report on automobile internship.pdf

7/29/2019 Report on Automobile internship.pdf

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A TECHNICAL REPORT

ON THE

STUDENTS IN WORK EXPERIENCE SCHEME (SIWES)

UNDERTAKEN AT

GENAIS AUTO COMPANY

54/56, SALVATION BUS STOP, OPEBI ROAD, OPEBI, LAGOS

COMPILED AND SUBMITTED

BY

OYEWOLE, David Olatunde

MEE/08/3547

TO

THE MECHANICAL ENGINEERING DEPARTMENT

FEDERAL UNIVERSITY OF TECHNOLOGY, AKURE

IN PARTIAL FULFILMENT OF THE REQUIREMENTS FOR THE AWARD OF

A BACHELORS DEGREE IN MECHANICAL ENGINEERING

DECEMBER, 2012


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Certification

This is to certify that this report is based on the knowledge and skills gained by me,

OYEWOLE, David Olatunde during my months of Industrial Training experience at

Genais Auto Company located at 54/56, salvation bus stop, Opebi road, Opebi, Lagos

State, Nigeria.

OYEWOLE, David Olatunde

(MEE/08/3547)

Signature and Date

Mr Felix Vinyo

Technical Director

Signature and date


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Dedication

In loving memory,

OYEWOLE, Johnson Adebayo

Till we meet to part no more

You will forever live in my heart.


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Acknowledgement

All glory to God for a successful Industrial Training exercise. Special thanks to the

management and staff of Genais Auto Company for giving me a chance to see first-hand, and

engage in the practical aspects of my course of study.

My profound gratitude goes to my parents, Mr and Mrs Oyewole, and my siblings for

believing in me, for the love, care and support given in cash and kind. Even though it has not

been easy on your finances, still you have decided to give me a chance at every necessary

junction of my life. May God bless you and cause you to increase on every side.

Also, my heartfelt appreciation goes to the Head of Department (past and present),

Lecturers, Technologists, Technicians, and the non-academic staff of the Mechanical

Engineering Department of the Federal University of Technology, Akure. The immense man-

hours invested into us, in and out of class as students, shall yield wonderful fruits to the benefit

of humanity in Jesus name. I pray that the Almighty God increase you in all directions. God

bless you.

I say a big thank you to my dearie, Chi, for standing by me through the trying times. I

wont fail to appreciate my roommate, Okatahi Joe, and my housemates in Hinterland III, Elijah

Adeoye, Lanre and Ope (The Dadas), and to the countless others I wont be able to mention due

to time and space constraints. My heartfelt prayer for us is that God will lift us all to the peak

points in our lives in Jesus name.

Lastly, to the innumerable people who are not mentioned here, not because of their

insignificance, but due to time and space limitations, thank you for being there for me even when

it was inconvenient. I pray for you that you will always matter where it matters in Jesus name.

Amen. God bless us all.


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Table of Contents

Certification ..................................................................................................................................... 2Dedication ....................................................................................................................................... 3Acknowledgement ........................................................................................................................... 4List of Tables ................................................................................................................................... 7List of Figures ................................................................................................................................. 8Abstract ........................................................................................................................................... 91. INTRODUCTION ................................................................................................................. 10

1.1 Historical background of Genais Auto Company........................................................... 101.2 Location .......................................................................................................................... 101.3 Organisational Structure of the Company ...................................................................... 101.4 Company Policy and Terms of Service .......................................................................... 111.5 Services offered by the Company ................................................................................... 12

2. OIL SERVICE ....................................................................................................................... 132.1 Service tools ................................................................................................................... 142.2 Service Procedure ........................................................................................................... 152.3 Maintenance of service equipment ................................................................................. 16

3. COMPUTER DIAGNOSIS................................................................................................... 173.1 Error Codes ..................................................................................................................... 183.2 Diagnostic Devices ......................................................................................................... 19

