A TECHNICAL REPORT ON THE STUDENTS INDUSTRIAL

WORK EXPERIENCE SCHEME (SIWES)

HELD AT

ADEWALE MECHANIC WORKSHOP OLOPEMARUN,

OGBOMOSO, OYO STATE.

BY

OLADEJO ABDULHAMID OLAYEMI

(Matriculation Number: 143076)

SUBMITTED TO

THE DEPARTMENT OF MECHANICAL ENGINEERING

FACULTY OF ENGINEERING AND TECHNOLOGY LADOKE
AKINTOLA UNIVERSITY OF TECHNOLOGY, OGBOMOSO,
NIGERIA

IN PARTIAL FUFILLMENT OF THE REQUIREMENTS FOR THE

AWARD OF BACHELOR OF TECHNOLOGY (B.TECH) DEGREE
IN MECHANICAL ENGINEERING

JUNE 2019
ABSTRACT

Training is a key factor in enhancing the efficiency and expertise of the workforce. The Students

Work Experience (SIWES) program prepares students for labor markets. It has become an

innovative phenomenon in human resources development and training in Nigeria. The goal of

SIWES is to promote industrialization in Nigeria, and an avenue between the world of teaching,

learning, industry and work with reference to a field of study such as engineering, science,

Agriculture, technology and other professional education programs.

The SIWES program was done at Adewale mechanic workshop olopemarun, ogbomoso .

My training was on troubleshooting and diagnosis of electrical, engine, and chassis and some

component system of light truck, SUV (Speed Utility Vehicle), Minivan and Mid SUV.

I acquired practical knowledge on how to repair, replace and install electrical, engine and chassis

system, braking, steering and balancing system.

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.

The SIWES program is an eye opening one and it also teaches student how to face the challenges

that may arise in any industrial set up.

DEDICATION

This report is dedicated to Almighty Allah for His favour, mercy and grace upon my life

during my industrial training at Adewale Mechanic Workshop and who has made the completion

of this report possible

I would also like to dedicate it to my parents Mr. and Mrs Oladejo and my Cousins for their

love, care, support, encouragement during the course of my program.

ACKNOWLEDGEMENT

My sincere gratitude goes to Almighty Allah, the giver of knowledge, wisdom, understanding,

ideas, time and energy which all together make the completion of this program possible.

Also my gratitude goes to the CEO, Managing Director Mr Adewale, all the engineers,

technicians and instructors for the way they taught me and for their kindness, may the Lord in

His infinity mercy bless their hand-work (Amen).

CERTIFICATION

This is to certify that STUDENTS INDUSTRIAL WORK EXPERIENCE SCHEME was done

by OLADEJO, Abdulhamid Olayemi (Matriculation Number: (143076) in the Department of

Mechanical Engineering, Faculty of Engineering and Technology, Ladoke Akintola University

of Technology, Ogbomoso.

___________________________ ____________________________

Supervisor Date

____________________________ ___________________________

Head of Department: Dr. T. B ASHAFA Date

TABLE OF CONTENTS

Title page

ABSTRACT ii

DEDICATION iii

ACKNOWLEDGEMENT iv

CERTIFICATION v

TABLE OF CONTENTS vi

1.0 INTRODUCTION

1.1 Background
1.2 Objectives

2.0 DESCRIPTION OF THE ESTABLISHMENT OF ATTACHMENT

2.1 Location and Brief history of establishment

2.2 Objectives of establishment

2.3 Organizational Structure

2.4 The various departments and sections in the establishment

3.0 SAFETY PRACTICES AND PRECAUTIONS IN THE WORKSHOP

3.1 Safety Practices

3.2 Safety Precautions in the Workshop

3.3 Equipment used and their functions

3,4 What is Automobile?

3.5 Who is an Automobile Engineer?

3.6 Purpose of Automobile Maintenance

4.0 Overview of work carried out and experience gained

4.1 Automobile Servicing

4.1.1 Purpose of Automobile Servicing

4.1.2 How Automobile Servicing is carried out

4.2 Automobile Engine

4.2.1 Description of an Automobile Engine

4.2.2 Lubrication/ Cooling system

4.2.3 Ignition system

4.2.4 Emission system

4.3 Driveline/ Drive train, Power transmission and Running system

4.3.1 Clutch system

4.3.2 Transmission system

4.3.3 Suspension system

4.3.4 Steering system

4.3.5 Braking system

4.4 Automobile Electrical system

4.4.1 Starting system

4.4.2 Charging system

4.4.3 Digital or Programmed Ignition system

4.4.4 Lighting system

4.4.5 Wiper and Washer system

4.4.6 Door lock control system

4.4.7 Sensors and Actuator

4.5 Repair and Maintenance process

4.5.1 Electrical Safety information

4.5.2 Tools required

4.5.3 Problems that affect the Electrical system and solutions

4.6 Troubleshooting of Automobile and Car Diagnostic Test

4.6.1 Troubleshooting of Automobile

4.6.2 Car Diagnostic Test

5.0 Summary, Conclusion and Recommendations

5.1 Summary and Problems encountered during the program

5.2 Conclusion

5.3 Recommendation
1.0 INTRODUCTION

1.1 Background

The Student Industrial Work Experience Scheme (SIWES) is an accepted skills programme
which forms part of the approved academic standards in the degree programme for Nigerian
Universities. In 1974, the Federal Government of Nigeria introduced the national policy on
Industrial training, called the Students’ Industrial Work Experience Scheme (SIWES). This
programme is under the umbrella of the Ministry of Education through the Industrial Training
Fund (ITF), was designed to help students acquire the necessary practical education/experience
in their fields of study and other related professions.

This is an effort which was created in order to bridge the existing gap between the theory
taught in the classroom and practice of science, agriculture, medicine, engineering, technology
and other professional programmes in the Nigerian tertiary institutions. This programme is aimed
at exposing the students to the use of various machines and equipments, professional work
methods and ways of safeguarding the work areas in industries as well as other organizations and
parastatals. The programme was established basically to impact elaborate practical understanding
to students with respect to their various disciplines. It is also intended that the student through a
process of relation to academic knowledge and practical industrial application would understand
the underlying principles and become better focused and acquire the practical applications
towards excellence in his or her discipline.

