Yesa-3102 (3.0) Eng

USER MANUAL
Gasoline Engine with

Auto Transmission Training System
YESA-3101
Ver. 3.0
#604, Samhwan Digital Venture Tower, 280-13, Seongsu-dong 2 ga, Seongdong-gu, Seoul 133-832, Korea
TEL: 82-2-2024-0077 / FAX: 82-2-2024-0070 / E-mail: sales@yes01.co.kr / Web: http://www.yes01.co.kr
WARNING
Copyright of this educational material is owned by YES01,
YOUNG-IL EDUCATION SYSTEM.
Unauthorized reproduction or copying may cause civil or
criminal liability.
The Chief Director of YES01, YOUNG-IL EDUCATION SYSTEM Co., Ltd.

CONTENTS
YESA-3102
1. Cautions ............................................................................................................. 1
2. Equipment Overview ....................................................................................... 3
3. Exercise ............................................................................................................. 3
1) Objectives ....................................................................................................... 7
2) Operation Requirements ............................................................................... 7
3) Theory ............................................................................................................. 7
4) Operation Sequence ...................................................................................... 14
5) Measurements ................................................................................................ 16
(1) Injector ........................................................................................................ 16
(2) W.T.S (Water temperature sensor) .......................................................... 18
(3) Ignition Coil ................................................................................................. 19
(4) C.K.P (Crank shaft position sensor) ......................................................... 20
(5) C.M.P (Cam shaft position sensor); C.A.P (Cam shaft angle sensor) .. 21
(6) O2 Sensor .................................................................................................. 22
(7) O.C.V (CVVT Oil control valve) ................................................................ 23
(8) T.P.S (Throttle position sensor) ................................................................ 24
(9) PG-A (Pulse generator A) / PG-B (Pulse generator B) .......................... 26
6) Diagnosis ........................................................................................................ 28
7) How to install Software .................................................................................. 34
8) Fault in insertion on computer ....................................................................... 38
Cautions
1-1 Installation of education system

1. Please install the product at stable place.
2. Please avoid dust, humidity and sunray.
3. Please install at stable place for not missing the product.
4. Please be cautious for the number of person, shock, fracture and safety while
moving the product.
5. Please check caster before moving the product.
6. Please set caster to immovable position after installing the product.
7. Please be cautious for workers’ safety while moving the product with forklift or
other machines.
8. Please check tightening of bolts and nuts after installation.
1-2 General cautions for safe use of educational system

1. Please make it sure to confirm cautions for installation and maintenance of
the product.
2. Please make it sure to notify the danger of the product to students before use.
3. Please dress up and keep the environment of the product clean and neat.
4. Please use proper tools and instruments for the product.
5. Please make it sure not to drop tools and parts.
6. Please check the operation of the product before starting education.
7. Please do not use your hand to pinpoint operating parts for safety.
8. Please make it sure to notify students to follow instructor’s order for educating
operating type educational system.
9. Please do not remove and rebuild cover and structure installed for safety.
10. Please follow safety rules of electricity for electric leakage, open circuit, and
over load.
11. Please do not fuel and do not wear glove for safety during operation.
12. Please keep away from the cross-sectioned part and operating part.
13. Please be cautious for rotating part and lever.
14. In case of unusual sound, vibration, and overload are discovered, please stop
the operation and inspect the product.
15. Power has to be shut down for inspection and maintenance of the product.
16. Please follow usual safely rules of industrial machinery for unspecified items.
17. Manufacturer is not responsible for any accident incurred by not following the
above mentioned items.
1
Cautions
1-3 Cautions for maintenance of educational system

1. Please make it sure to explain theory, operating procedures, and safety to
students before practical training.
2. Please make it sure to keep educational system and its environment clean
and neat.
3. Please make it sure to check lubrication of major operating part before use.
4. Please avoid severe use and shock because product is manufactured for
education purpose.
5. In case unusual symptom and trouble of product are appeared during
operation, please inspect and fix it with given procedures.
6. Please do not use any parts for replacement except genuine parts for the
product.
7. Please do not disassemble, fix, and rebuild the product except specified use.
8. Please keep the product clean before and after using it and cover it with a
cover.
9. Please check regularly the operation, electric leak age, and safety of product.
10. Please disconnect and store the battery of battery-equipped system unless it
is regularly used. In addition, recharge the battery regularly.
11. Please store the product with a cover in dust free and humid free place for
long-term storage.
2
Equipment Overview
Equipment Overview
Gasoline Engine with Auto Transmission Training System (YESA-3102)
Manufacturer Hyundai Motor Company

