Declaration

I, Yidenek Nigussie is a 4th year students of electromechanical engineering department in jimma

University institute of technology, I have been working as an intern in Marathon motors engineering
PlC. As required inthe curriculum, I have prepared this report and project from what I have observed
and practiced during my stay.

I hereby declare my internship report works I presented here is certify the best of my contribution and
knowledge that I have.

Name of student Signature Date

Approval
I declare that this final internship report is not a copy of somebody's document and I approve it is
completely own work.

Name of Advisor Signature Date

Supervisor's Name Signature Date

Background of the company

Marathon Motor Engineering PLC (MME) was founded in 2008 and officially inaugurate in February 2009 as
importer and distributor of Hyundai passenger, commercial vehicles and genuine parts in Ethiopia.

2009 was year of inception to MME and it starts by importing parts for existing Hyundai cars, provide services
and support current owners of Hyundai to earn their confidence and to use their reference. On the same time
there was a challenge of shortage of hard currency. It was the commencement of the global financial crisis that
led to the economic recession and ultimately created the social crisis that changes the lives of millions in number
of countries. Major institutions that have been successfully in business for years, even decades, had started losing
revenue, downsizing and many of them even closed down. Transactions slowed down, businesses shrank,
economies crumbled, and families struggled to survive.

2010 was year of earning. Despites its brief existence, MME started crating a positive image for Hyundai and
building a name as a strong competitor in the automotive market of the country. Parallel to this there were
challenges of lack of local market trust. The Ethiopian car market has been dictated for decades solely by car
brokers and also dominated by only one brand. Even if the competition is tougher MME starts winning tenders
to supply fleets for big government and non-government projects.

MME’s commitment, competency and noteworthy success won the confidence of Hyundai. After three years of
venture with only letter of intent, Hyundai granted MME a distributorship of agreement. Through diligent and
outstanding performance in customer care in sells, parts and service MME’s turnover has increased considerably.
Our target ‘’Bigger, Better and Stronger’’: Bigger investment, Better facilities and services, Stronger
performance. It reinforced mobile workshops, intensive care as well as roadside assistance; it laid the foundation
of 3S facilities Sells, Spare-parts and Services.

MME would like to reassure that the future is more brighter with Hyundai’s New Thinking New Possibilities.
Hyundai strongly believes that its distributors across the globe to be lifetime partners. Similarly, MME would
like to establish a lifetime partnership with its customers.

MME is also exclusive agents of SAME Tractor from Italy Since, 2016 and we import different type of tractors
Explorer3 115, Especial Explorer 95 and Laser tractor 130.

On 25th May, 2017 MME signed SKD assembly technical assistance agreement with Hyundai motor company.
The assembly plant will produce 5000 in one shift, and 10,000 at full capacity assorted models of cars per year.
Our 3 fully equipped facilities are

 Saries, Nifas silk lafto sub city

 Megenagna Infront of diaspora round about , Yeka sub city
 Haile road Haile building
 Hawassa, SNNPRS

Marathon Motor Engineering signed an assembly technical assistance agreement with Hyundai cementing
the company’s plans to start assembling vehicles in Ethiopia. The agreement was signed on Monday May 29,
2017 and a manufacturing plant is set to be constructed at a cost of half a billion birr.

“Globally, Hyundai is among the top five car makers so the fact that this elite brand will be assembled here will
give confidence to others who have plans to invest in the country,” said Melkamu Assefa, CEO and Managing
Director of Marathon Motor Engineering Plc who signed the agreement with Mike Song, Head of the Africa and
Middle East Department for Hyundai.
The manufacturing plant will be based in Addis Ababa Lafto sub-city on 30,000 square meters of land. It is
expected to rollout cars by the first quarter of 2018 and will provide jobs to 200 people.The plant will have the
capacity of assembling 2,000 to 2,500 vehicles annually and will have six to eight different models. “Though this,
there will be skill and technology transfer, the plant will be very modern, most of the machines will be imported
from South Korea and Hyundai will monitor all the technical aspects to maintain the brand’s high standards,”
Melkamu said.
Hopes are that this assembly plant will reduce the price of cars in Ethiopia. “There will be a 15 to 18 percent
reduction in the selling price over imported cars, since people will be able to afford new cars there will be less
accidents and it will also have a significant effect on the environment,” Melkamu said.

According to Marathon Motor Engineering, the company currently controls 30 to 35 percent of the market share
in the country and once its assembled cars hit the market, it estimates controlling a 40 percent share. The
company was inaugurated May 22, 2016 with two facilities: a six storey building that includes a mega show
room, a service center and a training center in Addis Ababa with an investment of 80 million birr and another
facility in Hawassa with an investment of over 37 million birr, also equipped with a service center for trucks and
buses, as well as a technical training facility

Its main customers or the end users of its products and services
Marathon Motors Engineering PLC most of its customers are governmental and non-organizations are the main
costumers of the company
Pages describing your overall internship experience
How I get into the company
As a mechanical engineer it is a big dream to join Marathon Motors Engineering PLC, As we know Marathon
Motors Engineering PLC is one of the biggest company in Ethiopia which import and give service for
automobiles and heavy vehicles, when i got my internship paper, i went directly to the Hawassa branch and
submitted to the human resource, then they gave me an appointment for a week then they told me that they are
going to accept me. Next join the company on June 20/07/2022 G.C and we stayed for three months and fifteen
days.
 WORKING SECTIONS

Marathon Motor engineering PLC have two main sections: -

1. Sales
In this section several automobile’s and bus’s are imported and assembled

2. Maintenance
Under maintenance section there are five sub sections in which Volvo trucks, Odaa buses, construction
machineries such as dozers, excavators, rollers, grader and damper trucks of Volvo products get
annual(service) and corrective maintenance.

