Step 2 – Electric Motor Installation

Install the electric motor using a custom adapter plate. Precision alignment with the drivetrain centreline is critical – even 0.1 mm of misalignment causes premature bearing failure and vibration.

Procedure

1. Select motor type:PMSM (Permanent Magnet Synchronous) or AC Induction
2. Measure original bell housing dimensions precisely
3. Order or fabricate custom motor adapter plate to match flanges
4. Machine adapter plate to within 0.05 mm tolerance
5. Install new pilot bearing in transmission input shaft
6. Bolt motor to adapter plate and check all clearances
7. Trial fit assembly into engine bay – check all clearances
8. Fabricate front and read motor mounting brackets from 10mm plate
9. lower motor assembly into position, align with drivetrain centreline
10. use dial indicator to verify aligment – max 0.1 mm runout
11. torque all mounting hardware to spec and thread-lock
12. route motor phase cables (U,V,W) to controller location

Safety Warnings

1. Motor phase cables carry lethal voltage when energised
2. Use proper lifting equipment – motors weigh 40-80kg
3. Ensure motor is NOT energised during installation

Pro tip

Consider retaining the original gearbox for better low-speed torque. Many conversions use 2nd or 3rd gear at a fixed ratio. An EV with a gearbox typically gives better range.