Engine type G 2.0 MPI-Theta2 (1,998 cc)
Transmission type 6-Speed Auto Transmission
Vehicle 12’ YF SONATA
Specification
3
Equipment Overview
1. Front View
No. Name No. Name

1 Transmission oil pressure gauge 9 Voltage meter
2 Battery (12V/60A) 10 Accelerator knob
3 ECU (Electronic control unit) 11 O.B.D Port
4 Cylinder head cover 12 Ignition key switch
5 Shift lever 13 Power socket
6 Exhaust manifold 14 Vacuum gauge
7 EOBD ECU Terminal 15 Oil pressure gauge
8 Cluster 16 Fuel tank
Name of parts
4
Equipment Overview
2. Right View
No. Name No. Name

1 Transmission oil pressure gauge 6 Shift lever
2 Radiator cap 7 EOBD ECU Terminal
3 Radiator 8 Transmission housing
4 Battery (12V/60A) 9 Fuse box
5 Air cleaner 10 Fuel tank
Name of parts
5
Equipment Overview
2. Left View
No. Name No. Name

1 Transmission oil pressure gauge 6 Cylinder head
2 Shift lever 7 Coolant tank
3 EOBD ECU Terminal 8 Crank shaft pulley
4 Cylinder head cover 9 Cylinder block
5 Oil level gauge 10 Oil pan
Name of parts
6
Exercise
Objectives
a. Waveform of gasoline engine can be measured using scanner and scope.
b. Self-diagnosis of gasoline engine can be measured using scanner and scope.
c. Names of main components of gasoline engine can be known.
d. Correct equipment operating method can be understood and operated.
Operation Requirements
a. This equipment requires gasoline fuel.
b. This equipment requires a flat place so that the equipment may be fixed on.
c. This equipment requires to be operated after fully understanding this manual.
Theory
1. Gasoline Engine Construction Overview

1.1 Block
All automotive and truck engines are constructed using a solid frame, called a block.
A block is constructed of cast iron or aluminum and provides the foundation for most
of the engine components and systems. The block is cast and then machined to very
close tolerances to allow other parts to be installed.
1.2 Rotating Assembly

Pistons are installed in the block and move up and down during engine operation.
Pistons are connected to connecting rods, which connect the pistons to the
crankshaft. The crankshaft converts the up-and-down motion of the piston to rotary
motion, which is then transmitted to the drive wheels and propels the vehicle. SEE
Figure 1-1.
1.3 Cylinder Heads

All engines use a cylinder head to seal the top of the cylinders, which are in the
engine block. The cylinder head also contains both intake valves that allow air and
fuel into the cylinder and exhaust valves, which allow the hot gases left over to
escape from the engine. Cylinder heads are constructed of cast iron or aluminum
and are then machined for the valves and other valve-related components. SEE
Figure 1-2.
7
Exercise
Figure 1-1 The rotating assembly for a V-8 engine that has eight pistons
and connecting rods and one crankshaft.
Figure 1-2 A cylinder head with four valves per cylinder,

two intake valves (larger) and two exhaust valves (smaller).
2. Engine Parts and Systems

2.1 Intake and Exhaust Manifolds
Air and fuel enter the engine through an intake manifold and exit the engine through
the exhaust manifold. Intake manifolds operate cooler than exhaust manifolds and
are therefore constructed of nylon-reinforced plastic or aluminum. Exhaust manifolds
must be able to withstand hot exhaust gases, so most are constructed from cast iron
or steel tubing.
2.2 Cooling System

All engines must have a cooling system to control engine temperatures. While some
older engines were air cooled, all current production passenger vehicle engines are
cooled by circulating antifreeze coolant through passages in the block and cylinder
head. The coolant picks up the heat from the engine and after the thermostat opens,
the water pump circulates the coolant through the radiator where the excess heat is
released to the outside air, cooling the coolant. The coolant is continuously circulated
through the cooling system and the temperature is controlled by the thermostat. SEE
Figure 1-3.
8
Exercise
Figure 1-3 The coolant temperature is controlled by the thermostat, which opens and allows
coolant to flow to the radiator when the temperature reaches the rating temperature of the
thermostat.
2.3 Lubrication System

