TECHNICAL REPORT ON STUDENTS INDUSTRIAL

WORK EXPERIENCE SCHEME (S.I.W.E.S)

AT

CRYSTAL AUTOMOBILE WORKSHOP,

ONITSHA – ENUGU EXPRESSWAY BESIDE
DE SANTOS HOTEL AWKA, ANAMBRA STATE.

BY
ONYEJEKWE VINCENT SOMKELE
2017244064

DEPARTMENT OF MECHANICAL ENGINEERING

FACULTY OF ENGINEERING
NNAMDI AZIKIWE UNIVERSITY, AWKA.

IN PARTIAL FUFILLMENT OF THE REQUIREMENT

FOR THE AWARD OF BACHELOR OF
ENGINEERING DEGREE
(B.Eng.)

2022
 DEDICATION

This report is dedicated to my Creator who has always been my helper.

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 ACKNOWLEDGEMENTS
My sincere gratitude to the management of CRYSTAL Automobile Services for
the professional training I acquired during my period there. I acknowledge the
Industrial Training Fund and Student Industrial Work Experience Scheme
(SIWES), for their effort in organizing and supervising my work experience. I
would love to express my sincere gratitude for the patience and understanding
shown to me by my parents during this period of training.

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 ABSTRACT
This report is a detailed illustration of the activities carried out, experience and
skills acquired during my six months training at CRYSTAL Automobile. It
explains the safe practices carried out during repairs and maintenance in
automobile workshop, it explains the automobile system as an engineering
product, and gives a substantial information about the major system components
of the automobile, the mechanical system, the electrical system and the
mechatronic system. It further, explains the processes involved in the repair and
the maintenance of a car that has a problem of overheating.

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 TABLE OF CONTENT

Cover Page ---------------------------------------------------------------------------- i

Dedication ----------------------------------------------------------------------------- ii
Acknowledgement ------------------------------------------------------------------- iii
Abstract ------------------------------------------------------------------------------- iv
Table of Contents ---------------------------------------------------------------------v
List of Figures ------------------------------------------------------------------------ vii

CHAPTER ONE: INTRODUCTION

1.1 Brief History of SIWES ------------------------------------------------- 1
1.2 Objectives of SIWES Program ----------------------------------------- 1
1.3 Stakeholders in the SIWES and Their Roles –------------------------ 2
1.4 Brief History of Crystal Motors ---------------------------------------- 5

CHAPTER TWO: WORK ASSIGNMENT DESCRIPTION

2.1 Automobile Workshop Safety ----------------------------------------- 7
2.2 Tools Used in Automobile Workshop -------------------------------- 10
2.3 Systems that make up the Automobile. ------------------------------- 17

CHAPTER THREE: REPAIR OF A VEHICLE WITH A PROBLEM OF

OVERHEATING: A CASE STUDY OF A FORD EDGE 2015 MODEL.
3.1 Description -------------------------------------------------------------- 28
3.2 What is Overheating? -------------------------------------------------- 28
3.3 How can Vehicle users fix the problem of overheating in their
Vehicles? ---------------------------------------------------------------- 30

CHAPTER FOUR: CHALLENGES, ISSUE ANALYSIS AND

LIMITATIONS
4.1 Challenges encountered during my period of SIWES
4.2 Suggestions for improvement
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CHAPTER FIVE: CONCLUSION AND RECOMMENDATIONS
5.1 Conclusion
5.2 Recommendations
5.3 References

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 LIST OF FIGURES

Fig 1.0 Crystal Automobile Organogram ............................................ 6

Fig 2.1 Fire Extinguisher ………......................................................... 7

Fig 2.2 Fire Buckets ………... ............................................................ 8

Fig 2.3 Overall .................................................................................... 8

Fig 2.4 Safety Boot ............................................................................. 9

Fig 2.5 Safety Gloves ........…………................................................. 9

Fig 2.6 Safety Googles …................................................................... 10

Fig 2.7 Oil Filter Wrench.................................................................... 10

Fig 2.8 Screwdrivers ....... ..... ............................................................. 11

Fig 2.9 Impact Gun ................ ............................................................ 11

Fig 2.10 Hammer ................................................................................ 12

Fig 2.11 Vise Grip ............................................................................... 12

Fig 2.12 Ratchet ................................................................................... 12

Fig 2.13 Funnel .................................................................................... 13

Fig 2.14 LED Work Light (Rechargeable) ........................................... 13

Fig 2.15 Pliers ...................................................................................... 14

Fig 2.16 Jumper Cables ………........................................................... 14

Fig 2.17 Tire Pressure Gauge and Inflator………................................ 14

Fig 2.18 Grinder ................................................................................... 15

Fig 2.19 Multimeter.............................................................................. 16

Fig 2.20 Working on an Automobile Engine ...................................... 17

Fig 2.21 Lubricating System ............................................................... 18

Fig 2.22 Cooling System ……............................................................. 19

Fig 2.23 Transmission System .......................................................... 20

Fig 2.24 Braking System .................................................................... 20

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Fig 2.25 Fuel System ………............................................................. 21

Fig 2.26 Suspension System .............................................................. 21

Fig 2.27 Steering and Control System ............................................... 22

Fig 2.28 Electronic Control Unit ....................................................... 23

Fig 2.29 Ignition System ................................................................... 23

Fig 2.30 Lighting System .................................................................. 24

Fig 2.31 On Board Diagnostics ......................................................... 25

Fig 2.32 Wiper Mechanism ............................................................... 26

Fig 2.33 Lock Control Mechanism …............................................... 26

Fig 3.1 BMW X4 2015 Model Engine............................................... 28

