2006 Audi A3 2.0 TDI. Symphony II PCCAR : OEM Indash Screen Prototype. Full pics!!

coucouillu · 04-16-2008, 06:09 PM

Hi all.

I have decided to start a worklog in order to show my work and have some advises all along my project.
With the experience I had with my old project in my Peugeot 306, in integrating all part in the car (the screen in the trunck, the VOOM case - for motherboard - under the dashboard, all cables under the carpet....), I was dreaming in a all in one solution, all in 2DIN size. Of course, you will tell me that there are 2 or 3 model which could fit into my dash like Infil G4 or other....But not OEM like I love.

So I thought about modify my current OEM radio into a home made prototype.

The project should be made with my old PCCAR parts and old prototype(s). Make some new with some old....

coucouillu · 04-16-2008, 06:10 PM

First of all, the car :

I have an october 2006 AUDI A3 Exclusive Line 170 HP. It has 27000Km.

It has a lot of good options.

Black/white leather
Moonroof
BiXenon headlights
18" wheels
Adjustable Steering Wheel
Auto AC with controls for driver and passenger
Auto-Dimming Rear-View Mirror
Bose Sound System
Center Console
Heated Seats (front only)
Leather Steering Wheel
Power Mirrors
Vanity Mirrors
Cruise Control
....

I saved money during 1.5 year to buy it.... I drove a french car for years and dreamed for a german one....

I am really satifacted with this car.

The only feature I would regret is the 4 motion.

It is really needed with this engine.

]

coucouillu · 04-16-2008, 06:10 PM

Before doing anything, I should be sure that what I want is feasible.

So I made some CADs under CATIA to learn more about space possibilities....

The first two pictures sow the unit with screen closed.

THe two last ones show the unit with the screen opened.

coucouillu · 04-16-2008, 06:11 PM

The RADIO which modification, you will see, is 80% of my project.

It is a SYMPHONY II, 6 CD Changer slot load + Tape.

The tape ??? It was good for my grand father, so no need of it. I removed it.

The CD changer ???? It isn't MP3. So no need of it. I removed it too.

You could see below that the Radio works without the CD chager and without the Tape mechanism.

So I decided to keep the OEM hardware for the Radio and to keep compatibility with orginal features like the BOSE system and the ODB dialog in my cluster (displays tha radio station name) :

Let's have a look inside :

You could see below that there isn't a lot of space in it.

coucouillu · 04-16-2008, 06:20 PM

I kept my very good Jetway J7F2WE2G, 2GHz for this project.

First modification was to remove all connector from the rear side of the Mobo.
All connections will be directly wired.
This process was long and risky (risk of burnt mobo).

Then, for better integration, I modified the heat sink because it interfered with the Radio modul of the OEM unit :

I also re-located 3 electronic composants in order to place the M3-ATX power supply :

coucouillu · 04-16-2008, 06:28 PM

I have chossen the M3 ATX because of its tiny dimensions.

I had to modify this part too.
It was to high in the case so I curved it at 90 degres.

I unsoldered the Blue ATX connector :

I cut a rectangular PCB with each side cut at 45° :

Done !

M3 ATX pluged on the Mobo:

coucouillu · 04-16-2008, 06:39 PM

The main job on the faceplate was to place the hole for the motorized indash screen and the "re-location" of the buttons.

So first, remove the CD crack and the top button and replace it with plasctic (piece of Sony PS2 case...

, It was the only thing under my hands).

I made it with an old solderer.

ATTENTION!! It is not healthy....

Then cut the exact dimensions of the screen :

FACEPLATE with moved buttons

CD EJECT and LOAD buttons are removed.

FACEPLATE puttied. Post #102

FACEPLATE painted. Post #105

coucouillu · 04-16-2008, 06:50 PM

It is a part from my old prototypes (V1 & V2) modified again for the mechanical part.

I took the mechanism of a LM Digital 6501.

Those mecanism are very reliable. I use them for years...

Details of the mechanism :

Some modifications have been made in order to fit with the composants of the screen:

And the screen is from a hacked indash Lilliput.

Here the pcb of the mechanism (Details POST #38) :

The LCD screen is an HITACHI 7" TX18D16VM1CAB from INDASH LILLIPUT GL701
Here is the HITACHI LCD SCREEN mainboard drived by a SyncMos SM89516 µcontroller :

It uses 8n1 SERIAL protocol to communicate.

Here are the different messages to send to it for each function :
(the last word is the checksum, sum of the previous bits)

Code:

'FLIP UP 		54,54,89,1C,4D
'FLIP DOWN 		54,54,89,1D,4E
'VGA 			54,54,8A,0,32	
'VIDEO1 		54,54,8A,1,33	
'VIDEO2 		54,54,8A,2,34	
'TV			54,54,8A,3,35
'SELECT C		56,56,AA,10,10,76
'CANNEL +		56,56,AA,10,10,76
'CANNEL -		56,56,AA,11,20,87
'TOGGLE			56,56,AA,2B,10,91
'MENU			56,56,AA,2C,10,92 (AVAILABLE IN TV MODE)
'DOWN			56,56,AA,11,10,77
'UP			56,56,AA,10,20,86
'+			56,56,AA,20,20,96
'-			56,56,AA,21,20,97
'0			56,56,AA,0,10,66
'1			56,56,AA,1,10,67
'2			56,56,AA,2,10,68
'3			56,56,AA,3,10,69
'4			56,56,AA,4,10,6A
'5			56,56,AA,5,10,6B
'6			56,56,AA,6,10,6C
'7			56,56,AA,7,10,6D
'8			56,56,AA,8,10,6E
'9			56,56,AA,9,10,6F
'_/__			56,56,AA,A,10,70