The Students Industrial Work Experience Scheme (SIWES) programme involves the
student, the Universities and the industries. This training is funded by the Federal Government of
Nigeria and jointly coordinated by the Industrial Training Fund (ITF) and the National
Universities Commission (NUC).
1.2 Objectives

SIWES provides avenue for student to acquire industrial skills and experience in their
approved course of study. It also prepare student for their industrial work situation after
graduation.

The objectives of the students’ industrial training work experience scheme are to:

1. Provide an avenue for students in the Nigerian universities to gain industrial skills and
experience in their course of study.
2. Prepare students for the work situation they are likely to meet after graduation.
3. Expose students to work methods and techniques in handling equipment and machinery
that may not be available in the universities.
4. Make the transition from the university to the world of world of work easier, and thus
enhance students’ contacts for later job placement.
5. Provide students with an opportunity to apply their theoretical knowledge in real work
situation, thereby bridging the gap between university work and actual practice.
6. Enlist and strengthen employers’ involvement in entire educational process of preparing
university graduates for employment in industry.
7. Provide students the opportunity to understand informal organizational interrelationships.
8. Help students to develop skills and techniques directly applicable to their careers.
 CHAPTER TWO
2.0 DESCRIPTION OF THE ESTABLISHMENT OF ATTACHMENT

Adewale Mechanic Workshop offers the Nigerian public high quality services for cars to suit
the Nigerian climatic and road conditions. What indeed has set Adewale Mechanic Workshop
apart from competition is the excellent range of services provided for all cars in general[ Toyota,
Mercedes Benz,Honda, etc.] that have met the demand of the market in terms of customer
satisfaction.

Adewale Mechanic Workshop is an automobile technology support company which offers

specialized services on automobiles especially exotic cars whose maintenance require absolute
competency, experience and vibrancy. The establishment diagnoses with computerized
equipment which detects internal defects and fix problems appropriately.

2.1 Location and Brief history of establishment

Adewale Mechanic Workshop is located at Oloremarun, Ogbomoso, Oyo State, Nigeria.

Adewale Mechanic Workshop was established in 2016. It was established by Mr Adewale
Olajide, who is an automobile engineer with the aim of having a company being the foremost
automobile technical support company whose services are likened to what is obtainable in the
international world and to provide solution to automobile problems by using standard technique
and modern equipments.

The company provides services such as Wheel Alignment, wheel balancing, general fault
detection, general servicing, general repairs of specialized vehicles, engine management and
Repair, Electric Parking brakes, Vehicle sensors, Fault diagnosis, Air Conditioning repair, Air
bags, Climate Control module, Relay and switches, wiring, fuses and connectors, all mechanical
work & repair, including exhaust clutch, shock absorber and all vehicle needs.

2.2 Objectives of establishment

Adewale Mechanic Workshop wholeheartedly offers its services to the customers. The
service/repair of a vehicle can be considered complete only when the customer has used it and is
fully satisfied with it. The objectives are as follows:
1. To provide effective and affordable solution to automobiles that requires specialist.

2. To diagnose and repair vehicles according to international standard.

2.3 Organizational Structure

Director

Manager

Engineer 1 Engineer 2

2.4Company departments:

1. Administration and Human Resources Department

2. Service Department

3. Parts Department
Sections in the company

1. Mechanical workshop

2. Welding

3. Vulcanizing

4. Electrical section
3.0 SAFETY PRACTICES AND PRECAUTIONS IN THE WORKSHOP
3.1 SAFETY PRACTICES

Mechanical workshop safety practices are important to follow because workshop rules
and regulations only ensure workers safety but also bring efficiency to the work process.
Safety guidelines, fire precautions and general work rules ensure that a symmetrical work
process is observed in workshops.

Safe practices are advised in order to prevent accident which is caused by either personal
element of the victim or threat which is beyond his control. Likely causes of accident in the
workshop include;

 Ignorance
 Over-confidence
 Carelessness
 Poor maintenance of equipment and engineering facilities
 Poor working condition/environment
 Tiredness
 Lack of protective devices
 Unsuitable clothing

3.2 SAFETY PRECAUTIONS IN THE WORKSHOP

Different workshops have different work practices and different machines; however,
there are certain rules that apply to mechanical workshop. The safety precaution measures are
put in place to prevent serious personal injury or damage to a costly equipment or
engineering facility. Some of the measures are:

 Ignorance should be avoided i.e an operator must properly understand the operation, use
and functions
 Use of loose clothing in the workshop should be completely avoided
 First aid box should be provided
 Fire extinguishers must be installed at strategic locations within the workshop
 Horse play should be avoided
  There must be enough ventilation
 Carelessness should not be tolerated as maximum concentration on the work being
executed is highly essential
 Clean workshop environment must be maintained. Grease or oil must not be tolerated on
workshop floors as dirty environment may lead to accident.

3.3 Equipment used in the work shop and their functions

1. Trolley jack: It is used for suspending or raising up the wheel of a vehicle, while the jack
stand helps to keep the vehicle away from falling.

2. Crane: This is used for removing a complete engine from a vehicle after the necessary
component has been removed from the engine.
3. Hand tools box/crate: it is used to keep all hand tools like spanners, pliers, hammers,
wrenches etc.
4. Compressing machine or compressor: This is the machine used for pumping air (source
of air) into a tire.

5. Battery charger: This equipment is used for charging vehicle battery up to 12volts.

6. Welding machine: This machine controls the arc welding process during welding.

7. Grinding machine: This is used to smooth the surface of work piece, most it is used in
finishing. It used mainly to sharp tools, to smooth rough surface of brake disc etc.

8. Transmission jack: used for easy removal of transmission (gearbox) from the engine
cabin.It has two pedals. One pedal for increasing the height of the jack and second pedal
for reducing the height of the jack.
3.4 What is Automobile
An automobile is a wheeled motor vehicle used for transportation. It consists of four wheels
and powered by internal engine. It is used to transport people and items from one location to
another. After years of various designs, inventors were able to develop a functional general
design that is utilized by major automakers as foundation of their designs.
Automobiles generally use gasoline or diesel to fuel the internal engine, but technology
advances have led to the design of vehicles that run on electricity and even water.