Fig 3.2 Checking Engine Coolant …………………………………. 29

Fig 3.3 Engine Overheating Light ………………………………… 29

Fig 3.4 Burnt Top Gasket …………………………………………. 30

Fig 3.5 Filling Engine Coolant ………………………………….…. 31

Fig 3.6 Washing a Radiator …………………………….………….. 32

Fig 3.7 Checking out an Overheating Engine ……………….…….. .32

Fig 3.8 An Overheated Engine ……………………………….……. 33

Fig 3.9 Repairing an Engine ……………………………………… ..34

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 CHAPTER ONE

INTRODUCTION
SIWES, which stands for Students Industrial Work Experience Scheme is a skill
training program or scheme, designed for students of universities, polytechnics,
colleges of education, colleges of agriculture and colleges of technology in
Nigeria. The idea of this scheme is to bridge the gap between what is learnt in the
classroom and what is done in the industries, giving students opportunity to have
some experience in their field of study.
1.1 BRIEF HISTORY OF SIWES
Before the inception of the SIWES program, concerns from various corners, most
especially from employers, that the theoretical knowledge obtained from higher
institutions was not enough, as graduates of higher institutions did not have
enough practical knowledge and so, could not meet up to the requirements of the
employers.
In the midst of all these, the Industrial Training Fund, (ITF), initiated, designed
and introduced in 1973 the SIWES scheme to acquaint students with equipment
and machinery available in the industries.
At the beginning, the ITF solely funded the scheme, but withdrew in 1978 due to
financial difficulties. So, the Federal government handed the management of the
scheme to the National Universities Commission (NUC) and National Board of
Technical Education (NBTE). By November 1984, the scheme was released to
ITF again, but this time it was to be funded by the Federal Government .
1.2 OBJECTIVES OF SIWES PROGRAMME
➢ Provide avenue for students in institutions of higher learning to acquire
Industrial skills and experience in their course of study.

➢ Expose students to work methods and techniques in handling equipment

and machinery that may not be available in their institutions.

➢ Make the transition from school to the world of work easier, and enhance
students’ contacts for later job placement.

➢ Provide students with the opportunity to apply their knowledge in real

work situation thereby bridging the gap between theory and practice.

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 ➢ Enlist and strengthen employers’ involvement in the educational process
and prepare students for employment after graduation.

1.3 STAKEHOLDERS IN THE SIWES SCHEME AND THEIR ROLES

SIWES is run as a joint venture through the contributory activities of stake
holders. These stakeholders include:
➢ The Federal Government

➢ Industrial Training Fund (ITF)

➢ Supervisory agencies

➢ Institutions

➢ Employers

➢ Students

Their roles include:

1.3.1The Federal Government:
➢ Providing adequate funds to the ITF through the Federal ministry of
Industry, Trade and Investment for the scheme.

➢ To make it mandatory for all ministries, companies, and parastatals to offer

places for the attachment of students.

1.3.2 Industrial Training Fund (ITF):

➢ Formulation of guidelines and policies on SIWES for distribution to all
SIWES participating bodies, institutions and companies involved in the
scheme.

➢ Regular involvement in organizing orientation programs for students

before their attachment.

➢ Receive and process Master and placement list from institutions through
their supervisory agencies.

➢ Supervise students on Industrial attachment.

➢ Disburse supervisory and students’ allowance.

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 ➢ Organize biennial SIWES national conference and SIWES review
meetings.

➢ Provide insurance cover for students on attachment.

➢ Provide logistics and materials necessary for effective administration of the

scheme.

➢ Ensure the visitation of ITF officers to the supervising agencies,

institutions, employers and students on attachment.

➢ Provide information on companies for attachment and assist in the

industrial placement of students.

➢ Continuously review and carry out research into the operation of the
scheme.

➢ Vet, process and verify students' logbook and ITF Form 8.

1.3.3 Supervisory Agencies:

➢ Ensure the establishment and accreditation of SIWES units in institutions
under their jurisdiction.

➢ Appointment of full time SIWES coordinators

➢ Adequate funding of the SIWES units in all institutions.

➢ Vet and approve master placement lists of students from participating

institutions and forward same to ITF.

➢ Develop, monitor and review job specifications in collaboration with

institutions towards the maintenance of national minimum academic
standard for all programs approved for SIWES.

➢ Liaise with ITF and participate in the biennial SIWES National Conference
and other relevant SIWES seminars, conferences, workshops, and
meetings.

➢ Research into the development of SIWES in line with advances in

technological development.

➢ Regularly review courses qualified for SIWES in collaboration with other

bodies.

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 ➢ Liaise with the ITF to ensure the implementation of all Federal
Government policies on the scheme.

1.3.4 Institutions:
➢ Establish SIWES coordination units with a separate account adequately
staffed and funded to ensure effective operation of the scheme.

➢ Appoint SIWES coordinators and supporting staff.

➢ Capture students bank details at the point of registration for SIWES.

➢ Apply job specifications as prepared for all the accredited courses and
award appropriate credit unit in accordance with the Federal Government
minimum academic standard guidelines.

➢ Identify placement opportunities for students' attachment with employers.

➢ Supervise students at their places of attachment and sign their log books,
submit all completed ITF form 8 to the nearest ITF area office.

➢ Employers

➢ Collaboration with institutions of higher learning in the preparation for job

specifications for approved courses.

➢ Appoint an industrial based supervisor for students on attachment.

➢ Allow students have access to their facilities.

➢ Participate fully in the assessment of programs and students by completing

the necessary instruments— ITF Form 8, student’s logbook etc.

➢ Accept students for Industrial attachment

➢ Provide welfare services-medication and payment for hospitalization of

students while on attachment.

1.3.5 Students:
➢ At the point of registration, students must submit their bank details to their
school's SIWES coordinators.

➢ Attend institutions in SIWES orientation programs before going on

attachment.

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 ➢ Obedience to constituted authorities and adhere strictly to all rules and
regulations of the organization where they are attached.

➢ Be regular and punctual at respective places of attachment.

➢ Avoid change of places of attachment, except in special circumstances

which must be determined and approved by their institution's supervisor,
the employer and/or the ITF.

➢ Complete student’s commencement attachment form (SCAF) and get it

endorsed by the employer for onward submission to ITF.

