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A cleaner way to drive

Draining fluids and preparing for engine removal – Day 1

I started to remove the greasy and dirty internal combustion engine and the related components that I will not need in the electric vehicle today. First, I needed the following tools/supplies; my EV friend, Steve, had most of these tools and brought them to help me with my first day on the job.

  1. 1986 Toyota MR2 maintenance manual
  2. Hydraulic jack
  3. 4 jack stands
  4. metric socket set with breaker bars
  5. metric wrenches
  6. drain pan and a few gallon milk jugs for holding fluids like engine oil and coolant
  7. gas tank to hold the fuel that remained in the car
  8. engine hoist
  9. rags/cardboard for cleaning and catching spills
  10. nitrile gloves, set of old clothes that you don’t mind getting dirty.
  11. masking tape, plastic zipper bags, and permanent marker: for labeling cables and wires and bagging loose parts that you might need later.
  12. a notebook to take down notes and diagrams on how things fit together and important measurements.
  13. Air tool and socket wrenches for removing the wheels and drive axels.

I found the Toyota factory manual for the 1986 MR2 for $90 on ebay and Chilton’s manual was $20, so I went with the latter. As it turns out, this manual was very helpful for someone like me that doesn’t have any experience working on cars.

Chilton's manual for $20

After jacking up the car, the first things to get rid of are the fluids that we will not need anymore in an electric car: engine oil,engine coolant, and fuel. Since the MR2 requires that the engine be lowered out of the car rather than lifted from the top, I needed to make sure that I jacked the car high enough so that the lowered engine will clear the body of the car.

Engine oil
drained oil out of enginealmost a gallon of oil

Coolant: To fully drain the coolant, three plastic covers underneath the car need to be removed to expose 2 more drain location in addition to the drain plug near the radiator fan in the front of the car.
CoolantRemove the coolant tank cap to let it flow!Remove the 3 plastic covers under the car to expose the 2 additional coolant drain plugs2 more drain locations underneath the carCoolant and engine oil

Since we will not be needing the cooling system anymore, we removed the radiator fan/coil and radiator tank.

For easier access under the car, the four tires were removed.

Before we can remove the engine, many components need to be disconnected/removed from it. The 12V auxiliary battery was first disconnected and removed. Next, the main wiring harness was disconnected from the engine. I tried to label connectors as I pull them from the engine so that if I need to reuse a connector, I will remember which wire to use. I ended up cutting the wires to the starter because I had trouble getting to the connector, I won’t need that component anyway. In the process of disconnecting the main wiring harness, we also removed the air flow meter and the intake manifold from the engine. The accelerator cable and bracket was also disconnected and the cable labeled and taped to the hood to keep it out of the way. The speedometer cable, which is connected to the transmission is also removed, labeled, and taped to the hood to keep it out of the way. After removing the speedometer cable from transmission, it is important to cover opening on the transmission where the speedometer cable used to be. Aluminum foil works great, per suggestion from Steve.

I decided to drain the fuel tank on a different date since it was getting late and Steve and I were working in a closed garage and I had a water heater with a pilot light in the garage (next time, I will drain the fuel first!!). Steve did manage to disconnect the fuel rail from the engine. He had to be very careful not to cut any of the fuel lines since I still had 1/4 tank of gas left.

After carefully navigating the fuel challenge, we ran into another issue, the air conditioning system was potentially still charged! Since the air conditioning compressor is mounted to the engine, I need to decide what to do about the air conditioning system before I remove the engine. We removed the exhaust system and called it a day.

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Posted in MR2EV, Removed Parts

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