3.2.1 On-board Diagnostic tools (OBD) .......................................................................... 193.2.2 PC-based Diagnostic tools ...................................................................................... 20

3.3 Diagnosis Procedure ....................................................................................................... 203.4 Maintenance of Diagnostic Devices ............................................................................... 21

4. GENERAL REPAIRS ........................................................................................................... 224.1 Engine repairs and replacement ...................................................................................... 224.2 Brake pad replacement ................................................................................................... 24


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4.3 Shock absorber replacement ........................................................................................... 255. CONCLUSION AND RECOMMENDATION .................................................................... 27

5.1 Conclusion ...................................................................................................................... 275.2 Recommendation ............................................................................................................ 27

REFERENCES .............................................................................................................................. 28


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List of Tables

Table 3.0 Digits in third place holders and their interpretations as related to the Powertrain.


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List of Figures

Figure 1.0 Organisational chart of Genais Auto Company

Figure 2.0 Some service tools and service materials

Figure 2.1 Removal of Oil filter with an oil filter remover during a service operation

Figure 3.0 An On-board Diagnostic (OBD-II) scanner, Genisys, in use

Figure 3.1 an On-board diagnostic (OBD) scanner

Figure 3.2 A PC-based diagnostic tool in use

Figure 4.0 A 4-cylinder gasoline-combusting, spark-ignition engine undergoing repairs

Figure 4.1 A hydraulic jack used for general repairs

Figure 4.2 An engine block


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Abstract

The importance of vehicles is an issue that cannot be overemphasized as the daily routine

of most individuals entails the interaction with vehicles to go about businesses and move people

and goods from one place to another. This implies that with the breakdown of vehicles, our lives

and businesses tend to experience a noticeable amount of stress compared to what it was before

the breakdown. This brings up the issue and ultimately the business of automotive maintenance

and repair. With the possibility of a breakdown on ones mind, the menacing topic of automotive

maintenance cannot be taken with levity.

This usually comes in form of questions like when should a car be serviced? How are

brake pads fixed or removed? How often should a service operation be done on a vehicle? How

can problems be easily detected in a vehicle? Is it possible to detect faults in a vehicle by using a

computer?

This technical report on the Students In Work Experience Scheme (SIWES) exercise

undertaken at Genais Auto Company, attempts to answer these questions using everyday

language. In cases where a seemingly clear answer is not available, this report hopes to shed

more light and at least create a clearer picture in the mind of the reader.


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CHAPTER ONE

1. INTRODUCTION

1.1 Historical background of Genais Auto Company

Genais Auto Garage (also called Genais Auto Company,) was set up in 1998 by the

CEO, George Umo. Starting on a rather low budget, it has grown over time to be a highly

sophisticated service centre laced with the responsibility of making sure that todays automobiles

with their computers on-board, stay functional.

From staff strength of four at its inception to twenty in 2007, its professional composition

has increased. The CEO being a seasoned engineer with great passion for the automobile, has not

stopped at his quest to acquire the best in diagnostic equipment and qualified staff in order togive customers vehicles the best of care and all round protection from break downs.

1.2 Location

Genais Auto Company is situated in the city of Lagos, the nations commercial capital, at

54/56, Salvation bus stop, Opebi road, Ikeja, Lagos State. This choice location gives the

company the much needed positioning for its clientele base as it opens the company to customers

from the Lagos mainland and the Lagos Island.

1.3 Organisational Structure of the Company

Fig. 1.0 Organisational chart of Genais Auto Company


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The figure above (Fig. 1.0) shows the organisational structure of the company. With a

staff strength of twenty (interns not included), the company is jointly run by the Chief Executive

Officer, Mr George Umo, who also acts as the Managing Director and Mr Felix Vinyo, the

technical director.