The following are the sections found under maintenance;

1. Body Workshop
2. Basic service Workshop
3. Motor Workshop
4. Electrical Workshop

1, Body Workshop- is where the cars body maintenance takes place. Basically, the things that are done in
body shop are welding, grinding, painting, drilling and modification of the trucks part.
2, Basic service Workshop- there are four types of service:-

Type-A Service

5000km/15000km/25000km/35000km/45000km/55000km/6500km &75000km

NO COMPONENT TO BE REPAIRED MAINTENANCE

CODE

1 Brake Pads & Discs I

2 Steering Wheel Linkage & Steering Gear Box Oil I

3 Engine oil With Filter R

4 Air Cleaner Filter I

5 Tire & Inflation Pressure I

6 External Leakage I

7 Drive Shaft Boots I

Type-B Service

10,000km/30,000km/50,000km & 70,000km Services

NO COMPONENT TO BE REPAIRED MAINTENANCE

CODE

1 Brake Pads, Discs & Drums I

2 Steering Wheel Linkage & Steering Gear Box Oil I

3 Engine Oil With Filter R

4 Spark plugs I

5 Air Cleaner Filter I

6 Brake Pedal & Parking Brake I

7 Brake Fluid I

8 Clutch Fluid I

9 Drive Shaft Boots I

10 Power Steering Fluid I

11 Battery I

12 Climate Control air Filter R

13 Tire & Inflation Pressure I

14 All Lights, Horns, Wipers & Washer I

15 External Leakage if Any I

Type-C Service

COMPONENT TO BE REPAIRED MAINTENANCE

CODE

1 Brake Pads & Discs I

2 Drive Shaft Boots I

3 Steering Wheel Linkage & Steering Gear I

Box Oil

4 Brake Linings & Drums I

5 Front & Rear Suspensions I

6 Engine oil with Filter R

7 Spark plugs I

8 Air Cleaner Filter I

9 Drive Belt I

10 Fuel Filter I

11 Valve Clearance I

12 Positive Crank Case Ventilation Valve I

13 Clutch Pedal,Brake Pedal & Parking Brake I

14 Brake Fluid I

15 Clutch Fluid I

16 Power Steering Fluid I

17 Brake Pipes, Hoses & Connectors I

18 Climate Control Air Filter R

19 Air Conditioning/ Cooler Refrigerant I

20 Battery I

21 Tire & Inflation pressure I

22 All lights ,Horns, Wipers & washer I

23 External leakage if any I

Type-D Service
 MAINTENANCE
No COMPONENT TO BE REPAIRED
CODE

1 Brake Pads & Discs I

2 Drive Shaft Boots I

3 Steering Wheel Linkage & Steering Gear Box Oil I

4 Brake Linings & Drums I

5 Front & Rear Suspensions I

6 Engine oil with Filter R

7 Spark plugs R

8 Air Cleaner Filter R

9 Drive Belt I

10 Fuel Filter R

11 Valve Clearance I

12 Positive Crank Case Ventilation Valve I

13 Clutch Pedal,Brake Pedal & Parking Brake I

14 Brake Fluid I

15 Clutch Fluid I

16 Power Steering Fluid I

17 Brake Pipes, Hoses & Connectors I

18 Climate Control Air Filter R

19 Air Conditioning/ Cooler Refrigerant I

20 Cooling and Heater Syste I

21 Tire & Inflation pressure I

22 All lights ,Horns, Wipers & washer I

23 External leakage if any I

24 Ball joint & Dust Cover I

25 Battery I

26 Manual Transaxle Oil I

27 Automatic Transaxle fluid I

28 Bolt and nuts on chasis and body I

3. Motor Workshop- is the workshop where important parts of the automobiles trucks and buses
maintenance takes place. These includes maintenance of gear box, steering gearbox,
differential, engine parts (cylinder head, oil sump), valve adjustment (clearance), gear timing,
clutch etc.

4. 4.Electrical Workshop- As the name indicates it is a workshop where every electrical related
problem is repaired. The tasks that are performed under this workshop is mainly diagnosis
of problems on automobiles, trucks and buses using a special diagnosis tool. Sometimes
when there is a part that has to be removed from the cars for other maintenance, they
remove the parts that are electrical such as Dashboard. And this workshop also tests the
batteries. Electrical shop is the one responsible for any electrical related problems.

