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A TECHNICAL REPORT ON STUDENT INDUSTRIAL WORK EXPERIENCE SCHEME (S.I.W.E.S)

UNDERTAKING AT SPECIAL GIFT TECHNICAL SERVICES GUDU DISTRICT, FCT ABUJA.
Technical Report · November 2016
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SIWES TECHNICAL REPORT 2015
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A TECHNICAL REPORT ON
STUDENT INDUSTRIAL WORK EXPERIENCE
SCHEME (S.I.W.E.S)
UNDERTAKING AT
SPECIAL GIFT TECHNICAL SERVICES GUDU

DISTRICT, FCT ABUJA.
BY
ABOLORUNKE FRIDAY NIYEHMI

ENG1102476
DEPARTMENT OF MECHANICAL ENGINEERING

FACULTY OF ENGINEERING
UNIVERSITY OF BENIN
SUBMITTED IN PARTIAL FULFILMENT OF THE AWARD OF

BACHELOR OF ENGINEERING (B.ENG) IN MECHANICAL
ENGINEERING
FROM
JUNE 2015 TO NOVEMBER 2016
6
ABSTRACT
This Industrial training report presents the experience garnered during my 6 months of industrial
training undertaken at Special Gift Technical Services, Gudu district Abuja.
My training was on the diagnosis, repairs, maintenance in automobile vehicles ranging from cars,
SUVs, light trucks and pick ups.
During this period, I acquired practical knowledge on how to repair, replace and install some
mechanical parts and systems also assisted in providing the units the functionality they need.
This report discusses the technical skills gained during the training period and justifying the relevance
of the scheme in equipping students with needed technical competence to thrive in the real world.
6
ACKNOWLEGDEMENTS
My appreciation goes to God almighty, through the help of the Holy Spirit made me to choose
mechanical engineering as my discipline.
To paraphrase an actor who just won an Emmy, “there are so many people to thank”. However, I will
like to thank the Industrial Training Fund for their foresight in putting this program to place and also to
the Mechanical Engineering department, University of Benin, for providing the platform on which was
engaged in the training.
I want to say a big thank you to my industrial based supervisor, Mr. Aminu Tijani and the technician in
my unit, Mr. Femi, Mr. Pious, Mr. Haba and Mr. Danladi, who helped with solutions to my numerous
questions.
I am grateful to Special Gift Technical Services for providing with the opportunity to be exposed to
engineering services to the automobile industry.
I also want to thank my mother she encouraged me all through my Industrial Training period and also
appreciate my uncle and dad for their effort to ensure I get a placement, also for their moral and
financial support.
Finally to my Institution based supervisor Engr. Idukpaye for his advice and support, to my other
friends and colleague like Blessing Ezinne, Abiola, Kelechi, Ngozi, Ejike Jude. I say thank you all.
Am highly grateful.
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TABLE OF CONTENT
Title Page
Abstract………………………………………………………………………………….1
Acknowledgements……………………………………………………………………...2
Table of Content…………………………………………………………………………3
List of tables……………………………………………………………………………..5
List of Figures…………………………………………………………….......................5
Chapter 1 Introduction to Training program……………………………………………………1

1.1 Purpose of Training………………………………………………………………6
1.2 Company’s profile....………..……………………................................................7
Chapter 2
The Training Program...................................................................................................2.
2.0 Description of Work done………………………………………………………..11
2.1 Automotive Mechanical System…………………………………………………11
2.10 Engine…………………………………………………………………….12
2.11 Lubrication System……………………………………………………….13
2.12 Cooling System…………………,,,………………………………………14
2.13 Transmission………………………,,…………………………………….15
2.14 Braking System……………………,,…………………………..…………15
2.15 Fuel System…………………………,,……………………………………17
2.16 Suspension System…………………….………………………………….18
2.17 Steering System…………………………..………………………………..19
Chapter 3 Repair and Maintenance Processes
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3.0 Safety Measures and Information……………………………………………..21
3.1 Tools Required………………………………………………………………..21
3.2 Trouble Shooting Engine……………………………………………………..23
3.3 Brake Problems……………………………………………………………….26
3.4 Suspension Issues……………………………………………………………..28
3.5 Transmission problems………………………………………………………..29
3.6 Six Step Approach…………………………………………………………….30
Chapter 4
Work experienced in IT Department……………………………………………….
Observations and Contributions…………………………………………………….
4.0 Observations………………………………………………………………….31
4.1 Contributions………………………………………………………………….31
4.2 Relevance of Experienced gained to class room knowledge…………………..
Chapter 5
Conclusion and Recommendation………………………………………………….
5.0 Conclusion…………………………………………………………………….32
5.1 Recommendation………………………………………………………………33
5.2 Challenges encountered during training period……………………………….33
References……………………………………………………………………………
LIST OF FIGURES
Figure 2.0: Typical cylinder arrangement
Figure 2.1: Cooling system
Figure 2.2: Transmission system
Figure 2.3: Brake system
Figure 2.4: Suspension system
Figure 2.5: Steering system
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Figure 2.6: Rack pinion system
Figure 3.1: Tools required
Figure 3.2: Tools required
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CHAPTER 1
INTRODUCTION TO TRAINING PROGRAM
1.0 PURPOSE OF TRAINING
The Student Industrial Work Experience Scheme (SIWES) was initiated in 1973 by the Industrial
Training Fund (ITF). This was to update practical knowledge of students in the Universities,
Polytechnics and Colleges of Technology. It was aimed at bridging the gab between the theoretical
knowledge acquired in classes and technical knowledge in the industry by providing students with the
opportunities to apply their educational knowledge in real work situations.
Over the years, SIWES has contributed immensely to building the common pool of technical and
allied skills available in the Nigeria economy which are needed for the nation’s industrial
development.
Furthermore, the place and relevance of SIWES is underscored by the fact that the scheme contributes
to improving the quality of technical skills generally available in the pool from which employers
source technical manpower
Its gives student the opportunity to blend the theoretical knowledge acquired in the classroom and with
practical hands on application of knowledge required to perform work in the industry. Also it prepares
students for employment and makes the transition from school to the world of work easier after
graduation.
I undertook my SIWES at Special Gift Technical Services which is located at Gudu District, FCT
Abuja from JUNE to NOVEMBER 2015.
2.12 ESTABLISHMENT’S PROFILE
Special Gift Technical Services located at Gudu district, FCT Abuja. Is an indigenous establishment
that deals with passenger and light goods vehicles such cars, station wagon, jeep, bus, truck and pick
up of various brands. Though not equipped with the latest technology available in developed parts of
the world, however with its equipment and tools it had been carrying out proper servicing and
maintenance of customer’s vehicle.
The establishment was founded in 2009 by its current Chairman/CEO (Mr. Olokode Olaleye) it has a
staff strength of approximately 30.
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1.2 ESTABLISMENT’S CORPORATE GOAL