All engines contain moving and sliding parts that must be kept lubricated to reduce
wear and friction. The oil pan, bolted to the bottom of the engine block, holds 4 to 7
quarts (4 to 7 liters) of oil. An oil pump, which is driven by the engine, forces the oil
through the oil filter and then into passages in the crankshaft and block. These
passages are called oil galleries. The oil is also forced up to the valves and then
falls down through openings in the cylinder head and block, then back into the oil
pan. SEE Figure 1-4.
Figure 1-4 A typical lubrication system, showing the oil pan, oil pump, oil filter, and oil passages.
2.4 Fuel System and Ignition System

All engines require both a fuel system to supply fuel to the cylinders and an ignition
system to ignite the air-fuel mixture in the cylinders. The fuel system includes the
following components.
9
Exercise
∙ Fuel tank, where fuel is stored and where most fuel pumps are located
∙ Fuel filter and lines, which transfer the fuel for the fuel tank to the engine
∙ Fuel injectors, which spray fuel into the intake manifold or directly into the cylinder,
depending on the type of system used
The ignition system is designed to take 12 volts from the battery and convert it to
5,000 to 40,000 volts needed to jump the gap of a spark plug. Spark plugs are
threaded into the cylinder head of each cylinder, and when the spark occurs, it
ignites the air-fuel mixture in the cylinder creating pressure and forcing the piston
down in the cylinder. The following components are part of the ignition system.
∙Spark plug - Provide an air gap inside the cylinder where a spark occurs to start
combustion
∙Sensor - Includes crankshaft position (CKP) and camshaft position (CMP) sensors,
used by the power-train control module (PCM) to trigger the ignition coil(s) and the
fuel injectors
∙Ignition coil - Increase battery voltage to 5,000 to 40,000 volts
∙Ignition control module (ICM) - Controls when the spark plug fires
∙Associated wiring - Electrically connects the battery, ICM, coil, and spark plugs
3. Four- Stroke Cycle Operation

3.1 Principles
The first four-stroke cycle engine was developed by a German engineer, Nickolaus
Otto, in 1876. Most automotive engines use the four-stroke cycle of events. The
process begins by the starter motor rotating the engine until combustion takes place.
The four-stroke cycle is repeated for each cylinder of the engine. SEE Figure 1-5.
A piston that moves up and down, or reciprocates, in a cylinder can be seen in
Figure 1-5. The piston is attached to a crankshaft with a connecting rod. This
arrangement allows the piston to reciprocate (move up and down) in the cylinder as
the crankshaft rotates. SEE Figure 1-6.
3.2 Operation
Engine cycles are identified by the number of piston strokes required to complete the
cycle. A piston stroke is a one-way piston movement either from top to bottom or
bottom to top of the cylinder. During one stroke, the crankshaft rotates 180 degrees
(1/2 revolution). A cycle is a complete series of events that continually repeats. Most
10
Exercise
automobile engines use a four-stroke cycle.
∙Intake stroke - The intake valve is open and the piston inside the cylinder travels
downward, drawing a mixture of air and fuel into the cylinder. The crankshaft rotates
180 degrees from top dead center (TDC) to bottom dead center (BDC) and the
camshaft rotates 90 degrees.
∙Compression stroke - As the engine continues to rotate, the intake valve closes
and the piston moves upward in the cylinder, compressing the air-fuel mixture. The
crankshaft rotates 180 degrees from bottom dead center (BOG) to top dead center
(TOC) and the camshaft rotates 90 degrees.
∙Power stroke - When the piston gets near the top of the cylinder, the spark at the
spark plug ignites the air-fuel mixture, which forces the piston downward. The
crankshaft rotates 180 degrees from top dead center (TOG) to bottom dead center
(BOG) and the camshaft rotates 90 degrees.
∙Exhaust stroke - The engine continues to rotate, and the piston again moves
upward in the cylinder. The exhaust valve opens, and the piston forces the residual
burned gases out of the exhaust valve and into the exhaust manifold and exhaust
system. The crankshaft rotates 180 degrees from bottom dead center (BOC) to top
dead center (TOC) and the camshaft rotates 90 degrees.
This sequence repeats as the engine rotates. To stop the engine, the electricity to
the ignition system is shut off by the ignition switch, which stops the spark to the
spark plugs.
The combustion pressure developed in the combustion chamber at the correct time
will push the piston downward to rotate the crankshaft.
11
Exercise
Figure 1-5 The downward movement of the piston draws the air-fuel mixture into the cylinder
through the intake valve on the intake stroke. On the compression stroke, tile mixture is
compressed by the upward movement of the piston with both valves closed. Ignition occurs at
the beginning of the power stroke, and combustion drives the piston downward to produce power.
On the exhaust stroke, the upward-moving piston forces the burned gases out the open exhaust
valve.
12
Exercise
Figure 1-6 Cutaway of an engine showing the cylinder, piston, connecting rod, and crankshaft.
13
Exercise
Operation Sequence
Caution
Do not let the rotating part to be in contact with foreign objects or the parts of the
body!
Caution
The practice must be conducted in the wide and flat area. This area must be able to
emit the exhaust fumes to the outside!
1. Check the cooling water and fuel quantity.
2. Turn on the ignition key switch.
3. Check whether the voltage of the volt meter is at about 12V.