➢ Record all training activities and other assignments in the logbook and
complete ITF form 8 to ensure proper assessment.

➢ Be diligent, honest, conscientious and take pride in the protection of

employer’s property throughout the attachment period.

1.4 CRYSTAL AUTOMOBILE WORKSHOP

CRYSTAL AUTOMOBILE LTD was incorporated in ANAMBRA, Nigeria with
Registration Number RC971941. Crystal Automobile Ltd is a registered
automobile diagnostics and repair centre in Nigeria established since 2018 by
Barr. Uchenna Okechukwu Ojator. It is a top-notch auto repair centre in the city
of Awka, Crystal Automobile has special expertise in modern automobile
diagnostics and repairs. Crystal Automobile Workshop coverage brands include
but are not limited to American, Asian and European vehicles such as Mercedes,
Volkswagen, Land Rover, BMW, Honda, Toyota, Lexus, KIA, Hyundai, Peugot
etc.
Crystal Automobile Ltd is a technology-enabled automobile workshop with
enhanced capacity to cater for after-sale maintenance and repair needs of modern
vehicles in Nigeria which is located at Unizik junction, along Awka/Enugu
Express road, Beside De Santos Hotel, Awka, Anambra State.
Operations carried out in Crystal Automobile Workshop include:
Servicing of Vehicles
Repairing of Vehicles
Replacement of Damaged Parts
Tire Service
Oil Maintenance

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1.4.1 WORKSHOP ORGANOGRAM.

DIRECTOR

ADMINISTRATIVE TECHNICAL
UNIT UNIT

MECHANICAL/
ELECTRICAL
MANAGER SECRETARY MECHATRONICS
TECHNICIANS
TECHNICIANS

INDUSTRIAL
TRAINING
STUDENTS

Fig 1.0. Crystal Automobile Organogram

1.4.2 DEPARTMENTS
➢ ADMINISTRATIVE UNIT
The administrative department is the part the performs the non-technical activities
in the workshop, they carry out the day to day task of stock taking, spare parts
sales, cash management, receipt of payment from customers and other
administrative activities.

➢ TECHNICAL UNIT
This is the department that does the automobile works of repairs and maintenance,
this is the department under which I was attached during the industrial training.
The department is manned by experienced technicians and craftsmen who make
recommendations to the director on issues like tools and equipment needed in the
workshop, goods to be stocked and the repair and maintenance of automobiles.

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 CHAPTER 2

WORK ASSIGNMENT DESCRIPTION

The period of my Students’ Industrial Work Experience Scheme exposed me to
real life practice of Automobiles repairs and maintenance, as I was exposed due
to the on job training method used for carrying out activities, the activities I
carried out during my period of training included, replacement of spoilt and
worn out parts of automobile, carrying out preventive maintenance on vehicles
as routine maintenance practices, carrying out inspections for vehicle faults,
testing of parts to be used for repairs and maintenance, and tools shop keeping.
2.1 AUTOMOBILE WORKSHOP SAFETY
CRYSTAL Automobiles Workshop, have been in existence for long, the safety
consciousness of the workers are very much embedded in their daily practices
as all workers are skilled craft men, some of the safety apparatus found around
the workshop for the safety of the environment are the fire extinguisher and the
fire bucket, also the personal protective equipment used during the course of
working in the workshop includes; the overall, the safety boot, the safety gloves
and the safety googles.
➢ Fire extinguisher.
Fire extinguisher are chemicals or substances that are used to put out a fire,
there are majorly six classes of fire extinguishers; (1) Water (2) Foam (3) CO 2
(4) Water Mist (5) Wet Chemical.
The type that is majorly used in the Automobile workshop as well as found in
cars are the Class B extinguisher, which is the CO2, this is because of the likely
fire out brake type, which is mainly fuel based or electrical gadget.

Fig 2.1. Fire Extinguishers

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 ➢ Fire Bucket.

Fig 2.2 Fire Buckets

A Fire Bucket is filled with sand or water and is used to extinguish fires. Sand is
often used where there is a risk of spilled flammable liquid which might ignite
and spread by flowing across the ground. The sand is deployed to act as a
barrier to the flowing liquid. Water filled fire buckets are sometimes used
where a water extinguisher might not be convenient, or where a supplement is
prudent.

➢ Overall.

Fig 2.3. Overall

This is a cloth that covers the remaining part of the worker's body against
unfavorable conditions like hot metals, chemicals, dirt and dust. Some overall
are fire-resistant, providing minimal protection from fire hazards.

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 ➢ Safety Boot.

Fig 2.4. Safety Boot

This safety boot protects the leg from hazard. While working in the workshop
oil spills and slurry deposits may be on the ground if stepped on with ordinary
shoes or barefoot one could slip, but the safety boot can withstand the slippery
effect due to the high friction teeth of the shoe sole. The tip is covered with a
metal piece to protect the leg against impact reactive force in case of a collision
with a hard surface. The metal tip also protects the leg against sharp objects that
could pierce the leg.

➢ Safety Gloves.

Fig 2.5. Safety Gloves

The safety gloves are hand protective equipment. The hands are majorly used in
all workshop operations and thus there is always the risk of getting one’s hands
injured. One must therefore select appropriate hand protection. The type
selected depends on what type of hazard one needs to be protected against.
Some gloves are designed to protect a worker from hot objects, others protect
the worker from corrosive chemicals. Hand protectors are also used against
friction during the use of hand-held tools.

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 ➢ Safety Goggles.

Fig 2.6. Safety Googles

The eyes are highly susceptible to injury from external hazards that can lead to
partial or complete blindness. To prevent this, safety googles are provided for
workers and industrial trainees, the safety googles is majorly used when
working in areas that poses risk of particles coming in contact with the eyes.