1.4 Company Policy and Terms of Service

As part of the companys policy and terms of service, every vehicle that gets admitted for

a service is subjected to vehicle inventory or vehicle check. Vehicle inventory is the intensive

examination of a vehicle that comes to the auto garage for a service, which may be any of the

following: vehicle service, engine repairs and replacement, body works, etc. It is a way in which

the company ascertains the integrity of a vehicle that comes into the garage for any job. In this

exercise, all parts and sections of the vehicle are checked and their conditions, whether working

or bad are noted and recorded.

The vehicle inventory is done in triplicates- a white copywhich is the customers copy; a

blue copy which is kept at the administrative office on which the items used and/or replaced in

the course of the repairs are noted, and a pink copy which is kept at the garage shop for future

reference.

To execute a vehicle inventory, the first thing to be done is to fill in the date and time of

the vehicles arrival. This is followed by details of the vehicle such as the manufacturer, the

vehicle model, the year of production, the engine type, the mileage of the vehicle, the registration

number and the chassis number.

The next thing after this is to take the customers details; the vehicle owners name and

telephone number, e-mail address, and home or office address (whichever the customer wishes to

give). After the customers details, the complaints of the customer are noted. These range from

common problems such as brake pad replacements, oil service, etc. to more complex ones like

faulty transmission systems, vehicle height calibration, etc.

After taking details of the vehicle, the customer and the complaints, the vehicle inventory

exercise goes into full swing. The things checked range from the fuel level to side mirrors, door

openers (inner and outer), door panels, window winds, windows, carpets, latches (hood, fuel and

trunk latches), the lights (headlights, parking lights, signal lights, etc.), tyres, rim size, tools, etc..

The inventory is concluded by attaching the name of the executant and date. The customer is

then given the document to append his name and signature in agreement with the information

therein.


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As part of the companys policy, a new intern is required to stay at this exercise for a

minimum of two weeks. This is to enable the intern to fully grasp the importance of the exercise.

The advantage of vehicle inventory is that in the advent of any claims of damages by a client, the

inventory done on such vehicle can be easily accessed and checked to confirm the integrity of

the customers claims and in most cases exonerate the company of such damage claims.

1.5 Services offered by the Company

The services offered by the company include:

Oil or Lube service,

Computer diagnosis,

Body works,

Engine repair and replacement, and

General repairs.

The different services offered at Genais Auto Company are discussed in detail in

subsequent chapters.


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CHAPTER TWO

2. OILSERVICE

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 usually

specified by the vehicles manufacturer in a service schedule and some modern cars display the

due date for the next service electronically on the instrument panel.

At Genais Auto Company, the vehicle service is carried out in the pit. The pit is a

compartment dug into the ground over which the vehicle will be parked. This location is ideal

because it creates the necessary space required by the mechanic to conveniently inspect the

underside of the vehicle and to drain the spent engine oil from the engine sump since it is located

at the downside of the engine. In cases where the pits have been occupied by other vehicles, theservice operation takes place at the vehicle lift. After service, the vehicle and engine are cleaned

and released to the customer.

The completed services are recorded electronically on a database by the service centre

upon the completion of each service. However, with recent customer demands, customer service

records can now be printed from the database.

At the completion of the vehicle service procedure, the engine and the vehicle body is

cleaned thoroughly so as to rid it of greasy and oily stains that might have come about during the

service.

Maintenance tasks during a vehicle service include;

Engine oil replacement

Oil filter replacement

Replacement of air filter

Cleaning/Replacement of spark plugs

Level check and refilling of brake fluid

Level check and refilling of power steering fluid

Level check and refilling of automatic transmission fluid

Inspection and replacement of the timing belt, if needed

Inspection of condition of the tyres

Other parts in the vehicle that are also checked and advised upon include the following:

Battery Engine components, etc.


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Fig 2.0 Some service tools and service materials

The necessary tools and materials are shown in the fig. 2.0. The tools required for a

service operation include sets of sockets, spanners, screwdrivers, ratchets, extension bars and the

T-bar. Necessary materials for a service operation include engine oil, motor flush, oil filter, and

oil supplement.

