Automotive Half Car Trainer FWD, EFI, Petrol Experiment Manual/ VH-HCT-02
2 ABOUT THE TRAINER
2.1. List of Items That Come with The Trainer
Figure 2.1.1 Perspective view of the Automotive Half Car Trainer FWD EFI, Petrol.
Figure 2.1.2 Automotive Half Car Trainer FWD EFI, Petrol system comprise
Petrol Engine Test Bed With Electronic Fuel Injection system comprises of the following main components: 1. EFI Live Petrol Engine with Automatic Transmission 2. Meter Combination 3. Steering wheel complete with horn switch 4. Air conditioning instrument control panel 5. EFI Engine Wiring Diagram Test Points and Fault Simulators 6. Body Electrical Wiring Diagram Test Points and Fault Simulators
LABTECH 3 Automotive Half Car Trainer FWD, EFI, Petrol Experiment Manual/ VH-HCT-02
7. Automatic Transmission Control Lever
8. Fuel Tank 9. Driver Seat 10. Front Suspension (Strut Shock Absorber) 11. Front Disc Brake 12. Frame 13. Rear Suspension (Shock Absorber) 14. Rear Drum Brake 15. Caster Wheel
2.2. Technical Data
The engine that you received has been produced to your requirements and specifications. It contains a particular brand and model engine which is suited to your needs and the instrumentation has been provided according to the specifications.
Table 2.1 Technical Data Specification
No. Description Specification Petrol Engine 4 cylinder in line, 4-stroke, Electronic Fuel 1 Engine Type Injection System, DOHC, 16 valves 2 Engine Model NISSAN QG16-DE Variable Valve Timing 3 Combustion Chamber Pent-roof Type 4 Cylinder arrangement 4 cyl, in-line 5 Displacement cm³ (cu in) 1.596 6 Bore x Stroke mm (in) 76.0 x 88.0 (2.992 x 3. 465) 7 Valve arrangement DOHC 8 Firing Order 1–3–4-2 9 Compression Ratio 9.5 10 Compression Pressure 13.5 kg/cm² 11 Research Fuel Octane Number 95 or more 12 Fuel System Electronic Fuel Injection System With oil filter 2.7 Liter Engine Oil change 13 Drain and Refill Without oil filter 2.5 Liter change 14 Max. Output Power 81 kW / 6000 Rpm 15 Max. Torque 143 N.m / 4400 Rpm 16 Ignition DIS (Direct Ignition System) Cooling system 17 6.6 Liter (with reservoir) Automatic Transmission RE4F03B 1st 2.861 2nd 1.562 3rd 1.000 18 Transaxle Gear Ratio 4th 0.697 Reverse 2.310 Final Drive 3.827 Fluid Capacity 7.0 Liter
LABTECH 4 Automotive Half Car Trainer FWD, EFI, Petrol Experiment Manual/ VH-HCT-02
2.3. Description of Main Parts
The Automotive Half Car Trainer FWD, EFI, Petrol has been designed to provide a flexible system approach to engine instruction and testing. At the art of design is a unique square-tube steel welded box frame, which is specially cross-braced to provide maximum strength and minimum weight. The basis of this design is found in advanced body chassis and main frame products, which feature square-tube frame designs similar in concept. Some of the unique Labtech EFI Live Petrol engine test bed features include; 1. All Body half car are clamped onto the tubular frame which allow them to be repositioned if the instructor want to. 2. Original instrument panel features most commonly used engine performance monitoring gauges. Original fuse on electrical system functions as protection. Position of wiring diagram, test points and fault simulators is adjustable for easy viewing. Original OBD II scanner port also provide for checking all the system of electronic fuel injection system by using engine scanner. So you can easily monitor the engine sensor and actuator condition. 3. The fuel tank is removable for cleaning purposes and has a drain system manual valve for more easy to clean the fuel tank. 4. A strong and quiet muffler is provided to reduce operational noise, and it is painted with 500oC heat-resistant paint. 5. The manual contains a description of each type of instrument and feature that available in our systems. Your particular engine may or may not have all features depending on the original order requirements. Also note that your engine unit may appear somewhat different from the illustrations of this manual depending on engine type and configuration. Please refer to Figure. 2.1.3 for the identification of major features of the Automotive Half Car Trainer FWD, EFI, Petrol.
Figure 2.3.1 Perspective view engine compartment of the Automotive Half Car Trainer FWD, EFI, Petrol.