2.1 Task performed by the company

The following tasks are performed by the company
Work performed by the company on last month's presented as follow. Most of the work on service
area; vehicle service is a series of maintenance procedures carried out in a certain time. The service
type is depending on the vehicle travel distance

Steps that is ordered to carried out the vehicle service and any maintenances
First the company receive the type of maintenance they went to order anything specific about
why the service or the maintenance are needed. This all give it to the service advisor ( my
Mentor) then the service advisor and receptionist write customer request to the card known as
job card, the card passes to the technician after opening job card on a network system that the
company have ; this software system have working time that include at what time the mechanic
receive thevehicle and when he have to submit back any spare part he need for the maintenance
also save tothis network system. Finally, the vehicle has been tested by the Forman then the
Forman have been tested the car the job card passed to the service advisor and he calls to the
customers to get their cars then the customer will have their car after washing process is done .

Marathon motor cars serviced based on the kilometer the car travel

Type A service: - is type of service that is performed on cars that travel 5000km, 15,000km, 25,000km, etc. It
keeps going on adding 10,000 and the types of service are listed in the table.

 Inspect brake pad and discs

 replace engine oil with filter
 check air cleaner and battery
 inspect steering wheel linkage, steering and gear box oil
 inspect front and rear suspension
  inspect external leakage if any
Type B service: - is type of service that is performed on cars that travel 10,000km, 30,000km,
50,000km, etc. It keeps going on adding 20,000 and the types of service are listed :

 Check Brake pad, discs brake, drums brake

 Steering link center arm linkages (grease)
 Replace Engine oil with filter
 Check Brake fluids and clutch fluids
 Drive shaft boots
 Check Brake pedal and parking brake
 Check Ball joints and dust covers
 Check Brake pipes and hoses
 Inspect All light, horn and wiper/washer
 Check and replace Fuel filter and fuel line
 Check and replace air cleaner element
 Inspect spark plug (gasoline)
 Check front and rear suspension
 Inspect oil leakage and water leakage

Type C service: - is type of service that is performed on cars that travel 20,000km, 60,000km,
100,000km, etc. It keeps going on adding 40,000 and the type of service are listed : -

 Check Brake pad, discs brake, drums brake

 Change air filter elements if the car is diesel and hand brake cable.

 Check steering linkage arms

 Inspect drive belts

 Inspect brake disk and drum run out

 Inspect air filter if the car is gasoline

 Inspect valve clearance

 Check battery and battery connection

 Check spark plugs if the car is gasoline

 Check any external leakage

 Checks ball joints

 Tighten all bolt and nut (including propeller shaft bolt)

  Inspect brake, clutch and power steering oils

 Check all light, horn, wiper and washer

 check wheel bearing grease Replace engine oil with filter

 Change fuel filter if the car is diesel

 Check front and rear suspension

 Check differential and gear box oil

 Check exhaust pipe

Type D service: - is type of service that is performed on cars that travel 40,000km, 80,000km,
140,000km, etc. It keeps going on adding 40,000 and the types of service are listed in the table. Most
of service work includes checking, cleaning and changing of the parts, if any part of the vehicle needs

 Check Brake pad, discs brake, drums brake

 Check ball joints and hand brake cable.

 Inspect Steering knuckle, linkage and arm

 Check fuel line

 Inspect brake disk and drum run out

 Check radiator coolant

 Replace differential and gear box oil

 Inspect valve clearance

 Check brake and parking brake cable

 Check any external leakage

 Tighten all body and exhaust pipe bolts

 Check front and rear suspension

 Check brake pipe, line and hose s

 Check all light, horn, wiper and washer

 Change fuel filter

 Check front and rear suspension

 Replace spark plugs

 Change engine oil with filter

 Inspect and replace drive belts

 Check all light, horn, wiper and washer

 2.1 Service components and how it works

2.1.1Brake system
Brakes are the most important component of an Automobile. The vehicle is started, accelerated and it
runs on the road. But stopping of the vehicle is as essential as its staring. Brakes are provided to stop
the vehicle with in the shortest possible distance Braking achieved by converting K.E in to heat
energy.

Symptoms of bad or falling brake master cylinder

Abnormal brake pedal behavior
Contaminated brake fluid.

Most of the Hyundai cars have ventilated disc in the front and solid disc in the rear side. it is also
located in the rear wheel in some advanced Hyundai cars such as Elentera, Santafe, Grand starex,
Veracruzand Maxcruz) have drum disc (which is located in the rear wheel). When providing service, it
is the mechanic duty to check if the discs wear out or not. if they wear out it should be reground or
replaced with new one. Disc brakes are checked every 10,000km.

