Audi A2 Conversion
Jump to navigation
Jump to search
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
# | orig function | our function | wire color |
---|---|---|---|
1,2 | GND | br | |
3 | permanent 12V | ro | |
4 | ignition 12V | ro/sw | |
5 | Lambda (first) heater | gr | |
28 | From generator (maybe DF) | li/bl | |
33 | Throttle second pot +5V | gr/ge | |
34 | Throttle second pot (signal) | br/gn | |
35 | Throttle first pot (signal) | ge/bl | |
36 | Throttle first pot +5V | 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 | bl/ws ge | |
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 | or/br or/sw | |
63 | Lambda (second) heater | li/ro | |
64 | Charcoal filter solenoid | bl/ge | |
65 | Fuel pump relay- control | ro/br | |
68/69 | Lambda (second) signal | bl/br ro/li | |
70/71 | Lambda (first) signal | bl sw | |
72 | Throttle second pot GND | 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 | gr | |
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 |
ro/gn gn/bl
ro/bl li/ro gn br/sw | |
93 | Coolant temp sensor | gr/ws | |
98 | +5V wiring to engine bay | gn/li | |
99 | Knock sensor | ws | |
100
114 |
EGR pot
EGR mot |
br/li
li/ge | |
102/103 | Ignition coil bank 1/2 | gn/ws gn/ro | |
106 | Knock sensor | br | |
108 | GND for engine sensors | 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 |