Special Gift Technical Services goal to our clients is to fix your vehicle to the proper working
condition in a clean and professional environment, so that you are happy and satisfied with the service
that was performed.
We also want you to have the trust and confidence in us that you are being treated honestly and fairly.
Also to have the freedom to approach us at any time with any questions or concerns with the service
that you are receiving.
The goal to my employees is to provide them with the bet working conditions possible with the proper
tools and equipment to repair our client’s vehicles. This in turn gives them the privilege to associate
with happy, satisfied and dedicated clients. Also, for the employees to have the freedom to input on
how to better improve the working conditions to better service our clients.
1.3 THE ESTABLISHMENT SCOPE OF WORK

In the area of specialization Special Gift Technical Services has the capacity of providing the following services
1. Sales
2. Service and Maintenance
3. Body and Paint job
4. Provision of authentic spare parts for vehicles
Special Gift Technical Services is made up of four (4) major departments,
1. Sales department
2. Service and Maintenance department
3. Body and Paint department
4. Spare parts department
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1.4 ORGANIZATION STRUCTURE

CHAIRMAN/CEO
DIRECTOR DIRECTOR DIRECTOR DIRECTOR

OF SALES SPARE PARTS MAINTENANCE BODY WORK &
& SERVICES PAINT
SALES & TRADING SPARE PARTS

MANAGER STORE KEEPER CHIEF CHIEF
MECHANIC ELECTRICIAN
SALES PERSON 1
SENIOR SENIOR
TECHNICIAN TECHNICIAN
SALES PERSON 2
JUNIOR JUNIOR
MANAGER
PAINTING
MANAGER BODY
WORK
INTERIOR BODY EXTERIOR BODY
WORK WORK
1.5 WORK FLOW IN THE SERVICE SECTION
Customer
Service Advisor
Service Advisor
Store
Manager
Some of Special Gift Technical Services Corporate customers include,

Workshop
 Eco-bank Technician
 Nigeria Police Force
 Ministry of Agriculture
 Funtaj International Schools Abuja
CHAPTER 2
6
THE TRAINING PROGRAM
2.0 DESCRIPTION OF WORKDONE

During my stay in Special Gift Technical Service, I was assigned to the service and maintenance
department as a Diagnosis/Mechanical Technician. Job duties in the department includes
Keep equipment available for use, inspecting and testing vehicles; completing preventive maintenance
such as engine tune-ups, oil changes, replacing filters, wheel balancing.
Maintain vehicle functional condition by listening to operator complaints; conducting inspections,
repairing engine failures, repairing mechanical systems malfunctions; replacing parts and components.
Verifies vehicle serviceability by conducting, test drives; adjusting controls and systems.
2.1 AUTOMOTIVE MECHANICAL SYSTEMS

2.10 ENGINE
Internal combustion engines run on a mixture of fuel and air, the core of the engine is the cylinder,
with the piston moving up and down inside the cylinder and this takes place in a four stroke process,
which are intake, compression, Power and Exhaust. The piston moves down on the intake stroke,
the intake valve is open and the fuel air mixture is admitted into the cylinder, and the piston moves up
during the compression with stroke both valves are closed, compresses the trapped fuel air mixture
that was brought during the intake stroke, thereafter the spark plug fires, igniting the compressed
airfuel mixture which produces a powerful expansion of the vapor which is used to drive the
crankshaft and this is the power stroke. Finally during the exhaust stroke, where the piston is at the
bottom of the cylinder the exhaust valve opens to allow the burned gas to be expelled to the exhaust
system.
Engine Types
The majority of engines in motor vehicles today are four stroke, spark ignition internal combustion
engines
6
There are several engine types which are identified by