Brake Pad
These are the disc brake component that holds the rotating disc by pressure force applied from the
wheel. The requirements are constant coefficient of friction over wide range of temperatureMust not
wear out rapidly nor should they wear the disc rotors Should resistance high temperature without
fading no noise

Through time the brake pad will wear out. And most of Nissan cars the wear out of brake pads make asound by its
wire found at one of the pad .The break pad wear out every 10000km and replacement.
Brake pad replacement
In this type the vehicle brake pad replacement are the following procedures
1. Loosen the wheel nuts slightly, then raise the car and support on safety stand
2. Remove the caliper bolt, and pivot the caliper up out of the way
Note check the hoses and pin boots for damage or deterioration
3. Remove the pad shims, pad spring and pad
4. If the pad thickness is less than service limit, replace the front pad at asset
5. Clean the caliper thoroughly, remove any rust, and check the grooves or cracks
6. Check the brake disc for damage or cracks.
7. Install the pad spring
8. Install the brake pads and pad shim correctly
9. Push in the piston so that the caliper will fit over the pad. Make sure that the piston boot is in
position to prevent damaging it when pivoting the caliper down
10. Pivot the caliper down into the position, the install caliper bolt and tighten it.
11. Check the brake by pressing the brake pedal several times.
 2.2 Suspension system
Suspension components support the weight of the vehicle. Make sure the vehicle is supported by
something other than the vehicle's suspension system, such as a hoist or jack stands, before
removing any suspension components. Some vehicles use the shock absorbers to limit the amount of
suspension travel. When removing the shock absorber an unsupported part of the suspension may
fall from the vehicle. If you are to remove the shock absorbers, make sure the vehicle suspension is
supported by suitable means. Strut assemblies contain a coil spring that is held under compression,
always use a spring compressor to release the spring pressure before disassembly. Always wear
protective clothing and the appropriate safety equipment.

Points to note:
Shock absorbers are also known as dampers. Their task is to reduce suspension oscillations.
The two most common types are strut cartridges and telescopic shock absorbers. Each type
has a different shock absorber replacement procedure.

Always replace shock absorbers and strut inserts in pairs so that the suspension has the same
characteristics for left and right sides.

Struts can be used for both the front and rear suspensions of front- and rear-wheel drive
vehicles. The strut and spring assembly for each are basically the same with the difference
being the types of arms and linkages that are used for its location due to the wide variety of
mounting types there is no set method of removing and replacing a strut, so always refer to the
manufacturer's manual for the recommended procedure.

use manual for the recommended procedure.

2.3 Engine oil replacement

Engine oil, or engine lubricant is any of various substances are often used for lubrication of internal
combustion engines. The main function of engine oil is to reduce wear on moving parts. it is important
to replace the engine oil every 5000 km. If the oil is not replaced, Oil undergoes thermal breakdown
due to high operating temperature. When this occurs, the oil becomes less effective as a lubricant.

we have to be sure that all the necessary equipment's are available. These are

► Oil filter
► Socket wrench
► Funnel
► Oil pan or bucket and rage

Procedure for changing Engine oil

1. First start the car and let it run for a minute or two.
2. Then under the vehicle, locate the oil pan and drain plug. Once you identify the drain plug.
3. Loosen the drain plug with the socket wrench, turning it counterclockwise.
4. After loosening, remove the plug slowly by hand and let the engine oil drain out.
5. During this activity a care must be taken b/c the engine oil is very hot which may have led to
burning of skin.
 Procedure for replacing engine oil filter
1. Keep the oil drain pan underneath the car and locate the oil filter.
2. Once you identify the oil filter loosen it with the filter wrench, turning it counterclockwise.
3. Remove the oil filter by hand.
4. Before installing the new oil filter, apply a little engine oil to the new gasket. This will prevent
the gasket from sticking, cracking or causing an oil leak.
5. Finally, install and tighten the new oil filter by hand.
Replacing new engine oil
1. It' s now time to fill the engine with new engine oil. The engine oil that the car uses should be
the right one according to the Hyundai cars specification.
2. Then loosen the oil-filler cap and pour your engine oil into the tank. Using a funnel w/c help
you avoid spilling. When finished, replace the oil cap and wipe away any spilled engine oil.
Start your engine and run it for a minute to allow the new engine oil to circulate thoroughly.
Before we take it to spin, it is must to check the oil level. To do this, tum off the car and
remove and clean the dipstick. Insert and remove it once more, this time checking that the oil
has the correct reading. Finally screw the cap back.

Type of engine oil used in MME

For benzene Hyundai cars that travel below 50,000km, oil is replaced with SW-40 fully
synthetic engine oil

For benzene cars(gasoline) that travel 50,000 and above use ca15w-40 Delo engine oil
For Hyundai cars like that travel 100,000km and above use 20w-50 Havoline engine oil.

For diesel cars, it uses its own type of oil called diesel oil. But, before we use the diesel oil we
will filter it with filter oil. Filtering oil is necessary because diesel engine oil get dirty(dark)
easily and need to be cleaned before replacing it with new one.

2.4 Air cleaner replacement

Air cleaner is typically a pleated-paper filter that is placed in the outside-air intake for the vehicle's
passenger compartment. Most of Hyundai air cleaner are rectangular and similar in shape to the
combustion air cleaner. Others are uniquely shaped to fit the available space of particular vehicles'
outside-air intakes. Air cleaner prevents abrasive particulate matter from entering the engine's
cylinders, where it would cause mechanical wear and oil contamination. As outside air flows through
the air cleaner, it becomes filled with dust and debris. This will not allow enough air to enter in to the
engine, and this can affect the performance of the vehicle over time. So, it is necessary to clean the air
cleaner every 5000km and if you notice any of the following problems, you may need to replace the
air cleaner.