3.5 Who is an automobile engineer

An automobile engineer is an engineer that specialize in automobile designing, testing,
repairing and assembling. Automobile engineer design the intricate details of the electrical,
hydraulic and mechanical systems inside a vehicle. The work of automobile engineer breaks
down into three categories:
1. Design
2. Research and Development
3. Production

3.6 Purpose of automobile maintenance

.
An automobile is constructed from a large number of parts, which can become worn down,
weakened or corroded to lower the performance, depending on the conditions or the length of
use. Constructed parts, which can be estimated that performance It is very important to carry out
regular maintenance on vehicle, without proper maintenance, the vehicle is prone to have serious
problems in the future that could lead to high cost of repairing. By performing routine
maintenance on the vehicle reduce the risk of serious problems occurring in the future and as
well as improving the driving quality of the vehiclegoes down, are needed to have a regular
maintenance, then adjust or replace to maintain the performance.
By carrying out regular maintenance, the following results can be achieved, ensuring the
customer's trust and peace-of-mind:

1. Much larger problems with the vehicle that may occur later can be avoided.
2. The vehicle can be maintained in a state which is in adherence to legal regulations.
3. The life of the vehicle can be extended.
4. The customer can enjoy an economic and safe driving experience.

T, R, I, A, L stand for symbols of maintenance operation.

T = Tighten to specified torque
R = Replace or change
I = Inspect and correct or replace as necessary
A = Check and/or adjust as necessary
L = Lubricate

4.0 OVERVIEW OF WORK CARRIED OUT AND EXPERIENCE

GAINED
This chapter shows the actual work done and experience gained in different sections of the
establishment.

In the mechanical section, vehicles are being repaired and different faults were rectified. Often
times it starts with diagnosing the vehicle using on vehicle diagnosing machine and other
diagnosing equipment when the owner seems not to be specific about the fault or did not know
where the really fault is. After diagnosing the vehicle, the fault is detected and necessary solution
is proffer to it.

Also, works such as removal of gear box in order to replace the oil seal or clutch plate and
overhauling of engines after their removal for their respective vehicles were done in this section.
Then, in this section, cars are being serviced in which component parts such brake pads, brake
shoes, oil filter and so were being serviced or changed as the case may be.

Moreover, fuel tanks and pumps were being repaired or replaced as the case may be. The
experience helps in knowing how to properly handle hand tools such as spanners, pliers, wrench,
and sockets with their handle and so on, also help in knowing how to properly service a vehicle
and the inlet manifold of an engine such as servicing of fuel injectors and removing of dusts
from the air filter. Also, identifying of sensors and their function was part of experience gained.
For example, Manifold Absolute Pressure (MAP) is a sensor controlling the amount of pressure
through which air enter the inlet manifold, then Mass Air Flow (MAF)is a sensor which controls
the amount of air that enter in to the cylinder from the inlet manifold.Then, each component part
of an engine was able to be identified and their functions. For example, connecting rod which
transmit motion from the crank shaft to the piston then calm shaft which is responsible for
opening and closing of inlet and exhaust valves and so on. Also, proper knowledge of how to
remove gear box and fix the damages such as clutch plate, disc, gear box oil seal and so on was
acquired with being able to distinguished between front and rear wheel vehicles including what
makes them different.

Also, from vulcanizing section, different types of tires were inflated to their specific values and
faulty tires were repaired. Then, in this section, balancing of vehicle wheels using digital wheel
balancer was done. The experience gained from this section includes knowing the proper way of
inflating tires to their specific pressure value and knowledge of how vehicle wheels were being
balanced.

Electrical section is the place where every fault related to electrical system of a vehicle is being
repaired.In this section, the knowledge of electrical system of vehicles was acquired.

Welding section is another section presents, in this section, damages from the mechanical section
which needed to be fixed were brought and fixed in welding section. And some repairs were
made in some part of vehicles using welding.Knowledge of how to fix minor damages in vehicle
component part was acquired in this section.

Machining section provides solution to minor damages in machine and hand tools, such as using
drilling machine to drill a necessary hole in an engine component as the case may be.

I also learnt that vehicles generally are divided into three basic systems which are:
1. Engine,
2. Electrical,
3. Driveline/ Power transmission and running system.

4.1 Automobile Servicing

4.1.1 Purpose of automobile servicing
A motor vehicle service is a series of maintenance procedures carried out at a set time
interval or after the vehicle has travelled a certain distance. The service intervals are
specified by the vehicle manufacturer in a service schedule and some modern cars display the
due date for the next service electronically on the instrument panel.
It is very important to carry out servicing, without proper servicing, the vehicle is prone
to have serious problems in the future that could lead to high cost of repairing. By adequate
 servicing on the vehicle reduce the risk of serious problems occurring in the future and as
well as improving the driving quality of the vehicle.

4.1.2 How automobile servicing is carried out

Maintenance tasks commonly carried out during a motor vehicle service include:
1. Change the engine oil.
2. Replace the oil filter.
3. Clean or remove dust from the air filter or replace if necessary.
4. Clean the fuel filter or replace if necessary.
5. Clean the spark plugs with wire brush or replace if necessary.
6. Check the level of brake fluid/ clutch fluid and refill if necessary.
7. Check brake pads/ liners, brake discs/drums and replace if worn out.
8. Check level of automatic/ manual transmission fluid and refill if necessary.
9. Grease and lubricant components.
10. Inspect the timing belt or timing chain and replace if needed.
11. Check the condition of the tires.
12. Balance the wheels if necessary.
13. Check for proper operation of all lights, wipers etc.
14. Check for any error codes in the ECU and take corrective actions.

