Peugeot 406 Coupe EV conversion

Talk about the 406's electrical system, what wires do what, how to add extra functionality, etc.

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Welly
The moderator formally known as Welton
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Re: Peugeot 406 Coupe EV conversion

Post by Welly »

Good update there! keep up the good work.

Check out this guys Video, staggering amount of work but brilliant too:

Cars in my care:

2005 Volvo S40 T5 German Diesel botherer with new tyre grippage
2010 Citroen C4 1.6 HDi turbo de' explosions, bizarre gearbox model
2010 Renner Twingo refreshingly simple

arber333
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Re: Peugeot 406 Coupe EV conversion

Post by arber333 »

Tnx this guy was my inspiration when i started my Mazda conversion in 2013. https://mazdamx3ev.wordpress.com/

Since then DIY inverter became reality, i made my DIY 3phase charger and Mazda made 150000km on electric. Its getting worn out too.
https://openinverter.org/forum/
Last edited by arber333 on Fri Jan 31, 2020 9:05 am, edited 1 time in total.

arber333
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Re: Peugeot 406 Coupe EV conversion

Post by arber333 »

I managed to get a quick test drive up and down the driveway to test Drive/Reverse signaling.
I had everything connected in my relay circuit so that EHPAS and vacuum pump worked. Since i had brakes and steering i told myself; now or never!
And i drove down the street and turned at intersection and drove back. I didnt have 12V DCDC converter active at the time so i was a bit afraid not to drain small AGM battery too much. It is only 35Ah.

However test drive was a success! The car shoot down the road and i had a great control of throttle and steering wheel.
I just love the ride quality. I never thought it would be that smooth. It is like riding a magic carpet.
I will try to record a video when i get DCDC working :).

Doggy
Mod with a 2.2 HDi, De-Fapped!
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Re: Peugeot 406 Coupe EV conversion

Post by Doggy »

That's great news, well done. 8)
2002 HDi 2.2 Exec Estate, (2008-12)
2003 HDi 2.2 6-speed Exec Estate (2012-19)
2009 Citroen C5 2.0 HDi VTR+ Estate

PeterN
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Re: Peugeot 406 Coupe EV conversion

Post by PeterN »

The extra weight of those batteries can't be doing the ride any harm. :wink:

Peter

frog
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Re: Peugeot 406 Coupe EV conversion

Post by frog »

Nice work, good progress :D Keep us posted!
Current "fleet":
2003 406 Estate 2.0HDi 110 - 7 seater
2001 Citroen Saxo 1.6i 8v 100

Previously owned:
2000 406 Sedan 2.0 HDi 90
2000 406 Coupé 2.0i 16v 138 - Riviera Blue

PP2000 user, can help with faults / diagnostics in the Netherlands.

arber333
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Re: Peugeot 406 Coupe EV conversion

Post by arber333 »

Well two steps forward and one back :cry: .
I needed to take apart the front battery box. While driving i heared some noises from the shaft and i needed to investigate. I found some wheel bolts untorqued and RPM sensor flange was hitting a bracket! Corrected now.

While Pug is very drivable, i cant seem to get speedo to show correct speed.
Since i got rid of the defunct ATX with it i lost speedo sensor. Just my luck that it pics up signal at final drive and not from ABS rings.
Well i went on and tried the reference and i figured i can use output shaft rotation with some 6.3 divider circuit. So at 840RPM on wheels i need to show dash 135Hz in order for it to display 100km/h.
I made a collar for my drive shaft and fitted a magnet with one digital hall sensor to read RPM.
I setup Arduino divider, but as i see it my function generator makes square signal that dips 2V below GND level. This works perfectly well with speedo. Now my Arduino reads RPM signal, but it sends square pulses that are in reference to GND. I guess this doesnt work with speedo... Probably speedo on the dash counts GND crossings. I need to change my circuit to get signal to dip below GND for a volt or 2.

arber333
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Re: Peugeot 406 Coupe EV conversion

Post by arber333 »

Today was a good day! I got my Pug rolling with all support elements operational. I still see DCDC is overheating and i need to turn it around and provide some better 12V cooling fans. Maybe i will also need to provide fresh air to inside of trunk.

We got liftoff and i tried various throttle pedal settings with and without regen.

