Audi A2 Conversion: Difference between revisions

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* Nissan Leaf 24 kWh battery pack with original BMS
* Nissan Leaf 24 kWh battery pack with original BMS
* Toyota Prius Gen 2 (2004-2009) transaxle with matching inverter
* Toyota Prius Gen 2 (2004-2009) transaxle with matching [[Toyota Prius Gen2 Inverter|inverter]]
* openinverter Prius Gen2 motor controller
* openinverter [[Toyota Prius Gen2 Inverter Controller|Prius Gen2 motor controller]]
* openinverter main board running stm32-car (VCU in ECU enclosure)
* openinverter main board running [https://github.com/jsphuebner/stm32-car/tree/audi-a2 stm32-car] (VCU in ECU enclosure)


== Pin mapping ==
== Pin mapping ==
We start out by mapping out useful pins of the original wire harness
We start out by mapping out useful pins of the original wire harness.


The semi-oval connectors are used throughout the engine bay. Numbering scheme: all start with part number 1J09737xx. 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.
=== ECU ===
=== 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
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]]
 
[[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 26:
!our function
!our function
!wire color
!wire color
!Engine connector
|-
|-
|1,2
|1,2
|GND
|GND
|
|as is
|br
|
|
|-
|-
Line 29: Line 38:
|
|
|ro
|ro
|
|-
|-
|4
|4
|ignition 12V
|ignition 12V
|
|as is
|ro/sw
|
|
|-
|-
|5
|5
|Lambda (first) heater
|Lambda (first) heater
|Reverse light loopback
|gr
|733 1
|-
|28
|From generator (maybe DF)
|
|
|li/bl
|
|-
|33
|Throttle second pot GND
|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 GND
|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
|Drive mode selection
|li/ro
|Cable from rear lambda
|-
|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
|Drive mode LEDs
|bl/br ro/li
|Cable from rear lambda
|-
|70/71
|Lambda (first) signal
|dcsw (70), prec (71)
|bl sw
|733 5/4
|-
|72
|Throttle second pot 5V
|as is
|gr
|gr
|
|-
|-
|73
|Throttle first pot 5V
|as is
|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
|
|
|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 oil pressure
Fake engine oil
|br/li
li/ge
|1J0973713G
6/5
|-
|102/103
|Ignition coil bank 1/2
|gn/ro - LIN
|gn/ws gn/ro
|1J0973724
|-
|106
|Knock sensor
|
|
|br
|
|
|-
|108
|GND for engine sensors
|as is
|gr/ro
|
|
|-
|109
|Intake manifold Temp/Pressure
|
|
|bl/gn
|
|}
Many positions in the connector are vacant and we populate them with signals that we need to direct to the BMS in the back of the car. I'm using a CAT5 Ethernet cable for that. It is simply routed under the seat carpet.
{| class="wikitable"
|+Additional pins on unused positions
!#
!our function
!wire color
!Comment
|-
|-
|28
|6
|From generator (maybe DF)
|CANH to BMS
|bl
|
|-
|7
|CANL to BMS
|bl/ws
|
|-
|8
|Permanent 12V to BMS
|or
|
|-
|9
|Switched 12V to BMS
|or/ws
|
|-
|10
|Charging active to BMS
|gn/ws
|
|-
|11
|Fuel tank simulation
|gn
|PB7 via NPN
|-
|12
|DC switch HV+
|br
|Forwarded from inverter (70)
|-
|13
|Precharge relay
|br/ws
|Forwarded from inverter (71)
|}
{| class="wikitable"
|+ECU pinout 1.6FSI
!#
!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
|
|
|li/bl
|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
|-
|-
|33
|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
|-
|-
|34
|26/45
|Throttle second pot (signal)
|Radiator fan controller
|
|
|br/gn
|sw/ge ge/gr
|-
|-
|35
|35
|Throttle first pot (signal)
|EGT
|
|
|ge/bl
|ro/gn
|-
|-
|36
|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
|-
|-
|40
|49/51/52/55
|To Climate control display
|Cruise control switch * If installed
|
|
|sw/ge
|bl/sw ws sw/ro bl/ro
|-
|-
|41
|53
|To Climate control display
|To airbag ECU
|
|
|sw/gr
|ws/bl
|-
|-
|43
|59
|To instrument cluster (function unknown)
|Instrument cluster
|
|
|gn/sw
|gn/sw
|-
|-
|51
|60/80
|Lambda (first) signal
|NOX heater
|
|br/ws br/ws
|-
|62/64
|Current supply relay
|
|
|bl/ws
|ro gr/ro
|-
|-
|52
|65
|Lambda (first) signal
|Generator DF
|
|
|ge
|li/br
|-
|-
|54
|67
|To instrument cluster (function unknown)
|Clutch pedal switch * if fitted
|
|
|bl/ws
|ro/ge
|-
|-
|63
|78
|Lambda (second) heater
|N79 crankcase breather heater
|
|
|li/ro
|br
|-
|-
|64
|81/100/101
|Charcoal filter solenoid
108/109
|Coils
|
|
|bl/ge
|ro/sw ro/bl ge/gn
ge/bl gn/ge
|-
|-
|65
|82/90
|Fuel pump relay- control
|G28 Engine speed sensor
|
|
|ro/br
|gr/br gr/ro
|-
|-
|68
|83
|Lambda (second) signal
|G40 Hall sender
|
|
|bl/br
|br/bl
|-
|-
|69
|84
|Lambda (second) signal
|G71 Intake manifold pressure sens
|
|
|ro/li
|ge/ro
|-
|-
|70
|85/87/96
|Lambda (first) signal
|EGR sensor + motor
|
|
|bl
|li/gr li/ws ro/ws
|-
|-
|71
|86
|Lambda (first) signal
|Coolant temp sensor
|
|
|sw
|gr/ws
|-
|-
|88
|88
|Injector 3
|N316 Intake manifold flap valve
|
|
|sw/li
|li/ge
|-
|-
|89
|89
|Injector 4
|F265 Controlled cooling thermostat
|
|ro/br
|-
|91
|G336 Intake flap potentiometer
|
|
|li/sw
|ge/ro
|-
|-
|96
|94
|Injector 1
|G247 Fuel pressure sensor
|
|
|br/bl
|gr
|-
|99
| +5V to sensors
|
|li/ro
|-
|105
|N205 Inlet Camsh. timing valve
|
|li/gn
|-
|113
|N276 Fuel pressure regulating valve
|
|gn/bl
|-
|-
|97
|92/93102
|injector 2
107/118/121
|Throttle body
|
|
|sw/gn
|li/ge li/gr ws
ro/gn ro/bl li
|-
|-
|98
|103/110/111
| +5V wiring to engine bay
|Knock sensor
|
|
|gn/li
|br br ws
|-
|-
|100
|106
|EGR pot
|Sensor gnd in engine bay
|
|
|br/li
|gr/gn
|-
|-
|114
|114/115
|EGR mot
116/117
 
