NAKAWA VOCATIONAL TRAINING COLLEGE

DEPARTMENT OF MOTOR VEHICLE ENGINEERING

A PROJECT REPORT ON REPAIR ANAD MATENANCE OF A COLLEGE PAJERO

BY

NKUUTU RASHID NANDALA

UBT104C/2023/T/D/A/0649

SUPERVISOR: MR ERIMA GEOFREY

SIGNATURE: ……………

A REAL LIFE PROJECT REPORT SUBMITTED TO UBTEB IN PARTIAL FULFUILMEMT FOR THE AWARD OF

VOCATIONAL DIPLOMA IN AUTOMOBILE ENGINEERING,

6TH APRIL 2024.

DECLARATION
I Nkuutu Rashid Nandala declare this report being authentic, all the information packaged in this report
is true to the best of my knowledge and has never been submitted to UBTEB and is ready for submission
to UBTEB.

Date: ……………………………………………………………….

Signature: …........................................................
APPROVAL
This is to approve that this report was done under my supervision and is ready for submission to UBTEB.

Name: .................................................................

Date: ..........................………………………………………..

Sign: ......................................................................

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DEDICATION
I dedicate this report to my parents who are always reminding me of my studies and the person I should

be my supervisor Mr. Erima Geofrey who reminded us always of the project, the principal of NVTC and

my coursemates.

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ACKNOWLEDGEMENT
I thank Mr. Erima Geofrey who supervised this project at NVTC, Kampala. Am so grateful for his efforts
and time that contributed to the production of this report.

I thank our supervisor for his willingness and efforts he made to ensure that we successfully reached
conclusion with this project. I thank my teammates and colleagues I worked with up to completion of
this project.

I thank the college that has been responsive for all that was required to accomplish the vehicle repair.

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 Table of contents

Contents
NAKAWA VOCATIONAL TRAINING COLLEGE ..................................................................... 0
DECLARATION ........................................................................................................................................ i
APPROVAL ............................................................................................................................................. ii
DEDICATION ......................................................................................................................................... iii
ACKNOWLEDGEMENT .......................................................................................................................... iv
ABSTRACT ............................................................................................................................................ vii
List of figures. ..................................................................................................................................... viii
List of tables ......................................................................................................................................... ix
List of abbreviations .............................................................................................................................. x
CHAPTER ONE: ...................................................................................................................................... 1
1.00 INTRODUCTION ............................................................................................................................. 1
1.20 OBJECTIVES ................................................................................................................................... 1
SCOPE .................................................................................................................................................... 1
CHAPTER TWO ...................................................................................................................................... 3
2.00 LITERATURE REVIEW ..................................................................................................................... 3
2.10 CLUTCH SYSTEM. ........................................................................................................................... 3
2.20 FUEL SYSTEM. ................................................................................................................................ 5
2.30 CHARGING SYSTEM. ...................................................................................................................... 6
2.40 STARTING SYSTEM......................................................................................................................... 7
2.50 COOLING SYSTEM. ......................................................................................................................... 9
CHAPTER THREE .................................................................................................................................. 13
CHAPTER FOUR ................................................................................................................................... 18
4.10 CLUTCH SYSTEM. ......................................................................................................................... 21
4.20 FUEL SYSTEM ............................................................................................................................... 22
4.30 COOLING SYSTEM ..................................................................................................................... 23
4.40 BRAKING SYSTEM ...................................................................................................................... 25
4.50 CHARGING SYSTEM ..................................................................................................................... 26
2.51Battery ......................................................................................................................................... 26
4.60 STARTING SYSTEM. ..................................................................................................................... 28
4.70 STEERING SYSTEM ....................................................................................................................... 29
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4.80 LUBRICATION SYSTEM................................................................................................................. 30
4.90 THE ENGINE SYSTEM. .................................................................................................................. 31
CHAPTER FIVE...................................................................................................................................... 32
5.00 CHALLENGES. .............................................................................................................................. 32
5.10 CONCLUSION. .............................................................................................................................. 32
5.20 RECOMMENDATIONS.................................................................................................................. 32
5.30 REFERENCES ................................................................................................................................ 32
5.40 APPENDIX .................................................................................................................................... 33

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ABSTRACT
The project aimed at repairing the college vehicle, acquiring practical skills. I carried out inspection on
the college pajero, here i discovered the clutch system had missing components. The cooling system had
a clogged radiator, the radiator pressure cap was missing, the expansion tank was worn out. The
charging system and starting system had the battery missing, battery terminals were missing. The
steering system had the power steering reserviour was missing the steering pump was also missing plus
the power steering belt. The lubrication system, engine system, braking system the fuel system had
faults. The project ended with the vehicle properly repaired and i also aquired practical skills.

