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3-cylinder engine

Proton has long had its own engine factory, with the first one having been opened in the Glenmarie industrial estate of Selangor in the 1990s. Over the years, this factory has provided millions of engines for various Proton models and continues to do so.

Now, with the new generation of engines in the carmaker’s latest models, it is time to have a new facility to assemble the 1.5-litre TGDI (Turbo Gasoline Direct Injection) JLH-3G15TD 3-cylinder engine used in the X50 and X70 models. This is the first time the engine is being assembled outside China at is one of the most advanced automotive engine assembly lines in the country at the Proton Tanjung Malim manufacturing complex in Perak.

Proton Tanjong Malim engine plant 2022

Proton Tanjong Malim engine plant 2022

Located within the Engine and Powertrain facility, the assembly line covers an area of 18,000 sq. metres and has a current maximum capacity of 180,000 engines when running on three shifts. The new facility is also part of the RM1.8 billion Proton is making to upgrade its facilities at Tanjung Malim, also known as Proton City.

Award-winning engine
The award-winning JLH-3G15TD engine is used not only by Proton but also by other brands in the diverse Geely Group. When the many other models are included, over 750,000 vehicles sold globally are now powered by this engine.

Proton Tanjong Malim engine plant 2022

The engine, the result of a project which started about 10 years ago, follows industry trends of downsizing to gain better fuel efficiency and also reduce undesirable exhaust emissions. While downsizing the displacement on its own has meant lower power output, this is not the case with the JLH-3G15TD. In fact, in spite of its smaller displacement and one cylinder less, its output is actually comparable to much bigger engines with 130 kW and 255 Nm.

This has been possible with advanced technologies, 4 valves per cylinder, dual variable valve timing, optimised thermal and lubrication systems, a low inertia turbocharger, and homogenised 200-bar direct fuel injection system. It is also capable of meeting Euro 6 requirements.

Proton Tanjong Malim engine plant 2022

Proton Tanjong Malim engine plant 2022

Localisation of parts
As a Malaysian carmaker, Proton has always prioritised localisation and where possible, it has sourced parts from Malaysian suppliers, although in the era of globalisation, there are also some suppliers from other countries in the region. For this new engine, there are currently 72 parts supplied by 19 Malaysian and 4 ASEAN vendors.

The company is also using the new assembly line to advance its human capital development goals, with 202 workers directly employed to work there. With an average age of just 24 years, they represent the next generation of skilled automotive manpower for the nation.

Proton Tanjong Malim engine plant 2022

“Proton’s new engine assembly line showcases the company keeping its promises to its stakeholders. When the agreement was made to partner with Geely in 2017, one of our commitments was to invest in Malaysia’s automotive industry both financially and through the introduction of new high technology components. The new assembly line does this while also giving PROTON an avenue to attract and develop young talents who will help drive the automotive industry and the company into the future,” said Roslan Abdullah, Deputy CEO of Proton.

A closer look at the facility
Featuring 88 stations consisting of 17 automatic, 15 semi-automatic and 56 manual stations, the high-tech assembly line was built using an IR 4.0 ethos applying a high level of automation to boost productivity. A climate-controlled clean environment with an anti-static station to allow for the discharge of static electricity protects the electronic components used, while the assembly line utilises a conveyor system. This is not only smoother but is also cleaner, more durable and less costly to operate than one that uses a chain.

Proton Tanjong Malim engine plant 2022

All workers on the assembly line have undergone extensive training with Geely as well as the suppliers of the machines used. The equipment comes from well known suppliers such as ABB, COMAU, FEV China, FEV India, WiBeda and Hangxin.

The Internet of Things (IOT) technology is deployed in the form of intensive data capture and analytical tools to ensure that the quality meets the standards required and are maintained. Additionally, 207 Error Mistake Proofing (EMP) controls and 34 intelligent high-resolution cameras have been installed on the line to prevent process and assembly defects and reduce downtime with 100% real-time defect detection capabilities.

Proton Tanjong Malim engine plant 2022

“Quality is the main priority at our new engine assembly line. We know we need to show Malaysians that Proton is capable of building reliable high-quality products, so we have left nothing to chance. Aside from the quality monitoring measures deployed on the assembly line, we also work closely with our counterparts at Geely to trouble shoot issues and share best practices in our efforts to produce a world-class engine,” added Encik Roslan Abdullah.

Proton constructing additional stamping facility at Tanjung Malim factory

The first product to be launched when the Zhejiang Geely Holding Group (Geely) became DRB-HICOM’s partner in Proton was the X70, ‘Malaysianised’ from the Geely Boyue within a year of the partnership agreement being signed. It has remained a strong seller in the 4 years it has been in the market and is sold overseas as well.

Although demand remains strong, Proton is not taking things for granted and has given it some updating for the 2022 model launched online this morning. As with most midcycle changes, the new features are largely cosmetic with no changes to stamped parts to avoid incurring new production costs.