Decreases in your car's gas mileage.

Spark plug problems, such as rough idling or difficulties starting the car, caused by an
overly rich air-fuel blend.
 "Service Engine" light coming on, which can be the result of deposits in the engine.
Problems with acceleration.

Visible soot, dirt or debris on the air filter

2.5 Fuel pump replacement

Hyundai fuel pump enables the gasoline you put in your car, truck, or SUV to travel from the gas tank
to the fuel injector system. Often, the Hyundai fuel pump is located within the tank itself, where the
gasoline cools the motor and keeps the pump running longer and more efficiently. Hyundai fuel pump
is either mechanically or electrically operated. A mechanical Hyundai fuel pump uses a fuel filter,
while an electrical Hyundai pump requires a fuel pump strainer in addition to the filter and the pump
itself The fuel filter and pump strainer are essential to the operation of Hyundai fuel pump, as
contaminants in gasoline can clog the pump and cause it to break down. So, you should make sure to
change your fuel filter regularly to keep dirt and contaminants out of the workings of fuel pump during
servicing. This replacement is mostly done every 60,000km for benzene Hyundai cars and every
30,000km for diesel Hyundai cars.

2.6 Sparkplug cleaning

Spark plugs are an important part of the ignition system. During servicing Nissan cars, it is important
to clean the spark plug for every40, 000km the car travel. When cleaning the spark plug it is also
important to inspect the ignition cable as well.

Heat Engine
Is a system that converts heat to mechanical energy, which can then be used to do mechanical
work. It does this by bringing a working substance from a higher state temperature to a lower state
temperature. A heat source generates thermal energy that brings the working substance to the high
temperature state. The working substance generates work in the working body of the engine

while transferring heat to the colder sink until it reaches a low temperature state. During this process
some of the thermal energy is converted into work by exploiting the properties of the working
substance. The working substance can be any system with a non-zero heat capacity, but it usually is a
gas or liquid. During this process, some heat is normally lost to the surroundings and is not converted
to work. Also, some energy is unusable because of friction and drag.

In general, an engine converts energy to mechanical work. Heat engines distinguish themselves
from other types of engines by the fact that their efficiency is fundamentally limited by Carnot's
theorem. Although this efficiency limitation can be a drawback, an advantage of heat engines is that
most forms of energy can be easily converted to heat by processes like exothermic reactions (such as
combustion), nuclear fission, absorption of light or energetic particles, friction, dissipation and
resistance. Since the heat source that supplies thermal energy to the engine can thus be powered by
virtually any kind of energy, heat engines cover a wide range of applications.
 1. Extenal Combustion Engine
An external combustion engine (EC engine) is a heat engine where a working fluid, contained
internally, is heated by combustion in an external source, through the engine wall or a heat
exchanger. The fluid then, by expanding and acting on the mechanism of the engine, produces
motion and usable work.111 The fluid is then dumped (open cycle), or cooled, compressed and reused
(closed cycle). In these types of engines, the combustion is primarily used as a heat source, and the
engine can work equally well with other types of heat sources.
2. Internal Conbustion Engine
An internal combustion engine (ICE) is a heat engine in which the combustion of a fuel occurs
with an oxidizer (usually air) in a combustion chamber that is an integral part of the working

fluid flow circuit. In an internal combustion engine, the expansion of the high-temperature and high-
pressure gases produced by combustion applies direct force to some component of the engine. The
force is applied typically to pistons, turbine blades, a rotor, or a nozzle. This force moves the
component over a distance , transforming chemical energy into useful kinetic energy and is used to
propel, move or power whatever the engine is attached to. This replaced the external combustion
engine for applications where weight or size of the engine is important.

2.7 Engine classification

Internal combustion engine classified in difrrent ways

1. Type of Ignition
Spark Ignition
An internal combustion engine , generally a petrol engine, where the combustion process of the
air-fuel mixture is ignited by a spark from a spark plug. This is in contrast to compression-ignition
engines, typically diesel engines, where the heat generated from compression together with the
injection of fuel is enough to initiate the combustion process, without needing any external spark.

Compration Ignition
An internal combustion engine in which ignition of the fuel is caused by the elevated
temperature of the air in the cylinder due to the mechanical compression; thus, the CI engine is a so-
called Desiel engine.Diesel engines work by compressing only the air. This increases the air
temperature inside the cylinder to such a high degree that atomised diesel fuel injected into the
combustion chamber ignites spontaneously.

2. Engine Cycle
Two srock cycle
A type of internal combustion engine that completes a power cycle with two strokes (up and
down movements) of the piston during one power cycle, this power cycle being completed in one
revolution of the crankshaft. A four-stroke engine requires four strokes of the piston to complete a
power cycle during two crankshaft revolutions. In a two-stroke engine, the end of the combustion
stroke and the beginning of the compression stroke happen simultaneously , with the intake and
exhaust functions occurring at the same time.
 Four strock cycle
an internal combustion (IC) engine in which the piston completes four separate strokes while turning the
crankshaft. A stroke refers to the full travel of the piston along the cylinder, in either direction. The four
separate strokes are termed.

