[FIRST DRIVE] Project Rising Sun: Suzuki SJ410k meets Leaf full stack

[Mhs]

Fabricobbled a mount for the Audi/VAG vag vas pump and Volvo vac switch...

Very nice built, which volvo vac switch are you using? Could you please share the part number?

[J0hannes]

Sorry, can't tell the part number sice I don't have one. I just browsed online wreckers with Volvo vacuum hose as search word and bought the one that had the part and connector.
The wreckers don't seem to know either what this is or to which category to put it as I didn't see a pattern while browsing the listings.
But here's one listing to demonstrate that at least this part isn't expensive to source
https://rrr.lt/en/used-part/dev383977-v ... -pipe-hose

[J0hannes]

Cleaned up the main fuse box and pulled out a few meters of copper. Then made some mounts (brackets).

Yet another scrap piece of metal found a new life as a sparse comb

Wip on the spaghetti, but hey it's cleaning up

Installed quite nicely to Suzuki air box mounts

Been hunting terminals
The single mini fuse terminal seems to be Sumitomo 8100-1233 (-1236, -1237) / Yazaki 7126-8850 (-8851, -8852)

Two-way Yazaki 7126-8822

The terminals used in relay sockets I have not identified yet
Possibly Yazaki F250-M-LC-M, See Rakuten

[tom91]

Looks alot like the things MTA would also use in their products https://www.12voltplanet.co.uk/mta.html

Or the TE terminals https://www.te.com/commerce/DocumentDel ... t=880398-2
https://www.te.com/en/product-881572-3.html

Then again its a Suzuki so likey uses Japanese terminals.

[J0hannes]

Then again its a Suzuki so likey uses Japanese terminals.

Oh, key piece of information left out in my post, I was working on the Leaf main harness (or what's left of it)
But yes, Japanese connectors/terminals are the usual suspects anyways

Most of the connectors on the Suzuki harness look like they are Sumitomo 250 series sealed and unsealed
DS 250, MT 090 and some others, luckily these are well available

I suspect that my parts donor Leaf was made in the UK, wire harnesses are made in France as they have French labels when you peel away all the sheathing and tape. For reference, I'll try to remember to get a picture next time around.

[J0hannes]

Today I got all the pumps running and updated to latest Zombieverter FW to make a test drive outside. Well, no test drive yet as there is some hiccup in reversing

The TRW pump needed just the alternator signal switched to inverter on and it was screaming again like there's no tomorrow. Water pumps are getting quieter, there must have been some air in the lines regardless of the fancy vacuum filling. Wired up the VW heater, but it did not seem to want to heat. Didn't do much diagnosing on that yet.

Heater params were VW, control enable, power 6500W and HeatPercent 100. I also used PB3IN as Heat request and that didn't seem to change things either. Tips are welcome I have the R50 and C45 changed as per the note mentioned in Zombieverter hardware NOTE : R50 will need to be changed to 1k and C45 to 1n in order for LIN to work properly. This will be amended on further builds. So if you have a board ordered before 14/03/24 this change is required.

Taming the spaghetti has proceeded as expected and there are very few on the "get back to this later" -list

Zombieverter will find its new home under the glovebox, similarly to the ICE ECU I had mounted there. That way I don't have to "recalibrate" my max water level

Had ordered a new LV connector for battery, crimped and pinned that. Reused the blind plugs from old connector. I'll save that for any and all possible future use scenarios

Since I have now tried 3 different FW releases and none of them had any torque in reverse, I started to look into this and did some CAN logging. Maybe my 2017 30kWh Leaf driveline (stack and battery) is a snowflake, or is it possible that this is a bug left unexposed? I don't know, but I will find out

Alishit, found the perfect high voltage warning sticker

[tom91]

eater params were VW, control enable, power 6500W and HeatPercent 100. I also used PB3IN as Heat request

Please post your params. You know PB3 is a pull to ground. Did you see the Heat request spot value go to ON?

[J0hannes]

Please post your params. You know PB3 is a pull to ground. Did you see the Heat request spot value go to ON?

Yes, heat request spot value changes to ON.

Params are same as I'm using now to test the 2.31 TH (with fw version this the heater works!)

[tom91]

he 2.31 TH (with fw version this the heater works!)

So the latest code from the Vehicle Testing branch has the heaters working?

Which FW version were you testing with before?

[J0hannes]

So the latest code from the Vehicle Testing branch has the heaters working?

Which FW version were you testing with before?

2.20A official release

[tom91]

2.20A official release

Yes that had a LIN bug, the main branch has fix and is being tested by Damien to release.

[J0hannes]

Well, in the meanwhile...

I've been sorting out the spaghetti and did a little test spin

[marcexec]

Congrats! One EV grin at a time

[J0hannes]

Congrats! One EV grin at a time

Yes! Feeling like a winner

Also
Tested today the quick fix by Tom91 for Zombieverter Leaf CAN messages and boy does it feel good to have torque in reverse!

Gave a shot on redoing the intermediate driveshaft. Been wanting to try out oil fill for balancing, so here goes nothing!

[J0hannes]

Had found a suitable cable feed through for HV battery cable from the boat section of local auto parts shop

As I have route it through the cockpit. Also had some interface plates cut, so I have something more rigid to mount the feed through to

I'll try to remember to snap a pic of the end result too

The hood closes now

Coolant reservoir would have had enough clearance

Leaf PDM doesn't really clear it, but damn that's close

It looked like it was close and so it is, but still the original bed sides fit.

Its still a WIP, but I figured that I can use the Leaf battery mounts also to build an interface to mount the bed sides