2.2 TOOLS AND EQUIPMENTS USED IN AUTOMOBILE

WORKSHOP
Benjamin Franklin once said “The best investment is in the tools of one's own
trade.”, and every staff in the workshop had their own set of tools for working.
During my internship I used the tools and equipment set belonging to my
assigned tutor and the company, some of them include but are not limited to

➢ Oil Filter Wrench

Fig 2.7. Oil Filter Wrench

An oil change is one of the most common works for an entry-level mechanic.
An oil filter wrench is an essential tool that is used to remove spin-on type oil
filters. Oil filter accumulates a lot of grime and grease, and thus it could be
impossible to remove them without the right tool. An oil filter wrench enables
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you to remove any oil filter. It enables you to hold the canisters of the oil filter
for easy removal. The different types of oil filter wrench you can use are strap-
style wrenches, specialist wrenches, universal oil filter wrenches, or socket-style
wrench

➢ Screwdrivers

Fig 2.8. Screwdrivers

This is another basic tool that every mechanic needs to have in their toolbox.
Screwdrivers come in different gauges and lengths, and they save a lot of time.
Get a screwdriver set that contains stubbed and small screwdrivers, skinny and
long screwdrivers as well and torque screwdrivers. If you want something more
advanced, then you can consider powered screwdrivers that come with
rechargeable batteries. These screwdrivers are used to rotate air or electric
motors.
➢ Impact Gun

Fig 2.9. Impact Gun

An impact gun is also known as an impact wrench. It is used to remove wheel
bolts and speed up other heavy-duty processes, whether in the engine, steering,
or suspension. Between the cordless and air-powered impact guns, consider the
cordless one since it is much more powerful.

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 ➢ Hammer

Fig 2.10. Hammer

A hammer enables you to do anything that needs mending and hitting. You can
use it to knock out nail heads or work with any stuck component. There are
several types of hammers, and it is advisable to get a hammer with a rubber
handlebar since it ensures a good grip. Some of the types of hammers used are
ball peen hammers, claw hammers, club hammers, dead blow hammers, framing
hammers, and sledgehammers. The most common type of hammer used by
mechanics is the ball-peen hammer. A Club hammer is, however, necessary when
dealing with big industrial vehicles.
➢ Vise-Grip

Fig 2.11. Vise-Grip

Vice-grips are also known as locking pliers. They are handheld clamps with a
shape similar to that of pliers. This tool is useful when you need to hold something
which is in an awkward position, grip something in place for a long time, or grab
something without gripping features.
➢ Ratchet

Fig 2.12. Ratchet

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Ratchets are also known as socket wrenches. They have a socket on one side
which allows a one-way turning. They are used for several automotive uses and
are easy to use on cramped, awkward angles and small spaces. You can use them
to loosen or tighten bolts easily and quickly. Socket wrenches set should at least
contain the three different sizes. There is a large one (1/2), a medium (3/8), and
small one (1/4). They allow you to work with accuracy, speed, and freedom.
➢ Funnels

Fig 2.13. Funnel

Funnels are helpful to mechanics when they need to pour any type of liquid or oil
to avoid spillage. Funnels have no alternative. If you change the oil of your
vehicle without using a funnel, the spilled oil may cause gasses and odors, which
may end up affecting the engine.
➢ LED Flashlight or Work Light

Fig 2.14. LED Work Light (Rechargeable)

An LED work light acts as a backup to provide you with light whenever you need
it. This will enable you to look in every corner of the vehicle to know where
exactly the problem is. Having proper lighting will make a big difference during
a repair. At times, you will also need the flashlight during the day to pull and fins
specific bolts from the vehicle.

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 ➢ Pliers.

Fig 2.15. Pliers

Pliers are used by mechanics when changing hoses, repairing brakes, and even
when working with other connectors. They are also useful in handling hot
objects and compressing and bending materials. Some common types of pliers
are bent nose pliers, slip joint pliers, lineman’s pliers, and diagonal pliers,
Fencing Pliers, among others.

➢ Jumper Cables

Fig 2.16 Jumper Cables

This is one of the most important tools for both beginner and experienced
mechanics. Jumper cables function as a bridge in the supply of 12v from working
to a dead car battery.

➢ Tire Pressure Gauge & Inflator

Fig 2.17 Tire Pressure Gauge & Inflator

One common task a mechanic does is maintenance and tire jobs. You will need
to check the air pressure of the car as you adjust them quite a number of times in

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a day. A Tire pressure gauge is the simplest air-compressed tool. The tire inflator
gauge will enable you to always have your tire pressure spot on..

➢ Grinder
Fig 2.18. Grinder

A grinder is quite useful, especially when working on metal cutting works or

exhaust lines. If possible, own a straight and 90-degree angle grinder. You can
use the straight grinder for exhaust works, brake system maintenance as well as
cutting disks for different purposes. The 90-degree grinder, on the other hand, is
ideal to use on wheel hubs, valve covers, wheels, and rims. Grinders are very
versatile tools. They perform multiple tasks, from sharpening, polishing, sanding,
routing out mortars, cutting pavers, stucco and tiles, and grinding metals.

➢ Multimeter

Fig 2.19. Multimeter

A multimeter is a crucial tool for electrical troubleshooting and diagnosis. It
enables you to measure amperage, resistance, and voltage. Ensure that the
multimeter can read amps. This is useful in checking fuses and batteries, just to
mention a few. It also helps mechanics to check if they have a hot wire and the
amount of juice flowing through it.

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 ➢ Air Compressor
Having an air-compressed system enables you to perform heavy-duty jobs with
minimal effort. An air compressor enables mechanics to run pneumatic tools and
some auto lifts. Use an air compressor that is easy to use and portable for
convenience purposes. The best air compressors range between 60 and 120
gallons. Other things to look at when buying an air compressor are horsepower,
requires pistons, PSI, and cubic feet per minute.

➢ Jack, Jack Stands, and Pole Jacks

You will mostly be needed to raise a vehicle, especially when repairing the
wheels. There are also other car maintenance tasks that need the vehicle to be
lifted. A jack stand or a floor jack assists you in the lifting of the car. Never opt
for a cheap jack or jack stand at the expense of quality since poor-quality jacks
can cause injuries. Pole jacks are useful in supporting axles and other parts of
raised vehicles.