119/120
|Injectors 1-4
|
|
|li/ge
|br/ge br/ws
br/gn br/ro
 
br/bl br/sw
|}
|}
== Silence errors ==
[[File:Tog2.png|thumb|Wave form to silence oil level warning]]
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.
ABS is solved just like in [[Touran Conversion]]
Same goes for oil pressure. With the sense line permanently shorted to GND we get an error at 0 rpm, with it open we get an error above 500 rpm or so. So we generate a signal that only pulls to GND above 700 rpm. I inserted the single pin into the grey 6-pin connector and bridged it to the VCU-generated signal on that same connector.
Low oil can only be cured by supplying the required signal: https://wiki.a2-freun.de/wiki/index.php/G266_-_Geber_f%C3%BCr_%C3%96lstand_und_%C3%96ltemperatur
I simulate the signal with a simple IO pin that is toggled "manually" as the time constants are rather long.
[[Category:VAG]] [[Category:Conversions]]

Latest revision as of 08:08, 24 May 2024

On this page we describe the conversion of an Audi A2 1.4i petrol to electric propulsion. We will use the following components:

Pin mapping

We start out by mapping out useful pins of the original wire harness.

The semi-oval connectors are used throughout the engine bay. Numbering scheme: all start with part number 1J09737xx. 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.

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

VAG wire color codes.png
ECU pinout 1.4i (AUA, BBY)
# 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 GND 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 GND 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 Drive mode selection li/ro Cable from rear lambda
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 Drive mode LEDs bl/br ro/li Cable from rear lambda
70/71 Lambda (first) signal dcsw (70), prec (71) bl sw 733 5/4
72 Throttle second pot 5V as is gr
73 Throttle first pot 5V as is 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

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 oil pressure

Fake engine oil

br/li

li/ge

1J0973713G

6/5

102/103 Ignition coil bank 1/2 gn/ro - LIN gn/ws gn/ro 1J0973724
106 Knock sensor br
108 GND for engine sensors as is gr/ro
109 Intake manifold Temp/Pressure bl/gn

Many positions in the connector are vacant and we populate them with signals that we need to direct to the BMS in the back of the car. I'm using a CAT5 Ethernet cable for that. It is simply routed under the seat carpet.

Additional pins on unused positions
# our function wire color Comment
6 CANH to BMS bl
7 CANL to BMS bl/ws
8 Permanent 12V to BMS or
9 Switched 12V to BMS or/ws
10 Charging active to BMS gn/ws
11 Fuel tank simulation gn PB7 via NPN
12 DC switch HV+ br Forwarded from inverter (70)
13 Precharge relay br/ws Forwarded from inverter (71)
ECU pinout 1.6FSI
# 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

Wave form to silence oil level warning

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.

ABS is solved just like in Touran Conversion

Same goes for oil pressure. With the sense line permanently shorted to GND we get an error at 0 rpm, with it open we get an error above 500 rpm or so. So we generate a signal that only pulls to GND above 700 rpm. I inserted the single pin into the grey 6-pin connector and bridged it to the VCU-generated signal on that same connector.

Low oil can only be cured by supplying the required signal: https://wiki.a2-freun.de/wiki/index.php/G266_-_Geber_f%C3%BCr_%C3%96lstand_und_%C3%96ltemperatur

I simulate the signal with a simple IO pin that is toggled "manually" as the time constants are rather long.

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