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
- Select motor type: PMSM (Permanent Magnet Synchronous) or AC induction
- Measure original bell housing dimensions precisely
- Order or fabricate custom motor adapter plate to match flanges
- Machine adapter plate to within 0.05 mm tolerance
- Install new pilot bearing in transmission input shaft
- Bolt motor to adapter plate and check all clearances
- Trial fit assembly into engine bay – check all clearances
- Fabricate front and read motor mounting brackets from 10mm plate
- lower motor assembly into position, align with drivetrain centreline
- use dial indicator to verify aligment – max 0.1 mm runout
- torque all mounting hardware to spec and thread-lock
- route motor phase cables (U,V,W) to controller location
Safety Warnings
- Motor phase cables carry lethal voltage when energised
- Use proper lifting equipment – motors weigh 40-80kg
- 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.