[youtube]https://www.youtube.com/watch?v=wVFfeTLZY84[/youtube]

I also found out the source of vibration. I didnt lock driveshaft bearing in place! Of course i didnt have the retaining plate since driveshafts were second hand. After a while i forgot about the fact RH shaft was only supported radially. I need to get a driveshaft bearing retainer to fix driveshaft in place. There is some wobbling in driveshaft when accelerating and regen and i am cautious because the bearing can be moved by hand.
I found online Nissan declares the retainer part 39776JD000 a consumable and to be replaced everytime driveshafts are taken off.
https://www.ebay.com/itm/NISSAN-OEM-11- ... 2784598170

arber333
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Re: Peugeot 406 Coupe EV conversion

Post by arber333 »

I got the speedo working as well. And yesterday i managed to get RPM to 850turns. ABS and some other relays under the hood started clicking. I get functioning brake system and i think my AC will start working now... I hope.
https://leafdriveblog.wordpress.com/202 ... edo-works/
https://leafdriveblog.wordpress.com/202 ... r-working/

Say, does anyone know the pot values for the throttle body? The only errors now on ECU remain two for the throttle body. I suspect this is the only cause for the engine warning light to stay lit.
If some of you know the throttle values maybe i can set it up to convince ECU to clear the errors.

My Pug was 406c 3.0L ES9J4S - XFX engine and auto transmission.
Attachments
PEUGEOT(DTC)_968590058628_20200522230635.pdf
(425.16 KiB) Downloaded 8 times

arber333
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Re: Peugeot 406 Coupe EV conversion

Post by arber333 »

OK, let me be more exact.
I need the voltage values from throttle body when car is running in idle. Could someone measure their throttle body connector contacts 1 and 2 (A1 and A2) which are outputs from throttle pot. You should measure either against chassis GND or pin 4 which is also GND.

Anyone with 3.0L V6?

tnx

steve_earwig
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Re: Peugeot 406 Coupe EV conversion

Post by steve_earwig »

I don't have a 406 to look at any more I'm afraid, but as far as I remember all the 406 throttle pots are the same, so presumably is the output. Unfortunately I can't verify this any more :evil: but even if they're not they must be somewhere close.

Impressive to see the thing moving under its own power 8)
Unskilled meddling sin©e 2007

2004 D9 2.0 HDi 110 Estate lhd VF38ERHZF81657352 - sold but being very well looked after.
1991 Yamaha TDM850 - fuel leaks galore!
2008 Toyota Recall4 2.0 VVTI ATM LHD JTMBH31V90D007261 - flimsy piece of crap.
1953 Matchless G3LS - It's alive!!

NinoB
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Re: Peugeot 406 Coupe EV conversion

Post by NinoB »

Hi.. Can 406 V6 ecu bsi key work perfectly on 406 2001 ew10 ecu bsi key?

frog
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Re: Peugeot 406 Coupe EV conversion

Post by frog »

Impressive results!

Regarding the accelerator pedal sensor, you already have the answer in the other forum:
From the "DW10ATED Engine - Accelerator Pedal Sensor.pdf" document I just e-mailed to you:
7.3 - Electrical features.
Allocation of the connector channels :
  • Channel 1: Output signal 1.
  • Channel 2: Output signal 2.
  • Channel 3: 5 volts.
  • Channel 4: Earth.
Accelerator pedal released :
  • Voltage between earth and channel 1: 0,5 volt.
  • Voltage between earth and channel 2: 0,28 volt.
Accelerator pedal pressed fully down :
  • Voltage between earth and channel 1: 3,35 volts
  • Voltage between earth and channel 2: 1,6 volt.
As far as I can check, your pedal sensor is the same as that for a DW10ATED (HDI) engine.
Current "fleet":
2003 406 Estate 2.0HDi 110 - 7 seater
2001 Citroen Saxo 1.6i 8v 100

Previously owned:
2000 406 Sedan 2.0 HDi 90
2000 406 Coupé 2.0i 16v 138 - Riviera Blue

PP2000 user, can help with faults / diagnostics in the Netherlands.

NinoB
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Posts: 148
Joined: Tue Jul 22, 2014 10:39 am

Re: Peugeot 406 Coupe EV conversion

Post by NinoB »

NinoB wrote:
Wed May 27, 2020 10:24 am
Hi.. Can 406 V6 ecu bsi key work perfectly on 406 2001 ew10 ecu bsi key?
Any advice

arber333
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Posts: 41
Joined: Wed May 09, 2018 10:02 am

Re: Peugeot 406 Coupe EV conversion

Post by arber333 »

Thanks for the voltages. I set my sensor up so it would be pretentioned as with a spring and pedal wire.
When i connected throttle sensor and wedged it in system started to behave strangely. After some minutes running good I got a warning from my dash that engine is overheating! There is also other development. 
1. Because of overheating cooling fans deploy
2. ATX relays start to chatter and i get warning of low battery voltage from ATX computer even though battery is at 14Vdc.
3. Errors on dash say: AT transmission defective, Engine is overheating. Of course first one is missing completely and the other one doesnt have oil temp sensor connected.
4. ABS cries error, but only because i turned one wheel up so it just needs me to drive it for a short time.

I think now i have to connect Oil temp sensor. DOH! To be honest I prepared and marked the wires so i can quickly pull them out and fit oil sensor rod somewhere in the car.What will be next? Fuel-air butterfly position sensor? Air mixture sensor...

A

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