Assembly Instructions for Electric Vehicle Conversion Kit for VW
Note: To begin this process, go over kit components list and familiarize yourself with the parts.
1._ Begin by sliding the coupler onto the series motor and tighten set screw. Take a measurement to make sure the splines match up, and adjust the shaft coupler accordingly. Bolt on adaptor plate to the motor using the four mounting holes on the motor. The motor is now ready to be installed.
2._ Using a floor jack or engine hoist, lift motor and slide onto transmission shaft. Rotate slightly to mesh the splines in the transmission shaft to the coupler. (If you can lift 80 lbs. this can be done by hand.) Slide motor plate assembly flush against transmission bell housing. Put in the four bolts or nuts around bell housing and tighten. You might have to cut off 1" or so off the transmission shaft for it to be flush against the transmission bell housing being that the motor shaft and transmission shaft will hit each other leaving 1/8' to a 1/4" gap still. Don’t tighten the bolts until you cut it.
3._ Build battery racks or install preassembled battery racks. Mount rear battery rack (4 - 6 batteries) behind or under back seat and bolt or weld to car frame. Additional batteries for the VW can be added in the gas tank compartment by removing the gas tank or cutting off the top of the tank (Make SURE it is cleaned, or fill with water first) .
4._ Run the large #2/0 Ga. cable from back to front if using more batteries than can fit in the engine compartment. Go under rear seat and between front seats and through the firewall. Make sure one cable is marked with red on both ends for the (+) positive terminal. Sometimes you can go through the a/c tubing holes in the firewall. Secure the cable.
5._ Install throttle box in engine compartment. It’s easiest to use self-tapping screws and secure it right to the inside of the firewall. Make sure you don't screw into your already placed batteries behind the seat. Attach "L" bracket the correct distance from the throttle box to mount the throttle cable sleeve. Attach cable to throttle box and adjust for proper range of travel.
6._ Mount controller, contactor, fuse, and shunt in an appropriate location in engine compartment. It is best to keep parts as close together as possible to make for short cable connections. Follow included schematics and pictures for best locations.
7._ Mount amp meter and volt meter in appropriate location on or near the dash. We usually mount them in front of the fuel and temperature gauges.
8._ Build heavy #2/0 Ga. wire cables using high current ring terminals or battery cable terminals. There will be eight, plus a few more depending on your battery setup: Battery (-) to controller (B-); Controller (M-) to motor; Motor to controller (B+); Controller (B+) to shunt; Shunt to contactor; Contactor to fuse; Fuse to motor; and one for the jumper on the motor. Please consult the wiring diagram for controller and the motor. Connect up all these cables. Build battery to battery jumpers using battery cable terminals. Connect batteries together. For the last connection, it is important to just tap the battery terminal with the cable . With a controller you will get an initial short spark, but only one. If arching occurs, re-check wiring for correct polarity. The controller will also blink red if wired improperly. If done correctly it will blink green for initial turn on and then will stay a steady green. This would be for the Alltrax Controller.
9._ Run the light gauge wire to amp meter and volt meter. Wire contactor to 12 volt accessory battery system through the key ignition switch. It is important NOT to wire the contactor in with the main battery pack. The voltage sag will cause the contactor to chatter and can destroy parts. Install 12 VDC accessory battery in existing battery rack (use deep cycle battery for best performance). Connect to existing wiring in vehicle. Wire the 5-k throttle box and key-on connections according to the schematic. The vehicle can now be tested. Make sure it is in neutral with parking brake applied or on jack-stands when testing for the first time. Never stand in front of the vehicle during this test!
10._ Wire main charger (36 - 72 VDC) to battery pack. Wire auxiliary charger (12 VDC) to accessory battery. Wire these two chargers together and to a charger port, usually located in front of vehicle, or in small gas tank compartment door. After test driving the vehicle, plug in and recharge.
As with a Gas Motor,
Never! Never! Never apply power to the motor without a load!!!
(Revving the motor in Neutral) You will blow the motor and the warrantee
WILL NOT cover it!
Welcome to the family of EV Drivers!