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List of figures.
Figure.1: clutch disc construction. ............................................................................................................... 3
Figure 2: showing the clutch slave cylinder was disassembled to see if it could be overhauled rather
than replaced................................................................................................................................................ 4
Figure 3: showing the master cylinder. ....................................................................................................... 4
Figure 4: showing a glow plug...................................................................................................................... 6
Figure 5: showing a scan tool used to dragonize charging system problems ............................................ 7
Figure 6: showing a technician checking battery voltage present at the output of the alternator and
battery sense terminals if no voltage, then there is fault in the wiring..................................................... 7
Figure 7: showing a hydrometer ................................................................................................................ 10
Figure 8: Checking the opening temperature of a thermostat. ................................................................ 11
Figure 9: showing a corroded water pump that needs to be serviced. .................................................... 11
Figure 10: safety gears to be considered before operating any task in workshop..................................... 12
Figure 11: showing the vehicle that was repaired. ..................................................................................... 18
Figure 12 showing some of tools that were used during the repair........................................................... 19
Figure 12.1: cleaning the work space ......................................................................................................... 19
Figure 12.2: showing parking vehicle on level ground................................................................................ 20
Figure 12.3: showing wedging the vehicle. ................................................................................................. 20
Figure 13: Showing the old master cylinder that was removed from the vehicle. ..................................... 21
Figure 14: The fuel injector pump............................................................................................................... 22
Figure 15: Radiator safely removed out of the vehicle for flushing ........................................................... 24
Figure 16:The servo and master cylinder for the braking system. ............................................................. 25
Figure 17 showing a vehicle battery. .......................................................................................................... 26
Figure 18: showing Diagram showing alternator ........................................................................................ 27
Figure 19: Applying silicon on the gasket to enable proper sealing of engine, this prevents leakages. .... 31

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List of tables.
Table 1: showing starting system symptom guide. ..................................................................................... 8
Table 2: showing radiator faults and maintenance repair. ......................................................................... 11
Table 3: showing protective gears. ............................................................................................................. 13
Table 4: Components of a clutch system, inspection report and repairs that I made ............................... 21
Table 5: showing fuel system componets, inspectttion report and repairs that were made. ................... 22
Table 6: The cooling system components, inspection report and repair. .................................................. 23
Table 7: Repair and maintenance of breaking system................................................................................ 25
Table 8: showing the charging system components, inspection report and repair that were made. ....... 26
Table 9: Inspections and repairs made on starting system. ....................................................................... 28
Table 10: Inspection and repairs on the steering system. .......................................................................... 29
Table 11: Inspection and repair of lubrication system. .............................................................................. 30
Table 12: Engine inspection and repair....................................................................................................... 31

ix
List of abbreviations
UBTEB: Uganda Business Technical Examination Board.

PPE: Personal Protective Equipment.

NVTC: Nakawa Vocational Training College.

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 CHAPTER ONE:
1.00 INTRODUCTION
In the automotive industry, auto motives have proofed there role to the community and its now
difficult to live in the early times were we had no vehicles.

Transportation is now simplified because of the automotive industry. Imagine carrying a

transporting 5 tons of sugarcane to kakira sugar works without vehicle!

After we have seen the importance of the auto motives, I write a report on repair and
maintenance of a college Pajero.

1.10 STATEMENT OF THE PROBLEM

Despite being a crucial asset for transportation within the college campus, the Pajero vehicle is
experiencing frequent breakdowns and mechanical issues. This report aims to identify the root causes of
these maintenance challenges and propose effective strategies to improve the reliability of the college
Pajero through comprehensive repair and maintenance protocols.

1.20 OBJECTIVES
1.21 General objective.

(i) The objective of the project was repairing a pajero at Nakawa Vocational Training
College.

1.22 Specific objectives

(i) Identify and address all mechanical issues and wear-and-tear components affecting the
performance of the college Pajero.

(ii) Conduct a thorough inspection to diagnose any hidden or potential problems that may
compromise the vehicle's functionality.

