2012 Nissan Leaf Drive System Tabletop Demo

Описание: Part 1:    • 2012 Nissan Leaf Teardown / Component Loca...  
Part 3:    • 2012 Nissan Leaf Minimal Drive System Demo  

Build thread on my plans to transplant the Leaf electric drive system into a 1973 Saab Sonett III.
http://www.diyelectriccar.com/forums/...
Documentation I've been putting together regarding the required components to keep the drive system functional:
http://www.diyelectriccar.com/forums/...

Currently connected: Motor/transaxle, Inverter, DC Junction Box, Charger, Charge port, QC Port, Battery, LBC/BMS, Battery JB, Safety Disconnect, Park Motor/Controller, IPDM and fuse boxes, VCM, BCM, Shifter and Gear Display, ESC (Shift Controller), Main and Upper Combination Meters, AV Unit and cluster switches, Menu buttons, Start button, NATS receiver, Front Interior SKS receiver, interior I-Key antennas, int buzzer and speaker, Pedal box (accelerator, brake position sensor and brake switches), 12V accessory battery, Cooling system water pumps (electrical only), coolant temp sensor, heater (HV only), AC Compressor HV cable with interlock defeated.

Hookup requires all 4 primary low voltage wiring harnesses: Main, Body, Motor Room, Motor Control. Not included are door harnesses and room lamp harness. All HV harnesses are connected to complete interlock.

Omitted currently are steering wheel controls, EPS and steering spiral sensor, steering column combination switch, HVAC inc AC compressor and HV heater (control), coolant / heating plumbing, all brakes (IBU, ABS, wheel sensors, yaw sensor, parking brake controller and motor, brake backup power supply, pressure sensors), all airbag components and controller, all door switches, seat heaters and switches, speakers, Digital audio unit, battery heaters and relay/control, interior / exterior lighting, TCU, GPS and TCU antennas, radiator fans.

Current status: After start up, drive ready light blinks for several seconds then goes solid. Once solid, can shift to D/N/R and transaxle spins in creep, and responds to accelerator. No response from brake pedal, I believe due to IBU not connected. May test this soon. After powering down, requires resetting DTCs on VCM before it will go ready again. I don't see a specific DTC causing this, may just be VCM reboot? Charging at L1 is now working fine, but the heater and charger HV DC lines were reversed at the time this video was shot which was preventing charging. This was also the cause of the long period of blinking before going ready, and the need to clear DTCs after powering down.

Current DTCs in "On" after clearing:
BCM:
U1000 CAN Com
U0415 Vehicle Speed (ABS)
B2557 Vehicle Speed (ABS / Comb Meter mismatch)
B2626 Outside 1 Antenna
B2627 Outside 2 Antenna
B2628 Outside 3 Antenna (door key sensors)
Charger: OK None
EV/HEV (VCM):
P3194 CAN Error (ABS)
P3195 CAN Error (IBU)
U1000 CAN Com
P31B9 CAN Error (Electronic Parking Brake)
P31EE AC Refrigerant Pressure Sensor
P31E8 Water Pump 1
P31EA Water Pump 2
P31B7 CAN Error (Airbag)
P31B8 CAN Error (TCU)
P1564 ASCD Switch (Steering Wheel Switch)
HVAC:
B2579 In-Vehicle Sensor
B2582 Intake Sensor
B278D Compressor Com
B2777 PTC Heater Com
B2790 Heat Pump Com
HV Battery: OK
IPDM: OK
Meter:
U1000 CAN Com
Motor Control: OK
MultiAV:
U1000 CAN Com
U1258 XM Antenna
U1244 GPS Antenna
U1266 TCU Com
Shift:
U1000 CAN Com

DTCs that were occurring after trying to charge with HV wiring problem:
EV/HEV (VCM):
P31C8 On Board Charger System (Charge Relay (-) Stuck)
P31C9 On Board Charger System (Charge Relay (+) Stuck)

These last 2 DTCs may be what need to be cleared before it will go ready again after driving and power cycling. They also may be interfering with charging, though I don't remember seeing them during previous charge attempts. I'll have to try that and check again.