Allen Lee’s Successful Electric Conversion of a 1988 Toyota 4Runner: A DIY Journey

Allen Lee’s 1988 Toyota

Following a head gasket fail on my 4Runner’s 22RE 4-cylinder engine, in August of 2019, I decided that the only way to drive it more was if I were to convert this into an EV; it was barely giving me 15 mpg on gas.

Fourteen months later, I had built my electrified 4Runner, ready to hit the roads and trails once it passed California’s EV conversion certification. This was the perfect pandemic project: I worked for Amazon then, and I would have been traveling a lot for work otherwise. Everything was performed at home, using lots of CAD—and by CAD I mean Cardboard-Aided Design!

The Details

I opted for a Hyper9 HV 144V dual shaft motor (120hp, 173 ft-lb/220 Nm) since it is up to 95% efficient and provides more horsepower and more torque than the original engine (116hp, 140 ft-lb/190 Nm). The dual-shaft also drives the original air-conditioning compressor using a 22R harmonic balancer and modified factory idler.

I used lots of  CAD—and I mean Cardboard Aided Design!

The radiator has been gutted. It holds two smaller ones. One cools the inverter; the other is a spare for a future battery cooling system if required. A Flex-a-Lite cooling fan is mounted behind them for cooling the A/C condenser and EV batteries. The original coolant reservoir tank has been modified to supply recirculated red coolant to flow between a Toyota Prius inverter pump, 30 Row AN10 cooler, and the inverter chill plate.

A 2005 Toyota MR2 Spyder electric power-steering pump is used to drive the factory power-steering gearbox. Unfortunately, Toyota does not make a vacuum pump for power brakes, so a vacuum pump from a 2015 Chevy Spark is connected to the vacuum booster.

The dual 3kW chargers (TSM2500) are mounted on the factory engine skid plate. The 50A 12V DC-DC converter is located in the upper right of the engine compartment. Both the BMS and J1772 charge controllers are located under the dash.

Future Upgrades

I will eventually replace the four Chevy Bolt battery modules either with new replacement Bolt batteries (for an 8% increase in range) or other higher capacity batteries. The previous gas tank location is available for addition batteries and range if required.

Fun fact: When I plug in at public chargers, most folks think that I am “ICEing,” taking up an EV charging stall so no one can charge their EV. It did look out of place when I was charging it at Amazon, too. Another fun fact: Prior to converting my 4Runner, my daily driver was a 2006 Chevy HHR because it got double the gas mileage. The HHR has since been sold, and my daily vehicle is the 4Runner. Since I bought the 4Runner in December 2016, I have put more electric miles on it than gas.

To sum it all up, this has been a relatively challenging but highly rewarding experience. If you are contemplating a conversion, I’d say go for it! No need to wait for your gas engine to go bang!

Allen’s Top 5 Tips:

Try to reuse as many of the original drivetrain brackets and parts as possible. I reused the motor mounts and brackets, the radiator, A/C idle pulley, and the charcoal canister bracket (it now holds the motor inverter).

An engine hoist is not only useful to remove the engine and install the electric motor, but it is also ideal to test fit and install the heavy batteries.

In advance, purchase assorted sets of rubber grommets, connectors, screws, heat shrinks, waterproof cable glands, and the like. You never know how many you will need. This saves time and money.

Keep things simple. For example, I am using the Toyota MR2 electric power-steering pump. The factory setup controlled the power-steering pump based on the vehicle speed. I could have done the same, but it was much simpler to use a switch. I only turn it on when parking or in parking lots.

Get the original vehicle wiring diagram as you will have to interface to many of those circuits.

FREQUENTLY ASKED QUESTIONS

Are the battery cells positioned above or below the motor in an electric conversion?

In an electric conversion, the battery cells are typically placed below the motor. This arrangement ensures effective use of space and enhances vehicle stability by lowering the center of gravity. Whether you’re working with aftermarket kits from brands like EV West or custom solutions, placing the cells beneath the motor is a common practice to optimize performance and safety.

What is the process of completing an electric vehicle conversion project that is partially finished?

Completing a Partially Finished Electric Vehicle Conversion

Taking on a partially finished electric vehicle (EV) conversion project can seem daunting, but with the right steps, you can transform it into a rewarding experience. Here’s a comprehensive guide to help you navigate through the process:

1. Assess the Current State

• Inventory Parts and Components:Begin by evaluating what has already been completed. Make an inventory of all installed components and any uninstalled parts you have.
• Evaluate Quality and Compatibility:Determine the quality of the parts and verify they’re compatible with each other and the vehicle.