LABTECH 5 Automotive Half Car Trainer FWD, EFI, Petrol Experiment Manual/ VH-HCT-02
Remarks: 1. Brake Fluid Reservoir 19. Radiator Cap 2. Engine Oil Filler Cap 20. Exhaust Manifold Cover 3. Engine Cover 21. Engine Oil Dipstick 4. Intake Manifold 22. Alternator Terminal (B+) 5. Electronic Throttle Actuator 23. Engine Coolant Sensor 6. Mass Air Flow Sensor 24. Head Lamp (HIGH-RH) 7. Air Cleaner 25. Head Lamp (LOW-RH) 8. Engine Control Module 26. Front Combination Lamp (Turn RH) 9. Radiator Inlet Hose 27. Windshield washer fluid reservoir 10. Radiator Outlet Hose 28. Coolant Reservoir 11. Engine Fuse/Fusible-link Box 29. Sight Glass 12. 12 V Battery 30. Engine Relays Box 13. Front Combination Lamp (Turn LH) 31. Air Conditioning Relay Box 14. Head Lamp (LOW-LH) 32. Power Steering Fluid Reservoir 15. Head Lamp (HIGH-LH) 33. Service Charging Port (Discharge) 16. Transmission Oil Dipstick 34. Service Charging Port (Suction) 17. Condenser 35. Brake Booster 18. Radiator 36. Motor Wiper
Figure 2.3.2 Perspective rear view of the Automotive Half Car Trainer FWD, EFI, Petrol. Remarks: 1. Dashboard 14. Rear Combination Lamp (Park RH) 2. Storage Compartment 15. Rear Combination Lamp (Stop RH) 3. Hazard Warning Flasher Switch 16. Rear Combination Lamp (Back-up RH) 4. Air Conditioner Control 17. Fuel Return Hose 5. Automatic Transmission Control Lever 18. Fuel Feed Hose 6. Meter/Gauges 19. Title Name 7. Horn Switch 20. License Lamp 8. Mufler 21. Fuel Filler Tube 9. Fuel Tank 22. Rear Combination Lamp (Turn LH) 10. Fuel Level Sensor 23. Hand Brake 11. Rear Suspension (Shock Absorber) 24. Fault Relay Box 12. Rear Drum Brake 25. Wiring Diagram and Test Points Board 13. Rear Combination Lamp (Turn RH)
LABTECH 6 Automotive Half Car Trainer FWD, EFI, Petrol Experiment Manual/ VH-HCT-02
Figure 2.3.2 Perspective left side view of the Automotive Half Car Trainer FWD, EFI, Petrol. Remarks: 1. Hood 10. Caster Wheel 2. Fender 11. Frame 3. Sider Combination Lamp (Turn LH) 12. Transverse Link 4. Wiring Diagram and Test Points Board 13. Stabilizer 5. Seat Driver 14. Tie Rod Outer Socket 6. Rear Drum Brake 15. Front Shock Absorber 7. Rear Coil Spring 16. Rotor Disc 8. Torsion Beam 17. Brake Caliper 9. Arm 18. A/T Transmission
2.3.1. Engine The engine on this trainer is a Petrol engine Model NISSAN QG16-DE, four stroke engine, 4 cylinder inline, with Automatic transmission. The engine is mounted on the original rubber mounts in a mounting engine half car body. The original body is supported by the frame which is made of square-tube steel to make it strong and rigid. The frame has four casters so it can be moved easily.
2.3.2. Fuel Tank
The fuel tank is made of stainless steel and it is completed with fuel sensor, refueling cap and drain valve. It is removable so that it is easy for cleaning and refueling purposes. The capacity of the fuel tank is ± 20 Liters. The fuel tank has several hoses which are connecting the fuel pump to fuel system. One of the hose is used to supply and circulate the fuel from electric fuel pump to fuel system (fuel pump-fuel filter-fuel rail/injector and pressure regulator), and another hose is fuel return from pressure regulator return back to fuel tank.
LABTECH 7 Automotive Half Car Trainer FWD, EFI, Petrol Experiment Manual/ VH-HCT-02
2.3.3. Test Points and Fault Simulators
The Automotive Half Car Trainer FWD, EFI, Petrol is completed with the EFI Engine Wiring Diagram Test Points and Fault Simulators, and Body Electrical Wiring Diagram Test Points and Fault Simulators.
