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POLITEKNIK
PORT D
ICKSON
Politeknik Port Dickson http://www.polipd.edu.my
e-Report
MODERN SYSTEM FOR VEHICLES, FUEL INJECTION SYSTEMS AND DIAGNOSE FAULTS
Published by Politeknik Port Dickson, Km 14 Jalan Pantai ,71050 Si Rusa , Port Dickson, Negeri Sembilan Darul Khusus , Malaysia .Copyright © 2018 by Politeknik Port Dickson. All rights reserved. No part of this e-book may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without written permission from the publisher.
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ABSTRACT
The TVTC program for the Saudi Arabian delegate had been conducted for 2
weeks commencing 3rd
to 14th
July 2017. This program provides knowledge on the
concept & principles of petrol and the hybrid engine systems/drive technology to all
participants. Participants were exposed to Engine Management System, Engine Control
System, Requirement & Purpose of Engine Management System, Sensors & Actuator,
and type of fuel injection systems. The Saudi Arabian delegate is consists of 29 members.
They were divided into 2 groups for training at 2 different places. For the first week, the
first group was attached to Petrol Engine System Training Program at Port Dickson
Polytechnic. Meanwhile, the second group was attached to Hybrid Engine System
Training Program at ADTEC Malacca. After completing the first 3 days course, both
groups were rotated according to the designed schedule at different venue for the
following week. For day 4 and day 5 of both weeks, they were brought to industrial site
visits at a few automotive industries like Bermaz Auto Berhad (Mazda 3S), Malaysian
Automotive Institute, Proton Holding Berhad (COE) and Mitsubishi, Tan Chong Motor
Assemblies (TCMA). The impact of this program is that international collaboration
networks in the field of technical and vocational education training (TVET) can be
established as well. Lectures are expected to improve their skills of knowledge delivery
in their sharing with others institution especially beyond the country. Polytechnic
Education Department has also promoted TVET Malaysia, especially the Malaysian
Polytechnic to the eye of world.
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TABLE OF CONTENT
1. TITLE 1
2. BACKGROUND/RATIONAL 1
3. OBJECTIVE 1
4. COURSE LEARNING OUTCOME 1
5. ACTIVITIES DETAILS 5
6. PROGRAM COMMITTEE MEMBERS 6
7. LIST OF PARTICIPANTS 7
8. PROGRAM IMPLEMENTATION 7
9. PROGRAM IMPACT 8
10. CONCLUSION 8
11. PHOTO GALLERY 9
12. VIDEO ACTIVITIES 25
13. APPENDIX 26
a. CONTRACT BETWEEN TVTC AND MOHE
b. INVOICE
c. COURSE ANALYSIS
d. TRAINING EVALUATION FORM
e. SLAID PRESENTATION
f. ATTENDANCE LIST
g. EMAILS COLLECTION
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1. TITLE
Technical and Vocational Training Corporation (TVTC): “Modern System for Vehicles,
Fuel Injection Systems and Diagnose Faults”
2. BACKGROUND/ RATIONAL
This program provides knowledge on the concept & principles of petrol and the hybrid
engine systems/drive technology to all participants. Participants were exposed to Engine
Management System, Engine Control System, Requirement & Purpose of Engine
Management System, Sensors & Actuator, and type of fuel injection systems.
3. OBJECTIVE:
i. To build up international collaboration and relationship with other countries
meanwhile to promote Malaysian Polytechnics.
ii. To empower Malaysian Polytechnics through TVET program and across global
boundaries.
iii. To exchange and enhance knowledge sharing between local and foreign lecturers.
4. COURSE LEARNING OUTCOME:
Upon completion of the course, participants should be able to:
i. understand the development of engine control system.
ii. understand the concept and basic principles of modern brake system.
iii. diagnose and troubleshoot EFI system by using scan tool.
iv. explain the principles and operational functions of hybrid vehicle.
v. perform a visual inspection of hybrid vehicles.
vi. perform precautions steps before and during the process of servicing hybrid
vehicle.