the number of cylinders and the way the cylinders are
laid. Straight line cylinders have their cylinders in
row while the “V” arrangement uses two banks of
cylinders side-by-side and its commonly used in V-6,
V-8 configurations
Fig 2.0
Some automobile engine parts include;
Spark plug
The spark plug supplies the spark that ignites the air/fuel mixture so that combustion can occur. The
spark must happen at just the right moment for this to work properly
6
Valves
The intake and exhaust valves open at the proper time to let in air and fuel and to let out exhaust.
Piston
Piston is a cylindrical piece of metal that moves up and down inside the cylinder.
Piston rings
Piston rings provide a sliding seal between the outer edge of the piston and the inner edge of the
cylinder, the rings serves two purposes.
• They prevent the fuel/air mixture and the exhaust in the chamber from leaking into the sump
during compression and combustion,
• They keep oil in the sumo from leaking into the combustion area where it would be burn and
lost.
Connecting rod
The connecting rod connects the piston to the crankshaft, it rotates at both ends so that its angle can
change as the piston moves and the crankshaft rotates.
Crankshaft
The crankshaft turns the piston’s reciprocating motion in the cylinder into circular motion.
Sump (oil pan)
The sump surrounds the crankshaft. It contains some amount of oil, which collects in the bottom of
the sump. Camshaft
The camshaft in an internal combustion engine makes it possible for the engine’s valve to open and
close, the asymmetrical lobes of the camshaft correspond to the engine valves
2.11 LUBRICATING SYTREM
Oil is the life-blood of the engine. An engine running without oil will last about as long as human
without blood. Oil is pumped to all the moving parts of the engine by and oil pump. The oil pump is
mounted at the bottom of the engine in the oil pan and is connected by a gear to either the crankshaft
or camshaft. This way, when the engine is running the pump is pumping simultaneously. There is
usually an oil pressure sensor near the oil pump that monitors pressure and sends this information to a
warning light on the dash board (this features is found in modern cars as it might be in your car), when
the ignition key is turned on, but before the car is started the oil light should light, indicating that there
is no oil pressure yet, but also letting you know that the warning system is working.
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2.12 COOLING SYSTEM
Fig 2.1
A car engine produces enormous amount of heat when it is running, and must be cooled continuously
to avoid engine damage, generally this is done by circulating coolant liquid usually water mixed with
an antifreeze solution through special passages.
How the cooling system work
Actually there are two types of cooling system found on motor vehicles: liquid cooled and air cooled.
Air cooled engines are found on a few older cars, but for most part, automobiles and trucks use liquid
cooling systems and that is what this write up will concentrate on subsequently.
The cooling system is made up of the passages inside the engine block and heads, water pump to
circulate the coolant, a thermostat to control the temperature of the coolant, a radiator cap to control
the pressure inside the system, and a plumbing consisting of interconnecting hoses to transfer the
coolant from the engine to the radiator and also to the car’s heater system where hot coolant is used to
warm up the vehicle’s interior on a cold day.
A cooling system works by sending a liquid coolant through passages in the engine block and heads.
As the coolant flows through these passages, it picks up the heated fluid then makes its way through a
rubber hose to the radiator in the front of the car. As it flows through the thin tubes in the radiator, the
hot liquid is cooled by the air stream entering the engine compartment from the grill in front of the car.
Once the fluid is cooled, it returns to the engine to absorb ,ore heat. The water pump has the job of
keeping the fluid moving through this system of plumbing and hidden passages. In order to prevent the
coolant from boiling, the cooling system is designed to be pressurized, under pressure the boiling point
of coolant is raised considerably. However, too much pressure will cause hose and other parts to burst,
so a system is needed to relieve pressure if it exceeds a certain point and this is job of radiator cap.
2.13 TRANSMISSION SYSTEM
A car transmission is simply the assembly of parts, including the gears and the propeller shaft that
transmit the power from the engine to the axle.
6
There are two kinds of transmission: Automatic and Manual Transmission
Fig 2.2
Main components of a transmission are:

Transmission Control Modules: one of the main part of a transmission is transmission control
modules, it controls the automatic transmissions, but is nonexistent in manual transmissions.
Transmission Filters: Another important component of transmissions is filters. Transmission depend
on transmission fluid, s coolant that allows the clutch to engage and disengage, gears to change, valves
to open and close, and so on. The filters ensures that any outside particles or substances are not mixed
in with the fluid.
Transmission shafts: transmissions are also connected to the engine crankshaft by means of a flywheel,
since the combustion engine inside the transmission cannot go below a particular speed. Therefore, the
output of the transmission is done via the driveshaft, hence the name drive wheels of a car.
Manual Vs Automatic Transmission
Manual transmissions typically run longer and are cheaper to fix and repair when compared to
automatic transmissions. Nonetheless, many people still prefer automatic transmission because of their
ease of use. Manual transmissions are more affordable and more traditional as well. We’ll dive into the
various factors with the cost of repairing or replacing a transmission later, as well as many problems
that can result, which will require you to repair or replace them. After all, transmissions are not
everlasting and like any part of the car, they need fixing on time or another and it’s better to do it when
you know approximately what is required and how much it will cost you.
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2.14 BRAKING SYSTEM
Fig 2.3
An automatic braking system is a group of mechanical, electronic and hydraulic activated components
which use friction/heat to stop a moving vehicle.
How the automotive Braking System works:

