EV Conversion Parts: Difference between revisions

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''<u>Notes from Tom: This page needs clean up !!!</u>''
== Motors ==
== Motors ==


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* Remy HVH-250
* Remy HVH-250


<br>There is a more general [[Motor List]] as well.
<br>There is a more general [[Motor List|motor list]] as well.


== Batteries ==
== Batteries ==
See the [[Batteries]] page for additional information.
CALB<br>
CALB<br>
LG Chem - BMW Hybrid<br>
LG Chem - [[BMW Hybrid Battery Pack|BMW Hybrid]]<br>
LG Chem - BMW I3<br>
LG Chem - BMW I3<br>
LG Chem - Chevy Volt<br>
LG Chem - Chevy Volt<br>
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== Brakes ==
== Brakes ==
Vacuum Pump 1
 
=== '''Vacuum Boosted''' ===
 
===== '''Vacuum Pumps''' =====
Vacuum pumps are available via several OEM and 3rd party manufacturers. Some options may include:
* [https://leedbrakes.com/p-33752-leed-brakes-bandit-series-vacuum-pump-kits.html Leed Brakes Bandit series] (apparently runs quiet)
* [https://www.aeroflowperformance.com/af49-1050-twin-piston-brake-vacuum-pump Aeroflow Performance Twin Piston Vacuum Pump Kit]
* The VAG 1J0612181B is a cheap and readily available pump used by VAG cars.
** These us 3 pins: +12v, Gnd and a sensing wire, which when brought to ground stops the pump.
** The part number for the relay on the side is: 1j0919433b
** The part number for the relay's connector is: 1J0 973 733
 
==== '''Vacuum Sensors:''' ====
* BOSCH 0 265 005 331 / 13581083
** Pin 3 - 5V
** Pin 2 - Gnd
** Pin 1 - Value - 0.48v under no vacuum
** Seems to have checkvalve built in.
 
=== '''Electrically Boosted:''' ===
There are a couple of options for electrically boosted braking systems, with one of the most popular being the [https://www.bosch-mobility-solutions.com/en/products-and-services/passenger-cars-and-light-commercial-vehicles/driving-safety-systems/brake-booster/ibooster/ Bosch iBooster].
 
More info on using the iBooster is available [https://www.evcreate.nl/electric-power-brakes/ here], and pinouts for the Tesla versions [https://www.evcreate.nl/wiring-the-tesla-ibooster/ here]
 
While the iBooster will provide brake assist with no inputs (failsafe mode), more sophisticated control (and integration with other systems) is possible using a [https://sghinnovations.com/product/ibooster-controller-ecu-gen2/ CAN-based controller such as this one from Seb Smith].
 
==== iBooster gen1 connectors: ====
Main connector (26-pin): Bosch "EuCon" 26p
 
* Main housing: 1928405762
* Cover: 1928405765
* Pins: Bosch BTC Terminal
** 1928498807 - BTC 4.8 / Terminal Sn / > 2.5 - 4.0 mm² (main power: pins 1 & 9)
** 1928498806 - BTC 2.8 / Terminal Sn / 1.5 - 2.5 mm² (constant power: pin 17)
** 1928498705 - BTC 1.5 / Terminal Sn / 0.35 - 0.5 mm² (ignition power: pin 20; signal pins 2, 8, 22, 23)
** 1928498805 - BTC 1.5 / Terminal Sn / 0.5 - 1.0 mm² (larger diameter alternative to 1928498705 above)
* Seals: Bosch BTC
** 1928301086 - BTC 4.8 / Seal / Blue (∅ 3.4 - ∅ 3.7 mm)
** 1928301206 - BTC 2.8 / Seal / Reddish Brown (∅ 2.0 - ∅ 2.7 mm)
** 1928301083 - BTC 1.5 / Seal / Grey (∅ 1.6 - ∅ 1.9 mm)
* Plugs: Bosch BTC
** 1928301207 - BTC 2.8 / Plug / Green
** 1928301087 - BTC 1.5 / Plug / White
 
Sensor connector (4-pin): TE MQS
 
* Housing: 1-967640-1
* Pins: 5-965906-5 (20 - 18 AWG)
* Seals: 1-967067-1 (∅ 1.4 - ∅ 2.1 mm)
 