5. ACTIVITIES DETAILS
a. Date : 3rd
– 14th
July 2017 ( Monday – Friday for 2 weeks )
b. Participants: 29 TVTC Saudi Arabia Delegates.
c. Organizer : Port Dickson Polytechnic
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d. Course venue :
i. Mechanical Engineering Department, Port Dickson Polytechnic (for Petrol
Engine Systems)
ii. Automotive Workshop in Advanced Technology Training Centre at
Malacca (for Hybrid Engine Systems)
e. Program Content:
Content Delivery
Method
1. Understand the development of engine control system
a) Explain types, function and location of sensors
b) Explain types, function and location of actuators
2. Understand the concept and basic principles of modern brake system
a) Understand the function, construction and operation of Electronic
Brake Force Distribution (EBD), Brake Assist (BA), Electronic
Stability Control (ESC) and Traction Control (TC).
3. Diagnose and troubleshoot EFI system by using scan tool
a) Diagnose the EFI system; identify the checking and testing method
on the system.
Lecture
4. Diagnose and troubleshoot EFI system by using scan tool
5. Diagnose the EFI system; identify the checking and testing method on
the system
Practical
6. Hybrid electric vehicle classification and systems.
- EEV
- Hybrid System
- Vehicle Model
- Safety and precautions
Lecture
7. Hybrid electric vehicle operations & maintenance skills training
- Hybrid management system
- Auxiliary battery and jump start
- Safety and precautions step
- High voltage current discharge
Practical
8. Site visit
a. 6 July 2017: Bermaz Auto Berhad, Shah Alam, Selangor.
b. 7 July 2017: Malaysian Automotive Institute (MAI), Rawang,
Selangor.
c. 13 July 2017: Proton Holdings Berhad, Centre of Excellence
(COE), Shah Alam, Selangor.
d. 14 July 2017 : Tan Chong Motors Assemblies (TCMA), Jalan
Segambut, Kuala Lumpur.
Group
visit
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f. Training Schedule at Mechanical Engineering Department, Polytechnic Port Dickson
POLITEKNIK PORT DICKSON, 71050 SI RUSA, NEGERI SEMBILAN
TRAINING : MODERN SYSTEM FOR VEHICLES, FUEL INJECTION SYSTEMS & DIAGNOSE FAULTS
(PETROL ENGINE SYSTEMS)
VENUE : JAB. KEJ MEKANIKAL, POLITEKNIK PORT DICKSON
DAY/TIME 8.45 am – 10.45 am 10.45 -
11.00 am
11.00 am – 1.00
pm
1.00 - 2.00
pm
2.00 pm - 4.00 pm 4.00 pm
DAY 1
- Introduction
- Petrol engine
system
TE
A B
RE
AK
- Petrol engine
system
LU
NC
H
- Types of petrol
engine
- Fuel delivery system
TE
A B
RE
AK
DAY 2
- Fuel injection
system
- Parts of fuel
delivery system
- Parts of fuel
delivery system
- Fuel Delivery test
DAY 3
- Engine diagnose
- Identifying faulty
code
- Identifying
faulty code
- Checking and
troubleshooting
DAY 4 INDUSTRIAL VISIT - WEEK 1 : BERMAZ AUTO BERHAD (MAZDA 3S) , SHAH ALAM
WEEK 2 : PROTON HOLDINGS BHD., SHAH ALAM
DAY 5 INDUSTRIAL VISIT - WEEK 1 : MALAYSIAN AUTOMOTIVE INSTITUTE (MAI), RAWANG
WEEK 2 : TAN CHONG MOTORS ASSEMBLIES (TCMA), KL
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g. Training Schedule at Automotive Workshop, ADTEC Melaka
ADVANCED TECHNOLOGY TRAINING CENTRE (ADTEC) ALOR GAJAH, MELAKA
TRAINING : MODERN SYSTEM FOR VEHICLES, FUEL INJECTION SYSTEMS & DIAGNOSE FAULTS
(HYBRID ENGINE SYSTEM)
VENUE : AUTOMOTIVE WORKSHOP, ADTEC MELAKA
DAY/TI
ME
8.45 am - 10.45 pm 10.45 –
11.00 am
11.00 – 1.00 pm 1.00 -
2.00 pm
2.00pm - 4.00pm 4.00p
m
DAY 1
- Opening Session
- Types of Hybrid System
- Why hybrid technology?