(iii) Develop a maintenance schedule and checklist to ensure regular servicing and preventive
care for the Pajero.

(iv) Implement necessary repairs and replacements to restore the vehicle to optimal working
condition.

(v) To acquire practical skills.

(vi) To relate theory knowledge with practical knowledge.

SCOPE
My scope of repair and maintenance of a college pajero was as the following:

I. Inspected for possible faults with the clutch system and then repairs were made.

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 II. Inspected the fuel system and then made the relevant repairs.
III. Inspected the cooling system for leakages, sludge and made necessary repairs.
IV. Inspected the braking system free play, brake shoes followed by relevant repairs.
V. Inspected the starting system for proper operation and repairs were made were
relevant.
VI. The charging system was inspected for proper operation of the alternator, battery
reliability and I made necessary repair.
VII. The steering system was inspected for stability, self-centering, responsiveness and I
made the required repairs.
VIII. The lubrication system was inspected and I made necessary changes with the oil.
IX. Inspected the engine system and I made the required repairs.

1.40 SIGNIFICANCE

1. Safety: Ensuring the reliability of the Pajero enhances safety for passengers and drivers,
reducing the risk of accidents or breakdowns.

2. Cost-effectiveness: Effective repair and maintenance protocols can minimize repair costs and
prolong the lifespan of the vehicle, ultimately saving the college money in the long term.

3. Operational Efficiency: A well-maintained vehicle contributes to the smooth functioning of

college operations, such as transportation for staff, students, and goods.

4. Image and Reputation: A reliable fleet reflects positively on the college's image and
reputation, instilling confidence in stakeholders and visitors.

5. Environmental Impact: Proper maintenance reduces emissions and fuel consumption, aligning
with sustainability goals and environmental regulations.

6. Learning Opportunity: The report can serve as a case study for students studying automotive
engineering or maintenance, providing practical insights into vehicle repair and maintenance
practices.

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 CHAPTER TWO
2.00 LITERATURE REVIEW
This chapter describes literature review on clutch system, fuel system, charging system, starting
system, cooling system and safety precautions

2.10 CLUTCH SYSTEM.

Clutch slips

Possible causes:

1. Clutch is worn or out-of-adjustment.

2. Clutch disc has oil on the surface.
3. Flywheel height is out-of-specifications.

Clutch grabs

Possible causes:

1. Clutch disc has oil on the surface.

2. Clutch linkage is binding.

Clutch noises

Possible causes:

1. Pilot bearing is defective or worn.

2. Release bearing is defective or worn.

CAUTION: Always take precautions when working around clutch lining material and assume that it
contains asbestos. These precautions should include wetting the friction disc before removal and
preventing any dust from the lining from becoming airborne.

HINT: The larger center hub section of the disc must be installed with the thicker portion facing the
pressure plate.

Figure.1: clutch disc construction.

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Figure 2: showing the clutch slave cylinder was disassembled to see if it could be overhauled
rather than replaced

Figure 3: showing the master cylinder.

Bleeding the clutch system.

If the hydraulic system has been opened to replace either a

clutch slave cylinder or master cylinder or both, air has to be
bled from the system. Fill the master cylinder with brake fluid
and open the bleeder valve at the slave cylinder. Gravity should
force the brake fluid to flow downward, expelling any trapped
air that may be in the system. When brake fluid starts to drip from the bleeder valve, close the
bleeder valve and check the clutch for normal operation. Sometimes depressing the clutch
pedal slowly as an assistant opens the bleeder valve at the slave cylinder will force any trapped
air out of the system. This is called manual bleeding and should be repeated as necessary until
the normal operation of the clutch returns.

NOTE: Most technicians who are experienced in clutch service know that some vehicles
are extremely difficult to bleed. Often it is necessary to use special service tools to either
vacuum bleed or pressure bleed the system.

PRESSURE BLEEDER.

A pressure bleeder is a pressurized container that holds brake fluid and is connected to
the clutch master cylinder reservoir.

To use a pressure bleeder, the reservoir cap is removed, and the pressure bleeder is
attached in its place. The bleeder is then pressurized to force brake fluid through the
system, expelling air bubbles.

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 The bleeder valve on the clutch slave cylinder is opened to allow air and fluid to
escape until no air bubbles are present.

2.20 FUEL SYSTEM.

Diesel Fuel

Diesel fuel is a thicker fraction (part) of crude oil. Diesel fuel can produce more cylinder
pressure and vehicle movement than an equal amount of gasoline.