When the brake pedal is depressed the pressure on the brake pedal moves a piston in the master
cylinder, forcing the brake fluid from the master cylinder through the brake lines and flexible hoses to
the calipers and wheel cylinders. The force applied to the brake pedal produces a proportional force on
each of the pistons.
The calipers and wheel cylinders contain pistons, which are connected to a disc brake pad or brake
shoe. Each output piston pushes the attached friction material against the surface of the rotor or wall of
the brake drum, thus slowing down the rotation of the wheel. When the pressure on the pedal is
released, the pads and shoes return to their release positions. This action forces the brake fluid back
through the flexible hose and tubing to the master cylinder.
Component of Automotive Braking System
Brake Disc: brake disc are comprised of a disc or rotor, a caliper assembly, disc brake pads and the
wheel bearings and hardware necessary to mount the components on the here it is created through
hydraulic lines to the vehicle. The caliper is connected to the master cylinder through tubes, hoses and
valves that conduct brake fluid through the system.
Brake Drum: brake drums are comprised of a drum and backing plate, a hub or axle assembly, brake
shoes, wheel cylinder, wheel bearings and hardware necessary to mount these components on the
vehicle. The wheel cylinder is connected to the master cylinder through tubes, hoses and valves that
conduct brake fluid through the system.
6
Brake Fluid: Brake fluid is a type of hydraulic fluid used in brake applications for automobiles and
light trucks. It is used to transfer force under pressure from where it is created through hydraulic lines
to the braking mechanism near the wheels. Braking applications produce a lot of heat so brake fluid
must have a high boiling point to remain effective and must not freeze under operating conditions.
2.14 FUEL SYSTEM
The fuel system is critical in storing and delivering the gasoline or diesel fuel your engine needs to
run. Think of it as your vascular system, with a heart (fuel pump), veins (fuel lines) and kidneys
(filter). A failure in any of these fuel system component has the same devastating effects as in your
body.
Component of the fuel system
Fuel tank: basically a holding tank for your fuel. When you fill up at a gas station the gas travels
down the filter tube and into the tank. In the tank there is a sending unit which tells the gas gauge how
much gas is in the tank. Some fuel thank houses the fuel pump and has more emissions controls to
prevent vapors leaking into the gas.
Fuel pump: on newer cars the fuel pump is usually installed in the fuel tank. Older cars have the fuel
pump attached to the engine or on the frame rail between the tank and the engine. If the pump is in the
tank or the frame rail then it id electric and is driven by your car battery. Fuel pumps mounted to the
engine use the motion of the engine to pump the fuel, most often being driven by the camshaft, but
sometimes the crankshaft.
Fuel filter: clean fuel is critical to engine life and performance. Fuel injectors and carburetors have
tiny openings which clog easily so filtering the fuel is a necessity. Filters can be before or after the fuel
pump. They are most often made from a paper element, but can be stainless steel or synthetic material
and are designed to be disposable in most cases. Some performance fuel filters will have washable
mesh, which eliminated the need for replacement.
2.15 SUSPENSION SYSTEM
Fig 2.4
6
Suspension is the term given to the system of shock absorbers and linkages that connect a car to its
wheels. The suspension system has two basic functions: 1) to keep the car’s wheels in firm contact
with the road to provide the traction and 2) to provide a comfortable ride for the passengers and isolate
them from road noise, bumps and vibrations.
Component of the suspension system
The basic components of a suspension system are as follows:
• Control Arms and Bushing: holds the steering knuckle, bearing support, or axle housing in
position, as the wheel moves up and down. The outer end of the control arm has a ball joint
and inner end has bushings. Vehicles, having control arm on the rear suspensions may have
bushings at both ends. The control arm bushing act as bearings, which allows the control arm
to move up and down the shaft bolted to the frame or suspension unit.
• Shock Absorbers and Struts: shock absorbers are necessary because springs do not settle
down fast enough. After the spring has been compressed and released. It continues to shorten
and lengthen for a time, such spring action on a vehicle would produce a very bumpy and
uncomfortable ride. It would also be dangerous because a bouncing wheel makes the vehicle
difficult to control; therefore a dampening device is needed to control the spring.
• Ball Joints: the ball joints are connections that allow limited rotation in every direction and
support the weight of the vehicle. They are used at the outer ends of the control arm where
arms attach to the steering knuckle. In operation, the swiveling action of the ball joints allows
the wheel and steering knuckle to be turned left or right and to move up and down with
changes in road surface.
• Strut Rods: the strut road fastens to the outer end of the lower control arm and to the frame.
This prevents the control arm form swinging toward the rear or front of the vehicle. The front
of the strut rod has rubber bushings that soften the action of the strut rod. These bushings allow
a controlled amount of lower control arm movement while allowing suspension to travel.
• Stabilizer bar: limits body roll of the vehicle during cornering
• Spring: supports the weight of the vehicle, permits the control ram and wheel to move up and
down, also helps in isolation of vibration.
2.16 STEERING SYSTEM
6
Fig 2.5 Fig 2.6
The direction of motion of a motor vehicle is controlled to a desired direction steering system. When
the driver turns the steering wheel, a shaft from the steering column turns a steering gear. The steering
gear moves tie rods that connect to the front wheels. The tie rods move the front wheels to the vehicle
right or left.
Today, there are two types of steering systems: 1) standard mechanical (reciprocating ball) steering
and 2) rack and pinion steering. The standard mechanical steering can be either power-assisted or
nonpower. Rack and pinion is almost always power assisted, although there are cases where it is not.
Standard mechanical (reciprocating ball) steering: The steering wheel is connected to the steering
box through the steering column. The steering box turns the rotation of the steering wheel 90o and, in
the case of power steering, uses high-pressure fluid to help actuate the steering. The steering box has
an arm attached to the output shaft called the pitman arm. This connects the steering to the steering
gear. The pitman arm is connected to one end of the center link (drag link). On the other end of the
center link is an idler arm. Between the idler and pitman arms, the drag link is supported in the proper
position to keep the left and right wheels working together. The inner tie rod
ends are attached to each end of the center link and provide points for the steering gear. From there it
goes to the outer tie rod ends through an adjustment sleeve. This sleeve joins the inner and outer tie
rod ends together and allows for adjustment when the front wheels are aligned. The outer tie rods ends
are connected to the steering knuckle that actually turns the front wheels. The steering knuckle has an
upper and lower ball joint on which it pivots and creates the geometry of the steering axis.
Rack and pinion steering: Rack and pinion steering, on the other hand, basically combines the
steering box and drag link into one unit. The steering wheel, through the steering column, is directly
connected to the track. Inside the steering rack is a pinion assembly that moves a toothed piston which
in turn moves the steering gear. One end of the inner tie rod ends is connected to each of this piston
and the other end is connected directly to the outer toe rod end. The inner tie rod end is actually
threaded into the outer tie rod end and can be rotated to make adjustments during a wheel alignment.
The advantage of rack and pinion steering is that it’s more precise than mechanical system. By
reducing the number of parts and pivot points, it can more accurately control wheel direction, making
the steering move responsive. The disadvantage of a rack and pinion steering system is that it’s prone
to leakage, requiring replacement of the steering rack assembly.
Components of steering system
• Power Steering fluid reservoir

• Power Steering Pump
• Rack and Pinion steering gear
• Steering Wheel
• Pitman Arm
6
• Steering Box
• Tie rod/Track rod
• Steering Column and Knuckle
• Drag Link
• Steering Shaft
6
CHAPTER THREE
Repair nd
a Maintenance Process
Mechanical systems in automobiles are a little complex and some problems, may need to be serviced
at the repaired shop.
3.0 SAFETY INFORMATION

Most accidentsservicing/mechanical
in repair involve
trips
slips,
and falls
or poor manual handling.
Other causes of incidents
sometimes resulting in seriousor injury
deathincludeworking under
inadequately supported vehicles, incidents involving
andvehicle
petrol movement.
Keeping work areas free of clutter is an important, but often overlooked, step in running a safe and
productive workshop. Requiring appropriate protective gear minimizes eye and finger lacerations,
which are common auto body shop uries.inj
Shops should purchase appropriate eyewear, and make
protective gloves available to prevent cuts from glass, sheet metal or other jagged objects.
3.10TOOLS REQUIRED
3.1
6
Fig 3.2
3.2 TROUBLESHOOTING ENGINES