- Safety & precaution T
EA
BR
EA
K
- Difference between hybrid
and conventional system
- Component layout &
functions
- Safety & precaution
LU
NC
H
- Vehicle
familiarization
- Test drive
TE
A B
RE
AK
DAY 2
- Hybrid management system
- High voltage battery for
hybrid car
- Auxiliary battery & jump
start
- Re-assemble of HV battery
unit
- Measuring high voltage
current
- Safety & precaution
- Hybrid transmission
system
- State of charge of
HV battery
- Safety & precaution
DAY 3
- Hybrid vehicle cooling
system
- Inverter with converter assy
unit
- Service point for hybrid
vehicle
- Types of injuries
- Risk of electric shock
- Safety & precaution during
repair / maintenance
- Safety procedure
during
breakdown/accident
- Course content
summarization
- Q&A and discussion
DAY 4 INDUSTRIAL VISIT - WEEK 1 : BERMAZ AUTO BERHAD (MAZDA 3S) , SHAH ALAM
WEEK 2 : PROTON HOLDINGS BHD., SHAH ALAM
DAY 5 INDUSTRIAL VISIT - WEEK 1 : MALAYSIAN AUTOMOTIVE INSTITUTE (MAI), RAWANG
WEEK 2 : TAN CHONG MOTORS ASSEMBLIES (TCMA), KL POLI
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6. PROGRAM COMMITTEE MEMBERS
1. Penaung : En. Roslee Bin Yahya
Director
Polytechnic Port Dickson
2. Pengerusi : Pn. Yusma Bt Yusof
Deputy Director (Academic)
Polytechnic Port Dickson
3. Timbalan Pengerusi 1 : En. Abdul Rahim Bin Ibrahim
Head of Mechanical Engineering Department
Polytechnic Port Dickson
4. Timbalan Pengerusi 2 : En. Azhar Bin Rostani
Head of Automotive Program
Polytechnic Port Dickson
5. Penyelaras: En. Raja Noorzihan Bin Raja Ab. Kadir
6. Urusetia & Setiausaha: Pn Nuratikah binti Seman
Cik Siti Nurul Hana Binti Ramli
En. Mutiman Bin Bin Mat
7. Bendahari : Pn. Emma Sri Rahayu Binti Mohd Nor
8. Jawatankuasa Persiapan Tempat : En. Zulfaka Bin Zainal
En. Wan Mohd Ridzwan Bin Wan Husin
En. Mohd Ridhuan Bin Othman
9. Jawatankuasa Persiapan
Perkakasan ABM :
En. Mohd Fakuruddin Bin Abd Manaf
En. Mohd Fikri Bin Mohd Soffian
En. Mohd Nahar Bin Ahmad
En. Mohd Normaizal Bin Rahman
En. Normizam Bin Halid
En. Mohd Zubir Bin Amir
En. Mohd Firdaus Bin Abu Bakar
En. Tan Wei Sin
10. Jawatankuasa Perolehan: En. Razali Bin Bakri
En. Muhamad Asri Bin Muhamad @Omar
11. Jawatankuasa Penyediaan Modul
Latihan :
En. Mohd Izad Affendy Bin Mohd Yusof
En. Ab Hakim Bin Ab Halim
En. Mohd Hilmi Bin Zaid
En. Salim Bin Matraji
En. Muhammad Fairuz Hazmi Bin M. Amin
En. Ahmad Hafrizalman Bin A Hamid
12. Jawatankuasa Fasiliti : En. Muhammad Sadli Bin Abdllah
En. Mawardi Bin Yusoff
13. Jawatankuasa Lawatan Industri : En. Ong Seng Keong
En. Mohd Fauzi Bin Mansor
14. Jawatankuasa Keselamatan &
Kesihatan :
En. Ahmad Syarifuddin bin Mohamad Nasir
15. Jawatankuasa Kudapan/Makanan : Pn. Norhazlina Bt Amon
Pn. Nurulhuda Bt Khalid
16. Jawatankuasa Sijil & Cenderahati: Pn. Noor Aslinda Bt Jalil
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Ust. Mohamad Faisal Bin Jumri
17. Jawatankuasa Pelaporan: Pn. Tham Sook Chan
Cik Noor Hasanah Tham Shu-Yin
18. Jawatankuasa Multimedia : En. Mohd Shafiq bin Radzali
En. Mohd Shahril Fahmi Bin Mohd Zaini
En. Mohamad Tarmizi Bin Arbain
19. Jawatankuasa Logistik &
Pengangkutan :
En. Ahmad Shukri Bin Endut
Pn. Juliah Bt Aman
En. Syarul Nizam Bin Mohamad Salleh
20. Jawatankuasa Sebutharga : Cik Nurul Huda Bt Mohd Shahrudin
Pn. Jamisahanum Bt Jamaludin
Pn. Suraidah Bt Abu Bakar
21. Jawatankuasa Dasar & Hubungan
Antarabangsa:
En. M. Nagarajan A/L P. Marimuthu
En. Ab Rahim Bin Ahmad
En. Azizul Azrin Bin Mahmor
Pn. Jamaliah Bt. M Salleh
22. Jawatankuasa LO, Aktiviti &
Lawatan Riadah :
Ust. Yusnizam Bin Yahaya
Ust. Omar Bin Abdul Rahman
Ust. Zamri bin Ibrahim
7. LIST OF PARTICIPANTS
All TVTC delegates have full 100% attendances during 2 weeks course.