2.1 Service tools

Some of the tools used for a typical service exercise are highlighted below:

Mechanical jack (hydraulic or electric),

Axle stand,

Funnel,

Set of sockets,

Set of spanners, Ratchet and extensions, etc.

Hydraulic jack: A mechanical jack is a device which lifts heavy equipment. It works on the

principle of pressure transmission. Mechanical jacks are usually rated for a maximum lifting

capacity. A hydraulic jack uses a fluid, which is incompressible, that is forced into a cylinder by

a pump plunger. Oil is used since it is self-lubricating and stable. In the case of electric lifts,

electrical power is required. The electric lift used at Genais Auto Company has a maximum

lifting capacity of 4100kg. The jack is used in lifting the vehicle in order to create enough

clearance for work to be done underneath it.


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Axle stand: Axle stands are tripod-shaped bodies used in keeping a suspended vehicle parked

while work is being done underneath it. After lifting the vehicle to the desired height using a

mechanical jack, it is used to keep the vehicle at that height. It is much safer as the risk of failure

of a hydraulic jack is greatly reduced.

Set of spanners: The set of spanners contains spanners of various sizes. The spanners are used

to loosen the guiding nuts of the protector covering the underside of the vehicle, especially when

the protector is hindering access to the engine sump. Other nuts and/or bolts that need to be

removed to access the oil sump can also be removed with the spanners.

Ratchet: A ratchet is a mechanical device that allows continuous linear or rotary motion in only

one direction while preventing motion in the opposite direction. A ratchet makes it easy to

loosen nuts since it eliminates the stress caused by using a spanner.

2.2 Service Procedure

A sample service exercise at Genais Auto Company is described below:

Location: In the pit, the electric lift or on the ground using manual hydraulic jacks.

Required tools: Ratchet, Extensions, Sockets, Oil filter remover, T-nut remover, air blower and

gun

Necessary Items: Engine oil, Oil flush, Oil supplement, Oil filter, Fuel treatment and Air filter

(if necessary)

Procedure:

1. Pour the Oil flush into the engine. This removes every trace of sludge formed in the

engine. The amount of flush required varies with the engine type. For four and six

cylinder engines, a can of flush is adequate but engines with more cylinders require two

cans of flush.

2.

Start the engine and leave it running for some minutes (recommended time, 20 minutes)

so that all the sludge present will dissolve completely into the engine oil.

3. If the underside of the engine has a protector shielding the engine sump, remove it.

4. With the aid of the T-nut remover and the appropriate socket, remove the retaining bolts

of the engine sump to drain the oil. Drain the spent engine oil.

5. Use the Oil filter remover to remove the Oil filter.

6. Replace the retaining bolt in position to prevent oil leaks.

7.

Replace the Oil filter with a new one.


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8. Pour the new engine oil and the Oil supplement into the engine. The volume of Engine

oil and oil supplement used is a function of the engines capacity.

9. Check the Engine oil level. Ensure it is filled to the maximum level.

10.Remove the Air filter from the air cleaner in the engine. Blow off the dust particles

trapped in it with the aid of the Air blower and gun. Replace the Air filter.

11.Check the level of the engine fluids such as brake fluid, power steering fluid and

transmission fluid.

12.When the fuel is to be supplied, add the Fuel treatment. This reduces the fuel

consumption rate and the rate of emissions of waste gases.

13.Clean the engine and body of the vehicle to rid it of any oily or greasy stains.

The vehicle is then ready to leave the garage.

Fig. 2.1 Removal of Oil filter with an oil filter remover during a service operation

2.3 Maintenance of service equipmentThe tools are kept in a dry place free from humidity in the store. For tools that require

special fluids for proper functioning, such as the hydraulic jack, the fluid level is checked from

time to time and refilled when necessary. Other tools that have special storage compartments

such as ratchets, sockets and spanners are properly cleaned and replaced immediately after use.