BELTS AND HOSES What
is it?
Belts and hoses are essential to the cooling, air conditioning and charging systems, and the engine.
Don’t take these routine replacement intervals for granted because they can break down and leave you
stranded.
What does it do?
The timing belt keeps the crankshaft and camshaft mechanically synchronized to maintain engine
timing. Whether serpentine, V-belt or fan belt (the belts on the outside of the engine), they all transmit
power from the front of the engine to accessories that need to be driven, such as the air conditioning,
the charging system and fans. Radiator and heater hoses carry coolant to and from the engine, radiator
and heater core.
Typical Wear and Tear
Key items that affect the replacement interval for belts and hoses:
Vehicle age
Electrolytic corrosion
Mileage
Oil contamination
Belt tension
Failed hose clamps
6
Symptoms
Squeaking noise from under the hood during start-up or operation
Coolant leaks
Dashboard light will illuminate
A/C System may fail
Engine overheating
Smell of burnt rubber
EMISSION SYSTEM
Car emission system keeps the engine running cleanly and efficiently in all sorts of operating
conditions. A steady or flashing warning light on your vehicle dashboard indicates a problem that is
currently happening and may require immediate attention. Failure to do so can reduce your gas
mileage or cause your vehicle to pollute.
What does it do?
Emission system controls the emissions, exhaust and pollutants (including gasoline vapors escaping
from the fuel tank), using an array of sensors, computerized engine controls and the exhaust
components. The emission system substantially reduces harmful gases such as carbon monoxide (CO),
unburned hydrocarbons (HC) and oxides of nitrogen (NOx) and, by law, must be maintained in
operating condition.
Some factors affecting the emission system include:

Driving and atmospheric conditions
Mileage
Vehicle age
Type of spark plug electrode material
Poor vehicle maintenance
Poor quality fuel
Damaged or worn sensors
Dry-rotted or cracked vacuum hoses
ENGINE COOLING SYSTEM