Group 1 Group 2
1 Alzahrani, Ali Jaman A. 1 Alshamrani, Abdullah Faiz A.
2 Altuwaiher, Abdulrahman Saleh A. 2 Alghamdi, Faisal Saleh M.
3 Alomar, Hamad Abdulaziz H. 3 Alhusayni, Yousef Ibrahim M.
4 Almuthyib, Ahmed Mushbb A. 4 Almatrood, Yousif Hassan M.
5 Hakami, Abdullah Nasser M. 5 Alghamdi, Saleh Saeed S.
6 Altuwaijri, Osama Abdullah A. 6 Alasqah, Mohammed Saad A.
7 Allahhawi, Abdulaziz Salman O. 7 Alelaiwi, Hassan Ali A.
8 Alomer, Abdullah Abdulaziz H. 8 Alabbasi, Abbas Zaid A.
9 Alqhtani, Fahad Saeed H. 9 Albenshaikh, Ali Yaseen Z.
10 Alyami, Matab Mhdi A. 10 Alguthami, Abdullah Housin M.
11 Assiri, Saad Abdullah M. 11 Alahmadi, Hamed Sulaiman S.
12 Suruji, Adnan Taher M. 12 Aljohani, Abdullah Eid A.
13 Binatian, Ahmed Ibrahim S. 13 Alshehry, Abdullah Zafer A.
14 Alnuaim, Nuaim Abdulaziz N. 14 Almudaimigh, Khalid Abdulrahman I.
15 Alshaye, Abdulaziz Ali A.
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8. PROGRAM IMPLEMENTATION
The TVTC program for the Saudi Arabian delegate had been conducted for 2 weeks
commencing 3rd
to 14th
July 2017 (Please refer to specific assigned time table as shown in part 4f
and 4g). This short term training schedule was specially designed to fulfill the requirement of the
TVTC program.
The Saudi Arabian delegate is consists of 29 members. They were divided into 2 groups for
training at 2 different places. For the first week, the first group was attached to Petrol Engine
System Training Program at Port Dickson Polytechnic. Meanwhile, the second group was
attached to Hybrid Engine System Training Program at ADTEC Malacca. After completing the
first 3 days course, both groups were rotated according to the designed schedule at different
venue for the following week. For day 4 and day 5 of both weeks, they were brought to industrial
site visits at a few automotive industries namely Bermaz Auto Berhad (Mazda 3S) (6 July 2017),
Malaysian Automotive Institute (7 July 2017), Proton Holding Berhad (COE) (13 July 2017) and
Mitsubishi, Tan Chong Motor Assemblies (TCMA) (14 July 2017). A certificate presentation
event was held on evening of 14 July 2017 at Port Dickson Polytechnic after completion of the
TVTC program.
9. PROGRAM IMPACT
i. International collaboration networks in the field of technical and vocational education
training (TVET) can be established as well.
ii. Polytechnic Education Department will be able to promote TVET Malaysia, especially the
Malaysian Polytechnic to the eye of world.
iii. TVET Malaysia is capable of breaking the global boundaries through long-life education and
training.
iv. Lecturers are expected to improve their skills of knowledge delivery in their sharing with
others institution especially beyond the country.
