The van up on cribs. Cribbing is a popular technique to get your car up off the ground high enough to actually do things to it. If you plan on doing it yourself, measure three times, cut once. Test a million times over before crawling under the vehicle. I basically rammed myself into the side of the van to see if it'd fall over before ever crawling underneath it.
Removing all Gasoline Parts
I won't belabor too much of this process as most of these specifics don’t apply to any other vehicle than the Acty. But after removing the rear suspension I moved onto the engine. Before breaking into that I bled all the fluids, oil, coolant, and gasoline. Then I started removing air hoses, fuel lines, and coolant/water lines. Using the “translated” van manual I started disconnecting the clutch cables, shift cables, throttle cable, and some of the electronics.
I pulled out the gas tank, and all the air conditioning components which was tough because this van came specially equipped with air conditioning, and I’m ripping it out?! Crazy.
Removing the engine
Actually removing the engine proved a bit more difficult than expected. The service hatch in the van to access the engine isn’t big so I had to do some advanced level yoga positions to get into some of the nooks and crannies in this engine...area? What’s it called when it’s not a bay? Anyway, the manual explained a fair amount about what most things were but didn’t really explain how to remove them. I was trying to be extra careful removing everything because I’m trying to sell this engine and all of these gasoline components. In the end I only cut two wires.
The next question was how was I going to remove the engine? The only way out is down because the service hatch isn’t big enough to fit the engine out the top. My first thought was to get a transmission jack and lower it out from the bottom using that. But then I found this hydraulic lift jack from Harbor Freight. This is a good find because it’ll also be great to install battery boxes when the time comes.
After a few weeks of tearing down I was able to get the jack under there, take off the engine mounts and lower the engine out. It’s a bit dirty, but that’s what you can expect from an engine that hangs underneath the car.
After removing all of the gasoline components it’s on to building the electric system. So first I’ll be separating the transmission from the engine and testing the clearances of the Warp 9 motor, scanning and designing the motor adapter, removing the coupler that’s on there (if I can).
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