Figure 2.3.3 Wiring Diagram Test Points and Fault Simulators
Fault Location : • Fault 1 = Compressor system • Fault 2 = Cooling Fan (High) system • Fault 3 = Electronic Throttle Control • Fault 4 = Fuel Pump system • Fault 5 = Fuel Injectors • Fault 6 = Ignition Coil • Fault 7 = Coolant Temperature Sensor • Fault 8 = Mass Air Flow Sensor • Fault 9 = Camshaft Position Sensor • Fault 10 = Crankshaft Position Sensor • Fault 11 = Back-Up Lamp • Fault 12 = Horn system • Fault 13 = Starter Motor system • Fault 14 = Turn Signal / Flasher Unit • Fault 15 = Lighting Switch • Fault 16 = Wiper Motor system • Fault 17 = Washer Motor system • Fault 18 = Charging System • Fault 19 = Fuel Sensor • Fault 20 = Brake Lamp system
LABTECH 8 Automotive Half Car Trainer FWD, EFI, Petrol Experiment Manual/ VH-HCT-02
2.4. Setting-up the Trainer
1. Unpack the Trainer from its package. 2. Make sure the parts of the trainer are completely installed, regarding part as listed in the previous Section 2.1. 3. Make sure the trainer is installed firmly into its stand.
2.5. Using the Trainer
Before operating the trainer, follow procedure below to avoid any damages to the trainer: 1. Place the engine trainer in a flat floor so it will stand in a sturdy position. 2. Ideally the engine exhaust is connected to an exhaust line to outside of the room. If this unit is not available, the room must have good ventilation to minimize exposure to dangerous carbon pollution. 3. Observe overall parts of the engine. Make sure there is no damage on the engine parts. 4. Observe overall connections sensor of the engine. Make sure there is no leakage. 5. Remove the radiator cap to fill the radiator with the water coolant, until it reaches maximum level in the radiator. Install the radiator cap correctly. Note: It is recommended to use distilled water 6. Check the engine oil level with a dipstick of engine oil. If it is low level, add the engine oil to its inlet, (Maximum oil tank capacity is ± 2.5 liters). The engine oil that used in this trainer is (15W-50) type. 7. Fill the fuel tank with clean petrol fuel. Use unleaded gasoline with an octane rating of at least 87 AKI (Anti-Knock Index) number (research octane number 91). CAUTION: • Do not use leaded gasoline. Using leaded gasoline will damage the three way catalyst. • Using a fuel other than that specified could adversely affect the emission control devices and systems, and could also affect the warranty coverage validity. • Please be always aware during operating the trainer. Gasoline is extremely flammable and highly explosive under certain conditions. You could suffer serious burns injury if it is misused or mishandled. • Always stop the engine and do not smoke or allow open flames or sparks near the vehicle when refueling. 8. Connect the battery cable. Red to (+) and black to (-). Always use a 12 volt battery as power source. Note: For a new battery, remove all battery caps and then fill in the battery with the battery acid. Allow the battery to be in opened condition for about 4 hours. Place all battery caps and then check the battery voltage. It should be ±12,8 VDC. 9. Observe the meter and gauges panel, make sure the ignition switch is in off position. 10. Do not depress accelerator pedal when starting, immediately after starting, do not rev up engine unnecessarily. (Do not rev up engine just prior to shutdown). 11. Now, the engine is ready to be started.
LABTECH 9 Automotive Half Car Trainer FWD, EFI, Petrol Experiment Manual/ VH-HCT-02
2.6. Safety Precautions
Follow these instructions to ensure that either the trainer or the student is safe when doing the experiments. 1. Please make sure the connection is correct before starting the engine. 2. Always check the oil level and water level. Make sure no leakage on the system. 3. Never touch the rotating parts and hot surface. 4. Follow the procedures when doing the experiments. 5. Do not attempt to disconnect battery cables while engine is running. 6. Disconnect battery cables after finishing the experiment.
2.7. Maintenance 1. Make sure the engine uses proper amount of good multigrade oil. Oil should be changed according to the usage of the engine or at least twice a year if it is used in a stationary condition. 2. Make sure the engine uses clean fuel and clean air whenever it is running. If the unit is not used for more than one month, the fuel tank should be drained and cleaned. 3. If the engine will be stored for long period, the battery cable should be disconnected and the radiator water should be emptied. 4. Do not allow the engine to run at idle speed for long period. 5. It is recommended to run the engine at least once a week periodically.
