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Here's the service intervals. When you change the reduction gearbox oil also change the sealing washers on the drain and filler plugs.

Modern AC recharging machines will evacuate the system without releasing any R134a into the atmosphere (which is illegal in most areas). The refrigerant get captured, weighed and filtered by the machine to be reused back in the car. I just had mine done and my local garage has a hook-up charge...

Great stuff Justin. Mine has now done 500 miles since being repaired. The only issue has been the gear linkage at the rear being a bit stiff, but after several lubrications and usage it's now moving freely.

My recently acquired 2012 iOn has done 16,000 miles but sat for over 2½ years at 80% SOC without being used at all until I fixed it. My battery shows 40.8Ah capacity. The RR (remaining range) shows between 70 and 81 miles when fully charged. I've driven it down to no bars showing and 2 miles RR...

Another option would be to upgrade the car to 3ø. Muxsan.com offers this upgrade for the Leaf and from what I can tell they add 2x 3.6kW chargers that work in parallel with the existing charger. Each charger works off of one of the phases. Obviously this would be a technically challenging...

Hi Gary, The hybrid board should read the voltage across pins 1 & 2 (HV and VL) and output the same voltage across pins 3 & 4 while maintaining isolation between the pack voltage and the 12 volt system. The main pcb will have a ADC that measures this voltage and then convert that voltage to the...

The SIP package would allow a pcb that used all the original mounting points. It is however longer and may need an extra insulation layer between it and the main pcb, or higher standoffs. I was considering doing a design for the SIP, however the parts library I used only had the DIP version, so...

I've got 1 of my original boards left. I'll order some more if that one goes. I've tweaked the design a bit, any suggestions? The mounting holes are 0.125 inch or just over 3mm and will fit common adhesive stand-offs. The end tabs can be snapped off at the V-cuts if you don't need them. If I...

Before you solder them into the mainboard, can you get a picture of them and the AD202 on my board so I can see if there is clearance? Another idea for fixing to the bottom cover would be self-adhesive Velcro fixed to the top of the AD202 so the board is mounted upside-down.

MCU voltage and pack voltage should always stay the same except for a slight voltage drop due to small resistances in the wires, connections, contactors, etc. On regen the MCU will raise the voltage on the HV bus but it will still be the same at the MCU and battery pack. I agree with this but on...

The pin spacing is 0.1" or 2.54mm. Those are listed at 1.25mm. I suppose you could solder in the wires at both ends. I've got 90 miles so far on mine, no problems. :) I wouldn't expect it to. Basically, as I understand it, the BMS reports battery voltage and the MCU reports the voltage it's...

What do people think of this design? I've added snap off sections on both ends to allow fixing to the inside of the bottom cover with adhesive pcb standoffs, or snap them off to mount like I did.

So far my car is working great with my PCB. It's now been MOTed and road taxed. I drove it quite hard to clean up the brakes after sitting for over 2½ years and it never missed a beat. No warning lights or fault codes set. The 6 volt difference between condenser voltage and pack voltage seems to...

I could add some break-off ears to my design that would allow people to use adhesive PCB standoffs for mounting to the bottom cover with fly-leads, or snap them off to mount vertically. What do people think of this idea?

I've got 2 boards left, I've sent you a PM. I am going to try and design a board for the SIP package which should fit better and then order both boards from China to make available for anyone else who needs one. The SIP package should be a better fit but harder to find than the DIP package

I was able to find the AD202 because of the excellent work already done here to document the existing ISA215N board. :) Understanding how it worked gave me the info to investigate possible alternatives. The AD202 is marked by the manufacturer as 'unsuitable for new designs' so production may...

Here's a schematic of the DIP pins to the main PCB connections. The 3 pin connectors on the right labelled pins 1-3 go to pins 3-5 respectively on the main pcb

I'm just using automotive gasket sealant, it should peel away if the cover needs removing in the future.

PM me your address and I'll post you one of my spare boards.

Here's some more pictures of my installation. I'm going to put another blob of sealant at the top of the board so it bonds with the lower cover. My concern is that the solder joints could crack due to vibration so hopefully the sealant will prevent this from happening.