2. Develop a Game Plan

• Research and Study:Understand the fundamentals of EV conversions and familiarize yourself with the components involved—batteries, motors, controllers, and charging systems.
• Create a Detailed Plan:Outline each step needed to complete the conversion. This should include purchasing missing components, scheduling tasks, and setting a realistic timeline.

3. Secure Necessary Components

• Identify Missing Parts:Make a list of needed components such as batteries, electric motors, and controllers.
• Purchase from Reputable Suppliers:Consider suppliers like EV West, Electric GT, or Thunderstruck Motors for reliable parts.

4. Focus on Key Aspects of the Conversion

• Electric Powertrain:Ensure the electric motor is correctly installed, aligned, and connected to the drivetrain. Test fit the motor mounts and axles for stability.
• Battery System:Select the appropriate battery type (e.g., lithium-ion) and ensure it is securely mounted and wired. Balance the pack for optimal performance.
• Control Systems:Install the control system to manage power distribution effectively across the motor and other electrical components.

5. Safety and Regulatory Compliance

• Ensure Safety Measures:Install fail-safes such as circuit breakers and fuses. Check insulation of high-voltage systems.
• Meet Local Regulations:Verify the conversion complies with local traffic and environmental regulations. This might involve emissions checks and alterations to meet road safety standards.

6. Testing and Troubleshooting

• Conduct Thorough Testing:Before hitting the road, conduct extensive testing on all systems—check for electrical faults, measure performance metrics, and ensure everything operates smoothly.
• Troubleshoot Issues:Address any problems that arise during testing, whether they’re performance-related or technical.

7. Documentation and Final Touches

• Document the Journey:Keep a detailed log of all modifications, including schematics and parts lists. This documentation is invaluable for future maintenance and potential resale.
• Aesthetic and Functional Finishing:Add any final touches, such as interior upgrades, that enhance the vehicle’s usability and appearance.

By following these steps, you’ll be well on your way to successfully completing your electric vehicle conversion project. Remember, patience and meticulous attention to detail are crucial in ensuring a seamless transition to electric power.

How do people feel about converting classic vehicles to electric?

The Emotional Pull of Converting Classic Cars to Electric

Converting classic cars to electric vehicles evokes mixed emotions among enthusiasts. On one hand, there’s a profound sense of nostalgia tied to these timeless machines—the kind that makes the heart ache at the thought of losing the raw experience of manual gears and the unique mechanics that defined a bygone era. Many enthusiasts lament the loss of the familiar growl of the engine and the hands-on impracticalities like using a choke, which once connected driver to car in a deeply personal way.

Yet, alongside this sentimentality is an undercurrent of appreciation for the strides being made in technology. Modernizing these classics by integrating electric power ensures their survival in a world moving towards sustainability. This transformation helps keep them on the roads, breathing new life into old steel for generations to enjoy, albeit in a different form.

The change is bittersweet. While it’s exciting to witness the fusion of the old and the new, it’s also a reminder of what is gradually being left behind. Nevertheless, the conversion trend promises a future where these classics can continue to be appreciated, ensuring that their legacy lives on even as their original engines become relics of the past.

In summary, the shift to electric power represents a blend of reluctance to let go and eagerness to embrace a cleaner, more sustainable driving experience. It’s a journey through nostalgia into the future, where classic cars remain icons, albeit in a more environmentally friendly form.

What issues can dirty brushes cause in electric motors, and how do they affect waterproofing?

Dirty brushes in electric motors can lead to several problems, one of the most significant being a decrease in efficiency. As brushes collect dirt and debris, their ability to maintain a clean contact with the motor’s commutator is compromised. This can result in erratic electrical flow, leading to reduced motor performance or failure to function properly.

Another issue is the potential for increased wear and tear on both the brushes and the commutator, which may cause premature component failure and increase maintenance costs. Additionally, dirty brushes can generate excessive heat, which further compounds wear and might even lead to motor overheating.