Caution
If the output voltage is below 10V, this requires recharging for being put into use.
Before running the equipment, conduct frequent check-up and maintenance for the
equipment.
14
Exercise
4. After checking that the gear lever is on P or N range, start the engine by turning
the ignition key switch to ST.
Caution
Once the engine starts, warm up the engine until it reaches about 700 ~ 900 RPM.
Warm up the engine until the water temperature gauge reaches about 90℃
(Intermediate position between H and C on the gauge).
15
Exercise
Measurements
Caution
The waveform can be different for the certain types and model years of the car.
Caution
Basically, we can use the oscilloscope or multimeter to measure the waveform or
voltage values. We can conduct the measurement by inserting + probe into the
terminal of sensor or actuator, and connecting - probe into ground terminal or main
body of the engine.
1. Injector
Injector is an actuator that is used to inject the fuel after ECU completes calculating
air-fuel ratio. Under the same pressure environment, by controlling the timing and
fuel quantity with the injector, we can configure fuel injection, so that it suits for the
vehicle’s conditions.
Basic structure of the injector
16
Exercise
Basic Structure of the Injector
The analysis of the waveform from the injector
① This represents the injector’s operating power voltage.

② This represents ON status of the transistor for running the injector
③ This represents operation time (Fuel injection time).
④ This represents OFF status of the transistor. (This stops fuel injection.)
⑤ This represents reverse-voltage when the magnetic field breaks down.
⑥ This displays the attenuation section of the injector’s coil.
⑦ This represents the voltage of alternator or B+ until next injection.
※Reference: The injection time is adjusted as the voltage of the alternator decreases.
17
Exercise
2. W.T.S (Water temperature sensor)

W.T.S (Water temperature sensor) is the sensor that detects the temperature of the
engine’s cooling water. It is implemented with bimetal thermometer and thermistor.
For the circulation of cooling water and the shut-down of cooling water, such
elements as thermal ferrite and PTC are used to provide on-off output at certain
temperature. Recently, as the electronic control is being actively implemented,
higher accuracy is being required regarding the information of cooling water
temperature. As thermistor is suitable for these needs and acceptable for measuring
water temperature, it is widely used in the business. It is the resistive sensor that
provides the information of the temperature of cooling water to ECU. It is located at
the coolant path of the intake manifold. Based on the output voltage of this sensor,
ECU determines the status of warming-up and provides an ample amount of fuel for
the cold engine.
The analysis of the waveform from W.T.S (Water temperature sensor)