Note Do Not Switch Injectors

In the past, it was common practice to switch diesel fuel injectors from one cylinder to another
when diagnosing a dead cylinder problem. However, most high-pressure common rail systems
used in new diesels utilize precisely calibrated injectors that should not be mixed up during
service. Each injector has its own calibration number.

Testing for resistance of glow plugs

Glow plugs increase in resistance as their temperature increases. All glow plugs should have
about the same resistance when checked with an ohmmeter. A similar test of the resistance of
the glow plugs can be used to detect a weak cylinder. This test is particularly helpful on a diesel
engine that is not computer controlled. To test for even cylinder balance using glow plug
resistance, perform the following on a warm engine.

1. Unplug, measure, and record the resistance of all glow plugs.

2. With the wires still removed from the glow plugs, start the engine.

3. Allow the engine to run for several minutes to allow the combustion inside the cylinder to
warm the glow plugs.

4. Measure the plugs and record the resistance of all glow plugs.

5. The resistance of all glow plugs should be higher than at the beginning of the test. A glow
plug that is in a cylinder that is not firing correctly will not increase in resistance as much as the
others.

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Figure 4: showing a glow plug.

2.30 CHARGING SYSTEM.

2.31 BATTERY STATE OF CHARGE

The charging system can be tested as part of a routine vehicle inspection or to determine the
reason for a no-charge or reduced charging circuit performance. The battery must be at least
75% charged before testing the alternator and the charging system. A weak or defective battery
will cause inaccurate test results. If in doubt, replace the battery with a known good shop
battery for testing.

2.32 CHARGING VOLTAGE TEST

The charging voltage test is the easiest way to check the charging system voltage at the battery.
Use a digital multimeter to check the voltage, as follows:

STEP 1 Select DC volts.

STEP 2 Connect the red meter lead to the positive (+) terminal of the battery and the black
meter lead to the negative (-) terminal of the battery.

STEP 3 Start the engine and increase the engine speed to about 2000 RPM (fast idle) and record
the charging voltage

2.33 SPECIFICATIONS FOR CHARGING VOLTAGE

The voltage should range from 13.5 to 15 V

If the voltage is too high, check that the alternator is properly grounded.

If the voltage is lower than specifications, then there is a fault with the wiring or the alternator.

If the wiring and the connections are okay, then additional testing is required to help pinpoint
the root cause. Replacement of the alternator and/or battery is often required if the charging
voltage is not within factory specifications.

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Figure 5: showing a scan tool used to dragonize charging system problems

Figure 6: showing a technician checking battery voltage present at the output of the alternator and
battery sense terminals if no voltage, then there is fault in the wiring.

2.40 STARTING SYSTEM.

To enable an internal-combustion engine to start up and run, the engine needs to be cranked at
a speed of around 100 rpm, which then enables the fuel to be atomized and the mixture to be
compressed sufficiently.

OVERVIEW The proper operation of the starting system depends on a good battery, good
cables and connections, and a good starter motor. Because a starting problem can be caused by
a defective component anywhere in the starting circuit, it is important to check for the proper
operation of each part of the circuit to diagnose and repair the problem quickly.

2.41 STEPS INVOLVED

STEP 1 Verify the customer concern. Sometimes the customer is not aware of how the
cranking system is supposed to work, especially if it is computer controlled.

STEP 2 Visually inspect the battery and battery connections.

The starter is the highest amperage draw device used in a vehicle and any faults, such as
corrosion on battery terminals, can cause cranking system problems.

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 STEP 3 Test battery condition. Perform a battery load or conductance test on the battery
to be sure that the battery is capable of supplying the necessary current for the starter.

STEP 4 Check the control circuit. An open or high resistance anywhere in the control circuit
can cause the starter motor to not engage.

Items to check include S terminal of the starter solenoid, Neutral safety or clutch switch,
Starter enable relay (if equipped), Antitheft system fault, (If the engine does not crank or start
and the theft indicator light is on or flashing, there is likely a fault in the theft deterrent
system.) Check service information for the exact procedures to follow before attempting to
service the cranking circuit.

STEP 5 Check voltage drop of the starter circuit. Any high resistance in either the power side
or groundside of the starter circuit will cause the starter to rotate slowly or not at all.

Table 1: showing starting system symptom guide.