10. CONCLUSION
This report is prepared to facilitate PPDs to identify the improvements as well as strategies that
can be done in the future or for coming collaboration program. As a whole, the TVTC program
has carried out successfully. The certificate presentation event was held on 14 July 2017 in front
of Hajah Kundur House at Port Dickson Polytechnic upon the completion of the TVTC training.
It is hoped that with the knowledge gained through the program, all Saudi Arab delegate will be
able to apply the new knowledge and techniques in the field of Automotive when they are back
to serve in their country later. It is recommended that such program can be implemented to
delegates of other countries as well.
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11. PROGRAM PHOTO GALLERY
MONDAY 3RD
JULY 2017 – POLIPD
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MONDAY 3RD
JULY 2017 – ADTEC MELAKA
TUESDAY 4TH
JULY 2017 – POLIPD
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TUESDAY 4TH
JULY 2017 – ADTEC MELAKA
WEDNESDAY 5TH
JULY 2017 – POLIPD
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WEDNESDAY 5TH
JULY 2017 – ADTEC MELAKA
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THURSDAY 6TH
JULY 2017 – SITE VISIT AT MAZDA
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FRIDAY 7TH
JULY 2017 – SITE VISIT AT MAI (MALAYSIA AUTOMOTIVE INSTITUTE)
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POLI
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MONDAY 10TH
JULY 2017 –POLIPD
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MONDAY 10TH
JULY 2017 – ADTEC MELAKA
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TUESDAY 11TH
JULY 2017 – POLIPD
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TUESDAY 11TH
JULY 2017 – ADTEC MELAKA
WEDNESDAY 12TH
JULY 2017 – POLIPD
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WEDNESDAY 12TH
JULY 2017 – ADTEC MELAKA
THURSDAY 13TH
JULY 2017 – SITE VISIT AT PROTON
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FRIDAY 14TH
JULY 2017 – SITE VISIT AT TAN CHONG MOTOR ASSEMBLIES
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CLOSING CEREMONY
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12. APPENDIX
a. CONTRACT BETWEEN TVTC AND MOHE
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b. INVOICE
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c. COURSE ANALYSIS
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d. TRAINING EVALUATION FORM
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e. SLAID PRESENTATION
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f. ATTENDANCE LIST
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g. EMAILS COLLECTION
Sent from my iPhone
On 28 Apr 2017, at 16:56, Yusma Yusof <[email protected]> wrote:
Dear Sir
Enclosed is the detail of the programs for TVTC training. I have submitted a copy to Jen.
Thank you.
Regards,
YUSMA BT YUSOF
Timbalan Pengarah Akademik
Politeknik Port Dickson 019 5948593/06-662 5289 "Making Politeknik Port Dickson a towering TVET Institution"
<CV_MOHD NAHAR AHMAD.doc>
<CV_MOHD ZUBIR AMIR.doc>
<QUOTATION FOR 15 PAX.doc>
<QUOTATION FOR 30 PAX.doc>
<Training Schedule.docx>
---------- Forwarded message ----------
From: Ramhari Lamichhane <[email protected]>
Date: 29 April 2017 at 10:28
Subject: Re: Proposal for TVTC
To: Yusma Yusof <[email protected]>
Dear Yusma,
Good morning!
Thanks for proposal. It seems bit high
for teaching aids. Can you clarify the items of teaching aids.
If possible, please reduce translator and teacher cost as well.
Regards,
POLITEKNIK
PORT D
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From: Yusma Yusof [mailto:[email protected]] Sent: Wednesday, May 3, 2017 12:58 PM To: International CoOperation Dept <[email protected]> Cc: Ramhari Lamichhane <[email protected]>; [email protected] Subject: PROPOSAL FOR TRAINING
Dear Sir,
Assalamualaikum warahmatullah
Greetings from the land of sunshine!
We have been referred to by the Director General of Colombo Plan Staff College of Manila to
your esteemed organisation on the needs to conduct a short course on Modern Systems for Vehicles, Fuel Injection Systems and Diagnose Faults.