➢ Oil Drain and Oil Caddy

Transmission of fluid and changing oil is a common task for auto mechanics. An
oil drain enables mechanics to catch and store fluids and oil from lifted vehicles.
This keeps the floor free from oil. They also help in the storage of old oil, which
can later be recycled to be used for asphalt, heating oil, and many other ways.

➢ Battery charger and jumper

Most tasks in an auto repair shop will involve charging or dead batteries. You can
only handle these tasks if you have a good jumper and battery charger. The battery
charger will come with an operation manual that you should go through and
understand before use.

➢ Engine hoist/ Engine crane

An engine crane is a must-have piece of equipment if you want to do any work
on the car engine. It enables one to remove the car engine without using too much
effort. Consider buying an engine hoist that can support the maximum weight of
the vehicles you will be servicing.

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2.3 SYSTEMS THAT MAKE UP THE AUTOMOBILE.
The automobile system in its manufacturing and design stage has lots of
engineering fields knowledge applied, this makes the automobile product a
composite product, that is having the expertise of different professionals from
different fields working together in the manufacturing team to produce best
possible products, the major parts of the automobile are the mechanical parts,
the electrical parts and the mechatronic parts.

2.3.1 AUTOMOBILE MECHANICAL SYSTEM

The mechanical systems of the automobile comprise of the different sub units in
the automobile that work with mechanical principles, these parts are mainly
designed by mechanical engineers specialized in the Automobile field. Below
are the mechanical parts of the automobile.
➢ Automobile Engine.
The heart and soul of your vehicle is the internal combustion engine. The
engine block features parts such as the timing chain, camshaft,
crankshaft, spark plugs, cylinder heads, valves and pistons.

Fig 2.20. Working on an Automobile Engine

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 ➢ Automobile Lubricating System.

Fig 2.21. Lubricating System

Lubrication plays a key role in the life expectancy of an engine. Without oil, an
engine would succumb to overheating and seizing very quickly. Lubricants help
mitigate this problem, and if properly monitored and maintained, can extend the
life of your motor. The process of lubrication in an internal combustion engine
begins in the sump, commonly referred to as the oil pan. From here, the oil is
pulled through a strainer, by the oil pump, removing larger contaminants from
the mass of the fluid. The oil then goes through the oil filter. It is important to
note that not all filters perform the same.
A filter’s ability to remove particles is dependent upon many factors, including
the media material (pore size, surface area and depth of filter), the differential
pressure across the media, and the flow rate across the media. Oil is pumped
through passageways to the various components of the engine such as the cam,
main bearings, rod, pistons, etc. Gravity then pulls the oil back down to the
bottom of the motor to drain back into the sump, and the cycle repeats.
➢ Cooling System.

Fig 2.22. Cooling System

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The cooling system is an important part of an automobile engine. The cooling
system serves three important functions. First, it removes excess heat from the
engine; second, it maintains the engine operating temperature where it works
most efficiently; and finally, it brings the engine up to the right operating
temperature as quickly as possible. The cooling system is composed of six main
parts—an engine, a radiator, a water pump, a cooling fan, hoses, and a
thermostat. During the combustion process, some of the fuel energy is
converted into heat. This heat is transferred to the coolant being circulated
through the engine by the water pump. Hoses carry the hot coolant to the
radiator, where the heat is transferred to air that is pulled past the engine by the
cooling fan. The coolant is then carried back to the water pump and
recirculated.

➢ Transmission System.

Fig 2.23. Transmission System

A car’s transmission system is a complex and integral part of the way the car
runs, it is probably the most complex system in the automobile system. The
transmission system simple transmits the torque generated by the engine to the
wheels of the car. The arrangement of the transmission system is dependent on
whether the car is an all-wheel drive, front-wheel drive, or rear-wheel drive.
Modern manufactuer cars use an automatic transmission system compared to
the old but still in the market manual transmission system. The main differnce
between both is the use of the torque converter in automatic transmission
compared to the clutch plate technology.

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➢ Braking System.

Fig 2.24. Braking System

A brake system is designed to slow and halt the motion of vehicle. To do
this, various components within the brake system must convert vehicle’s
moving energy into heat. This is done by using friction. The type of brake
system used in automobile are the mechanical brake system which is that
used for the car’s hand brake and the hydraulics brake system, commonly the
Anti-Lock Brake System (ABS), ABS operates at a much faster rate and
more effectively than most drivers could manage. Although ABS generally
offers improved vehicle control and decreases stopping distances on dry and
some slippery surfaces, on loose gravel or snow-covered surfaces ABS may
significantly increase braking distance, while still improving steering
control.

➢ Fuel System.

Fig 2.25. Fuel

System

The fuel system is made up of the fuel tank, fuel pump, fuel filter and
injectors or carburetor, the system is responsible for delivering fuel to the

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 engine as needed. Each component must perform flawlessly to achieve
expected vehicle performance and reliability.

➢ Suspension System.

Fig 2.26. Suspension System

Suspension system is the system of tires, tire air, springs, shock absorbers
and linkages that connects a vehicle chassis to its wheels and allows
relative motion between the two. The suspension system helps in
distributing the car load to the ground in order the maintain balance and
stability at different speeds.

➢ Steering and Control System.

Fig 2.27. Steering and Control System

The steering control system is a path tracking system that controls the
steering actuator based on the current vehicle position, heading from the
INS, and reference path from the path planner. The steering control
system consists of a path tracker and primitive driver. The path tracker
consists of the following three modules: a velocity planning module,
look-ahead distance decision module, and path tracking module. The
velocity planning module plans the velocity using the curvature of the
21
 path, the side friction factor, and the super-elevation. The look-ahead
distance decision module determines the look-ahead distance depending
on the velocity of the vehicle. In addition, after selecting the goal point on
the reference path based on the look-ahead distance, the path tracking
module generates the desired steering angle. The primitive driver consists
of a throttle/brake controller and steering controller. The steering
controller controls the steering actuator to follow the reference path.
2.3.2 AUTOMOBILE ELECTRICAL SYSTEM
The electrical systems of the automobile comprise of the different sub units in
the automobile that work with electrical principles, these parts are mainly
designed by electricians and electrical engineers specialized in the Automobile
field. Below are the electrical parts of the automobile.
➢ Electronic Control Unit.

