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Automotive Half Car Trainer FWD, EFI, Petrol Experiment Manual/ VH-HCT-02

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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

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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

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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.

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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)

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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.

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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

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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.

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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.

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