Tools like the axle stands used in the suspension of vehicles while work is done underneath them

are kept in the store far from open space in order to prevent them from rainfall, which will

ultimately lead to corrosion.


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CHAPTER THREE

3. COMPUTER DIAGNOSIS

Computer diagnosis of a vehicle is the use of specially built computers called scanners,

to run certain tests on the vehicle in order to ascertain the working condition, detect errors and

faults in the engine and to sometimes (in the advent of error codes), clear errors from the vehicle

computers memory. Sometimes, a generic computer may also be used as a scanner if it is

connected to a scanner kit and the scanners software is installed on it. The computer is

connected to the vehicles master computer (precisely, through the Assembly Line Diagnostic

Link,ALDL) by a special cable via one of its universal serial bus ports (USB ports).

Popular scanning programs that run on computers include Abrites, VCDS, SDD, All

Data, etc. There are various types of scanners used in the automotive industry. These range from

on-board diagnostic scanners (OBD) to laptop computers. At inception, the company started with

an On-board diagnostic scanner but with latest innovations in the automotive industry, the firm

has evolved. Now armed with the latest technology in automobile diagnosis, more vehicle brands

can now be easily diagnosed and repaired.

To run the diagnosis, the scanner or computer is plugged into the Assembly Line

Diagnostic Link (ALDL). The engine is turned to the ON position via the key and the promptsdisplayed on the screen of the scanner are followed. The scanner then presents results in codes

which represent faults and errors the scanner has detected in the vehicle.

Fig 3.0 An On-board Diagnostic (OBD-II) scanner, Genisys, in use


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3.1 Error Codes

Error codes are alphanumeric representations of the faults detected by the scanner in a

vehicle. Each error code on a scanner starts with one of the following letters:

1. B: faults related to the body

2. C: faults related to or stemming from the chassis.

3. U: faults originating from the networkof the vehicles components.

4. P: faults stemming from the Powertrain.

The letter is followed by four digits that correspond to a specific error. The first digit is

used by the automaker for specialty codes while the second digit represents specific problems.

The last two digits indicate a subsection in the area with the detected problem. The error

codes can be checked on the automakers website depending on the type of scanner used. Some

scanner software provides diagnostic wizards that display interpretations for the codes and

possible scenarios for fixing problems.

The number 0 in the second place holder is a generic code shared by all automakers but

some manufacturers use a specific code, so the number 1 may appear. The third place holder

determines the area of the problem.

Table 3.0 Digits in third place holders and their interpretations as related to the Powertrain.

Code Interpretation

0. Fuel and Air metering and Auxiliary Emissions Control

1. Fuel or air problem

2. Fault in injector circuit

3. Ignition problem or engine misfiring

4. Auxiliary Emissions Control problem

5.

Vehicle speed or idle control problem

6. Computer or output circuit problem

7. Transmission related problem

8. Transmission related problem

The third and fourth digits of the diagnostic report further identify the subsection of the

malfunctioning system. Generally, the error codes that appear from the diagnostic report vary by

vehicle make and manufacturer preference.


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An example of an error code could be P0122. This error code can be interpreted as

follows; Throttle Position Sensor/Switch A Circuit Low Input. This code means that the cars

computer has detected a fault connected to the powertrain that the TPS (Throttle Position Sensor)

is reporting too low a voltage. On some vehicles that lower limit is 0.170.20 volts.

Some scanners can monitor Mass Air Flow (MAF) and engine revolutions per minute

(RPM) or determine if the car will pass an emissions inspection. When done with the diagnosis

and repairs, the errors are cleared and any associated warning lights such as Check Engine Light,

Tyre Pressure light are turned off.

Computer diagnosis is very efficient because it saves time since it reduces the workload

and time taken to humanly test the components one after the other, which may lead to the

jeopardy of the components.