Problem. Problem Possible Causes

1. Starter motor whines. 1. Possible defective starter drive; worn

starter drive engagement yoke; defective
flywheel; improper starter drive to flywheel
clearance.

2. Starter rotates slowly. 2. Possible high resistance in the battery

cables or connections; possible defective or
discharged battery; possible worn starter
bushings, causing the starter armature to drag
on the field coils; possible worn starter brushes
or weak brush springs; possible defective (open
or shorted) field coil.

3. Starter fails to rotate. 3. Possible defective ignition switch or neutral

safety switch, or open in the starter motor
control circuit; theft deterrent system fault;
possible defective starter solenoid.

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4. Starter produces grinding noise. 4. Possible defective starter drive unit;
possible defective flywheel; possible incorrect
distance between the starter pinion and the
flywheel; possible cracked or broken starter
drive-end housing; worn or damaged flywheel
or ring gear teeth.

5. Starter clicks when engaged. 5. Low battery voltage; loose or corroded

battery connections.

2.50 COOLING SYSTEM.

This system describes coolant-testing, operation of the thermostat, the radiator faults.

2.51 COOLANT TESTING.

1. Visual inspection.

Coolant should be clean and bright.

2. Freeze/boiling point.

A high freezing point or low boiling point indicates dilution (too much water).

3. Ph.

The wrong pH indicates buffer loss, which is used to help maintain the pH level.

4. Coolant voltage.

A high voltage indicates the wrong pH or a stray current flow.

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Figure 7: showing a hydrometer

Note.

The hydrometer measures the density of the coolant. The higher the density is, the more
concentration of antifreeze in the water. Most coolant hydrometers read the freezing and
boiling points of the coolant.

2.52 THERMOSTATS.

The thermostat controls the minimum normal temperature. The thermostat is a temperature-
controlled valve placed at the engine coolant outlet on most engines.

THERMOSTAT TESTING There are three basic methods used to check the operation of the
thermostat.

1. Hot water method. If the thermostat is removed from the vehicle and is closed, insert a
feeler gauge in the opening so that the thermostat will hang on the feeler gauge. The
thermostat should then be suspended by the feeler gauge in a container of water or coolant
along with a thermometer. The container should be heated until the thermostat opens enough
to release and fall from the feeler gauge. The temperature at which the thermostat falls is the
opening temperature of the thermostat. If it is within 5°F (4°C) of the temperature stamped on
the thermostat, the thermostat is satisfactory for use. If the temperature difference is greater,
the thermostat should be replaced.

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Figure 8: Checking the opening temperature of a thermostat.

2.53 WATER PUMPS

This pressurizes the coolant in circulation throughout the engine.

Figure 9: showing a corroded water pump that needs to be serviced.

2.54 RADIATORS

The radiator is a liquid-to-air heat exchanger that consists of two tanks and a core or matrix
from which heat is radiated from the coolant to the air.

Table 2: showing radiator faults and maintenance repair.

Radiator faults. Radiator maintenance repair.

I. Clogged radiator. 1. Flushing and cleaning.

II. Rusting of the radiator. 2. Flushing and cleaning.

III. Damaged fins. 3. Replace.

2.70 SAFETY AND PRECAUTIONS.

2.71 Safety tips

Disconnect the Battery Before Work Begins

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It is always a safe idea to disconnect the negative (-) battery cable before performing major work to the

Breathing gear.

vehicle as a safety precaution.

Shop Cloth Disposal

Always dispose off oily shop cloths in an enclosed container to prevent a fire, whenever oily cloths are
thrown together on the floor or workbench, a chemical reaction can occur, which can ignite the cloth
even without an open flame. This process of ignition without an open flame is called spontaneous
combustion

Do not use incandescent trouble lights around gasoline or other flammable liquids. The liquids can cause
the bulb to break and the hot filament can ignite the flammable liquid that can cause personal injury or
even death.

2.72 Safety precautions.

1. Ensure PPEs before starting any task in the workshop

Figure 10: safety gears to be considered before operating any task in workshop.

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 Face gear.

Hand gloves.

Saftety shoes.

Full overall.

Hearing gears.

Table 3: showing protective gears.

CHAPTER THREE
3.00 METHODOLOGY

This chapter describes various methods carried out during the inspection and repair of the college
pajero.

3.10 Inspection and repair.

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3.11 Clutch system.

Inspection.

The clutch system was inspected visually by looking at both the master and slave cylinder.
These were badly corroded this called replacement rather than over hauling them.