4.2 AUTOMOBILE ENGINE

4.2.1 Description of Automobile Engine
The engine is made of many components to help it convert heat energy into mechanical energy
efficiently when the air-fuel mixture is burned.
In order for an engine to operate smoothly under a wide range of operating conditions, the
following three conditions must be satisfied:
1.Good air-fuel mixture
2. Good compression
3 Good spark
Parts of automobile engine includes:
1. Cylinder head
 2. Cylinder head gasket
3. Cylinder block
4. Crankshaft
5. Connecting rods
6. Bearings
a. Connecting rod bearing
b. Crankshaft bearing
c. Thrust washer
7. Pistons
a. Piston pin
b. Piston rings
8. Camshaft
9. Crank case
10. Engine valve
4.2.2 Lubrication/ Cooling system
Lubrication system
The lubrication system supplies engine oil to each engine part, creating a film of engine oil,
which reduces the effects of friction and wear by allowing engine parts to slide smoothly and
perform optimally.
There are many rotating and sliding parts in an engine. As the engine operates at high engine
speed, if these parts were not lubricated, a great amount of friction would occur, resulting in
wear and seizure. To keep the engine rotating smoothly, the friction on each part needs to be
minimized. Parts are;
a. Oil pump
b. Oil filter
c. Oil strainer
d. Oil cooler
I learnt that oil cooler helps to maintain lubrication properties when the engine oil rises above
100°C. If the temperature rises above 125°C however, engine oil lubrication properties will
deteriorate suddenly. Therefore, to maintain lubrication properties, some engines are equipped
with oil cooler. Normally, all of the oil flows into the oil cooler and then flows to each engine
part after it is cooled.

Cooling system
The cooling system is made up of the passages inside the engine block and heads, a water pump
to circulate the coolant, a thermostat to control the temperature of the coolant, a radiator to cool
the coolant, a radiator cap to control the pressure in the system, and some plumbing consisting of
interconnecting hoses to transfer the coolant from the engine to the radiator and also 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 the passages, it picks up heat from the engine. The heated
fluid then makes its way through a rubber hose to the radiator in the front of the vehicle. As it
flows through the thin tubes in the radiator, the hot liquid is cooled by the air stream entering the
engine component from the grill in front of the car. Once the fluid is cooled, it returns to the
engine to absorb more heat.

4.2.3 Ignition System

The three essential elements of a gasoline engine are: good air-fuel mixture, good compression,
and good spark.
The ignition system generates a powerful spark through proper ignition timing in order to ignite
the air-fuel mixture.
1. Powerful sparks: In the ignition system, sparks are generated between the electrodes of the
spark plugs to burn the air-fuel mixture. Because even air has electrical resistance, when it is
compressed highly, tens of thousands of volts must be generated to ensure the generation of
powerful sparks that can ignite the air-fuel mixture.
2. Proper ignition timing: The ignition system must provide proper ignition timing at all times to
accommodate the changes in engine speed and load.
3. Sufficient durability: The ignition system must be able to provide sufficient reliability to
withstand the vibrations and heat that are generated by the engine. The ignition system uses the
high voltage that is generated by the ignition coil to produce sparks, which ignite the air-fuel
mixture that has been compressed. The air-fuel mixture is compressed and burns in the cylinder.
This combustion generates the motive force of the engine.
Through self-induction and mutual induction, the coil generates the high voltage that is necessary
for ignition. The primary coil generates several hundred volts and the secondary coil generates
tens of thousands of volts.

The types of ignition systems are as follows:

1. Breaker points type
2. Transistorized type
3. Transistorized type with ESA (Electronic Spark Advance),
4. DIS (Direct Ignition System)
Instead of a distributor, this type employs multiple ignition coils to supply high voltage directly
to the spark plugs. The ignition timing is controlled by the ESA function of the engine ECU.
This system is predominant in recent gasoline engines
How to Inspect Ignition system:
1. Allow the engine to warm up and short the terminal TC and CG on DLC3. Read the blinking
pattern of the MIL(Malfunction Indicator Lamp)
2. Check spark: if there is no spark, then the engine will never start
Spark test
(1) Disconnect all injector connecters so that fuel cannot be injected.
(2) Remove the ignition coil (with igniter) and spark plug.
(3) Re-install the spark plug in the ignition coil.
(4) Connect the connectors with it, and ground the spark plug. Check that the spark plug
generates a spark when cranking at this condition. This test determines which cylinder does not
have a spark. NOTICE: Do not crank for the spark test over 5 - 10 seconds.

4.2.4 Emission System

The emission control system reduces the emissions, which are harmful to the environment and
human beings produced by automobiles.
The term emission gas means the evaporated fuel from the fuel tank and the blow-by gas, which
passes between the piston and the cylinder wall, including the exhaust gas. The emission gas is
harmful to the environment and human beings because it includes such harmful substances as
CO (carbon monoxide), HC (hydrocarbon) and NOx (nitrous oxides).
Vehicles equipped with diesel engines emit not only gases such as CO, HC, NOx but also
carbon particles, which also affect the environment and human beings.
(1) CO (carbon monoxide)
(2) HC (hydrocarbon): HC is generated during incomplete combustion in the same way as CO.
(3) NOx (nitrous oxides): NOx is generated by the nitrogen and oxygen in the air of the air-fuel
mixture when the temperature of the combustion chamber rises above about 1,800°C (3,272°F).
The higher the combustion temperature rises, the more NOx is generated. When the air-fuel
mixture is lean, more NOx is generated because the ratio of oxygen in the air-fuel mixture is too
high. Therefore, NOx is generated according to the two factors of the combustion temperature
and oxygen concentration.
Emission purification countermeasures are mentioned below, but devices vary by country and
the emission regulations vary by region.
1. Catalytic Converters: The catalytic converter makes harmful substances (CO, HC and NOx)
react chemically with harmless ones (H2O, CO2, N2) according to the exhaust gas passed.
Generally platinum, palladium, iridium and rhodium, etc., are used as catalysts for automobiles.
Recently the monolithic type is used.
2. Exhaust Gas Recirculation (EGR) System: The Exhaust Gas Recirculation (EGR) System
recirculates some of the exhaust gases to the intake air system.
3. Positive Crankcase Ventilation (PCV) System: Blow-by gas includes a large amount of
unburned gas, which leaks out from the gap between the piston ring and cylinder wall into the
crankcase. The Positive Crankcase Ventilation (PCV) system forces the blow-by gas into the air
intake system and re-burns it. Using the vacuum of the intake manifold, blow-by gas is drawn in.