In terms of waterproofing, while many electric motors are designed to be resistant to water ingress, dirty brushes can still pose a threat. If debris hampers the sealing mechanisms or causes misalignment, it could jeopardize the motor’s waterproof capabilities, making it vulnerable to moisture damage. Regular cleaning and maintenance of the brushes are essential to ensure optimal performance and to maintain the motor’s protective features against environmental challenges like water exposure.

What is an electric assist used for in vehicle conversions?

Electric assist systems play a crucial role in vehicle conversions, enhancing the driving experience by making steering more manageable. These systems are particularly beneficial in off-road or specialized vehicles where precise control is essential.

Key Benefits of Electric Assist Systems:

• Improved Steering Control:Electric assist systems provide additional torque, making it easier to steer, especially at lower speeds. This is particularly useful for vehicles equipped with larger tires or specialized suspensions.
• Enhanced Maneuverability:With electric assist, maneuvering tight trails or difficult terrains becomes less physically demanding on the driver, allowing for more precise handling.
• Reduced Driver Fatigue:By lessening the physical effort required for steering, these systems help reduce driver fatigue on long journeys, particularly in tough conditions.
• Versatile Applications:Apart from off-road vehicles, electric assist systems are also used in converting classic cars or custom builds that require refined handling without altering the vehicle’s original structure extensively.

Why Consider an Electric Assist?

Consider installing an electric assist if you are upgrading your vehicle for off-road adventures or if you simply want a smoother, more controlled driving experience on modified vehicles. Its ability to enhance steering performance significantly transforms how a vehicle handles diverse driving situations.

What changes are made during an electric conversion of a Toyota truck?

When converting a Toyota truck to electric, several key modifications are typically made to ensure optimal performance and comfort:

1. Battery Placement: The batteries, often the heaviest component, are strategically placed under the truck to maintain balance and utilize space efficiently.
2. Steering Assistance: An electric assist steering system can be installed, which is known for enhancing maneuverability. This system is beneficial, especially for heavy-duty vehicles ensuring smoother and easier steering.
3. Air Conditioning System: Since traditional air conditioning is usually powered by the engine, electric vehicles often upgrade to electric AC compressors. These are popular add-ons during conversions, enabling effective climate control without relying on the engine.
4. Heating and Cooling Solutions: Advanced conversions may incorporate a heat pump system, which is versatile enough to provide both heating and cooling. This dual-function system is compact and energy-efficient, perfect for managing cabin temperature.
5. Heater Installations: Directly powering resistant heating elements is a more straightforward option, although not as efficient as a heat pump. It is often used in budget-conscious conversions to deliver necessary heating.

By integrating these changes, a conventional Toyota truck can be successfully transformed into an efficient and functional electric vehicle.

What are the waterproofing considerations for electric motors like NetGain, Leaf, or Tesla used in vehicle conversions?

Waterproofing Considerations for Electric Motors in Vehicle Conversions

When it comes to converting vehicles with electric motors, understanding waterproofing is crucial for both functionality and longevity. Electric motors used in these conversions, like those from NetGain or sourced from vehicles such as the Nissan Leaf or Tesla models, have varying degrees of protection against water exposure. Here’s what you need to know:

Motor Enclosure Types

1. Open vs. Sealed Units
   Many older motor models were designed with open enclosures, which left them vulnerable to environmental elements like rain and dirt. However, modern electric motors, especially those adapted from electric vehicles (EVs) like Nissan Leaf and Tesla, typically feature sealed units. These sealed designs prevent moisture and contaminants from entering critical areas.
2. Impact of Water Exposure
   For open motors, exposure to water can lead to serious issues, akin to what happens with alternators in traditional vehicles. Water and debris can shorten their lifespan and lead to operational failures.

Maintenance and Precautions

• Inspect Regularly
  Regular inspections can help ensure the motor remains free of debris and that seals have not degraded. This proactive approach is essential, especially after driving in adverse conditions.
• Water Exposure Risks
  If a vehicle frequently encounters wet conditions or deep water crossings, additional waterproofing measures may be necessary. This could include applying specialized coatings or adding protective barriers.
• Brush Maintenance
  Although many contemporary motors minimize issues with brushless designs, those that do use brushes require regular checks. Dirt accumulation can impair performance, so keeping these components clean is vital.

In summary, while modern electric motors used in vehicle conversions are more water-resistant than older counterparts, understanding their limits and maintaining them appropriately ensures reliability. Whether opting for a fully sealed unit or reinforcing an existing setup, protecting against water invasion is key to a durable and efficient electric vehicle conversion.

