Episode 5: Unboxing the Complete EV Conversion Kit
In Episode 4, we finalized one of the most important stages of the project—planning the battery layout. By carefully measuring the available space and designing the battery placement, we established the foundation for a safe, reliable, and well-balanced electric Hilux.
Now it’s time to introduce the hardware that will bring the conversion to life.
In Episode 5, we unbox the complete EV conversion kit and take a closer look at every major component that will be installed into our Toyota Hilux.
🎥 Watch Episode 5 on YouTube:
https://www.youtube.com/watch?v=62D15mZT7_s&list=PLH_S-bVz1dh8&index=5
More Than Just a Motor and Batteries
When people think about an EV conversion, they usually picture two things: an electric motor and a battery pack.
In reality, a professional conversion is a fully integrated electric drive system made up of multiple components that must work together seamlessly.
Every connector, every controller, and every cable has an important role in ensuring the vehicle performs safely and reliably.
In this episode, we unpack the complete conversion kit and explain the purpose of each major component.
Permanent Magnet Synchronous Motor (PMSM)
At the heart of the conversion is our high-efficiency Permanent Magnet Synchronous Motor (PMSM).
Compared with the original diesel engine, the electric motor offers:
- Instant maximum torque
- Higher drivetrain efficiency
- Lower maintenance requirements
- Quiet operation
- Smooth acceleration
Combined with the original Toyota Hilux manual transmission, it delivers excellent driving performance while minimizing modifications to the vehicle.
Motor Controller – The Brain of the Powertrain
If the motor is the heart of the vehicle, the controller is its brain.
The controller precisely regulates power delivery between the battery pack and the motor while managing:
- Torque output
- Motor speed
- Regenerative braking
- System protection
- Vehicle communication
A properly matched motor-controller combination is critical for both performance and long-term reliability.
High-Voltage Wiring Harness
Reliable electrical connections are just as important as selecting the right motor.
Our custom-designed wiring harness simplifies installation while ensuring:
- Safe high-voltage connections
- Reliable CAN communication
- Organized cable routing
- Easier troubleshooting and maintenance
A clean wiring system also reduces installation time and improves long-term serviceability.
Electronic Accelerator Pedal
Unlike a conventional diesel pickup, an electric vehicle uses an electronic accelerator pedal.
The pedal communicates directly with the motor controller, allowing precise torque control and delivering the immediate throttle response that makes electric vehicles so enjoyable to drive.
Detailed Specification
For Hilux, we choose below 360V 120KW(rated 60kw ) PMSM liquid cooling kit with 10000 Peak rpm and 350Nm Peak torque to ensure original driving performance.
On-Board Charger (OBC)
The onboard charger converts AC power from the grid into DC power for charging the battery pack.
Our charger is designed to provide:
- Stable charging performance
- High efficiency
- Battery protection
- Compatibility with common AC charging sources
Reliable charging is essential for both private owners and commercial fleet operators.
DC-DC Converter
Although the Hilux becomes fully electric, it still requires a traditional 12V electrical system.
The DC-DC converter replaces the original alternator and supplies power to:
- Vehicle lighting
- Dashboard instruments
- Cooling fans
- Auxiliary electronics
- Other low-voltage accessories
This ensures all factory electrical systems continue to operate normally after the conversion.
Every Component Is Designed to Work Together
Besides the major hardware, the complete kit also includes:
- High-voltage connectors
- Signal cables
- Mounting hardware
- Protection devices
- Communication modules
- Integration accessories
Rather than supplying individual components, GMT provides a complete, integrated EV conversion solution where every part has been engineered to work together.
This approach simplifies installation, improves compatibility, and reduces commissioning time.
A Successful Conversion Starts with System Integration
One of the biggest differences between a professional EV conversion and a collection of aftermarket parts is system integration.
Each component—from the motor and controller to the battery system, charger, and wiring harness—is selected, tested, and configured to operate as a complete electric powertrain.
That preparation helps minimize installation challenges and ensures the vehicle performs as intended from day one.
What’s Coming Next?
Now that every component has been unpacked and inspected, it’s time to start assembling the system.
In Episode 6, we’ll wire the entire EV powertrain, perform the first no-load functional test, and connect the electric motor to the original Toyota Hilux manual transmission using our custom adapter plate and coupling assembly.
You’ll finally see the individual components begin working together as one complete electric drivetrain.
Planning Your Own Hilux EV Conversion?
Every EV conversion is unique.
Choosing the right motor, battery, controller, and transmission configuration depends on how the vehicle will be be used.
At GMT, we’ve already helped customers electrify vehicles such as the Toyota Hilux, Isuzu D-Max, and other commercial vehicles. We’re also documenting our own Hilux EV conversion project step by step to share the real engineering process behind a successful conversion.
If you’re considering converting your own pickup truck, we’d be happy to help.
Simply contact us by [email protected] with your vehicle details, and we’ll provide a preliminary Bill of Materials (BOM), recommended system configuration, and an estimated project budget based on your project requirements.