The brake fluid passage were all disconnected

For the above inspection, I noticed that the clutch pedal free play adjustment would be needed.

Repair.

I replaced a new master cylinder and a new slave cylinder, tightly connected back the brake
fluid lines an them replaced a new brake fluid in the clutch system.

I adjusted the clutch pedal free play by bleeding the clutch system.

3.12 Fuel system.

Inspection.

I inspected the fuel system visually by looking for signs of rust and corrosion and leaks on fuel
lines and the fuel tank, I then inspected the diesel filter whether the drainage plug was in good
condition and the diesel filter itself, then I inspected the fuel injector pump, I also inspected the
injectors for signs corrosion and damage.

The inspection I made as I have explained gave the following results; the hose pipe that links
the diesel filter to the injector pump was worn out and required replacement, clogged diesel
filter which called for replacement of a new one, the injector nozzles were still okay’ the hose
clamps were also missing.

Repair.

I placed a new hose that links diesel filter and the injector pump.

I serviced the injector pump and then placed a new bangle nut.

3.13 Cooling system.

Inspection.

I inspected the cooling system an found the following faults;

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The radiator was corroded, the radiator pressure cap was missing, the hosepipes were worn
out, the clamps were missing, the fan belt was worn out and the expansion tank needed
replacement with a new one since it was badly worn out.

Repair.

I flashed and cleaned the radiator to remove sludges and rust, I replaced a new radiator
pressure cap, I replaced worn out hose pipes with new ones and then placed new clamps,
finally I replaced a new fan belt and expansion tank.

3.14 Braking system.

Inspection.

I made inspection on braking system visually by looking at the braking system. In the inspection,
I found the faults below;

Worn out brake pads and brake shoes, worn out break adjusters, clogged slave cylinder and
master cylinder, grooved brake disc. Missing brake fluid.

Repair

I replaced new brake pads and brake shoes, rear brake adjustors, I over hauled the slave and
master cylinders, resurfaced the brake discs and then I added braking fluid after I bled the
braking system.

3.15 Charging system.

Inspection.

During the inspection on charging system, I realized the battery and battery terminal were
missing, the alternator belt was missing but the alternator was in good condition

Repair.

I replaced a new battery starting with the positive battery. I replaced the missing terminals with
new ones and I assembled the alternator back then placed the fan belt

3.16 Starting system.

Inspection

When inspecting the starting system, I realized the starter motor was in good condition but it
had lose connection, the ignition switch was missing and the starter relay was missing.
15
Repair.

I used a multimeter to locate the start position on the ignition switch before installing it. I
tightened the starter motor connections and I installed the new starter relay.

3.17 Steering system.

Inspection.

Inspecting the steering system, I discovered the steering pump was missing, the steering pump
belt was missing, the steering reservoir was also missing and the steering fluid was required.

Repair.

I replaced a new steering pump, steering pump belt, steering reservoir and then added steering
fluid in the system.

3.18 Lubrication system.

Inspection.

Inspecting the lubrication system, I used a dipstick to check engine oil level and its state of
service then I checked differential fluid using an inspection plug, then i checked the manual
transmission oil by removing the fill plug. The oil filter was corroded and needed replacement.

The engine oil level was okay but milky, the differential oil had exceeded the manufactures
recommendations and the manual transmission fluid had metal particles.

Repair.

I changed engine oil, differential oil, manual transmission oil and changed oil filter for a new a
one.

3.19 The engine.

Inspection

I inspected the engine glow plugs using a multimeter for their resistance, continuing with the
inspection I found that the cylinder head was worn out, the air filter was chocked. I also inspect
the timing belt but it was good condition.

Some of the glow plugs had lost resistance

Repair.

16
I replaced glow plug that had lost resistance with new ones, I replaced a new air filter and a
new cylinder head.

17
 CHAPTER FOUR
4.00 VEHICLE TO REPAIR

REG NO. UM2323

MODEL: PAJERO
MAKE: MITSUBISHI
ENGINE NUMBER:4D56

Figure 11: showing the vehicle that was repaired.

1.2List of tools and equipment’s
Spanners, Pliers, Screwdriver, Magnet, multi meter, Car jerk

18
Figure 12 showing some of tools that were used during the repair.

Figure 12.1: cleaning the work space

19
Figure 12.2: showing parking vehicle on level ground.

Figure 12.3: showing wedging the vehicle.

