In April 2013 an Automotive Engineer certified MR02EV as road legal, I obtained a vehicle safety compliance certificate (an engineering certificate) and was able to legally register the car in NSW Australia. Following is an extract from the engineer’s report which gives you a flavor of the information required.
Section 3. Description of vehicle or modifications to vehicle in accordance with the Heavy Vehicle Codes for Modifications and the Light Vehicle Codes for Modifications
This vehicle has been converted to an electric vehicle. The original 1.6 litre 88Kw internal combustion engine has been removed and replaced with a MES-DEA Type 200-250 AC induction motor rated at 30kW continuous power and is driven by an MES-DEA Type TIM600W inverter. The original manual gearbox has been retained and mounted as per standard, an aluminium adapter has been machined by to connect the electric motor to it and original engine mounts and a new fabricated engine rear bracket secure the motor. The original clutch is removed and the armature of the new motor is coupled to the input shaft of the gearbox. The emissions produced are zero (ADR 37/00).
Traction battery pack contains 56 ThunderSky Lithium-ion cells, which are managed by the Batrium BMS. These do not contain any spilable liquid; therefore they are classified as Class A.
A 30mm box tube steel frame supports a fabricated aluminium box (875mm wide, 500mm length and 250mm deep) with clear poly-carbonate lid to house the batteries in the rear engine compartment above the motor and gearbox. The steel frame is secured by 10mm 8.8 grade bolts threaded into the chassis rails. Access cannot be gained to the batteries without the use of tools. High voltage warning labels are attached to the box.
Demisting of Windscreen
The original water filled heater and fan/blower assembly and ducting have been retained. The original controls for the fan have been retained. A HotStart TPS series tank water heater and pump has been installed and connected to the heater hoses. The vehicle therefore continues to comply with ADR 15/00.
The vehicle has the original hydraulic braking system and vacuum actuated brake booster. An electric MES-DEA Type 70/6E vacuum pump has been added as well as a seven liter vacuum reservoir. The volume of the vacuum reservoir allows for the brake pedal to be depressed at least six times before the vacuum pump starts to replenish it. The original brake warning light has been retained and still operates. A LED light has been added to the instrument cluster which illuminates when the vacuum sensor (in the brake booster vacuum line) senses a low vacuum. The vehicle therefore continues to comply with ADR 31/00.
There is no noise emitted from the new engine so the vehicle continues to comply with ADR 28/00.
The original fuel tank (40litres), and exhaust system have been removed. The electronics are housed in the boot with all wiring adequately insulated and high voltage labels in place. All electrical cables are clamped at less than 600mm intervals as per ADR 42/00 and are also protected from chafing or heat.
Motor Start Procedure
- Close charge flap (old petrol flap) to avoid starting the vehicle when charging.
- Place foot on brake pedal.
- Turn key to the crank position
A green LED light mounted on the dash then illuminates to indicate that the vehicle is ready to drive.
I have a Degree in Electrical Engineering from the University of Technology Sydney and am employed in Broadcast Television Industry. My hobby is the (continuing) modification of MR02EV. I am also the National Treasurer of the Australian Electric Vehicle Association.