① The voltage drops as the increase in the temperature of the engine.
② There is a brief voltage spike due to the opening of thermostat, which causes
the cooling water of the radiator to be mixed.
18
Exercise
3. Ignition Coil
This induction coil is called ‘Ignition Coil’ that creates the spark for ignition plug in the
battery-based ignition system. In the center of the coil, there is a metal rod stacked
with 0.3mm silicon steel plate. On the top of this rod, there is 1st coil that is coiled for
200 ~ 500 times with the enamel wire, whose radius is about 0.5 ~ 0.8 mm. On the
top of this coil, there is 2nd coil that is coiled for 1,700 ~ 3,000 times with the enamel
wire, whose radius is about 0.06 ~ 0.08 mm. After putting this into the case, pour in
the oil to insulate it. The required insulation resistance is over 10MΩ at 80℃.
Basic Structure of the ignition coil
The analysis of the waveform from ignition coil
① Ignition Voltage: This shows the required voltage when the spark is created
between the poles of the plug.
② Attenuated Vibration Section: This shows that the remaining energy in
ignition coil attenuates towards 1st coil of the ignition.
③ Spark Line: This shows that there is continuous ARC discharge between the
poles of the plug.
19
Exercise
4. C.K.P (Crank shaft position sensor)

Crank shaft position sensor is composed of the permanent magnet, coil, and anti-
frost core. It is located on the upper side of the fly wheel with teeth, which can
produce the signal corresponding to the number of sensor wheel. ECU accepts this
signal as its input and calculates the number of revolutions. The number of
revolutions will be the basic component for such engine control elements as fuel
injection and ignition timing control.
The analysis of the waveform from C.K.P (Crank position sensor)
① The middle gear part indicates the reference signal for top dead center of
no.1 cylinder and no.4 cylinder. This shows two waveforms without bumps.
② Besides the large gear in the middle, the maximum voltage and minimum
voltage of small gears should be the same when the engine’s number of
revolutions is constant. (This varies according to the difference between
maximum voltage and minimum voltage.)
③ This vehicle’s number of tooth for the rotation wheel is 60 with every 2 teeth
carved, which means that the angle between each gear is 6°.
20
Exercise
5. C.M.P (Cam shaft position sensor); C.A.P (Cam shaft angle sensor)
C.M.P (Cam shaft position sensor) is the sensor that detects the compression status
of no.1 cylinder and no.4 cylinder. Based on this signal, the ignition sequence will be
determined. According to the measurement methods, there are optical-type and hall-
device type.
Basic Structure of the C.M.P (Cam shaft position sensor)
The analysis of the waveform from C.M.P (Cam shaft position sensor)
① The maximum voltage should be close to the reference voltage. It should be

level when observed continuously.
② The minimum voltage should be close to the ground voltage. It should be
level when observed continuously.
③ The shape and period of the waveform should be constant while RPM is
constant.
④ According to RPM, the period for one cycle should vary.
⑤ This represents the reference signal for top dead center of no.1 cylinder.
⑥ This represents the reference signal for top dead center of no.4 cylinder
21
Exercise
6. O2 Sensor
O2 Sensor is installed at the exhaust manifold in order to control air-fuel ratio. In
order to do so, it measures the O2 concentration in the exhaust fumes and controls
the air-fuel ratio. According to the methods, there are Zirconia O2 sensor and
Titanium O2 sensor.
Basic Structure of the O2 Sensor
The analysis of the waveform from O2 sensor
① It is considered dense when the maximum voltage is around 0.8V.

② It is considered scarce when the minimum voltage is around 0.2V.
③ The average value of the maximum voltage and the minimum voltage should
be 0.4 ~ 0.6V.
④ Determine the deterioration of O2 sensor and the status of the air-fuel ratio
by observing average feedback period, the time for diluteness/density, and
the time for density/diluteness.
22
Exercise
7. O.C.V (CVVT Oil control valve)

The CVVT (Continuous Variable Valve Timing) system control signal corresponding
to the engine by the ECM speed and the engine load, the intake or advance the
closing timing of the exhaust valve (Advance) or late (Retard) of the device. Due to
CVVT control, between the intake valve and the exhaust valve the valve overlap
(Overlap) or valve underlap (Underlap) is generated and, because of this pumping
loss reduction, the internal EGR occurs, the combustion stability, the volume
efficiency, the expansion work and increased Due to the improved fuel economy,
reduced emissions (NOx, HC), the effect of engine performance. The system ECM of
the PWM (Pulse Width Modulation) receive signals cam changing the path of the
engine oil pager (Cam Phaser) to CVVT oil control to supply or to outlet the fluid
valve (OCV: Oil Control Valve), the temperature of the engine oil measurement
CVVT oil temperature sensor (OTS: Oil Temperature Sensor), is configured to
change the phase of the cam shaft with hydraulic pressure of the engine oil to the
cam phaser (Cam Phaser). Oil is delivered from CVVT oil control valve by rotating a
camshaft associated with the rotor in the cam phaser to rotate in the direction of
rotation of the engine camshaft (intake advance / exhaust perception) or opposite
(inlet perception / exhaust advance angle), the phase of the cam angle the changes.
Basic Structure of the O.C.V (CVVT Oil control valve)
Item Nominal value

