Subaru Legacy AWD 2008, Leaf motor

[Ruudi S]

This is my first all wheel drive car. Bought it because we have winters with snow and ice here. I am driving daily i-MiEV (RWD) or Leaf (FWD) and frequently feel that with one driving axle electric motor potential is not fully used. I have had a chance to try Jaguar i-pace, so I wanted and electric 4WD car for myself too.
The car was already without diesel boxer engine. Seller told me that this car was the first new diesel Subaru sold in Estonia. I want to give this car second life with electric power. Body is not bad, much better then my first car conversion. But I'll lift it up and then we'll see what I got. There are plastic covers on sides and under covers also, these need to be removed to see the real situation.
Buying decision was made when I saw here in openinverter forum two Legacy models that's conversion has been started. And I saw that these cars have electric power steering! This is very important since steering system changing is not allowed here. I will keep the original manual transmission to get it running like 4WD car should and attach first gen Leaf motor to it.
I haven't decided the way to build up the electrical system but I have full Leaf electric system in my garage with wiring and all the parts except battery. I have tried many months but not managed to get the Leaf harness and system to work yet. I am thinking of buying some 96S plug in hybrid pack for this project. I need to fit everything in engine compartment maybe onboard charger can be at the rear. Heating will be electric and webasto. Car was equipped with AC, someday may add leaf AC compressor also.
Here Chademo chargers are being replaced so the car needs a CCS fast charging system also.
Zombiverter would control most of the parts but does it handle the 2012 Leaf high voltage junction block
(actually it's called PDM power delivery module) and I got the answer from forum here:
viewtopic.php?f=17&t=5846

Re: Does the Nissan Leaf Gen 1 PDM work with Zombieverter?
Post by tom91 » Thu Dec 12, 2024 7:12 pm

It works with:

Inverter + Motor - Gen1, Gen2 and Gen3

PDM - Gen1, Gen2

Thank you tom91 for clarifying that!

[Ruudi S]

Today washed the car and lifted up for the first time. Under body plastic covers were broken and they carried a lot of sand. Some bolts didn't come loose and snapped. Removed the exhaust pipe I'll try to sell it, seems like its stainless steel so I don't know if anybody needs it.
In the summer I should sandblast the underfloor and stop the rust.
I'll find new used plastic covers.
Cut the clutch disk and got the center piece with spline for making the Leaf motor to subaru gearbox adapter.
Next I will try to fit the Leaf motor under the bonnet to see how to attach it to old engine attachment place.

[Ruudi S]

Trying for the first time how the Leaf motor fits

Motor and gearbox shafts are touching but there's still a gap. I'll make a adapter plate from steel about 14mm thickness. Motor position in this car is strange it's not horisontal and a lot of room is wasted under the motor but what to do, under there is very bad place for anything. Our roads in winter time are salty muddy and sandy. I'm thinking maybe adding somekind of frame and adding a few Leaf original motor mounts in addition to subaru original mounts. Then it would be easier to attach all the other parts like AC compressor, Leaf HV junction block, inverter, on board charger and so on.

[maland2]

Sweet build! I'll be following along since I'm also considering converting my '06 Outback. It sounds like you're planning on packaging the battery under the hood which makes sense, I've been struggling with figuring out how to package the modules in my build. Do you have any plans for active battery heating to allow charging below ambient? I saw you mentioned webasto, are you planning on using one of their coolant heaters like this? https://www.heatso.com/webasto-thermo-t ... truck-kit/

Good luck with your build!

[Ruudi S]

Sweet build! I'll be following along since I'm also considering converting my '06 Outback. It sounds like you're planning on packaging the battery under the hood which makes sense, I've been struggling with figuring out how to package the modules in my build. Do you have any plans for active battery heating to allow charging below ambient? I saw you mentioned webasto, are you planning on using one of their coolant heaters like this? https://www.heatso.com/webasto-thermo-t ... truck-kit/

Good luck with your build!

Thanks, I don't think I can fit the battery under the hood. At first I plan to use small cheap hybrid battery like bmw hybrid 10kWh and fit it in the boot. This is for getting the car just to drive and get it registered. Then I'll see what's available at the time and see what can be done.
Under the bonnet will be: motor, inverter, electic and fuel heater, onboard charger, AC compressor, high voltage junction block, vacuum pump.
I hope I don't need to heat the battery it heats when charging at night and also when driving. When thats' not enough then I'll deal with it, maybe some electric floor heater cable or leaf battery heater elements?
Yes webasto or eberspaecher, I am using them in my daily electric cars (i-MiEV and Leaf) fuel heater at cold wintertime one has diesel heater other has gas heater and I like gas heater, I don't like diesel heater smell and oily hands when adding fuel.
I'll add nissan leaf original electric coolant heater also for preheating when car is plugged in or the wheather is not so cold or at shorter trips. Would like to control it with OVMS app.

This winter I drove a few times 2006 Outback it was automatic and 2.0 petrol engine, it was amazing in the snow. But I didn't like the visits to gas station. Very expensive to drive 10 litres per 100 km. But difference with my car is that it didn't have electric power steering rack.
Does your car have electric power steering? My diesel had.

[Bratitude]

I have adapter plates for this, but if you want do them your self have the files posted

[Ruudi S]

I have adapter plates for this, but if you want do them your self have the files posted

Thanks I'll memorize your offer If I cannot make those plates myself. I have CNC plasma table at work. I am not sure if plasma is good enough accuracy for this kind of work but I'd give it a try. I use half of the leaf reducer case and also the reducer small input shaft with its splines.