What is it?
The engine cooling system affects your car’s overall dependability and engine longevity. Cooling
systems have advanced over the years with new coolant formulations and new radiator designs and
materials. If you suspect a problem with your cooling system, you should check it immediately.
What does it do?
6
The key parts of the cooling system remove heat from the engine and automatic transmission and
dissipate heat to the air outside. The water pump circulates coolant through the engine. The coolant
absorbs heat and returns it to the radiator where heat is dissipated. The thermostat regulates the coolant
temperature to keep it consistent for efficient engine operation.
Factors that affect the replacement of cooling system parts include:
Driving habits
Operating conditions
Type of vehicle
Type of coolant
Frequency of regular maintenance such as coolant changes
Symptoms
Overheating
Sweet smell
Leaks
Repeatedly need to add fluid
EXHAUST SYSTEM
What is it?
Exhaust system has come a long way from the old days of exhaust pipes and mufflers. Today, the
exhaust system is safety and emissions control rolled into one. Have your car’s exhaust system
inspected regularly and check it immediately if you suspect any problems.
What does it do?
The exhaust system routes dangerous exhaust gas from the engine out and away from the car to keep
from affecting the occupants. Next, the exhaust system reduces exhaust noise from the engine. The
catalytic converter reduces the level of harmful pollutants in the exhaust. The oxygen sensors mounted
in the exhaust system monitor the level of oxygen in the exhaust gases to maintain efficient engine
operation and to monitor the converter’s operation.
Maintain a safe car with regular exhaust system checks. Factors that affect replacement requirements
include:
Driving habits (short trips take their toll on exhaust system life)
Road conditions (salt, road spray, bumps)
Vehicle type
Age of exhaust system parts
6
Symptoms
Loud noise
Rattling noise when starting, accelerating or braking
Drowsiness while driving
Rotten eggs smell
FILTERS AND FLUIDS
What is it?
Filters are important to the longevity of your car and interior comfort. Maximize your car investment
by replacing filters regularly.
What does it do?
The oil filter traps contaminants, allowing the oil to flow through the engine unrestricted. The fuel
filter separates harmful contaminants that may cause problems with carburetors or intricate fuel
injectors. The air filter traps dirt particles, which can cause damage to engine cylinders, walls, pistons
and piston rings. The air filter also plays a role in keeping contaminants off the airflow sensor (in
fuelinjected cars). The cabin filter helps trap pollen, bacteria and dust that may find their way into a
car’s ventilation system.
Filters are normal wear items that require regular checks and replacement.
3.3 BRAKE PROBLEMS
Brake problems usually indicate the need for certain repairs or replacement parts, so here is a quick
review of some common fixes:
LOW BRAKE FLUID This may be the result of worn disc brake pads, or it may indicate a leak in the
brake system. If the BRAKE WARNING LIGHT is also on, most likely the problem is a leak (though
the Brake Warning light may also come on if the master cylinder reservoir has a fluid level sensor).
Leaks are dangerous because they can cause brake failure. The brake calipers, wheel cylinders, brake
hoses and lines, and master cylinder all need to be inspected. If a leak is found, the defective
component must be replaced. Your vehicle should NOT be driven until the leak can be repaired LOW
BRAKE PEDAL The brake pedal may be low if the shoe adjusters on rear drum brakes are rusted or
6
sticking and not compensating for normal lining wear. Adjusting the rear drum brakes may restore a
full pedal. But unless the adjusters are cleaned or replaced the problem will return as the linings
continue to wear. Other causes include worn brake linings or a fluid leak.
SPONGY OR SOFT BRAKE PEDAL This is usually caused by air in the brake system, either as a
result of improper bleeding, fluid loss or a very low fluid level. The cure is to bleed all of the brake
lines using the sequence recommended for your vehicle. Another possible cause is a rubber brake hose
that is "ballooning" when the brakes are applied.
EXCESSIVE BRAKE PEDAL TRAVEL Possible causes include worn brake linings front or rear (or
both), misadjusted drum brakes, or air in the brake lines. This can be dangerous because the brake
pedal may run out of travel before the brakes are fully applied. Pumping the pedal when you apply the
brakes usually helps, but you need to diagnose and fix the problem.
PEDAL SINKS TO FLOOR This may occur while holding your foot on the brake pedal at a stop
light. If the pedal goes slowly down, it means the master cylinder is not holding pressure. This is also a
potentially dangerous condition because a worn master cylinder or a leak in the hydraulic system may
cause the brakes to fail.
BRAKE PEDAL PULSATION Indicates a warped brake rotor (one that is worn unevenly). The rotor
needs to be resurfaced or replaced. The faces of a rotor must be parallel (within .0005 inch on most
cars) and flat (no more than .003 inches of runout as a general rule on most cars and trucks, but some
cars cannot tolerate any more than .0015 inches of runout). Excessive runout can be corrected by
resurfacing the rotors in place with an on-car brake lathe, or by installed special tapered shims
between the rotors and hub to correct the runout.
SCRAPING NOISE FROM BRAKES Usually indicates metal-to-metal contact due to worn out disc
brake pads (or shoes on rear drum brakes). Your vehicle needs a brake job now! In fact, it is overdue
for a brake job. Your vehicle is also dangerous to drive in this condition because it may take longer to
stop. The rotors and/or drums will likely have to be resurface or replaced because you waited too long
to replace the pads and shoes.
BRAKE SQUEAL Can be caused by vibrations between the disc brake pads and caliper, or the pads
and rotor. Harder semi-metallic brake pads tend to be noisier than non asbestos (NOA) or ceramic
brake pads. The noise can usually be eliminated by replacing the old pads with new ones (ceramic
pads are usually the quietest, but may not be available for some applications because the vehicle
requires semi-metallic pads), and resurfacing or replacing the rotors. Installing noise dampening shims
behind the pads, spraying the rotors with some type of aerosol brake noise control compound and/or
6
applying a small amount of high temperature brake grease (never ordinary grease) to the backs of the
pads can also help suppress noise. Also, if any pad mounting hardware such as shims or anti-rattle
clips are missing, these should be replaced
BRAKE CHATTER Can be caused by warped rotors or rotors that have been improperly finished.
GRABBY BRAKES Oil, grease or brake fluid on the brake pads will cause them to slip and grab.
This may create a jerky sensation when braking. The cure is to inspect the pads for contamination,
replace them if they have oil, grease or brake fluid on them, and eliminate the cause of the
contamination (such as replacing a leaky brake caliper or curing a nearby oil/grease leak). Badly
scored drums or rotors can also cause uneven or grabby braking. Resurfacing may be needed.
DRAGGING BRAKES This can cause a steering pull and/or increased fuel consumption. The
constant drag will also accelerate brake wear and cause the brakes to run hot (which can increase pedal
effort and the risk of brake fade if the brakes get too hot). Dragging brakes can be caused by weak or
broken retracting springs on drum brakes, a jammed or corroded disc brake caliper piston, a floating
caliper with badly corroded mounting pins or bushings (uneven pad wear between the inner and outer
pads is a clue here), overextended drum brake self-adjusters or a sticky or frozen emergency brake
cable.
BRAKES PULL TO ONE SIDE If your vehicle suddenly swerved to one side when you apply the
brakes, there is uneven braking side-to-side. This usually means one front brake is not working
properly. The pull will be toward the side with the good brake (because it is doing all the work). Brake
pull can be caused by brake fluid, oil or grease on the brake pads, a stuck caliper, a blockage in the
brake line to one of the front calipers, or sometimes loose wheel bearings. A brake pull can also be
caused by different types/brands of brake pads side-to-side on the front brakes. Different friction
materials have different friction characteristics, so the brakes will pull toward the side that generates
the most friction
HARD BRAKE PEDAL Lack of power assist may be due to low engine vacuum, a leaky vacuum
hose to the brake booster, or a defective brake booster. The booster is located between the master
brake cylinder and firewall in the engine compartment. Sometimes a faulty check valve will allow
vacuum to bleed out of the booster causing a hard pedal when the brakes are applied. This condition
can be diagnosed by starting the engine (to build vacuum), shutting it off, waiting four or five minutes,
then trying the brakes to see if there is power assist. No assist means a new check valve is needed.
6
3.4 SUSPENSION ISSUES

Suspension components, including springs, shock absorbers (or struts on some vehicles), anti-roll bars,
control arms and other parts, are like combat troops serving on the front lines: They take a pounding
daily from pock-marked streets, railroad tracks, rain, snow, road salt, gravel, all manner of dirt and
grime, and the occasional piece of scrap metal or other debris that drivers see too late to avoid. Under
those conditions, just about any suspension component can be damaged or worn out from years of
abuse, resulting in a number of symptoms and/or noises that should be your wakeup call to see a car
doctor. Here are some common issues vehicle owners are likely to encounter:
• Poor wheel alignment: The wheels have to be pointed in the right direction (literally) and
aligned for toe-in, camber and caster. If they aren’t, your steering won’t be centered when
you’re going straight and tire wear will increase. Wheels get knocked out of alignment by
potholes and curbs, but getting the wheels aligned won’t fix damaged springs, controls arms or
other parts that affect alignment. When you buy new tires, it’s a good idea to have the
alignment checked so suspension issues don’t shorten tread life.
• Shock absorbers: They really should be called “dampers,” and when they wear out you
should notice more bouncing after a bump and a whole lot of shaking going on over rough
roads because they can’t keep the tires planted on the pavement. Shocks contain fluid that
dampens the bouncing, and once they start to leak, performance will deteriorate.
• Springs: These are what hold the weight of the car, and as they wear they can sag or break. If
your car is on level ground but one corner is lower than the others, that’s a sign of a damaged
spring. You can measure the height of the corners to confirm your visual cue. You might also
hear clunking noises over bumps, and the car may not corner with confidence because a
damaged spring can’t control the weight it’s supporting.
• Ball joints: These are pivot points that attach the suspension to the wheels, and they absorb
some of the shock from up-down movement and rotate as the steering angle changes. You’ll
know they need replacing when you can hear them squeaking and creaking, especially when
turning. You’ll know you waited too long if a ball joint breaks and suspension parts are
dragging on the pavement. A mechanic can tell if they need replacing by the amount of wheel
movement they can force by hand or, in some cases, by wear indicators on the ball joints.
• Control arms: These are hinges that hold the wheels to the frame and connect the steering to
the wheels, so when you turn one the other responds. Lower control arm bushings are more
prone to wear out on front-wheel-drive cars than on rear-wheel-drive cars. Bushings are rubber
and/or metal parts that help absorb shock, and when they wear they can cause ride and
handling problems and accelerate tire wear. So can a bent control arm. Signs of wear include
6
clunks or rattles -- because the wheels move back and forth in acceleration and braking -- and
loose, imprecise steering.
3.5 TRANSMISSION PROBLEMS

