Dismantling - Labeling Components Before Removing

It is an exciting and sort of nerve-racking experience to begin tearing down a vehicle. It is important before beginning to make some preparations. Label each wire and connector for later identification. Some wires, such as the start signal wire, will probably be used later for the EV subsystems.

Entire view of engine compartment.

Distributor cap - I'll be glad to be rid of this mess!

Cruise control vacuum unit.

Turbo intake tube in the middle, power steering reservoir on the lower left and brake fluid reservoir on the bottom right.

Another view of the distributor mess.

Coolant temperature sensor in the middle, valve cover top right-hand corner.

Another shot of the valve cover and coolant temperature sensor.

The throttle-body can be seen in the top left-hand corner, as well as the turbo intake tube in the top of the picture.

My favorite part under the hood was the valve cover with Turbo written on it.

A lower view of the engine. You can see the starter solenoid on the left, engine support in the middle, oil filter on the right, and the oil pressure sensor sending unit under the filter.

A one-way valve on the vacuum system. You can see a small vacuum reservoir in the bottom right-hand corner that was stock on the 200sx.

Several of the emissions control systems, e.g. EGR - exhaust gas recirculation.

A general view of the entire engine. What a mess!

This shot has the exhaust manifold protection cover and turbo intake tube removed.

Another view with a few parts removed.

Yet another.

You can see the vehicle wiring schematics in the upper left-hand corner. These were invaluable to help route signals through existing wires.

A final fiew of the internal combustion motor while still intact.

A view under the turbo hood.

You can see how I labeled everything under the hood for clear identification later. Some might skip this step, but inevitably, you'll need to know what some of the wire are at some point of the conversion.

Another final view with the labels visible. In retrospect, I would have used something other than masking tape. It tore easily and was affected by water and moisture.

 

 

Updated June 5, 2006



  1. Introduction
  2. End of Internal Combustion
  3. Dismantling
    1. Engine
      1. Labeling
      2. Parts Boneyard
      3. Removing
    2. Exhaust
    3. Gas Tank
    4. Heater
  4. Battery Racks
    1. Designing
    2. Building
    3. Installing
    4. Insulating/Heating
    5. Enclosure
  5. Driveline
    1. Motor Arrived
    2. Sending Transmission
    3. Motor Mounting
    4. Installing
    5. Cooling
  6. Electronics
    1. Cabling
      1. Crimpers
      2. Crimping Lugs and Terminals
      3. Installation
    2. Charging System
      1. House Wiring
      2. Charging Port
      3. PFC-20 Arrives
      4. Charger Control Board Revision
    3. Current Protection Devices
    4. DC/DC
    5. Heater
    6. Electronics Box
    7. E-meter
    8. Fuel Door
    9. Motor Controller
      1. Zilla Arrives
      2. Installing
      3. Liquid Cooling Version I
      4. Liquid Cooling Version II *
      5. Main Contactor
      6. Throttle
      7. Interfacing/Wiring
      8. User Interface
    10. Battery Regulators
      1. MK2
      2. PowerCheq *
      3. MK2B *
      4. Modular Chargers *
    11. Electronics Panel
    12. Tach Sensor
      1. Home-brew attempt
      2. Zolox unit *
    13. Gauge Interface *
    14. Miscellaneous Wiring
  7. Power Brakes
  8. Power Steering/AC
  9. Batteries
  10. Publicity/Displaying
    1. First-week Photos
    2. Utah State University Project Day
    3. Visits
  11. Appendix
    1. Preliminary Design Review: PDF PowerPoint Macromedia Flash OpenOffice
    2. Final Design Review: PDF PowerPoint Macromedia Flash OpenOffice
    3. Final Report: PDF Microsoft Word OpenOffice

* To be documented ... someday

Index updated November 25, 2006

© 2005 www.evsource.com
Logan, Utah USA