[Click here to download the 2022 Proton X70 brochure]

These include quartz black finishing on the front and rear bumpers, new 19-inch alloy wheels, power tailgate with foot sensor for handsfree opening and Nappa leather seats with new black headlining. Other features remain unchanged for each of the 5 variants.

2022 Proton X70 1.5

2022 Proton X70 1.5

1.5-litre 12-valve 3-cylinder engine
However, under the bonnet, there is significant change with an additional engine option. This is the 1.5-litre JLH-3G15TD engine jointly developed by Geely and Volvo. It is already used in the X50 as well as export versions of the X70. If you add the other Geely Group models it is used in, the engine is powering vehicles in 22 countries.

Actually, if you look at Geely’s history, you will find that its very first car, the HQ/Haoqing, had a 3-cylinder engine. This was the 1-litre unit that was originally developed by Daihatsu for its Charade and which Geely licensed to make and use in its own models. That was back in the late 1990s and with the technology of that period, the output was around 50 ps with 70 Nm of torque.

2022 Proton 1.5-litre engine

The 1.5-litre 3-cylinder 12-valve engine in the latest X70 produces 177 ps/255 Nm and it shows just how far engine technology has advanced. Of course, it has a larger displacement and has a turbocharger and direct fuel injection to boost power output, as well as other technologies that were not available in the 1990s.

3-cylinder engines have been around all along since the late 1970s when Daihatsu started mass-producing them for the Charade and other models. Millions of Malaysians have also been driving cars with them as they are used in Perodua models. But the reason why this configuration has gained more widespread use over the past 15 years has been that the industry has been downsizing powerplants to improve fuel efficiency and reduce emissions. With turbocharging and more advanced fuel delivery, it has been possible to squeeze more out of a 3-cylinder engine with a smaller displacement. The reduced displacement and size means less consumption, which Proton claims is 7% less than the 1.8-litre engine.

2022 Proton 1.5-litre engine

The earlier generation of 3-cylinder engines were noisy, partly because of vibrating more due to their odd firing pulses and also because they were usually in low-cost models. Today, with more extensive measures against noise, vibration and harshness (NVH), their inherent noises are masked more effectively from the cabin.

One interesting measure in the X50 engine is the use of a softer material for the engine cover, which is usually just hard plastic that doesn’t absorb sound so well. Furthermore, much of the engine bay is also covered up, helping to contain mechanical noises.

Is it less durable?
There are some who feel that a 3-cylinder engine may not be as durable and lasting as a 4-cylinder engine because it has to work harder. Where durability is concerned, the engine has been tested thoroughly over 12 million kms in all types of conditions. And because it is already in over 750,000 vehicles globally, there is plenty of real-world feedback to help the engineers identify any areas needing improvement or rectification. So what Malaysians are now getting (the engine is assembled at the Tg. Malim factory as well) could be considered an optimised version with all the improvements made over the past few years.

There’s a 7-speed dual-clutch transmission (wet type) which sends power to the front wheels or all four wheels, the latter all-wheel drive system having been demanded by some customers. It was available initially in the CBU models from China but omitted with the locally-assembled version. Whether to pay the extra RM5,800 for having AWD is really up to you. Where we would have said (and that would be years ago) that AWD can help make driving safer with better grip and stability, there are many active systems like ESC and traction control which can also provide stability and grip in slippery conditions so the added cost of AWD (plus some extra weight) may not be necessary any longer.

2022 Proton X70 1.5

2022 Proton X70 1.5

2022 Proton X70 1.5

First driving impressions
As the cosmetic and feature changes are minimal, let’s jump straight to the first impressions we had of the X70 running with the 1.5-litre engine. Though it’s been in the X50 a while, this writer has not driven that model so far so the comparisons would be with the X70 1.8 that has been on sale for 4 years now – and the last time we drove the car was just before the MCO began.

Anyway, Proton’s drive event earlier in the week was for us to get brief impressions of the performance which they expect to be of interest to many in view of the heavier and larger vehicle size. It was a short drive around Selangor, about 130 kms, with mostly highways and moderate traffic conditions. A more comprehensive video report will be done later when we can get a new X70 for a longer period.

Generally, if not told whether it is a 1.5 or 1.8 engine, most people are unlikely to discern the difference except either someone who owns one or the enthusiasts who are more sensitive to the smallest differences. However, when accelerating hard, there is still that familiar ‘motorboat noise’ of 3-cylinder units but it is not too intrusive due to the good NVH measures. It sounds ‘distant’ and is at a frequency that does not irritate. In terms of engine smoothness, there’s virtually no difference to the X70 1.8 when cruising.

On paper, the difference in 0 to 100 km/h time is said to be just 3/10ths of a second longer than the X70 1.8 and though this seems insignificant, there is some perceptible difference at the lower end when you accelerate hard. To compensate for the lower output but heavy body, the maximum torque is available 250 rpm earlier than in the 1.8 engine, but the engine doesn’t surge off the way the X70 does.