20
4.10 CLUTCH SYSTEM.
The clutch system in a vehicle is a crucial component that facilitates the
transfer of power from the engine to the transmission, allowing for smooth
gear changes and control of vehicle speed. At its core, the clutch system
consists of three main parts: the clutch pedal, clutch disk, and pressure
plate.
Table 4: Components of a clutch system, inspection report and repairs that I made.
Components. Inspection report. Repair.

Master cylinder Faulty. Replaced another one.

Slave cylinder. Good condition. The slave cylinder was inspected and it
was found that it had no faults.

Clutch fluid. Contaminated. The clutch fluid was replaced since the
old one was contaminated.

Figure 13: Showing the old master cylinder that was removed from the vehicle.
The release lever were inspected for wear, the clutch disc plate was
inspected, the shift lever and thrust bearing were also inspected and these
were all okay.

Testing

After replacing components the clutch system was tested for proper operation, Leaks and
smooth engagement and disengagement of the clutch is checked and ensured adjustment of
the clutch pedal free play according to the manufacturer specifications.

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4.20 FUEL SYSTEM
The fuel system in a vehicle is responsible for delivering the proper amount
of fuel to the engine for combustion, ensuring optimal performance and
efficiency.
Table 5: showing fuel system components, inspection report and repairs that were made.
Component Inspection. Repair.

Fuel filter. This was inspected and The fuel filter was pumped to suck fuel from
results gave a corroded the fuel sump; this managed to show leakages
fuel filter that required a because of loose connections. This helped us
new fuel filter, this was to recognize the leakages and we managed to
replaced. tighten all loose connections

Fuel injector. The fuel injector pump I opened the banjo bolt, thoroughly cleaned it,
was inspected and we cleaned the inside of the pump and the fuel lift
found out that it was pump was assembled back. Pumping again,
corroded around the the fuel could then come out with much higher
banjo bolt and it pressure.
couldn’t do it operations
rightfully.

Fuel. Good condition. The fuel was okay but just made some
addition of more fuel

Figure 14: The fuel injector pump.

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4.30 COOLING SYSTEM
The cooling system in a vehicle is essential for regulating the engine’s temperature and preventing
overheating.

4.31 Functions of the cooling system.

To clean the engine.

To cool engine.

To air in super chargers and turbo chargers.

Table 6: The cooling system components, inspection report and repair.

Component Inspection Repair

Radiator Through the inspection This had a solution we took by flashing the
made, I realized the radiator to the point of all sludges moving out.
radiator was clogged.

Radiator cap Inspection made helped For this, the head of department managed to
us realize the radiator get a new cap that we could replace.
cap was missing.

Radiator hose pipes During the inspection New hosepipes were replaced.
on the cooling system,
we evidenced swollen
hosepipes and some
were almost bursting.

Hose pipe clamps I realized during the New clamps were installed ensure the hose
inspection that clamps pipes are held tight to the radiator and the
were missing. engine.

Fan belt Visually inspecting, we I got a new fan belt installed.

noticed the fun belt
worn out and almost
breaking because of
the cracks we saw on
this belt.

Expansion tank The expansion tank This was replaced with a new expansion tank.
was so much corroded
and broken.

Procedures to service the radiator.

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The radiator was removed from its mounting by untightening the bolts

A container was placed below the radiator’s drain valve.

The drain valve was untightened to allow the contaminated coolant out of the radiator
completely.

The radiator was removed and flushed.

After flushing the radiator, it was placed back correctly.

Figure 15: Radiator safely removed out of the vehicle for flushing

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4.40 BRAKING SYSTEM
The braking system is responsible for slowing down or stopping the vehicle safely

Table 7: Repair and maintenance of breaking system.

Components Inspection report. Repair.

Brake pads Worn out. These were replaced with new ones.

Brake shoes Worn out. These were also replaced with new ones.

Rear brake adjusters Worn out. We managed to replace these with new ones.

Brake slave cylinder Clogged. This was properly serviced and then
assembled back.

This slave cylinder is placed on each wheel of

the vehicle.

Brake fluid Required. The head of department provide the brake

fluid and i managed.

Discs Grooved. These were properly resurfaced and

assembled back correctly.

Brake master cylinder This was dirty and This was serviced and placed back correctly.
corroded.

Figure 16:The servo and master cylinder for the braking system.