Fig 2.28. ECU

Electronic Control Unit (ECU) refers to dedicated vehicle embedded

microcontrollers that controls one or more of the electrical systems or
subsystems in a vehicle. Types of ECU include central control
module, engine control module, powertrain control module, transmission
control module, electronic brake control module, speed control unit, body
control module, suspension control module, human–machine interface,
telematic control unit, brake control module (including Anti-lock Braking
System (ABS) and Electronic Stability Control (ESC)), battery
management system, door control unit and seat control unit. Some
modern motor vehicles have up to 80 ECUs.

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➢ Ignition System.

Fig 2.29. Ignition System

The ignition system’s job is to ignite the air-fuel mixture in a gasoline
engine. In addition to the spark plugs that spark in the combustion
chambers, the ignition system consists of an ignition coil, which converts
battery voltage to higher voltage, and the spark plug wires that join these
components. Advancements have greatly reduced the need for ignition
system service. Where distributor caps and rotors once needed
replacement, electronic ignitions typically keep on firing. In new
vehicles, spark-plug replacement intervals are often around 100,000
miles. Spark plug wires still require attention and occasional replacement,
though an individual coil-on-plug eliminates those wires entirely.

➢ Lighting System.
The lighting system of a motor vehicle consists of lighting and signaling
devices mounted on the front, rear, sides, and in some cases on the top of
a motor vehicle, and lights the roadway for the driver. The lighting
system also makes the vehicle more visible, especially in low light
conditions. It gives warning to other drivers and pedestrians of a vehicle's
presence and direction of travel. Emergency vehicles usually carry
distinctive lighting equipment to alert drivers and pedestrians of their
rapid movement during an emergency.

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 Fig 2.30. Lighting System

➢ Diagnostics (OBD) System

Fig 2.31. On Board Diagnostics

OBD stands for On-Board Diagnostics and is a computer system inside of

a vehicle that tracks and regulates a car’s performance. This on-board

24
 computer system collects information from the network of sensors inside
the vehicle, which the system can then use to regulate car systems or alert
the user to problems. A technician can then simply plug into the OBD
system to collect vehicle data and diagnose the problem. OBD systems
have been a great help in helping users better understand vehicle
diagnostics. The ports for computer diagnostics are usually found
underneath the steering wheel compartment in the driver’s side.

2.3.3 AUTOMOBILE MECHATRONIC SYSTEM

The mechatronic systems of the automobile comprise of the different sub units
in the automobile that work with electro-mechanical principles, these parts are
mainly designed by engineers with skill in electronics, mechanics and electricity
and specialized in the Automobile field. Below are the mechatronic parts of the
automobile.

➢ Wiper Mechanism
The windshield wiper motor supplies the mechanical force to operate the
windshield wipers. It also includes a sensor that helps “park” the wipers in the
proper position when they are turned off. During replacement, mechanics will
inspect, lubricate, and torque all of the components of the wiper linkage.
Adjustment of the wiper arms and replacement of the wiper blades may also be
necessary.

Fig 2.32. Wiper Mechanism

The wiper control switch, wiper control unit, wiring, or broken linkage
components can all behave like a failed wiper motor. Failure to properly inspect
25
these items during the diagnosis may lead to the unnecessary replacement of the
wiper motor. Modern windshield wiper systems do not have a linkage at all,
there are separate motors that have sensors on them too keep them in synchrony.
➢ Lock Control Mechanism

Fig 2.33. Lock Control Mechanism

This mechanism controls the opening and closing of the car doors, boot(trunk)
as well as the bonnet, in most cars, the power-door-lock actuator is positioned
below the latch. A rod connects the actuator to the latch, and another rod
connects the latch to the knob that sticks up out of the top of the door. When the
actuator moves the latch up, it connects the outside door handle to the opening
mechanism. When the latch is down, the outside door handle is disconnected
from the mechanism so that it cannot be opened. To unlock the door, the body
controller supplies power to the door-lock actuator for a timed interval.

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 CHAPTER THREE
REPAIR OF A CAR WITH A PROBLEM OF OVERHEATING:
A CASE STUDY OF A BMW X4 2015 MODEL.
3.1 DESCRIPTION:
The BMW X4 2015 car is a four-door crossover with coupelike styling. There
are two trim levels: xDrive 28i and xDrive 35i. The "xDrive" moniker indicates
all-wheel drive, while the numbers denote whether the engine is a turbocharged
four-cylinder (28i) or a turbocharged-six (35i).

Fig 3.1. BMW X4 2015 MODEL ENGINE

The engine is made of composite materials of cast iron, Aluminum and split
plenum. It has a compression ratio of 10:1, displacement: 122 cu.in for a 250
Hp @ 5,000 rpm, a coolant capacity of 10.2 quarts, an oil capacity of 6.9 quarts
and an engine operating temperature range of 1950c – 2200c. The Cooling
system of the vehicle comprise of a 3.5L Coolant radiator, Thermostat, Coolant
Pump, Coolant Tubes, Engine Fan, and few Temperature Sensors at sensitive
positions of the engine as well as vehicle chassis.
3.2 WHAT IS OVERHEATING?
As combustion takes place continuously inside the engine of a car for smooth
operation. There need to be a consideration of the operating temperature of the
engine, in this case of the BMW X4 2015 model, the operating temperature
ranges from 1950c – 2200c, the engine is designed to withstand this operating
temperature as well have a cooling system to aid the maintenance of the engine

27
temperature to ensure efficiency and effectiveness of operation. Whenever the
temperature of the engine rises above the normal operating temperature range,
the engine is said to be overheating.