Coil resistance (Ω) 6.9 ~ 7.9 (20℃)
23
Exercise
8. T.P.S (Throttle position sensor)

T.P.S (Throttle position sensor) is a rotational variable resistor that rotates with the
throttle body and throttle shaft. When throttle shaft rotates, the output voltage from
throttle position sensor changes. Based on the voltage variations, ECU will detect
the opening of the throttle valve. According to the opening, it determines the
operating area. Based on the pre-defined values in each operating area, it conducts
fuel quantity and ignition sequence control.
Basic Structure of the E.T.C (Electronic throttle control)
24
Exercise
The analysis of the waveform from T.P.S (Throttle position sensor)
① This represents the opening of the throttle valve under idle status.
② This represents that the amount of air intake increases (accelerates) as the
throttle valve opens.
③ This represents that maximum opening status of throttle valve, called (WOT).
④ This represents the closure of throttle valve (decelerating).
⑤ This shows the closed state of the throttle valve.
※Reference: Although the voltage of no.1 status and no.5 status should be the same,
due to carbon or other foreign elements, the throttle valve will not be able to
close completely, which could cause difference in voltage.
25
Exercise
9. PG-A (Pulse generator A) / PG-B (Pulse generator B)

Input speed sensor (PG-A) is a crucial input sensor that detects the revolution counts
of the transmission’s internal rotor and conveys it to TCM. It is composed of normal
input and output sensor. This input sensor plays as vital input information in
electronic control and necessary information for such operation regions as feedback
control, damper clutch control, gear step control, line pressure control, clutch
operation pressure control, and other standards used to determine sensor
breakdown.
Output speed sensor (PG-B) is an important input sensor that detects the turbine
shaft of the transmission and output revolution counts, and conveys these to TCM. It
is composed of normal input and output sensor. This output sensor plays as vital
input information in electronic control and necessary information for such operation
regions as feedback control, damper clutch control, gear step control, line pressure
control, clutch operation pressure control, and other standards used to determine
sensor breakdown.
Basic Structure of the PG-A / PG-B
The waveform of PG-A (Pulse Generator A)
26
Exercise
The waveform of PG-B (Pulse Generator B)
27
Exercise
Diagnosis
Caution
When conducting the practice with the sensors or actuators shut down, it should be
done quick and fast. After finishing the practice, all the sensors and actuators should
be restored to the normal operation state and fault code should be removed.
Caution
Since this equipment is not operating at the same condition as the actual vehicle,
fault code can occur on the parts, except for the auxiliary engine device.
1. Checking the code number for sensors and actuators

* Numbers in the brackets (00) represent the code numbers for sensors and actuators in EOBD ECU.
EOBD ECU
◎ ◎ ◎ ◎ ◎
(01) (02) (03) (04) (05)
#1 #2 #3 #4
W.T.S
INJECTOR INJECTOR INJECTOR INJECTOR
◎ ◎ ◎ ◎ ◎
(06) (07) (08) (09) (10)
#1 #2 #3 #4
C.K.P
IG. COIL IG. COIL IG. COIL IG. COIL
◎ ◎ ◎ ◎ ◎
(11) (12) (13) (14) (15)
O2 Sensor O2 Sensor I.S.C

C.M.P O.C.V
UP DOWN ACTUATOR
◎ ◎ ◎ ◎ ◎
(16) (17) (18) (19) (20)
P.GENERATOR P.GENERATOR ATM

T.P.S GROUND
A B CONTROL RELAY
28
Exercise
2. Adjusting the operation of sensors and actuators

