pot
EGR mot |
Fake engine oil | br/li
li/ge |
1J0973713G
6/5 |
102/103 | Ignition coil bank 1/2 | gn/ws gn/ro | ||
106 | Knock sensor | br | ||
108 | GND for engine sensors | as is | gr/ro | |
109 | Intake manifold Temp/Pressure | bl/gn |
# | Org Function | Ours | Color |
---|---|---|---|
1/2 | GND | br br | |
3/5 | permanent 12V | gn/ge gn/ge | |
4/20/21
39/40 |
First Lambda | ge ro/ge bl/ge
br/ge li/gr | |
6 | N290 Fuel metering valve | ro/bl | |
7 | Fuel pump relay control | ro/br | |
8/10 | CAN-H CAN-L | or/sw or/br | |
11/16/31
32/50 |
NOX controller | sw br/ws bl
ws/sw ge/ro | |
12 | Heater output switch | ge/br | |
13/17/30 | Air mass meter | gr/ro gr/ws li/ws | |
14 | Thermo-switch for coolant circulation | ro/ws | |
15/18/43
33/19/24 |
Throttle POT1/2 (signal/Gnd/+5) | ge/li br/ro ge/li
br/gn gr/ge gr | |
23/46 | Climate cotroler | sw/gr sw/ge | |
26/45 | Radiator fan controller | sw/ge ge/gr | |
35 | EGT | ro/gn | |
36 | Brake vaccum sensor | bl/br | |
37 | Sensors GND | ge/bl | |
48/57 | Brake light switch NO/NC | ro/sw ws/ro | |
42 | +5V to sensors | ge/gn | |
49/51/52/55 | Cruise control switch * If installed | bl/sw ws sw/ro bl/ro | |
53 | To airbag ECU | ws/bl | |
59 | Instrument cluster | gn/sw | |
60/80 | NOX heater | br/ws br/ws | |
62/64 | Current supply relay | ro gr/ro | |
65 | Generator DF | li/br | |
67 | Clutch pedal switch * if fitted | ro/ge | |
78 | N79 crankcase breather heater | br | |
81/100/101
108/109 |
Coils | ro/sw ro/bl ge/gn
ge/bl gn/ge | |
82/90 | G28 Engine speed sensor | gr/br gr/ro | |
83 | G40 Hall sender | br/bl | |
84 | G71 Intake manifold pressure sens | ge/ro | |
85/87/96 | EGR sensor + motor | li/gr li/ws ro/ws | |
86 | Coolant temp sensor | gr/ws | |
88 | N316 Intake manifold flap valve | li/ge | |
89 | F265 Controlled cooling thermostat | ro/br | |
91 | G336 Intake flap potentiometer | ge/ro | |
94 | G247 Fuel pressure sensor | gr | |
99 | +5V to sensors | li/ro | |
105 | N205 Inlet Camsh. timing valve | li/gn | |
113 | N276 Fuel pressure regulating valve | gn/bl | |
92/93102
107/118/121 |
Throttle body | li/ge li/gr ws
ro/gn ro/bl li | |
103/110/111 | Knock sensor | br br ws | |
106 | Sensor gnd in engine bay | gr/gn | |
114/115
116/117 119/120 |
Injectors 1-4 | br/ge br/ws
br/gn br/ro br/bl br/sw |
Silence errors
After disconnecting the engine and removing the ECU we have 3 errors: Low coolant level, low oil, ABS/ESP. Coolant level can be silenced by simply shorting out the corresponding sense pins. We will use the coolant reservoir of the Prius inverter. We might insert a sensor for super neat integration, but not for now.
Low oil can probably be cured by coding of the instrument cluster like in Touran:
I programmed the instrument cluster to ignore the missing sensor. You need a CAN OBD adapter with matching software. Then in adaptation channel 39 change value to 0 (=sensor not present). Found here: http://wiki.ross-tech.com/wiki/index.php/VW_Golf_(1K)_Instrument_Cluster
And finally ESP is silenced by sending appropriate CAN message as stm32-car does.