3.2 Diagnostic Devices

The tools and devices used during a diagnosis operation are referred to as diagnostic

devices. The devices used during a diagnosis at Genais Auto Company range from specially built

On-board diagnostic (OBD-II) scanners to laptop computers. The diagnostic softwares that run

on computers are referred to as PC-based diagnostic tools.

3.2.1 On-board Diagnostic tools (OBD)

OBD is an automotive term referring to a vehicles self-diagnostic and reporting

capability. OBD systems give the vehicle owner or a repair technician access to state of health

information for various vehicle sub-systems. The OBD scanner used at Genais Auto Company is

an OBD2 type scanner.

Fig. 3.1 an On-board diagnostic (OBD) scanner


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3.2.2 PC-based Diagnostic tools

Some specially designed diagnostic softwares also run on computers. Such diagnostic

softwares are referred to as PC-based diagnostic tools. Examples of such softwares used at

Genais Auto Company include All Data, Abrites, SDD, VCDS, etc.

Fig. 3.2 A PC-based diagnostic tool in use

3.3 Diagnosis Procedure

A typical computer diagnosis exercise on a vehicle at Genais Auto Company is described

below:

Required tools/devices: On-board diagnostic scanner or a laptop with PC-based diagnostic

software, an OBD or USB connector.

Procedure:

1. With the vehicle engine in its OFF mode, plug the OBD scanner or laptop computer to

the Assembly Line Diagnostic Link (ALDL) via the OBD or USB connector.

2. If the device being used is a multi-platform device, i.e. runs on various vehicles, select

the manufacturer, year of vehicle manufacture, model of the vehicle, engine type, and all

other relevant information as required by the diagnostic device.

3. Turn the ignition to the ON mode.

4. Follow the prompts on the screen to initiate the diagnosis.

5. When the diagnosis is complete, take note of the error codes.

6. Turn off the ignition, and the scanner.

7. Clear the screen and turn the scanner off. Repeat steps 3 to 5. This helps to remove wrong

errors from the scan results hereby giving better results.8. When done, clear the screen, and turn off the engine ignition and turn off the scanner.


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3.4 Maintenance of Diagnostic Devices

The diagnostic devices are kept in their special storage packs so as not to hamper their

safety. The laptop computers used in diagnosis are always kept charged so that in the case of

power failure, diagnosis can still be run on their battery power. It is also ensured that the laptops

are free from malicious software and spyware. For the PC-based softwares, it is ensured that new

updates are downloaded and installed when available.


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CHAPTER FOUR

4. GENERAL REPAIRS

A general repair as implied in this chapter refers to repairs and replacements done on any

parts of the vehicle with the exception of the vehicle body. Repair and replacement services done

at Genais Auto Company include suspension repairs such as brake pad replacements, shock

absorber replacement, stabilizer linkage replacement, stabilizer bushing replacement, etc.

Some of the repairs I served as an assistant in include:

Engine repairs, overhaul and replacement,

Brake pad replacement,

Shock absorber repair and replacement, etc.

4.1 Engine repairs and replacement

The Engine is the component of any vehicle that takes the chemical energy in the fuel

and converts it through a series of processes into useful mechanical energy so as to generate

sufficient power to propel the vehicle. The engine acts as the powerhouse of the vehicle.

Automobile engines come in various designs, sizes and configurations. The structure on which

other components of the engine are attached to is called the Engine block. The engine also

supplies the necessary drive needed by the generator, the air-conditioning compressor and the

power steering pump.

Automobile engines can be classified in various ways. These range from the method of

ignition to fuel type used, number of cylinders, piston arrangement, method of mixture

preparation, method of ignition, etc. The most common type of engine found in vehicles is the

gasoline-burning, liquid-cooled, spark-ignition, four stroke, and multi-cylinder engine. It has the

intake and exhaust valves in the cylinder head, and electronically controlled ignition and fuelinjection system.