4.3 Driveline/ Drive train, Power transmission and Running system

A drive line is a mechanical components used for transmitting torque and rotaion.
4.3.1 Clutch system
 An automotive clutch is used to connect and disconnect the engine and manual transmission or
transaxle. The clutch is located between the back of the engine and the front of the tansmission.
Types of clutches includes:
1. Single disc type
2. Double disc type
3. Multiple disc type
The clutch is the first drive train component powered by the engine crankshaft. The clutch lets
the driver control power flow between the engine and the transmission or transaxle. The clutch
release mechanism allows the operator to operate the clutch and it consists of the clutch pedal
assembly, a mechanical linkage, cable or hydraulic circuit and the clutch fork.

Clutch Operation
When the operator presses the clutch pedal, the clutch release mechanism pulls or pushes on the
clutch release lever or fork. The fork moves the release bearing into the center of the pressure
plate, causing the pressure plate to pull away from the clutch disc releasing the disc from the
flywheel. The engine crankshaft can then turn without turning the clutch disc and transmission
input shaft.
When the operator releases the clutch pedal, spring pressure inside the pressure plate pushes
forward on the clutch disc. This action locks the flywheel, the clutch disc, the pressure plate and
the transmission input shaft together. The engine again rotates the transmission input shaft, the
transmission gears, the drive train and the wheels of the vehicle.

Clutch Troubleshooting and Overhaul

An automotive clutch normally provides dependable service for thousands of miles. However,
stop and go traffic will wear out a clutch quicker highway driving. Every time a clutch is
engaged, the clutch disc and other components are subjected to considerable heat, friction and
wear. There are five types of clutch problem: slipping, grabbing, dragging, abnormal noises and
vibration.
When adjustment or repair of linkage fails to remedy problems with the clutch, the clutch must
be removed for inspection. Faulty parts must be discarded and replaced with new or rebuilt
components. If replacement parts are not readily available, a decision to use the old components
should be based on the manufacture’s and the maintenance supervisor’s recommendations. When
the clutch is removed, clean and inspect all components for wear and damages. After cleaning,
inspect the flywheel and pressure plate for signs of unusual wear such as scoring or cracks. A
clutch disc contains asbestos ( a cancer causing substance), be careful on how you clean the parts
of the clutch.

4.3.2 Transmission system

Manualtransmission is designed to provide the operator with option of maneuvering the vehicle
in either the forward or reverse direction. This is the basic requirement of all automotive
vehicles. It also provide the operator with a selection of gear ratios between the engine and wheel
so that the vehicle can operate at the best efficiency under a variety of operating conditions and
loads. If in proper operating condition, a manual transmission should do the following:
1. Be able to increase torque going to the drive wheel for quick acceleration.
2. Supply different gear ratios to match different engine load conditions.
3. Have a reverse gear for moving the vehicle backward.
4. Provide the operator with an easy means of shifting transmission gears.
5. Operate quietly with minimum power loss.

Automatic transmission is designed to match the load requirements of the vehicle to power and
speed range of the engine. Automatic transmission, however does this automatically depending
on throttle position, vehicle speed and the position of the control lever. It is built on models that
have two, three or four- forward speeds and in some are equipped with overdrive. Operator
control is limited to the selection of gear range by moving a control level. The automatic
transmission is coupled to the engine through a torque converter. The torque converter is used
with an automatic transmission because it does not have to be manually disengaged by the
operator each time the vehicle is stopped.
Parts of transmission are:
1. Torque converter
2. Valve body
 3. Oil pump
4. Bands and clutches
5. Input shafts
6. Planetary gears
7. Output shaft
8. Pistons and servos

Transmission Troubleshooting and overhaul

Transmissions are designed to last for the life of the vehicle when lubricated and operated
properly. The most common cause of failure results from shifting when the vehicle is not
completely stopped or without waiting long enough to allow the gears to stop spinning after
depressing the clutch pedal. Many problems that seem to be caused by the transmission are
caused clutch, linkage or driveline problems.
Due to the variations in construction of transmissions, there is need to always refer to the
manufacturer’s service manual for proper procedures in the removal, disassembly, repair,
assembly and installation.

sensors
(Various signals) Engine & ECT
Vehicle speed Counter gear speed ECU
sensor sensor
Oil pump
Planetary
Torque converter gear unit

Input turbine
speed sensor
Solenoid valves

Shift lever
Hydraulic control unit
Automatic Transmission or transaxle with its parts.

4.3.3 Suspension system

Suspensions system transmits the driving and braking forces, which are generated due to friction
between the road surface and the wheels, to the chassis and body. It supports the body on the
axles and maintains the proper geometrical relationship between the body and wheels.

It consists of the following principal components:

1. Springs: Neutralize the shocks from the road surface.
2. Shock absorbers (dampers): Acts to improve riding comfort by limiting the free oscillation of
the springs.
3. Stabilizer (sway bar or anti-roll bar): Prevents lateral swaying of the vehicle.
4. A linkage: Acts to hold the above components in place and to control the longitudinal and
lateral movements of the wheels.

Sprung weight and unsprung weight

The body is supported by springs. The weight of the body, etc., which is supported by springs is
called the sprung weight. On the other hand, the wheels and axles, and other parts of the
automobile which are not supported by springs, make up the unsprung weight. It is generally said
that the greater the sprung weight of an automobile, the better the riding comfort becomes,
because, as the sprung weight is made larger, the tendency of the body to be jolted decreases.

Types of Suspension and their characteristics

Suspensions can be divided into the following two types according to their structures.
1. Rigid axle suspensions: Both wheels are supported by an axle housing or axle beam.
Therefore, the left and right wheels move together.
2. Independent suspensions: Each wheel is supported by an independent arm, which is mounted
to the vehicle body. Therefore, the left and right wheels move independently
Note that: The suspension improves the riding comfort and driving performance of the vehicle.
EMS (Electronically-Modulated Suspension) and air suspension electronically control the
damping force of the shock absorbers and air springs to further improve riding comfort and
driving performance.