3. Valve Location
I- Head It also called (overhead valve) engine. I-head combustion chambers have overhead
valves. The engines with this type of combustion chamber are used in high speed vehicles.
L- Head It also called Valves in block (flat head) engine. It is used for side valves.

T- Head T-shape combustion chamber projects around the cylinder head. The spark is fitted at
the top and valves in the sides. These types of engines have a good efficiency.

F-Head F-head combustion chamber projects at one side of the cylinder head.

4. Basic Design
Reciprocating Engine
has one or more cylinders in which pistons reciprocate back and forth. The combustion chambers
located in the closed end of each cylinder. Power is delivered to a rotating output crankshaft by
mechanical linkage with the pistons. B. Rotary Engine is made of a block (stator) built around a large
non-concentric rotor and crankshaft. The Combustion chambers are built into the no rotating block.

5. Position and Number of Cylinders of Reciprocating Engines

Single Cylinder Engine has one cylinder and piston connected to the crankshaft.
In-Line Cylinders are positioned in a straight line, one behind the other along the length of the
crankshaft. In-line four-cylinder engines are very common for automobile and other applications.

V-engine There are two banks of cylinders at an angle with each other along a single crankshaft. The
angle between the banks of cylinders can be anywhere from 15° to 120°, with 60°90° being common.
Opposed CylinderThere are two banks of cylinders opposite each other on a single crankshaft. These
are common on automobiles with an even number of cylinders from two to eight or more.

W- Engine It is the same as a V engine except with three banks of cylinders on the same crankshaft.
Opposed Piston Engine There are two pistons in each cylinder with the combustion chamber in the
center between the pistons.

6. Type of Cooling
Air cooled.
Liquid cooled, water cooled.

7. Fuel Use
There are a number of Fuel Used
Gasoline engine.

Diesel engine.
 2.2.5 Engine Component
Block Body of engine containing the cylinders is made of cast iron or aluminum. In many older engine
valves and valve ports were contained in the block.

Cylinder Head It is the top most part of the engine, which covers the cylinder block. This will also
carries the valves, rocker arms and springs for the opening and closing of the valves. It has also inlet
and exhaust ports, combustion chamber and camshaft in some engine, likewise nozzle if diesel engine.
The head contains the spark plugs in SI engines and the fuel injectors in CI engines and some SI
engmes.

Head Gasket is serves as a sealant between the engine block and head where they bolt together. They
are usually made in sandwich construction of metal and composite materials.

;: >
Valves is used to allow flow into and out of the cylinder at the proper time in the cycle. Most engines
use poppet valves, which are spring loaded closed and pushed open by camshaft action. Valves are
mostly made of forged steel

Water jacket System of liquid flow passages surrounding the cylinders, usually constructed as part of the
engine block and head. Engine coolant flows through the water jacket and keeps the cylinder wallsfrom
overheating.

Cam shaft Rotating shaft used to push open valves at the proper time in the engine cycle, either
directly or through mechanical or hydraulic linkage (push rods, rocker arms, tappets). Camshafts are
driven off the crankshaft by means of a belt or chain (timing chain).

Push rods Mechanical linkage between the camshaft and valves on overhead valve engines with the
camshaft is the crankcase. Many push rods have oil passages through their length as part of a
pressurized lubrication system.
Rocker Arm They are fitted on the rocker arm shaft and moves along with the push rod. It is found on
the cylinder head. It uses to open the valve by the power coming from the pusher rod.

Combustion Chamber The combustion occurs at the end of the cylinder between the head and the
piston face. The size of the combustion chamber continuously changes from a minimum volume when
the piston is at TDC to a maximum when the piston is at BDC.

Glow plug Small electrical resistance heater mounted inside the combustion chamber of many CI
engines, used to preheat the chamber enough so that combustion will occur when first starting a cold
engine. The glow plug is turned off after the engine is started.

Cylinders The circular cylinders in the engine block are the pistons reciprocate back and forth.
Cylinders may be machined directly in the engine block, or a hard metal (drawn steel) sleeve may be
pressed into the softer metal block.

Piston The cylindrical-shaped mass that reciprocates back and forth in the cylinder, transmitting the
pressure forces in the combustion chamber to the rotating crankshaft.

Piston rings Metal rings that fit into circumferential grooves around the piston and form a sliding
surface against the cylinders walls. Near the top of the piston is usually two or more compression rings
made of highly polished hard chrome steel. The purpose of these is to form a seal between the piston
and cylinder walls and to restrict the high-pressure gases in the combustion chamber from leaking past
the piston into the crankcase

Connecting rods rod connects the piston with the rotating crankshaft , usually made of steel or alloy
forging in most engines but may be aluminum in some small engines

Crankshaft rotating shaft through which engine work output is supplied to external systems. The
crankshaft is connected to the engine block with the main bearings. It is rotated by the reciprocating
pistons through connecting rods connected to the crankshaft

Main bearing the bearings connected to the engine block in which the crankshaft rotates.
 Flywheel Rotating mass with a large moment of inertia connected to the crankshaft of the engine. The
purpose of the flywheel is to store energy and furnish a large angular momentum that keeps the engine
rotating between power strokes and smoothest out engine operation.