The most popular automobile engine is the one based on the constant volume process

also called the Otto cycle. The process was named after the individual that first proposed such a

design, Nicolas August Otto, a German engineer in 1876. Though his proposed design has seen

various adjustments through time, it still remains the foundation for gasoline-combusting, spark-

ignition four stroke engines.


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Fig. 4.0 A 4-cylinder gasoline-combusting, spark-ignition engine undergoing repairs

Common engine repairs done at Genais Auto Company include engine overhaul,

camshaft replacement, piston replacement, etc. In cases where the engine has been confirmed to

be in a really bad condition, customers are advised to get a new engine instead.

Engine replacement exercises usually start with the removal of the hood (bonnet) as it

may hinder the proper removal of the engine. Once the bonnet is removed, the engine is carefully

detached from the transmission system. Then the engine is unseated from its seat and every

component that might hinder its easy removal. The engine is lifted out of the vehicle with the aid

of a special hydraulic jack with a maximum lifting capacity of 3 tons.

To overhaul an engine, the engine is removed from its position and dismantled to its

components. The components are then properly cleaned to remove dirt and greasy particles that

may hinder the proper functioning of the engine. Reasons for overhauling an engine range from

having too much sludge in the engine to having water in some areas where it is not desired. The

overhauling process is a labour intensive exercise since it requires valuable man-hours for it to

be done effectively.

Sometimes, an engine repair may simply be the repair of components attached to the

engine like the alternator, water-pump, power steering pump and the air-conditioning systems

compressor. At other times, engine repairs may simply be the properly welding of the engine

block in the advent of a fracture.


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4.2 Brake pad replacement

The brake system is a very important subsection of the suspensions system of an

automobile. Without the brakes in the vehicle, it automatically becomes a weapon of destruction

because it wont be able to stop when it is needed to do so. To achieve this mission, the brake

system comes with a wide range of components like the brake drum, brake piston, brake

callipers, and most important of all, the brake pads. Often times, brake pads get used up and need

to be replaced. The procedure for a brake pad removal exercise at the company is described

below.

Replacement of brake pads

Location: in the workshop

Required tools: Wheel spanner, Hydraulic jack, Tyre chock, Set of sockets, Set of spanners, etc.

Necessary items: new brake pads

Procedure:

1. Using tyre chocks, keep the vehicle stationary.

2. With the aid of the wheel spanner, slack the wheel nuts keeping the tyre in place.

3. Elevate the vehicle to a convenient height using the hydraulic jack, to allow enough space

for the removal of the tyres.

4. Loosen the tyre nuts completely and remove the tyres.

5.

The wheel is now exposed. With the aid of ratchets and necessary sockets, remove the

bolts and screws guiding the brake calliper.

6. Lift the calliper and carefully remove one of the brake pads to be replaced.

7. With one of the pair left, carefully pull the calliper so as to press the brake piston against

the brake drum. This enables it to return to its original position before the brake pads

were reduced.

8. With the piston in its position, remove the remaining brake pad.

9.

Fit the new pair of brake pads to the brake calliper.

10.Ensure the brake pads are properly fitted.

11.Return the brake calliper to its position and tighten the guiding bolts and nuts.

12.Replace the wheel in position and tighten the wheel nuts to keep it in place.

13.With the aid of the hydraulic jack, bring the vehicle down to ground level.

14.Tighten the wheel nuts again to ensure they are secured in place.

After the steps above, the exercise is complete and the vehicle is worthy to leave the

workshop.


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4.3 Shock absorber replacement

The automobile frame and body are mounted on the front and rear axle not directly but

through the springs and shock absorbers. Without shock absorbers and springs the vehicle would

not be able to dampen the vibrations resulting from its motion.