==== iBooster Sourcing ====
{| class="wikitable"
|+VAG (VW, Audi, Porsche) part numbers:
!Part Number
!Generation
!Models available in
|-
|[https://parts.vw.com/p/65932554/5QE614105AH.html 5QE614105AH]
|
|Volkswagen e-Golf (2016-2018)
Audi A3 Sportback e-tron (2017)
|-
|5QE614105AK
|Gen 1
|Volkswagen e-Golf (2016-2018)
Volkswagen Passat GTE (2017)
 
Volkswagen Golf GTE (2017)
|-
|[https://parts.vw.com/p/74221192/5QE614105AN.html 5QE614105AN]
|Gen 2
|Volkswagen e-Golf (2018-2019)
|-
|[https://parts.vw.com/p/71928656/5QE614105AQ.html 5QE614105AQ]
|Gen 2
|Volkswagen e-Golf (2018-2019)
|-
|[https://parts.vw.com/p/65932554/5QE614105S.html 5QE614105S]
|
|Volkswagen e-Golf (2016-2018)
Audi A3 Sportback e-tron (2017)
|}
{| class="wikitable"
|+Tesla part numbers:
!Part Number
!Generation
!Models available in
|-
|1037123-00-A
|Gen 1
|Tesla Model S
Tesla Model X
|-
|1037123-00-B
|Gen 1
|Tesla Model S
Tesla Model X
|-
|1044671-00-D
|Gen 2
|Tesla Model 3/Y
|-
|1044671-00-E
|Gen 2
|Tesla Model 3/Y
|-
|1044671-99-F
|Gen 2
|Tesla Model 3/Y
|}
An alternative list (mostly the same) of iBooster donors can be found here: https://www.evcreate.nl/ibooster-donor-vehicles/
 
The start of a selection table can be found under [[Bosch iBooster]].


== Charger ==
== Charger ==
Line 28: Line 144:
[[Tesla Model S/X Charger|Tesla Gen 2 10kW(?)]]<br>
[[Tesla Model S/X Charger|Tesla Gen 2 10kW(?)]]<br>
[[Tesla Model 3 Charger/DCDC ("PCS")|Tesla PCS]]
[[Tesla Model 3 Charger/DCDC ("PCS")|Tesla PCS]]
[[Mitsubishi Outlander PHEV]]


== Contactors ==
== Contactors ==
[[EV Conversion Parts - Contactors - Panasonic AEV14012]]
[[Panasonic AEV14012 Contactor|Panasonic AEV14012]]


== DC/DC ==
== DC/DC ==
Chevy Volt / Lear<br>
Chevy Volt / Lear<br>
Prius Inverters
Prius Inverters
tesla model s


== High Voltage Junction Box ==
== High Voltage Junction Box ==
Line 40: Line 160:


== Power Steering ==
== Power Steering ==
[[EV Conversion Parts - Power Steering Pump - Opel_Astra]]
[[Opel Electric Power Steering Column]]
 
[[Opel Power Steering Pump]]
 
[[Toyota Prius Electric Power Assist Steering]]
 
[[VW Electromechanical Power Steering Rack]]
[[Category:Conversions]]
[[Category:Parts]]

Latest revision as of 11:01, 9 May 2025

Notes from Tom: This page needs clean up !!!

Motors

AC Induction Motors

  • Siemens 1PV5135-4WS14

PMSM (Permanent Magnet Synchronous Motors)

These Requires FOC Firmware.


There is a more general motor list as well.

Batteries

See the Batteries page for additional information.

CALB
LG Chem - BMW Hybrid
LG Chem - BMW I3
LG Chem - Chevy Volt
LG Chem - Chrysler Pacifica Hybrid
Tesla

Brakes

Vacuum Boosted

Vacuum Pumps

Vacuum pumps are available via several OEM and 3rd party manufacturers. Some options may include:

  • Leed Brakes Bandit series (apparently runs quiet)
  • Aeroflow Performance Twin Piston Vacuum Pump Kit
  • The VAG 1J0612181B is a cheap and readily available pump used by VAG cars.
    • These us 3 pins: +12v, Gnd and a sensing wire, which when brought to ground stops the pump.
    • The part number for the relay on the side is: 1j0919433b
    • The part number for the relay's connector is: 1J0 973 733

Vacuum Sensors:

  • BOSCH 0 265 005 331 / 13581083
    • Pin 3 - 5V
    • Pin 2 - Gnd
    • Pin 1 - Value - 0.48v under no vacuum
    • Seems to have checkvalve built in.

