The vintage Fiat 500 (Nuova 500, 1957-1975) is one of the lightest, simplest cars you can convert to electric. At ~500 kg curb weight, it needs minimal power to move — a 7.5 kW motor gives 70 km/h top speed with the original gearbox. This article walks through a real CMVTE conversion with photos, videos, and the exact parts used.
Fiat 500 Conversion Specs
| Spec | Value |
|---|---|
| Curb weight | ~500 kg (with battery) |
| Motor | 7.5 kW PMSM, 72V, air-cooled |
| Controller | 72V FOC, with regenerative braking |
| Battery | 72V 200Ah LFP (14.4 kWh) |
| Top speed | 70 km/h |
| Range (full charge) | ~150 km |
| Charging | 3.3 kW OBC, 4.5 h full charge |
| Kit price (motor + controller + battery + charger) | $5,000-$7,000 |
Step-by-Step Installation
This conversion uses CMVTE's complete kit. Here are the steps documented during the actual build:
- Prepare the kit: CMVTE ships the complete package — motor, controller, battery, charger, DC-DC converter, throttle pedal, wiring harness, and adapter plate for the Fiat 500 gearbox.
- Remove the engine: Drain fluids, disconnect fuel lines, unbolt the engine and gearbox as a single unit. The original exhaust and fuel tank also come out, freeing up space under the rear cargo area for the battery.
- Cut the half-shafts: The original shafts between the gearbox and wheel hubs are cut. The inner ends are welded to CMVTE's new gearbox output shafts. The outer ends (hub side) are kept original. A custom shaft set is fabricated by welding the two pieces together.
- Install the motor + gearbox: The PMSM motor bolts to the CMVTE gearbox with the adapter plate. The assembly mounts to the original engine mount points. No chassis modification is needed.
- Install the controller: Mounted in the engine bay, wired to the motor with 3-phase HV cables. The FOC controller is programmed for the 7.5 kW PMSM motor profile.
- Install the battery: The 72V 200Ah LFP pack goes in the original fuel tank area under the rear cargo floor. The pack is IP67-sealed and bolted to the chassis crossmembers.
- Wire the system: Connect the OBC, DC-DC converter, throttle pedal, and CAN bus network. CMVTE provides a color-coded wiring diagram specific to the Fiat 500's original electrical system.
- Install a new dashboard: The original gauges are replaced with a CAN bus display showing speed, SOC, motor temperature, and regen status.
- Test and tune: Low-speed test to verify throttle response and regen. Full-speed test to confirm top speed, range, and thermal stability.
Upgrade Options
| Component | Standard (this build) | Upgrade Option | Upgrade Price |
|---|---|---|---|
| Motor | 7.5 kW PMSM, 72V | PMSM-15 (15 kW / 30 kW peak) | +$1,500 |
| Battery | 72V 200Ah LFP (14.4 kWh) | 96V 200Ah LFP (19.2 kWh) | +$2,000 |
| Controller | 72V FOC fan-cooled | 96V FOC water-cooled | +$800 |
| Top speed (upgraded) | 70 km/h | 100 km/h | |
| Range (upgraded) | 150 km | 200+ km |
The 7.5 kW build is perfect for city driving and short commutes. If you need highway capability or longer range, the upgrade path keeps all existing wiring and mount points — just swap the components.
Video Walkthrough
CMVTE Fiat 500 conversion solution →
Get a Kit for Your Fiat 500
We have pre-designed adapter plates for all Fiat 500 generations (Nuova, 500L, 500 Twin-Air). Tell us your model year and target speed — we'll ship the complete kit with wiring diagram and phone support.
WhatsApp / Phone: +86 181 2358 8272
Email: [email protected]
Mention "Fiat 500" for a kit quote with adapter plate drawing.