Step 1 - Clear all DTC's with a engine scan tool (diagnostic trouble codes.) Visit - Scan PCM
Step 2 - Start the engine and observe the MIL, if it does not illuminate continue to next step
(service engine soon or check engine light.)
Step 3 - Drive the vehicle while trying to maintain a constant throttle position as it accelerates
up through all four gears. If the transmission is shifting properly, it should be in 4th gear by the
time you reach 45 to 50 mph on level ground. Repeat this procedure from a standing start 3 to
5 times. Rescan the PCM for trouble codes, if none appear the problem could have been a
onetime occurrence. If a trouble code has returned repair as needed and recheck system.
Problem Guide
Will not go into gear:
•Broken gear selector cable.
•Brake lock solenoid or brake light switch has failed not allowing the gear selector to move out
of "Park."
•Excessively low transmission fluid (Note: If transmission is operated for an extended amount
of time with a low fluid level the transmission might fail prematurely.)
•Shorted electrical component not allowing the PCM to control the transmission. Example:
shorted fuse or VSS (vehicle speed sensor.)
•Flex plate (flywheel) is broken completely not transferring engine power to the transmission.
Goes into gear but fades out of gear or is slipping while driving:
•Transmission fluid is low.
•Transmission clutch discs or bands are worn out or burned.
•Faulty transmission shift solenoid.
Goes into gear but does not shift out of first gear:
•Blown fuse to the PCM controller
•Faulty vehicle speed sensor (VSS)
•Shorted second gear control solenoid
•Faulty transmission controller (PCM)
Tips and Fixes
•When the vehicle is cold or going around corners the transmission fades in and out of gear: In
most cases this means the transmission fluid is low. The transmission will lose hydraulic
pressure causing the transmission to drift in and out of gear. Check your transmission fluid
when the car is on flat ground with the engine idling in park, (Some Chrysler products must be
checked in neutral.)
•Transmission is shifting too late or not at all. On most cars the transmission is controlled by
the PCM (powertrain control module) if the vehicle speed sensor fails the PCM has no input so
the computer will not shift the transmission properly. The best way to check this sensor is to
make sure the speedometer is operating correctly, if not replace the VSS and recheck.
6
•The transmission skips second gear, shifts from first gear to third gear and the "service engine
soon" or "service engine soon" MIL is illuminated. Scan the computer to help locate the
transmission control solenoid that is malfunctioning.
•Fluid Level and Leaks
•A common complaint with automatic transmissions is them leaking fluid. Leaks can occur
from the output shaft seal, input shaft seal, pan gasket, fluid cooler or lines. When adding
transmission fluid, do not overfill, doing so could cause the fluid to become aerated which will
affect transmission operation.
•If the fluid level is low with no visible leaks, check the radiator for fluid in the coolant. The
cooler inside the radiator may be leaking and cross-contaminating the radiator coolant (the
coolant will be milky pink.) Also check the condition of the fluid, some discoloration and
darkening is normal as the fluid ages, but if the fluid is brown or has a burnt smell its badly
overused and a transmission service is needed.
•Most transmission problems can be prevented by changing the fluid and filter (if applicable)
according to manufacturer specifications. In extreme conditions installing an aftermarket auxiliary
cooler parallel can be installed furthering the cooling effect. This prevents fluid overheating on
vehicles used for towing or performance applications.
3.7 SIX STEP APPROACH

At this stage it is important to emphasize the need to be methodical. A simple but effective approach is
diagnostic work know as six step approach.
This six-step approach maybe, recognized as an organized approach to problem solving in general. As
quoted here it may be seen that certain steps are recursive. That is to say it may be necessary to
previous steps as one proceeds to solution.
The six steps are:

1. Collect evidence;
2. Analyze evidence;
3. Locate the fault;
4. Find the cause of the fault and remedy it;
5. Rectify the fault (if different from 4)
6. Test the system to verify that repair is correct.
6
CHAPTER 4
4.1 WORK EXPEIENCE IN IT DEPARTMENT
For the Last month of my industrial training at Germaine Auto Center I was Transfer to Information
Technology Department.
In IT department asides the normal mechanic work like checking engine, checking suspension
problems etc, I was involved in providing the infrastructure for automation, the governance for the use
of the network and operating systems, and assistance in providing the operational units the
functionality they need.
GOVERNANCE:
Providing the operating parameters for individuals' and operating units use of the IT systems,
networks, architecture, etc. (This includes responsibility for conventional IT security and data
assurance).
INFRASTRUCTURE:
Providing the operating network and circuitry and all equipment needed to make the IT system work
in accordance with an established operating standard and system "size."
6
FUNCTIONALITY:
Providing the capacity for operating applications development, storing and securing the electronic
information the organization owns, and providing direct operating assistance in software use and data
management to all functional areas in the organization.
4.2 OBSERVATIONS AND CONTRIBUTIONS