Electrically Boosted:

There are a couple of options for electrically boosted braking systems, with one of the most popular being the Bosch iBooster.

More info on using the iBooster is available here, and pinouts for the Tesla versions here

While the iBooster will provide brake assist with no inputs (failsafe mode), more sophisticated control (and integration with other systems) is possible using a CAN-based controller such as this one from Seb Smith.

iBooster gen1 connectors:

Main connector (26-pin): Bosch "EuCon" 26p

  • Main housing: 1928405762
  • Cover: 1928405765
  • Pins: Bosch BTC Terminal
    • 1928498807 - BTC 4.8 / Terminal Sn / > 2.5 - 4.0 mm² (main power: pins 1 & 9)
    • 1928498806 - BTC 2.8 / Terminal Sn / 1.5 - 2.5 mm² (constant power: pin 17)
    • 1928498705 - BTC 1.5 / Terminal Sn / 0.35 - 0.5 mm² (ignition power: pin 20; signal pins 2, 8, 22, 23)
    • 1928498805 - BTC 1.5 / Terminal Sn / 0.5 - 1.0 mm² (larger diameter alternative to 1928498705 above)
  • Seals: Bosch BTC
    • 1928301086 - BTC 4.8 / Seal / Blue (∅ 3.4 - ∅ 3.7 mm)
    • 1928301206 - BTC 2.8 / Seal / Reddish Brown (∅ 2.0 - ∅ 2.7 mm)
    • 1928301083 - BTC 1.5 / Seal / Grey (∅ 1.6 - ∅ 1.9 mm)
  • Plugs: Bosch BTC
    • 1928301207 - BTC 2.8 / Plug / Green
    • 1928301087 - BTC 1.5 / Plug / White

Sensor connector (4-pin): TE MQS

  • Housing: 1-967640-1
  • Pins: 5-965906-5 (20 - 18 AWG)
  • Seals: 1-967067-1 (∅ 1.4 - ∅ 2.1 mm)

iBooster Sourcing

VAG (VW, Audi, Porsche) part numbers:
Part Number Generation Models available in
5QE614105AH Volkswagen e-Golf (2016-2018)

Audi A3 Sportback e-tron (2017)

5QE614105AK Gen 1 Volkswagen e-Golf (2016-2018)

Volkswagen Passat GTE (2017)

Volkswagen Golf GTE (2017)

5QE614105AN Gen 2 Volkswagen e-Golf (2018-2019)
5QE614105AQ Gen 2 Volkswagen e-Golf (2018-2019)
5QE614105S Volkswagen e-Golf (2016-2018)

Audi A3 Sportback e-tron (2017)

Tesla part numbers:
Part Number Generation Models available in
1037123-00-A Gen 1 Tesla Model S

Tesla Model X

1037123-00-B Gen 1 Tesla Model S

Tesla Model X

1044671-00-D Gen 2 Tesla Model 3/Y
1044671-00-E Gen 2 Tesla Model 3/Y
1044671-99-F Gen 2 Tesla Model 3/Y

An alternative list (mostly the same) of iBooster donors can be found here: https://www.evcreate.nl/ibooster-donor-vehicles/

The start of a selection table can be found under Bosch iBooster.

Charger

Built-In
Chevy Volt / Lear
Tesla Gen 2 10kW(?)
Tesla PCS

Mitsubishi Outlander PHEV

Contactors

Panasonic AEV14012

DC/DC

Chevy Volt / Lear
Prius Inverters

tesla model s

High Voltage Junction Box

Building a junction box

Power Steering

Opel Electric Power Steering Column

Opel Power Steering Pump

Toyota Prius Electric Power Assist Steering

VW Electromechanical Power Steering Rack

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