Working Priciple Of Engine

Most internal combustion engines both spark ignition and compression ignition; operate on either a
four-stroke cycle or a two-stroke cycle. But during our duration we have only seen how four-stroke
diesel engine cycle.

First stroke Intake as the piston starts down on the intake stroke, the intake valve opens and the fuel-
air mixture is drowning into the cylinder.

Second stroke Compression The piston moves up and compresses the trapped air fuel mixture that
was brought in by the intake stroke. When the piston reaches BDC, the intake valve closes and the
piston travels back to TDC with all valves closed. This compresses the air-fuel mixture, raising both
the pressure and temperature in the cylinder. Combustion of the air-fuel mixture occurs in a very short
but finite length of time with the piston near TDC.

Third stroke Power the spark plug fires, igniting the compressed air-fuel mixture which produces a
powerful expansion of the vapor. The combustion process pushes the piston down the cylinder with
great force turning the crankshaft to provide the power to propel the vehicle. Each piston fires at a
different time, determined by the engine firing order. By the time the crankshaft completes two
revolutions , each cylinder in the engine will have gone through one power stroke.

Fourth stroke Exhaust with the piston at the bottom of the cylinder, the exhaust valve opens to allow
the burned exhaust gas to be expelled to the exhaust system. The piston travels up to the top of the
cylinder pushing all the exhaust out before closing the exhaust valve in preparation for starting the
four stroke process over again.

2.2.6 Diesel Engine Systems

Fuel System The fuel system is critical in storing and delivering the gasoline or diesel fuel engine is
needs to run.

The basic component parts of diesel fuel system

Fuel tank Basically holding fuel for your engine.

Fuel pump suck fuel from fuel tank and delivers to engine nozzle. Electrically or mechanically
driven pump is used supply fuel from the fuel tank (reservoir) to the engine.

Mechanical fuel pump are diaphragm pumps mounted on the engine operated by an eccentric cam.
Electrical fuel pump they are located anywhere in vehicle, because do not depend on eccentric for
operation. Fuel filters: Is key to properly functioning fuel delivery system. Fuel injectors and
carburetor have tiny opening which clog easily so filtering the fuel is necessary

Fuel injectors inject fuel to engine cylinder in the form of fine spray.
 Cooling System The fuel burned inside the engine produces a lot of heat. Keeping the engine
temperature under control is the work of the cooling system. The cooling system circulates liquid
coolant (antifreeze) from the engine into the radiator installed in the front of the car where the coolant
is cooled down by the air flow passing through the radiator fins. A problem with a cooling system can
cause the engine to overheat, and this can result in serious damage to the engine. One of the common
problems with a cooling system is lack of coolant caused by leaks. Coolant leaks are very common in
many cars.

There are two different types systems of cooling the engine.

Indirect Cooling System Engines with this type of cooling system are also called water-
cooled engines. In this type, water serves as cooling medium which circulates in the water
jackets to absorb the heat of the engine.

Direct Cooling System Engines with this type of cooling system are also called air-cold
engines. During operation, air drawn by a blower leading to air metal fins. Purpose of cooling
system to keeps the engine at its most efficient temperature at all speeds and operating
condition.

Component of cooling system in automotive

Water jacket it is a water passages on the cylinder head. Water pump: - it pushes the hot coolant out
of the water jackets and to the radiator.

Thermostat it is a kind of sensor, when the engine is cold the thermostat closes to prevent coolant
circulation to the radiator.

Radiator is a heat exchanging device used to remove heat from the engine coolant after the engine
has been cooled. The radiator is usually mounted in front of the engine in the flow of air as the
automobile moves forward.

Fan it pulls or pushes outside air through the radiator. Electrical system I have observed the
maintenance of the vehicles or machineries and also I have maintain electrical installation failure that
are essential to the vehicles connected to the main parts for the purpose of engine start or run
smoothly.

Intake manifold Piping system which delivers incoming air to the cylinders usually made of cast
metal, plastic, or composite material. In most SI engines, fuel is added to the air in the intake manifold
system either by fuel injectors or with a carburetor. The Individual pipe to a single cylinder is called a
runner.

Lubrication system
The lubrication system circulates engine oil to internal engine parts for the purpose of decrease
the friction.
 Engine lubrication method
Pressure-fed oiling

Oil is provided by the oil pump to the crankshaft bearings, camshaft bearings, lifters and
rocker arms.

Splash oiling oil sprays out and on moving parts used between parts with moderate load such as piston
rings, cylinders, and camshaft lobes

Engine oil provides lubrication between moving parts for the purpose of
lubrication

Sealing, cooling
Cleaning

Lubrication System Component

Oil pan (Oil sump) oil reservoir usually bolted to the bottom of the engine block, making up part of
the crankcase. The oil pan is a reservoir for engine oil and helps the oil to lose the heat that it picked
up in the engine.