4.3.4 Steering system

The purpose of the steering system allows the driver to control the direction of the vehicle by
turning the front wheels. The function of the steering system is to convert the rotary movement
of the steering wheel in driver’s hand into angular turn of the front wheels on road.
There are two types of steering:
1. Rack-and-pinion type
2. Recirculating-ball type
Steering Mechanism
Tilt and Telescopic steering mechanism
1. Tilt Steering Mechanism: The tilt steering mechanism allows selection of the steering wheel
position (in the vertical direction) to match the driver's driving posture.
2. Telescopic Mechanism: The telescopic steering mechanism allows forward or backward
adjustment of the steering wheel position to suit the driver's posture.
Steering Lock Mechanism
This is a theft deterrent feature that disables the steering wheel by locking the steering main shaft
to the column tube when the ignition key is pulled out. And it is of two types; the push button
ignition key cylinder type and push type ignition key cylinder type.

4.3.5 Braking system

A brake system transmits force from a driver’s foot to the car’s brakes. The brake then transmit
the force to the tires and road, where the friction slows and stop the vehicle. Brakes translate a
push of a pedal to slowing down of the vehicle.
In order to decrease the speed of a running vehicle and bring it to a stop, it is necessary to
generate force to slow the rotation of the tires. The energy (kinetic energy) of the tires working to
rotate is converted into the heat of friction (thermal energy) by operating the brakes which works
to stop the rotation of the tires. Some of the terminologies are:
 1. ABS (Anti-lock Brake System): An ABS is a brake control unit that uses a computer
control to automatically prevent the tires from locking due to emergency braking. This
system raises the vehicle stability further and shortens the braking distance. Therefore,
the tires do not lock up and the steering wheel can be steered even when the brake is
depressed suddenly. The vehicle is kept in control, and can stop safely.
2. EBD(Electronic Brake force Distribution): braking force appropriate to the condition of
the vehicle is distributed among the front and rear wheels and left and right wheels using
the ABS brake hydraulic control unit.
3. BA (Brake Assist): The BA is a system that assists brake operation when drivers cannot
apply enough force on the brake pedal
4. TRC (Traction Control system)
Sometimes when the accelerator is depressed too much while starting off or accelerating on
slippery surfaces, etc., the excessive torque that is generated causes the drive wheels to slip,
causing the vehicle to lose the start-off/ acceleration ability and the steering control. The
brake hydraulic pressure control of drive wheel and the engine output control by the fuel
cut-off control lower the motive power when the accelerator pedal is depressed. Thus the
TRC ensures the vehicle start-off/ acceleration ability and steering control.
5. VSC (Vehicle Stability Control system)
While the ABS and TRC are mainly used to stabilize brake operation and accelerator
operation during braking and acceleration, the VSC ensures the “steering and direction
stability” of the vehicle. The system detects sudden steering and sideways slip on slippery
surfaces and then provides optimum control of the braking for each wheel and the engine
power to attenuate front wheel skid and rear wheel skid. The brake control method
(controlled wheels) for the various wheels differs depending on the model (FF, FR).

4.4 Automotive Electrical System

4.4.1 STARTING SYSTEM
Since the engine cannot be started by itself, external power is required to generate the first
combustion to start it. To start the engine, the starter rotates the crankshaft via the ring gear. The
starter is required to generate extremely large torque from the limited power from the battery
and should be compact and light as well. For this reason, a DC (direct current) series motor* is
used for the starter. To start the engine, the crankshaft has to rotate faster than the minimum
cranking speed. The minimum cranking speed required to start the engine differs depending on
the engine's construction and operating conditions, but it is generally 40 to 60 rpm for a gasoline
engine and 80 to 100 rpm for a diesel engine.

Description of a Starter A Starter

I did troubleshooting on several cars having starting problems, by checking the battery, starter
and the ignition switch using Multi-meter. I observed that most time the battery terminal was
not connected firmly, and also observed that the battery is not connected to the ground (i.e. to
the vehicle metal sheet) or has removed. I also learned how to do overhauling on the starter

4.4.2 CHARGING SYSTEM

Vehicle is equipped with many electrical devices to drive safely and comfortably. The vehicle
requires electricity not only while driving but also while it stops. Therefore, the vehicle has a
battery for a power supply and a charging system to generate electricity by the engine running.
The charging system supplies electricity to all the electrical devices and charges the battery.

Charging system mainly consists of the following devices.

1. Alternator : While the engine is running, this generates a nearly equal amount of electricity
to operate the electric devices used for the vehicle and to charge the battery

The functions of alternator include:

The alternator plays a major role in the charging system. Alternator has three functions of
generating electricity, rectifying current and regulating voltage.
(1) Generation: Transmitting the engine revolution to the pulley via the v-ribbed belt turns the
electro magnetized rotor, generating alternating current in the stator coil.
(2) Rectification: Since the electricity generated in the stator coil is alternating current, this
cannot be used for the DC electric devices installed on the vehicle.
To use the alternating current, the rectifier is used to rectify the alternating current into direct
current.
(3) Regulation of voltage: IC regulator regulates the generated voltage to make the voltage
constant even when the alternator speed or the amount of current flowing into the electric
devices fluctuates

2. Battery: This is a power source when the engine stops and it supplies electricity to the electric
devices to start the engine or when the alternator does not generate electricity. However,
electricity generated by the alternator is charged to the battery once the engine starts running.
 A Battery
3. Charge warning light: This informs of the malfunction in the charging system
4. Ignition switch : This starts the engine, causing the alternator to generate electricity
I learned how to inspect the charging system. In No-Load Test (inspect charging circuit without
load) and Load Test (inspect charging circuit with Load). In the IC regulator type alternator,
No-Load Test specified value of the regulated voltage is between approx. 13.5V and 15.1V
(when the engine speed is 2,000 rpm). If the measurement result is outside the specified value,
the alternator may have a problem. If the value is higher than the maximum limit, the problem is
in the IC regulator. While the value is lower than the minimum limit, the problem could be in a
component of the alternator except for the IC regulator.
I noticed that in the load test when the electric load is applied, whether the alternator can
output according to the load is checked by measuring the output current. The important point in
this test is applying heavy load as much as possible. If electrical load is insufficient even if the
alternator is normal, it may not exceed 30A of specified value (when the engine speed is 2,000
rpm). Therefore, if the output current is 30A maximum, it is necessary to increase electrical load
and inspect again. The measurement result is less than the specified value, the alternator can be
judged faulty. In this case, the possibility of a malfunction is at the part that has a generating
function or rectifying function.