For your information, Politeknik Port Dickson is a Malaysian government owned TVET
institution and it is located in a tourist-beach town of Malaysia. We are MQA,APACC and MS: ISO 2008 accredited and has been operating for 26 years. We have produced more than 40 000 students thus-far, graduating from our four main departments : civil, mechanical , electrical and commerce.
Our Mechanical Department is a well established department with a mixture of experience,
vibrant and talented lecturers. The department alone has bagged many medals of achievement and is well known in robotic competitions in this region. Hence, we are more than ready to conduct the course requested using the latest petrol and hybrid engine trainers.
We also have two support departments that cater for soft skills subjects hence the need for
Arab language translator is not a problem as we have with us lecturers who graduated from the middle east universities such as Al Azhar University.
Please find enclosed the quotation for a 10 day short course. Participants will be placed at a
nearby hotel which is owned by the Islamic State Council and food is guaranteed halal.
Should you need to investigate us further, you could visit our website at : www.polipd.edu.my
If you have any queries, please do not hesitate to contact me using this email address or whatsapp using the number given.
We are ready to receive our guests of knowledge and looking forward to this collaboration.
With Allah's rahmah and His blessing, thank you.
Warm regards,
YUSMA BT YUSOF
Deputy Director of Academic
POLITEKNIK
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Politeknik Port Dickson
Negeri Sembilan
---------- Forwarded message ----------
From: International CoOperation Dept <[email protected]>
Date: 4 May 2017 at 16:47
Subject: RE: PROPOSAL FOR TRAINING
To: Yusma Yusof <[email protected]>
Cc: Ramhari Lamichhane <[email protected]>, "[email protected]"
<[email protected]>, اد رقطا ي زي زهران يع ,<[email protected]> ال ن يوي محمد م ل خ ال
On 4 May 2017 at 16:47, International CoOperation Dept <[email protected]> wrote:
Dear Yusma,
Walaikum Assalam wr wb.
Greetings from TVTC, Riyadh, SA
Thanks for your proposal, which contains, introduction of your polytechnic, financial proposal and CV’s of the teachers.
Further, after going through the proposal, our HR department has requested the following information:
1. Please send us the contents and subjects of the trainings in sequence, that will be taken in training classes ( to be more clear here, please send us the complete time table of the trainings of 10 working days)
2. As given in your financial proposal, if the No. of trainees increase to 30 trainees, the total price will be US$ 76869.45 (We want to have your clarification here, can we send the 30 trainees in two groups to comply with this price?)
2. Could you please send us the web link of hotel you mentioned where our trainees would stay?
Your early reply will be appreciated.
With thanks & regards
Ibrahim A. Al Rasheed
Director General for Intl. Cooperation, TVTC
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From: Yusma Yusof [mailto:[email protected]] Sent: Friday, May 5, 2017 1:45 PM To: International CoOperation Dept <[email protected]>; Ramhari Lamichhane <[email protected]>; [email protected]; اد طارق ي زي زهران يع ;<[email protected]> ال ن محمد ميوي ل خ <[email protected]> ; Azhar Bin Rostani <[email protected]> ال Subject: Re: PROPOSAL FOR TRAINING
Assalamualaikum warahmatullah
Dear Ibrahim
After discussing in length with my team on the earlier quotation, we have decided to offer a
better deal by increasing the number of translators and trainers. Therefore, you will find a slight increase in price. The quoted price is solely for training and does not include any excursion that might be requested later.
Enclosed are the following :
1. The detailed training schedule based on two groups of fifteen participants per group ( 30 participants in total)
2. The re-edited quotation based on two groups of fifteen participants
3. The hotel's website is www.klanabeachresortpd.com.my It is a four star hotel and the CPSC (Colombo Plan Staff College) team stayed at that hotel last November during their site visit to Politeknik Port Dickson.
For site visits, we have identified three well known companies: Honda, Perodua and Proton
Malaysia and we also plan to include CIAST ( Centre for Instructor and Advanced Skill Training) so that the participants will get a better view on technical training in Malaysia.
Our team is very excited on the potential of this collaboration and we are very much looking
forward to your favourable reply. If you have further enquiries, please do not hesitate to contact me.
With Allah's blessing, wassalamualaikum warahmatullah.
Warm Regards,
YUSMA BT YUSOF
Deputy Director of Academic
Politeknik Port Dickson
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