But then again, how often does the average driver floor the pedal when moving off, unless he or she is in a real hurry? In real-world driving (which is how I assess a car), the acceleration is strong enough to move off briskly and get up to speed fast enough.

The more important thing is how quickly the car can accelerate in mid-range as this is when you overtake others or join a highway. With plenty of torque, there’s little lag and the engine doesn’t hesitate, accelerating cleanly from low revs. And the 7-speed DCT also provides a good spread of gears to smoothly transition up and down.

One thing that would be interesting to check is how the engine performs on steep inclines, Unfortunately, we could not do this as our route was generally flat. That it has only 4% less power may not be an issue on level roads but the heavy weight could have an effect on performance when climbing slopes. In the lighter X50, it is okay but we’re not sure about the X70 and that’s something we’ll have to find out later on.

2022 Proton X70 1.5

While Proton still has the supply issues delaying deliveries, the earlier you book, the better since you get in the queue earlier. The prices quoted are without sales tax and the Finance Minister has said before that the exemption will not be extended again. So the number of customers who book today who can get the lower price may be very few as there are still others waiting for their X70s.

Proton delivers more vehicles as the two factories increase output

Three-cylinder engines in cars are nothing new; Daihatsu popularized the engine configuration in the late 1970s with its Charade and then it was widely used by Perodua. Since the 21st century began 20 years ago, manufacturers have been downsizing engines as one way to reduce fuel consumption. However, unlike those older small engines, today’s downsized engines have a lot of advanced technology to help them develop high outputs and run even more efficiently.

The HR10DET engine in the all-new Nissan Almera Turbo is a good example. It has a displacement of 1 litre but can generate up to 100 ps with 152 Nm. This is comparable to a 1.5-litre engine so the driver enjoys the benefit of a smaller displacement which will consume less fuel – without sacrificing performance, which was the case before.

Nissan HR10DET engine in Nissan Almera Turbo

Some of the features which helps the HR10DET engine, which has 3 cylinders, achieve its high output are 4 valves per cylinder for better breathing efficiency and two overhead camshafts in the cylinder head (DOHC).

Boost from turbocharger
A major contributor to the power output is the use of a turbocharger. Once found only in high-performance engines, the turbocharger is now commonly used for small engines to boost output and response. In the case of the Nissan engine, maximum torque is available between 2,400 and 4,000 rpm, a range that is frequently used in daily driving. With maximum torque available, overtaking can be done quickly and safely.

The turbocharger has an Electronic Wastegate which operates far more efficiently than a conventional mechanical wastegate. A sensor monitors compression levels and enables the wastegate to activate whenever necessary, allowing turbocharging to be maximized. As a result, turbo lag is virtually eliminated for strong acceleration when needed.

Cooling down the air
For a turbocharger to operate at its best, the air flowing through needs to be cool so it can be compressed as much as possible, maximizing the charge. For this reason, an intercooler is installed behind the front grille and effectively cools down the air.

BHPetrol RON95 Euro4M

Technology from GT-R engine
Friction robs an engine of power and engineers work hard to find ways to bring internal friction down. For the HR10DET engine, they drew on the Mirror Bore Coating technology from the legendary Nissan GT-R. Mirror Bore Coating technology can raise energy efficiency by reducing the friction significantly inside the engine.

Rather than inserting a cylinder liner, the technology uses molten iron sprayed onto the surface of the cylinder bore to form a layer of iron coating on the walls inside. This achieves a mirror-like finish that is exceptionally smooth, thereby bringing down friction levels.

Normally, the cylinder liner is 2 mm thick but with Mirror Bore Coating technology, the layer is just 0.2 mm thick, saving weight. The extremely thin layer allows better heat conduction which results in enhanced cooling performance and less engine knocking. The efficiency of the engine as a whole is improved, and fuel economy as well as engine power are enhanced.

D-Step Logic System
The powertrain of the Almera Turbo also includes a next-generation XTRONIC CVT with D-Step Logic System to improve shift feel and responsiveness. The D-Step Logic System is a computer program that uses dynamic inputs such as vehicle speed, accelerator pedal position and application speed to determine ideal gear ratios needed to provide smooth, constant acceleration.

Drivers will feel the shifting being like a conventional automatic transmission with a torque converter (which we can confirm after our short test drive) and with the flexibility and smoothness of a CVT. A Sport mode is available to gain stronger acceleration when required.

“The all-new 1-litre turbo engine is designed to meet our customers’ needs. It provides the highest level of fuel economy – up to 18.4 kms per litre – which can provide up to 650 kms on one full tank. The CO2 emission level has also significantly been reduced by 18% compared to its predecessor. making the All-New Almera Turbo even more environmentally friendly,” said Christopher Tan, Sales & Marketing Director of Edaran Tan Chong Motor.

Selected Nissan showrooms around the country are offering test-drives of the new model so you can experience for yourself the performance of the car. Visit www.almeraturbo.com.my to locate a showroom and by the way, when you take a test-drive, you could also win an Apple iPhone SE worth RM2,199.

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