4.4.3 DIGITAL (PROGRAMMED) IGNITION SYSTEM.

Programmed ignition makes use of computer technology and permits the mechanical, pneumatic
and other elements of the conventional distributor to be dispensed (this is the direct ignition
system). The control unit (ECU or ECM) is a small, dedicated computer which has the ability to
read input signals from the engine, such as speed, crank position, and load. These readings are
compared with data stored in the computer memory and the computer then sends outputs to the
ignition system.

4.4.4 LIGHTING SYSTEM.

Lights used for vehicles are classified according to the purpose: for illumination, signaling or
informing. For example, headlights are used for illumination to see at night, turn signal lights
for signaling to other vehicles or pedestrians, and taillights for informing of the vehicle's own
presence or position. Besides the general lighting system, vehicles are equipped with systems
with various functions depending on the areas or grades.

4.4.5 WIPER AND WASHER SYSTEM

The wiper and washer system is a system that keeps the view clear by removing raindrops on
the windshield glass and the back window glass when it rains.Used with washer, the system can
clear dirt from the windshield glass.
For these reasons, this is an essential system for driving vehicles safely. Recently, some models
have functions in which the wiper speed changes in response to the vehicle speed, and the wiper
automatically operates when it rains.

4.4.6 DOOR LOCK CONTROL SYSTEM

The door lock control system does not simply lock/unlock the doors by mechanical operation,
but also controls the electric motor according to the operation of the door lock control switch
and key.
The system also has key confine prevention function, two-step unlock function and security
function. The functions covered by the system vary depending on the model, grade and area.

WIRELESS DOOR LOCK REMOTE CONTROL SYSTEM

The wireless door lock remote control system is a system that sends out signals from the
transmitter that is built in the key or key holder to lock/unlock the doors even when away from
the vehicle. When the door control receiver receives the signal sent out by the transmitter, it
sends the operation signal to the integration relay.
The integration relay controls the door lock motors upon receiving the operation signal. In
addition to this function, the integration relay has automatic lock function, repeat function,
answer back function, and other functions.
The functions of the wireless door lock remote control system vary depending on the models,
grades and areas.

4.4.7 SENSORS AND ACTUATOR

Sensors
Sensors are the components of the system that provide the inputs that enable the computer
(ECM) to carry out the operations that make the system function correctly. In the case of vehicle
sensors it is usually a voltage that is represented by a code at the computer’s processor. If this
voltage is incorrect the processor will probably take it as an invalid input and record a fault.
The fact that the controller itself receives an incorrect sensor signal normally means that the
sensor and/or the circuit that connects it to the controller is not working properly and, as with
many other parts of electronic systems, it may not be the sensor itself that is at fault. However,
it is probable that a fault code has been produced that says ‘sensor fault’. This just means that
the sensor signal that reached the controller was defective.
Types of sensors are electromagnetic sensor(used by crankshaft, camshaft and
ABS),combustion knock sensor(used for knock sensor), optical sensor(used for photodiode like
for solar sensor), etc.

Actuators
Actuators normally rely on one of two electrical devices for their operation; they are either
operated by a solenoid or by an electric motor. Solenoid-operated actuators are normally
controlled in one of two ways. Tests on vehicle systems should be approached with caution. It is
dangerous to make assumptions, and it is vitally important that you should either be familiar
with the product that you are working on, or have to hand the necessary data that relates to the
product.
 A typical Injector for a multiple-point injector system

4.5Repair and Maintenance Processes

Some of the component of systems are complex, and some problems, like issues with the
onboard computer, may need to be serviced at a repair shop or dealership.

4.5.1Electrical Safety Information

Working with the electrical system in a vehicle is generally quite safe. Automotive electrical
systems run at 12V, which does not pose a danger of shocks or electrocution. However, many
electrical components are easily damaged, so care should be taken when handling them.
Introducing incorrect voltages or currents can break many systems. One part of the electrical
system that is potentially dangerous is the high-voltage side of the ignition coil, which should
not be serviced while power is applied. Additionally, electric or hybrid-electric vehicles use
many high-voltage batteries and powertrains, which are dangerous and potentially fatal if
mishandled.

4.5.2Tools Required
 The simplest tool that can be used in electrical diagnosis is 12 volts test light.. This light can be
used to check if power is being received at any point in a circuit, which can be handy for simple
or quick tests. However, test lights do not provide very much information. A digital multimeter
have two probes that can be connected to a circuit to test voltage, amperage, resistance,
continuity, and more. Basic electrical and automotive tools, such as wire cutters, wrenches, and
screwdrivers, are used to service automotive electrical systems.

.
4.5.3 Problems that affect the electrical system and solutions
Battery problems
Battery problems are the most common cause of electrical issues in vehicles. To test a battery,
connect a multi-meter in voltage mode across the terminals of the battery. A fully charged
battery should read 12.6V, while a halfway-charged battery will be around 12.4V. A battery that
shows 0V is dead and needs to be charged. One common problem is loose or corroded
connections at the battery post, which can cause intermittent problems or prevent starting.
Cleaning the posts and connections with a wire brush and tightening them will solve these
problems. A battery that frequently goes dead might simply be old, and can be tested at an auto-
parts store.
Note: A good battery that still goes dead is an indication of an electrical problem. With the car
off, disconnect the negative battery cable and connect the multi-meter in amperage mode in
between the negative battery post and the cable. A reading of more than 50mA indicates a
parasitic load somewhere in the system that is draining the battery. Disconnect fuses one by one
from the fusebox while checking the reading. When the system that is draining the battery is
disconnected, the multimeter reading will drop to below 50mA.

Grounding problem
Another common problem in automotive electrical systems is improper grounding connections.
In a vehicle, the metal body of the car serves as a ground, and connects each component back to
the negative post on the battery. Each component and system is connected to by a grounding
connector, which is generally an O-ring connected to a screw post. Vibration from driving can
cause these connections to become loose over time, which opens the circuit, causing failure or
intermittent issues. Cleaning and tightening these connections solves most grounding issues.