1) Enter the code numbers from ‘1. Checking the code number for sensors and
actuators’ on EOBU ECU set-up panel.
●
00 ●
● ● ●
1 2 3
● ● ●
4 5 6
● ● ●
7 8 9
● ● ●
ENTER 0 START/STOP
Example
When trying to shut down W.T.S, enter code number ‘05’
When trying to shut down C.K.P sensor, enter code number ‘10’
2) After entering the code number, press ‘START/STOP’ button to stop the
operation of the actuator or engage the actuator into the normal operation.
3) After checking the symptoms, press ‘START/STOP’ one more time to restore
it back to the normal operation.
29
Exercise
3. Checking the fault code (Using the vehicle diagnosis tool)

1) Insert the vehicle diagnosis cable (This manual is based on HI - DS.) into
DLC Port (OBD Port).
The example of DLC (Data link cable) Port (OBD-II Type)
2) After connecting the diagnosis tool, select the corresponding engine

manufacturer and vehicle (model year). Then, enter into ‘Self-diagnosis’
section under ‘Engine control’ section.
Manufacturer Selection Screen Engine type Selection Screen
Notice
Manufacturer: Hyundai motor company
Vehicle: 12’ YF SONATA
Engine type: G 2.0 MPI-Theta2 (1,998 cc)
3) After the connection is completed without error, check the fault code for the
particular sensors and actuators by configuring the shut-down or operation of
the sensors and actuators at ‘2.Adjusting the operation of sensors and
actuators’
4) After checking the fault code, restore the sensors and actuators back to the
normal operation. And then, initialize them using ‘Erase Memory’ function.
30
Exercise
Example of fault code Erasing Memory
31
Exercise
4. Checking sensor data (Using vehicle diagnosis tool)

1) Insert the vehicle diagnosis cable (This manual is based on HI - DS.) into
DLC Port (OBD Port).
The example of DLC (Data link cable) Port (OBD-II Type)
2) After connecting the diagnosis tool, select the corresponding engine

manufacturer and vehicle (model year). Then, enter into ‘Sensor data’ section
under ‘Engine control’ section.
Manufacturer Selection Screen Engine type Selection Screen
Notice
Manufacturer: Hyundai motor company
Vehicle: 12’ YF SONATA
Engine type: G 2.0 MPI-Theta2 (1,998 cc)
32
Exercise
3) After the connection is completed without error, we can check the status of
engine or its revolution counts. Also, we can check the engine data that
varies according to the surrounding environment.
Sensor Data Values
33
Exercise
How to install Software
Software Requirements
a. 32bit/64bit Windows® OS PC with the resolution that is equal or higher than
1024 x 768.
b. Microsoft .NET Framework 4.5 or higher
c. 2GB RAM or higher
d. Full Internet Connection
e. The latest version of Adobe Reader
1. Insert the disc into the PC that you want to install this program.
2. Open ‘My Computer’ on the desktop.
34
Exercise
3. Access the drive that contains the disc.
35
Exercise
4. Run ‘AUTOSIM_setup.exe’ in the disc.
5. Press ‘Next’ to complete the installation.
6. Depending on the needs, click on ‘Adobe Reader’ and ‘Microsoft .Net Framework
4.5’ shortcuts on the desktop in order to install them.
Notice
If the PC that you use already has ‘Adobe Reader’ or ‘Adobe Acrobat’ installed, it is
unnecessary to install ‘Adobe Reader’.
Notice
If the PC that you use already has ‘Microsoft .NET Framework 4.5’ installed, it is
unnecessary to install ‘Adobe Microsoft .NET Framework 4.5’.
36
Exercise
7. Once all the installations have been completed, run ‘AUTOSIM.exe’ shortcut on
the desktop.
37
Exercise
Fault insertion on computer
Notice
This function requires the electric car equipment that supports Auto Fault.
1. Connect the electric car equipment to PC through ‘USB Cable’
2. At Select Menu section, click on ‘AUTO FAULT’ button.
38
Exercise
3. Click on ‘CONNECT’ button on the bottom in order to synchronize the electric car
with PC.
39
Exercise
4. Once the connection is complete, the corresponding port No. will be displayed on
‘Port’ section. Green lamp will light up at Connection part.
40
Exercise
5. Check the Fault code number on page 25.
6. Click the Fault button then click ‘SEND’ button.
41
Exercise
7. You can turn the corresponding Fault back to its original state by clicking ‘CLEAR’
button. Even though you do not press it, after 30 seconds, it will automatically return
to its original state.
42
Exercise
8. Once the practice session is over, press ‘DISCONNECT’ button to cut off the
connection.
43
Exercise
44
YESA-3102
Published by:
YES01 U Learning Engineering Institute
YES01, YOUNG-IL EDUCATION SYSTEM Co., Ltd
Main Office and Factory, Technical Institute