Suspension is the term given to the system of springs, shock absorbers and linkages that

connects a vehicle to its wheels and allows relative motion between the two. Suspension systems

serve a dual purposecontributing to the vehicles handling and braking for good active safety

and driving pleasure, and for keeping the vehicle occupants comfortable and reasonably well

isolated from road noise, bumps and vibrations. These goals are generally at odds, so the tuning

of suspensions involves finding the right compromise.

Suspension repairs at Genais Auto Company include the repairs of shock absorbers(which usually entails the removal and replacement of shock absorber springs), stabilizer linkage

shafts, etc. A typical scenario involving the replacement of a shock absorber is described below;

Required tools: Hydraulic jack, Wheel spanner, Sets of spanners and sockets, Ratchet

Procedure:

1. Using tyre chocks, keep the vehicle stationary.

2. Slack the wheel nuts or bolts keeping the tyre of the respective shock absorber to be

replaced in place.

3. Elevate the vehicle to a convenient height using the hydraulic jack, to allow enough space

for the removal of the tyres.

4. Loosen the tyre nuts completely and remove the tyres.

5. If its located in the front part of the vehicle, open the hood to get access to where the top

of the shock absorber is screwed and/or bolted to.

6. With the aid of the necessary tools Ratchet, Spanner or T-bar, loosen the guiding nuts

of the shock absorbers.

7. Repeat step 6 for the bottom mounting hook of the shock absorber.

8. Remove the old shock absorber and replace with the new one.

9. Fix it properly according to the guiding marks on it. These marks are guides to the proper

orientation of the shock absorbers.

10.Fix the bolts and/or nuts and tighten them to keep the shock absorber in place.

11.Fix the tyre, bolt them in place and reduce the vehicles elevation to ground level.

12.

Tighten the tyre again to ensure they are not loose. The process is complete.


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Fig.4.1 a hydraulic jack used for general repairs

Fig. 4.2 An engine block


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5. CONCLUSION AND RECOMMENDATION

5.1 Conclusion

Though the industrial training lasted just for some months, I learned quite a lot. I had the

privilege to participate as an assistant in a sizeable number of repairs and services. The

automotive maintenance industry is a rapidly evolving industry with a lot of potential, especially

in a developing nation like Nigeria due to the fact that a lot of vehicles moving around are based

on technological advancements that are way beyond the reach of the typical roadside mechanics.

This poses a threat to the survival of the local mechanic but also opens up a new world of

opportunities should he be willing to try them out.

5.2 Recommendation

Having participated and as a beneficiary of the Students In Work Experience Scheme

(SIWES), the following recommendations are prescribed;

1. The University community should invite and encourage corporate bodies and

organisations with seasoned professionals in relevant fields to hold seminars and

workshops that will enlighten the minds of the students to recent developments and

challenges in their discipline.

2.

As a way of encouragement, lecturers should be provided with multimedia teaching aids

when and where necessary as this would help this students get a clearer picture of the

topics discussed in the classrooms.

3. Due to the nature of the nations economy, the students should be assisted in securing

attachment for their Industrial training period as this will eliminate the waste of time

encountered in searching for a place of attachment.

4. More practical classes should be held so as to further reduce the breach between the

classroom and the professional field. Also, more field trips and excursions should be

organised as this would encourage the students because the link between the classroom

and field work would be further emphasized.


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REFERENCES

Heywood, J. B. (1998), Internal Combustion Engine Fundamentals.

Top signs of Engine Trouble,http://howstuffworks.com/engine

On-board diagnostics,http://en.wikipedia.org/wiki/on-board_diagnostics
http://howstuffworks.com/enginehttp://howstuffworks.com/enginehttp://howstuffworks.com/enginehttp://en.wikipedia.org/wiki/on-board_diagnosticshttp://en.wikipedia.org/wiki/on-board_diagnosticshttp://en.wikipedia.org/wiki/on-board_diagnosticshttp://en.wikipedia.org/wiki/on-board_diagnosticshttp://howstuffworks.com/engine

report on automobile internship.pdf

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