Fig 3.2. Checking Engine Coolant

The causes of this overheating of the engine includes;

➢ Cooling System leaks.
➢ Blocked Hoses from corrosion and Mineral deposits.
➢ Radiator clogging
➢ Faulty Water Pumps
➢ Shortage of Coolant.
➢ Broken Radiator Pressure cap.
➢ Low Oil quantity in the engine.
➢ Thermostat Failure.
➢ Bad belts drive.
➢ Faulty Temperature Sensors.
Above are the reasons why the engine of a car could overheat, when this
overheating occurs, there is a high tendency that it could damage one of more
parts of the engine components if not fixed on time and properly.

Fig 3.3. Engine Overheating Light

When overheating is about to occur or has occurred in some cases these are
some signs to be looked out for as a car user while driving.
➢ Blinking of the Temperature gauge light.
➢ Coolant Leaking on the ground underneath the engine chamber.

28
 ➢ Hot hood.
➢ Ticking noise (From the engine area).
➢ Burnt Smell of Heated materials.
➢ Steam coming from the Hood.
➢ Thumping Noises.
➢ Reduction in the Engine Power.
As these signs become conspicuous and the car users neglect a maintenance on
the car, the overheating would most likely result in:
➢ Burning of the Engine Cylinder Gasket.

Fig 3.4. Burnt Top Gasket

➢ Warped Cylinder (A Deformation on the cylinder block).

➢ Cracked Engine Block.
➢ Damage of the vehicle Exhaust.
➢ Scuffed Pistons (Deformation of the Piston of the engine).
➢ Heavy engine damage.
➢ Explosion of the vehicle.
3.3 HOW CAN VEHICLE USERS FIX THE PROBLEM OF
OVERHEATING IN THEIR VEHICLES?
Just as Vehicles manufacturers always have a long-term service of their
products at the center of their design, production and sales plan, it is of the best
interest of the customers, that is the vehicle users to also be cautions of the long
service term of the Automobile. Using the Automobile comes with its
responsibilities, as the Automobiles do not think for themselves, although
Modern day designs of Autonomous Vehicles, are smart in terms of their data
coordination. However, the Automobile Industry in Nigeria has a 99% of Man
controlled vehicles, by this statistic all users of vehicles are entrusted with the
responsibilities of their Automobiles.
29
The problem of Vehicle Overheating in vehicles, and be solved by the
engineering maintenance styles, which are;
➢ Preventive Maintenance.
➢ Predictive Maintenance.
➢ Corrective Maintenance.
These three engineering maintenance styles should be used by all vehicle
owners as the situation presents itself in order to solve the problem of
overheating. One style is not superior to the other two, as situation of vehicles
usage differs, not withstanding it is advisable that the vehicle users, prevent the
problem from occurring, because this means is safer, cheaper and effective.
3.3.1 THE PREVENTIVE MAINTENANCE PRACTICES FOR
OVERHEATING.
As vehicle owners use their vehicles for their different purposes, it is ethical that
every vehicle owner should have at least a mechanic that is professional and
reliable, this way the life of the Vehicle is being at check. Below are some of
the practices to be carried out to prevent the problem of vehicle overheating.
➢ Use the recommended engine oil for the Vehicle.
➢ Avoid a third-party modification of the engine cooling system. (especially
by unprofessional).
➢ Routinely check the coolant level before using the vehicle, and top up
when necessary.

Fig 3.5. Filling Engine Coolant

➢ Use a 50%: 50% coolants – water combination as the radiator cooling

fluid.
➢ Always be responsive to the indicator lights on the dashboard.
➢ Practice parking of vehicles under shades.

30
 ➢ Wash the radiator after long usage and after journeying on a dusty path
for a long time.

Fig 3.6. Washing a Radiator

3.3.2 THE PREDICTIVE MAINTENANCE PRACTICES FOR

OVERHEATING.
Sometimes preventing the problem might be difficult, this should encourage
vehicle users to be sensitive to slight deviation of the vehicle from its normal
operating condition, this sensitivity involves the using of the human senses in
most case, and sometimes the mechanic advice after checking the vehicles for
potential faults. Some of these are the means of predicting the overheating
problem as well as solving it.
➢ Stop and check the coolant level whenever there is an indication by the
temperature light.

Fig 3.7. Checking out an Overheating Engine

31
 ➢ Whenever the dashboard of the car becomes unusually hot, vehicle users
should stop and check the vehicle for faults.
➢ Advice from the Automobile mechanic should be followed.
➢ Unusual sounds heard while driving should not be neglected, as they are
indications of potential faults in the vehicle.
➢ Whenever the car is to be parked for a long period of time without any
driving, ensure to drain the old coolant, add a new one and remove the
battery connection of the car.
➢ Vehicles should be driven often and long-time idle parking should be
avoided as much as possible.
➢ Whenever a low specification oil is used in a vehicle, the vehicle users
should ensure to drain the oil earlier than the speculated operation time.
➢ Original parts should be used during repairs, or best possible option if
availability of first-class parts is out of reach.

3.3.3 THE CORRECTIVE MAINTENANCE PRACTICES FOR

OVERHEATING.
Whenever a fault has escalated and probably caused a damage to the vehicle,
the most professional solution in most situation is to carry out a corrective
maintenance practice, which may include, replacement of the spoilt and faulty
parts wherever necessary. Overheating most times have a chain effect of
damage it causes to the vehicle, a series of damage overheating often cause is
to, reduce the oil level of the car, reduce the coolant level of the car, burn the
engine cylinder top gasket, cause oil leakage from any possible outlet in the
engine, introduce oil into the exhaust pipe, cause the exhaust fume to be very
smoky, start a melting of plastics around heated areas of the car, cause a fire
explosion of the vehicle.

