Development of upgraded Toyota 4A to 5afe electronic fuel injected instructural trainer / by Wayne Zander G. Bay, et. al....

Design Project (Bachelor of Industrial Technology Major in Automotive) Cavite State University.

Includes bibliographical references.

College of Engineering and Information Technology (CEIT), Department of Industrial Engineering and Technology

BAY, WAYNE ZANDER G., CAPINA, JUSTINE RAPHAEL C., COPON, ARVIN V. and LOPEZ, IRIS LOI I. Development of Upgraded Toyota 4A to SAFE Electronic Fuel Injected Instructional Trainer. Undergraduate Design Project. Bachelor of Industrial Technology major in Automotive Technology. Cavite State University, Indang, Cavite. June 2019. Adviser: Prof Danielito R. Escano.
The design project shows the conversion of a carbureted engine to electronic fuel injected. The carbureted engine was the Toyota 4A which has an 8 valve single overhead camshaft (SOHC) inline four-cylinder head and carbureted fuel injection system. While the Toyota SAFE was a 16 valve with double overhead camshaft and a gasoline engine with electronic fuel injected fuel system. The design project aimed to design, construct and develop, and to test and evaluate the upgraded Toyota 4A to SAFE electronic fuel injected instructional trainer. This presents the advance technology in developing of converting the mechanical operation of carbureted engine to electronic fuel injected engine through the process of installing the cylinder head of electronic fuel inject engine on the top of carbureted engine cylinder block. The upgraded Toyota 4A to SAFE electronic fuel injected instructional trainer shows the basic fundamentals of the fuel system, ignition system, starting system and electrical system to perform an exact combustion of air-fuel mixture that enhances the power output in the engine.
The converted engine and other components was placed on the frame that has dimension of 48"x25-x20" and was fully supported by the engine support, transmission support to hold it when the engine runs. The major component of the converted engine was the electronic control unit that gathers data from different sensors and gives signal from the coolant temperature towards the oxygen sensor to ensure the function of every system in the engine are controlled to have excellent engine performances.
The design project conducted a rewiring in the engine harness of Toyota SAFE to connect on the terminal blocks to simply identify the engine sensors when diagnosing the troubles. Also, the design project aimed to show the basic function of OBD-I. This contributes knowledge and skills to the Automotive students in troubleshooting the electrical system of the converted engine by using a jumper wire in the OBD-I to give signal to the check engine which was located in the panel gauge. The check engine would flash in a specific pattern to easily identify which sensors were unplug or malfunctioning in the panel. The design project was properly tested and evaluated by five Automotive instructors and twenty-five Automotive students. The converted engine was proven that it has a capacity to operate the fuel system, starting system, ignition system and electrical system as well. The evaluators were satisfied to the good performances of the converted engine and suggested to ensure the banana jack durability. The overall grand mean of the evaluation was 4.8 with an outstanding degree of level which proved that the performance of upgrading the Toyota 4A to Toyota SAFE have a high power engine and enhance the efficiency of the converted engine. The design project contributed to help the automotive students to learn the function and parts of two different engines but has similarity in system. The total cost spent on the development of the converted engine instructional trainer was ₱hp. 45, 406.00.

Submitted to the University Library July 24, 2019 DP-660