Fuses/ Relays
If a system, such as the radio or headlights, suddenly stops functioning, it is likely that a fuse
has blown. Fuses are located at the fuse box, underneath the dash on the driver’s side, or in the
power center under the hood. Each should have a diagram showing which fuse goes with which
system. Fuses protect electrical systems and components by opening when too much current is
flowing in the circuit. When a fuse blows, the wire connecting each side burns open,
disconnecting the circuit. Replacing blown fuses with a new fuse of the same amperage rating
reconnects the circuit. If a fuse has blown, it is likely that the problem is a short or overload in
the circuit or component the fuse is protecting. If this is the case, replacing the fuse only fixes
the problem temporarily.

4.6 Troubleshooting of Automobile and Car Diagnostic Test

4.6.1 Troubleshooting of Automobile

Troubleshooting is the identification or diagnosis of trouble in a system caused by failure of one

component or the other. Like people, vehicle sometimes experience little hiccups and need a bit
of checkup and some extra attention to get back on track. The most important thing is to first
recognize the problem and then fix it with proper tools because the vehicle might have been
given symptoms like noises, shakes, bumps etc. Here are some common car troubles and
solutions.
1. Problem starting the car: The car will either takes a long time to start or the car won’t
start at all. There are number of reasons which can cause a car engine not to start, the
most common is when the battery is dead. Pay attention to the noise it makes when
turning the key. If the car is completely silent then it might be a problem with the battery
terminal cable connections, but if the car crank and did not start, then it might be the
spark plugs or fuel supply to the engine.
2. Engine overheating: When the engine is overheating, there may be smoke coming from
the bonnet or the needle on your engine temperature gauge may be through the roof.
Overheating can be caused by a few different factors. The simplest cause may be that the
car needs more coolant or the water in the radiator has dried. Yet depleted coolant can be
caused by bigger problem like leaks or faulty hoses, so always check for the underlying
cause before simply filling it up. Another common reason for overheating may be when
the radiator fan which keeps the engine cool is faulty, so check the fan motor connection
and fan thermostat.
3. Noisy brakes: The car will produce more unpleasant sound/ noise. There could be a
number of reasons for noisy brakes. It could be that the brake pads are loose, worn out, or
there may be brake dust inside the drum. If there is nothing wrong with the brake pad
then one can suspect it to be brake dust and brake dust can be extremely dangerous if
accidentally inhaled.
4. Uneven tyre wear: It may not be obvious that the car tyres are unevenly worn, but worn
out tyres can be dangerous due to their reduced grip on the road. The best way is to jack
up the car and inspect each tyre individually, noting whether there are any dips and dents
in the tyre tread. Rotate the tyres and have wheel alignment regularly and do wheel
balancing also.
5. Air conditioner not working: When the air conditioner is switch on and you notice that it
is just blowing room-temperature air around rather than cold air then it is faulty. The
most likely cause of this that there is no refrigerant left in the system. This could be
caused by a leak in the system somewhere which will have to be fixed before refilling the
refrigerant.
 4.6.2 Car Diagnostic Test
Regular diagnostic tests can detect problems with the vehicle before they require
expensive repairs or total breakdown. Diagnostic tests can reveal problems within a car’s
engine, transmission, exhaust system, brakes and other major components and as well as
performance issues with the fuel injector, air flow and coolant, ignition coils, and throttle.
Before emergence of car diagnostic tests, identifying problems was a time consuming
and expensive, especially considering car owners only brought their cars to mechanics
after a break down or severe malfunction. Using specialized software, car diagnostic tools
quickly and accurately point to problem areas in a car’s engine or elsewhere, thanks to
built-in processors, microchips and sensors. Now computerized car components can
detect problems long before they cause a breakdown. Diagnostic tools can also check a
car’s computer system for manufacturer notifications and stored information about the
car’s history, giving technicians a complete picture in order to perform the best repair
possible. You don’t have to wait for the check engine light to get a car diagnostic test, if
you hear or feel something is “off”, mechanics can use diagnostic testing to uncover car
problems. However, many technicians recommend taking car for a diagnostic check at
least once in a year, which will uncover minor problems that can’t be seen or heard and
that won’t trigger the check engine lights.
Skills acquired for effective diagnosing are as follow:
1. Use of appropriate ‘dedicated’ test equipment effectively.
2. Make effective use of wiring diagrams and use of instruction manuals effectively.
3. Use multi-meters and other (non-dedicated) equipment effectively.
4. Interpretsymptoms of defective operation of a system and, by suitable processes, trace the
fault and its cause.
5. Work in a safe manner and avoid damage to sensitive electronic components.
6. Fit new units and make correct adjustments and calibrations.
7. Test the system, and the vehicle for correctness of performance.
5.0 SUMMARY, CONCLUSION AND RECOMMENDATION

5.1 Summary and Problems encountered during the program

The SIWES program is a very wonderful one but getting placement in a relevant company
pose as a very difficult problem in the first place as well as accommodation in the placement
region after getting placed.

5.2 Conclusion

Over-viewing of the aims of the students Industrial Work Experience Scheme (SIWES) reveals
that it has lot of help to offer undergraduate engineering students in order to utilize their God
given talents. This SIWES really helped in enhancing the level of relationship with other
students in general and technicians in particular and also teaches how to face the challenges that
may arise in any industrial set up as there are many challenges that came up during the course of
the program.

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
hands-on 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 Automobile Technology in the immediate society and the world as a
whole, and making me to know that automobile is not only about the mechanical aspect but also
include the electrical/electronic aspect too, now look forward to impacting the knowledge
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.
I suggest the continuation of orientating of students before starting the program to prepare
their minds towards the task ahead.
 5.3 Recommendations

Through the work experience program, I did achieve a lot of its stated objectives, nevertheless
the following recommendations are suggested to improve the qualitative context of the program:

1. Orientation of students before going out from the school to prepare their minds towards
the task ahead
2. It should be taken with utmost seriousness because it really exposes students to technical,
practical and physical work experience
3. Participation of various professional, regulatory and statutory bodies such as NSE in the
supervision of student
4. Payment of befitting student allowance to assist in student’s finances during the period of
training.

I also plead with SIWES to help students in securing places for training because most
companies grant students placement based on influence and favoritism making it very
difficult for the non-influential students to secure a place for training.