32
Fig 3.8. An Overheated Engine

These effects can happen within seconds, and whenever any of them occurs the
risk of accident increases, cost of repair is increased as well. Whenever there is
a damage caused by overheating some of the repairs done in the vehicle
includes:
➢ Replacement of the Engine Cylinder Top Gasket.
➢ Washing of the radiator.
➢ Replacement of the water pump.
➢ Servicing of the Engine.

Fig 3.9. Repairing an Engine

➢ Replacement of coolant hoses.

➢ Replacement of compression rinse in cases where the damage affects the
piston rinse.
➢ Replacement of the vehicle’s Engine, in cases where there is a damage
that makes the existing engine not repairable, or not cost efficient after
comparing with the replacement of a new one.
Overheating is one of the many problems of a Vehicle, it is quite common in
Nigeria and from my experience during my training, I could relate some factors
of country’s weather conditions, Vehicle users’ negligence and bad quality of
automobile spare parts to be the three major reasons why overheating is
common in this part of the world.

33
 CHAPTER FOUR
CHALLENGES, ISSUE ANALYSIS AND LIMITATIONS
4.1 CHALLENGES ENCOUNTERED DURING MY PEREIOD OF
STUDENT INDUSTRIAL WORK EXPERIENCE SCHEME TRAINING
• It was very difficult getting a good place for my SIWES, as most
organizations were reluctant to receiving Interns.
• I had to provide our own safety wears and daily transport fare which
became stressing at some point during my training.
• Most times we were not allowed to work independently on customers
vehicles for the fear of causing damage, this made me do less serious jobs
independently.
• The company wasn’t fully equipped with sophisticated equipment that
could make learning easier therefore we had to manually carry out certain
operations which made work and work environment quite difficult and
uncomfortable.

4.2 SUGGESTION FOR IMPROVEMENT

• If the SIWES unit can send supervisors at the onset of the student’s training
program to help discuss and plead with the organization on the need to
allow students full time on job training.
• Some companies might reduce their number of intakes if they are to
provide for them safety wears, therefore I suggest that the Industrial
Training fund increase allowance given to students, if possible, give them
some of the money at the beginning of program, so as to help them get
things necessary for the training and settle other training expenses
• Lecturers should help Students build self-esteem. Some students don’t
know the worth of studying mechanical engineering & they feel inferior
because they receive very little practical training from school before been
sent out for some month of training. The society should be enlightened on
how to kindly treat trainees.
• The government through the industrial training fund should help equip
centers where students are trained, by this, companies would be indebted
to accept more and train them better. Also, students would have
opportunity to be trained to the point of competing with international
standard.
34
 CHAPTER FIVE
CONCLUSION AND RECOMMENDATIONS
5.1 CONCLUSION
The idea behind the Student's Industrial Work Experience Scheme, SIWES, is
indeed a great one, it gave me a fantastic opportunity to have a hands-on
experience in a major scope in mechanical engineering, it made me understand
the importance of team work in achieving success, most importantly exposed
me to best practices in handling mechanical problems with confidence. . I got a
feel for how an engineer's job looks and feels. I am glad because, despite the
obstacles I faced during the course, I learned a lot. Certainly, the major aim of
this training, which is the correlation of theoretical knowledge and practical
experience, was a huge success. I gained valuable practical skill in automobile
repairs and maintenance; I say thank you to the Industrial Training fund for this
great initiative to the undergraduate program.

5.2 RECOMMENDATIONS
Despite everything I've learned as a result of the Students Industrial Work
Experience Scheme (SIWES) and the government's and ITF's tireless efforts to
ensure that this program remains a huge success, there are some challenges
students face in the course of this training that require immediate attention of
the ITF, the university and the respective departments in particular and they are
as follows.
1. The ITF should assist students in finding internship placement options, as it is
always a herculean struggle for students to find placement in time for the
program.
2.All Nigerian industries should be informed of the relevance of this program to
students and should be required to accept students for training.
3. The majority of government entities should make it a service to pay students
a monthly stipend.
4. I believe this SIWES should be completed after the 300l first semester exams
since most students do not know how relevant some courses are to their
discipline. This makes students approach such courses with so much laxity. I
believe they would approach several courses differently if the experience had
come earlier. (Onyido, 2019).

35
5.3 REFERENCES

Aribodor.D.N. N “Guide on Students’ Industrial Work Experience Scheme (SIWES)”

2019, pp. 1-3.

Engineering Workshop Safety.

https://www.cmu.edu/ehs/Workplace-Construction/personal-protective-

equipment.html

Automobile Mechanical Systems

https://www.routledge.com/Automobile-Mechanical-and-Electrical-

Systems/Denton/p/book/9780415725781

Automobile Mechanical Systems

https://innovationdiscoveries.space/automobile-mechanical-and-electrical-

systems-pdf/

Mechanical and electrical systems in car

https://www.goodreads.com/en/book/show/13657113-automobile-mechanical-

and-electrical-systems

Car lock mechanism

https://www.altonalocksmiths.com.au/understanding-complex-lock-parts-and-

mechanisms-in-car-door-

locks.php#:~:text=The%20door%2Dlock%20actuator%20is,with%20a%20thin

%20metal%20rod.&text=This%20rod%20helps%20the%20knob,and%20unlo

cking%20your%20car%20door.

How automobile works - mechanical process, electrical processes and mechatronic

processes, http://www.madehow.com/Volume-1/Automobile.html

36
Automobile Suspension System

https://gomechanic.in/blog/car-suspension-explained/

Onyido, John 2018 Technical Report on Students Industrial Work Experience Scheme

(S.I.W.E.S), Uche kings Automobile Service”

Overheating, causes, signs and effects.

https://www.bigmechanic.com/car-overheat.html

Solving the Problems of overheating in modern day vehicles.

https://blog.nationwide.com/how-to-keep-your-car-from-overheating/

2015 Ford Edge Technical Specifications.

http://procurement-notices.undp.org/view_file.cfm?doc_id=58525

37