OBSERVATIONS
As a student my first observation was the cognition of the difference between the school
environment and the labor market, as it is a different ball game entirely.
I also observed that safety was paramount and it could easy be seen as the primary goal of every
staff of the company and not only the technicians. As safety equipment and instructions were
always put in place or made available at strategic locations within the company. workshop to the
service desks to the customer care centers to the offices to the receptions.
Neatness was also a key attribute as even though the job is usually seen as a dirty job, technicians
were always admonished to be as neat as possible in their dressing and in carrying out their duties.
This was further encouraged by rewarding technicians that could fully adhere to this . - The
hospitality shown to customers was of another level as customers were treated with so much
care and respect. From provision of free breakfast and lunch, to a brief internal training, to free
medical checkup the customers were always made to feel at ease.
- Communication played a vital role in the successful execution of jobs, from among personnel in
a section to departments communicating with other departments present in the company and also
customers with company’s personnel. Good flow of information was required and as a result most
jobs that were returned or problematic, come about as a result of poor communication between
parties.
4.2 CONTRIBUTIONS
My contributions were shown in my work done and services given as a Diagnosing / Mechanical
technician in the establishment, which was basically diagnosing and repair of mechanical
components of automobiles. I was able to maximize the job efficiency and work output in my
section, because after a couple of months my section supervisor gave me the access to work
directly with the spare parts and material store department, thereby speeding up the job completion
process, as he wasn’t always around to attend due to official reasons. I was also able to revive the
job registration process as it was slightly overlooked prior to my attachment because of the
magnitude of work in the section, but after successfully reviving it, it became useful in
doublechecking the vehicles that came into the section and technicians that worked on them
6
CHAPTER 5
CONCLUSION AND RECOMMENDATION 5.0

CONCLUSION
My 6months industrial attachment as a junior technician at special gift technical services was a
huge success and a great time of acquisition of knowledge and skills. Through my training I
was able to appreciate my chosen course of study even more, because I had the opportunity to
blend the theoretical knowledge acquired from school with the practical handson application of
knowledge gained here to perform very important tasks that contributed in a way to my
productivity in the company. My training here has given me a broader view to the importance
and relevance of Mechanical Engineers in the immediate society and the world as a whole, as I
now look forward to impacting it positively after graduation. I have also been able to improve
my communication and presentation skills and thereby developed good relationship with my
fellow colleagues at work. I have also been able to appreciate the connection between my
course of study and other disciplines in producing a successful result.
5.1 RECOMMENDATION
I use this means to make the following recommendations concerning the training of students
in Industrial Attachments
. i. I would like to recommend that the Engineering curriculum in the University of
Benin be adjusted such as would provide going on industrial attachments for a longer
period of time as opposed to 6 months or making the program to occur twice
throughout an engineering degree program. ii. Allowances should be paid to students
during their programme just like NYSC and not after. This would help them a great
deal to handle some financial problems during their training course.
5.2 CHALLENGES ENCOUNTERED DURING PERIOD OF TRAINING 
I wasn’t allowed to drive cars after repair. So I could not do active test using Diagnostic
machines on my own.  And I was not allow to go out to repair car. I was restricted to the
workshop.
REFERENCES
1. Taylor, C. F.: The Internal Combustion Engine in Theory and Practice, vol. I, p. 506, MIT Press,.
2. Society of Automotive Engineers (1998). Automotive Engineering Handbook. Warren dale, PA:
Society of Automotive Engineers, Inc.
3. wikipedia.com/automobile/dictionary
6
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A TECHNICAL REPORT ON STUDENT INDUSTRIAL WORK EXPERIENCE SCHEME (S.I.W.E.S)

The user has requested enhancement of the downloaded file.

SPECIAL GIFT TECHNICAL SERVICES GUDU

ABOLORUNKE FRIDAY NIYEHMI

DEPARTMENT OF MECHANICAL ENGINEERING

SUBMITTED IN PARTIAL FULFILMENT OF THE AWARD OF

Chapter 1 Introduction to Training program……………………………………………………1

Chapter 3 Repair and Maintenance Processes

Figure 2.2: Transmission system

Figure 2.3: Brake system

Figure 2.4: Suspension system

Figure 2.5: Steering system

Figure 2.6: Rack pinion system

Figure 3.1: Tools required

Figure 3.2: Tools required

INTRODUCTION TO TRAINING PROGRAM

1.0 PURPOSE OF TRAINING

2.12 ESTABLISHMENT’S PROFILE

1.2 ESTABLISMENT’S CORPORATE GOAL

1.3 THE ESTABLISHMENT SCOPE OF WORK

Special Gift Technical Services is made up of four (4) major departments,

1.4 ORGANIZATION STRUCTURE

DIRECTOR DIRECTOR DIRECTOR DIRECTOR

SALES & TRADING SPARE PARTS

1.5 WORK FLOW IN THE SERVICE SECTION

Some of Special Gift Technical Services Corporate customers include,

THE TRAINING PROGRAM

2.0 DESCRIPTION OF WORKDONE

2.1 AUTOMOTIVE MECHANICAL SYSTEMS

There are several engine types which are identified by

Some automobile engine parts include;

2.11 LUBRICATING SYTREM

2.13 TRANSMISSION SYSTEM

Main components of a transmission are:

How the automotive Braking System works:

2.14 FUEL SYSTEM

2.15 SUSPENSION SYSTEM

2.16 STEERING SYSTEM

Components of steering system

• Power Steering fluid reservoir

3.0 SAFETY INFORMATION

3.2 TROUBLESHOOTING ENGINES

What does it do?

Typical Wear and Tear

What does it do?

Typical Wear and Tear

Some factors affecting the emission system include:

ENGINE COOLING SYSTEM

What does it do?

Typical Wear and Tear

Factors that affect the replacement of cooling system parts include:

What does it do?

FILTERS AND FLUIDS

What does it do?

Typical Wear and Tear

3.3 BRAKE PROBLEMS