Phoenix Turbine Builders Club

Fiero HEV Conversion Project: Step One

Removing the engine & transmission

August 2007

Now that we have covered the basics of EV's and HEV's, let's get started with our conversion.

The first thing we need to do is remove everything from the vehicle that will not be needed in an HEV. This will include the engine and all of its associated parts, such as ignition controllers, pumps, etc.

Begin by removing the battery for safety.

In most cases, the engine may be unbolted from the transmission and engine mounts, all lines and wires removed, and then winched out of the engine compartment (after removing the hood). Fiero's are a bit different.

The shop manual suggests unbolting the drive cradle and dropping everything out the bottom of the vehicle. Since the cradle bolts on our 1984 Fiero were completely rusted solid, we took a different approach.

All extraneous parts such as manifolds, alternator, AC pump, and engine stabilizers were first removed. Engine and transmission mount bolts were removed, and the entire engine/transmission unit was winched out the top.

After the engine was set down on a dolly, the transmission was separated from it and set aside. Since the Fiero comes with a standard 4/5 speed manual shift transmission, we will keep the trans, flywheel and clutch.

Before removing the flywheel from the engine crank, carefully measure the gap between the back of the engine and the back of the flywheel. Mark this distance in the shop manual for future reference.

With all of the useful parts removed, the engine can be sold or recycled. Next, go back to the engine compartment and label lines and wires for future reference. Measure the engine compartment and begin planning how and where the new HEV parts are going to fit.

Remember, the transmission is going back into its original place, and the traction motor will be located directly on the end of it, or offset to one side or the other if a speed reducer is used (more on that later). There is also an engine/generator unit, an APU (auxiliary power unit), a battery bank, and a power management set of modules, as well as a 12-volt accessory battery and charger, coolant pump, and possibly a steering pump if your car has power steering.

Our Fiero has manual steering and power brakes, so we do not need a PS pump, and the brake vacuum system can be hooked up to the new engines.

At this time we are planning to use water-cooled marine outboard powerheads for our generator and APU power, so these can be plumbed into the existing cooling system. Also, since the Fiero is a rear engine car, the engine compartment is located in front of the trunk space, making it very convenient to drop the batteries and power controllers right in the trunk.

With the clutch pack, flywheel and transmission now out of the vehicle, it is probably a good idea to recondition or replace parts before they go back into the vehicle.

Next month we'll get to the intricate job of laying out and building the transmission adapter plate, and discussing which traction motors are best.