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4.50 CHARGING SYSTEM
The charging system in a vehicle is responsible for generating electrical power to recharge battery and
supply electricity to the vehicle’s electrical components.

2.51Battery
A new battery was installed since it missed one.

The battery was tested on its performance using a multimeter for the battery voltage, and
hydrometer for its specific gravity.

Below in the diagram, is the battery to be replaced in the vehicle.

Functions of a battery

 The battery is essential for starting the engine

 Supplies electrical energy to all electrical components of a vehicle when the vehicle
engine is not running.

Figure 17 showing a vehicle battery.

Table 8: showing the charging system components, inspection report and repair that were made.
Component. Inspection report. Repair.

Battery. Missing. The missing battery was replaced with a new

one.

Battery terminals. Missing. The missing battery terminals were replaced

with new ones.

Alternator belt. Missing. This was also replced with a new one

Alternator. Good condition. The alternator was okay.

And this was assembled back.

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Figure 18: showing Diagram showing alternator

The alternator charges the battery as the vehicle is moving since the alternator needs drive from
the engine to operate.

The alternator also supplies electricity to all electrical components of the vehicle.

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4.60 STARTING SYSTEM.
The starting system in a vehicle is responsible for initiating the engines operation.

The starting system essentially consists of;

Starter motor

Ignition switch

Battery

Table 9: Inspections and repairs made on starting system.

Components Inspection report. Repair.

Starter motor The starter motor was The starter motor was assembled back.
checked and inspected but it
had no fault.

Ignition switch Through the inspection, i This was replaced back after finding zero
noticed the ignition switch faults.
was missing.

Battery Missing. The battery was replaced with a new

one.

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4.70 STEERING SYSTEM
The steering in a vehicle is responsible for allowing the driver to control direction of the vehicle’s
movement with ease.

Importance of steering system.

To ensure self-center effect.

Provide easier steering.

It allows the vehicle take different directions.

Table 10: Inspection and repairs on the steering system.

Components Inspection repair
report.

Power steering pump Missing. The power steering pump was replaced with
the new one.

Steering belt Worn out Replaced with a new one.

Steering fluid reservoir Missing Replaced a new one.

Steering linkages Worn out Replaced with new ones.

Steering fluid required Added the steering fluid to maximum.

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4.80 LUBRICATION SYSTEM
The lubrication system is responsible for reducing friction between moving parts thereby minimizing
wear and tear and ensuring smooth engine operation.

Importance of the lubrication system.

To cool the engine.

To clean the engine.

To minimize were between moving parts in the engine

Table 11: Inspection and repair of lubrication system.

Component Inspection Repair.
report.

Engine oil Out of service The engine oil was changed and replaced with
a new oil.

Differential fluid Out of service. The differential fluid was drained and replaced
with a new differential fluid.

Manual transmission oil Out of service. Transmission oil was drained and replaced
with a new one.

greasing Needed Greasing was done for all the required areas.

Oil filter Corroded. This was replaced with a new one.

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4.90 THE ENGINE SYSTEM.
The engine system in a vehicle is the heart of its powertrain, responsible for generating mechanical
energy to propel the vehicle

Functions of the engine.

To generate power to propel the engine.

To power the alternator which generates electricity.

To generate mechanical power by combustion of fuel.

Table 12: Engine inspection and repair.

Component Inspection report Repair

Glow plugs. Lost resistance Replaced new ones

Timing belt Still good Assembled back

Air filter Chocked A new one was replaced

Cylinder head Worn out It was replaced.

Figure 19: Applying silicon on the gasket to enable proper sealing of engine, this prevents leakages.

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 CHAPTER FIVE
5.00 CHALLENGES.
Lack of skills and experience
Limited working space caused overcrowding.
Insufficient tools for all trainees (hoists, car jacks.)
Limited time to finish the project.

5.10 CONCLUSION.
In conclusion i managed to acquire practical skills.

I manged to diagonise and identified all vehicle mechanical issues.

I managed to repair the college pajero faults

5.20 RECOMMENDATIONS.
Trainees should be given adequate time to do their project.
Trainees should give more working space to prevent overcrowding.
Purchasing these materials before the project time.
The college should get technicians to repair the un covered parts of the college pajero.

5.30 REFERENCES
Automotive technology 4th edition by James D. Halderman-1.

Hillier’s fundamental of motor vehicle technology (Book 1) 5th Edition

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5.40 APPENDIX

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