What type of motor and transmission setup is used in some electric vehicle conversions?

I opted for a Hyper9 HV 144V dual shaft motor (120hp, 173 ft-lb/220 Nm) since it is up to 95% efficient and provides more horsepower and more torque than the original engine (116hp, 140 ft-lb/190 Nm). The dual-shaft also drives the original air-conditioning compressor using a 22R harmonic balancer and modified factory idler.

In addition to the motor upgrade, the conversion includes a 5-speed manual transmission. This choice maintains the classic driving feel while integrating seamlessly with the electric motor setup. The manual transmission allows for fine-tuned control and complements the enhanced performance of the electric motor, ensuring a dynamic and responsive driving experience.

This combination of a high-efficiency electric motor with a traditional manual gearbox not only boosts performance but also preserves the vehicle’s original character, blending the best of both worlds in this electric vehicle conversion.

What type of transmission is used in the conversion?

A 5-speed manual transmission is paired with the motor in the conversion.

What is the type of motor used in the conversion?

The conversion uses a 100 horsepower DC motor.

Where is the controller placed in an electric vehicle conversion?

Both the BMS and J1772 charge controllers are located under the dash. This setup allows for easy access during maintenance or troubleshooting, integrating seamlessly with the vehicle’s existing interior layout.

For those working on electric vehicle conversions, it’s important to note that the primary controller is often situated under the truck. This placement is strategic, offering protection and efficient space utilization, especially in truck models where space under the dash might be limited.

By positioning the main controller under the truck, you create a sturdy and accessible environment for key components while maintaining a clean and organized dashboard area. Such configurations ensure that the vehicle’s aesthetic and functionality are preserved, catering to both performance enthusiasts and those who prioritize ease of use.

What type of vehicle does their article imply by its description?

The description implies a larger vehicle, such as a truck, due to the context provided.

How does the placement of the controller in their article differ from that in your article?

Their article specifically mentions the controller being under a truck, which implies a larger vehicle context, unlike the more general placement of components under the dash in your article.

How is the response simplified in their article?

The response simplifies by focusing solely on the location of the controller and its associated cells without introducing additional components.

What components are associated with the controller in this setup?

The cells are associated with the controller in this setup.

Where is the controller located in a larger vehicle like a truck?

The controller is positioned beneath the truck.

How is an electric air conditioning system incorporated into older vehicles during an electric conversion?

A 2005 Toyota MR2 Spyder electric power-steering pump is used to drive the factory power-steering gearbox. Unfortunately, Toyota does not make a vacuum pump for power brakes, so a vacuum pump from a 2015 Chevy Spark is connected to the vacuum booster. The dual 3kW chargers (TSM2500) are mounted on the factory engine skid plate. The 50A 12V DC-DC converter is located in the upper right of the engine compartment. Both the BMS and J1772 charge controllers are located under the dash. A Flex-a-Lite electric cooling fan in conjunction with a Perform fan controller is used when the A/C is turned on and if the batteries get too hot.

Incorporating an electric air conditioning system into an older vehicle during an electric conversion is straightforward due to readily available components. Companies offer electric AC compressors specifically for electric vehicles, providing a seamless integration into existing AC systems. For those seeking versatility, there are advanced options like a baby heat pump, which can efficiently deliver both heating and cooling in a single package.

These systems are becoming commonplace in conversions, aligning with other necessary modifications such as the installation of a power-steering pump and vacuum pump. Just as the Flex-a-Lite electric cooling fan manages battery temperatures, the electric AC compressor or heat pump ensures optimal cabin comfort, making the transition to electric power more comprehensive and user-friendly.

Are there advanced climate control options for electric vehicle conversions?

Yes, there are more advanced options available, such as integrated systems that include a heat pump. These systems can provide both heating and cooling in one package, adding versatility to the climate control capabilities of the converted vehicle.

Is adding an electric AC system a common practice in vehicle conversions?

Indeed, incorporating an electric AC system is a standard practice when converting older vehicles to electric, especially if the original vehicle had an AC system.

Are electric AC compressors available for electric vehicles?

Yes, there are companies that specialize in selling electric AC compressors designed for electric vehicles. These components are readily available for those looking to convert vehicles to electric while maintaining air conditioning functionality.