#604, Samhwan Digital Venture Tower,
280-13, Seongsu-dong 2 ga,
Seongdong-gu, Seoul 133-832, Korea
TEL: 82-2-2024-0077
FAX: 82-2-2024-0070
E-mail: sales@yes01.co.kr
Web: http://www.yes01.co.kr
Contact: If you have any question about equipments or materials,

please contact us:
Material Development: YES01 U Learning Engineering Institute
E-mail: sales@yes01.co.kr
If Part or all of this material is copied or reproduced

Without prior consent of YOUNG-IL EDUCATION SYSTEM
Co., Ltd such act will be in conflict with The Copyright Law.

Yesa-3102 (3.0) Eng

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USER MANUAL

Gasoline Engine with

Copyright of this educational material is owned by YES01,

YOUNG-IL EDUCATION SYSTEM.

Unauthorized reproduction or copying may cause civil or

The Chief Director of YES01, YOUNG-IL EDUCATION SYSTEM Co., Ltd.

1-1 Installation of education system

1-2 General cautions for safe use of educational system

1-3 Cautions for maintenance of educational system

Gasoline Engine with Auto Transmission Training System (YESA-3102)

Manufacturer Hyundai Motor Company

No. Name No. Name

No. Name No. Name

No. Name No. Name

1. Gasoline Engine Construction Overview

1.2 Rotating Assembly

1.3 Cylinder Heads

Figure 1-2 A cylinder head with four valves per cylinder,

2. Engine Parts and Systems

2.2 Cooling System

2.3 Lubrication System

2.4 Fuel System and Ignition System

3. Four- Stroke Cycle Operation

automobile engines use a four-stroke cycle.

1. Check the cooling water and fuel quantity.

2. Turn on the ignition key switch.

3. Check whether the voltage of the volt meter is at about 12V.

Basic structure of the injector

Basic Structure of the Injector

The analysis of the waveform from the injector

① This represents the injector’s operating power voltage.

2. W.T.S (Water temperature sensor)

The analysis of the waveform from W.T.S (Water temperature sensor)

Basic Structure of the ignition coil

The analysis of the waveform from ignition coil

4. C.K.P (Crank shaft position sensor)

The analysis of the waveform from C.K.P (Crank position sensor)

Basic Structure of the C.M.P (Cam shaft position sensor)

① The maximum voltage should be close to the reference voltage. It should be

Basic Structure of the O2 Sensor

The analysis of the waveform from O2 sensor

① It is considered dense when the maximum voltage is around 0.8V.

7. O.C.V (CVVT Oil control valve)

Basic Structure of the O.C.V (CVVT Oil control valve)

Item Nominal value

8. T.P.S (Throttle position sensor)

Basic Structure of the E.T.C (Electronic throttle control)

The analysis of the waveform from T.P.S (Throttle position sensor)

9. PG-A (Pulse generator A) / PG-B (Pulse generator B)

Basic Structure of the PG-A / PG-B

The waveform of PG-A (Pulse Generator A)

The waveform of PG-B (Pulse Generator B)

1. Checking the code number for sensors and actuators

O2 Sensor O2 Sensor I.S.C

P.GENERATOR P.GENERATOR ATM

2. Adjusting the operation of sensors and actuators

3. Checking the fault code (Using the vehicle diagnosis tool)

The example of DLC (Data link cable) Port (OBD-II Type)

2) After connecting the diagnosis tool, select the corresponding engine

Manufacturer Selection Screen Engine type Selection Screen

Example of fault code Erasing Memory

4. Checking sensor data (Using vehicle diagnosis tool)

The example of DLC (Data link cable) Port (OBD-II Type)