Oil pump the engine oil pump develops oil pressure and flow to circulate oil throughout the
lubrication system. Pump used to distribute oil from the oil sump to required lubrication points. The
oil pump can be electrically driven, but is most commonly mechanically driven by the engine.

Oil Pickup Screen the oil pickup screen prevents any large particles, such as dirt, sand, or metal
shavings, from being circulated in the lubrication system.

Oil Pump the engine oil pump develops oil pressure and flow to circulate oil throughout the
lubrication system.

Oil level indicator also known as dipstick indicates the level of the oil in the oil pan.
Oil pressure indicator: Gauge or light that indicates oil pressure. Informs the driver pressure or lack
of pressure in lubrication system.

Pressure Regulator valve that limits engine oils pressure. The oil pump has enough capacity to
deliver sufficient oil pressure and flow at idle speeds. At higher engine speeds, the pump will produce
too much oil pressure and flow.

Oil Filter removes small particles and contaminants from the engine oil. The filter is always installed
on the outlet side of the oil pump. The oil filter contains an internal bypass. This allows oil to flow
past the filter if the element becomes clogged.

Oil Galleries oil galleries are internal engine passages that carry the oil. They are cast or drilled into
the engine block and heads.

Gaskets and Seals are used in the intake system to seal air and fuel in and to prevent vacuum leaks.

Braking system
Braking system is the system used to retard the speed of the moving vehicle or bring it to rest in a
shortest possible distance whenever required.
 Basic components of brake system
Energy supply
Actuating (control)
Transmission device

Energy supply it's a source supplies the energy required for braking.
The most important types of braking energy are

► Pneumatic
► Hydraulic
Control (Actuators) initiate the action of the brake system and control the braking action. The control
action can be triggered by the driver through

Brake pedal
Hand lever

Transmission device includes all those parts of a brake system through which the energy is
transmitted to the brakes. It began at thbrake pedal or brake lever and ends at the wheel brake.

Types of brake
1) Mechanical brakes
►
Levers
►
Cables and
►
Cams for purpose of braking
2) Hydraulic brakes
Brake pipes continues fluid circuit between the master-cylinder and the wheel cylinders.
Master-cylinder convert the foot-pedal force to hydraulic pressure.
Disk-brake consisting of a disc bolted to the wheel hub and sandwiched between two pistons and
friction pads.

Drum-brake consists of two brakes -shoes and lining supported on a back plate bolted to the axle-
casmg.

Wheel cylinders convert the transmitted hydraulic line pressure in to braking effort as it acts on the
cross-sectional area by brake fluid to transfer of braking force.

Brake booster the brake booster is designed to create a greater braking force from a minimum pedal
effort. The brake booster is located between the brake pedal and the master cylinder.

Master Cylinders contains piston assemblies used to generate hydraulic pressure for the brake
system. consists of reservoir piston and cylinder.
 Drum brakes braking power is obtained when the brake shoes are pushed against the surface of the
drum which rotates together with the axle.

Components of drum brake

Wheel cylinder( Shoe-expander)
Backplate

Brake-shoes
Brake drums

Wheel cylinder two pistons operate the shoes, one at each end of the wheel cylinder it consists of:-two
piston, two rubber cups and springs

Disc brake the braking power is when the fluid from the master cylinder is forced into a caliper where
it presses against a piston. Because a disc brake assembly can absorb more heat than a drum brake
assembly, most cars use disc brakes for their front brake systems.
Component

► Disk Rotor the disk rotor is made of gray cast iron.

► Caliper is mounted to the torque plate and steering knuckle or wheel carrier & have pistons.
► Brake Pad have Constant coefficient of friction over wide range of temperature.
Intake system and exhaust system
Intake system it's a system used for delivering fresh air to an engine.
Air intake system main components.
Air cleaner It's a device which cleans and filters the air before entering the combustion
chambers of an engine. Unfiltered air may contain millions of particles of abrasive dust and
other matter, which could cause rapid wear.

Turbocharger Is a device delivers pressurized into the engine so that more fuel can be burnt
and the engine output increased.

Inlet manifold to deliver into the cylinder either mixture of fuel and air from the carburetor or only air
from air cleaners.

Exhaust systems It is usually piping used to guide reaction exhaust gases away from controlled
combustion inside an engine. The entire system conveys burnt gases from the engine.
 Components of exhaust system:
Exhaust manifold attaches to the cylinder head and takes each cylinder exhaust and combines
into one pipe.

Catalytic converter this is muffler like part converts harmfully carbon monoxide and
hydrocarbons to water vapor and carbon dioxide. The converter is mounted between exhaust
manifold and muffler.

Muffler the muffler is serving to quiet down to acceptable levels. Most mufflers uses baffles
to bounce the exhaust around dissipating the energy and quieting the noise.

Exhaust pipe between all of the above mentioned parts is the exhaust pipe which carries the
gases through its journeys out your tail pipe.

2.8 Power transmission system

A machine consists of a power source and a power transmission system, which provides
controlled application of the power. Often transmission refers simply to the gearbox that uses gears
and gear trains to provide speed and torque conversions from a rotating power source to another
device. The term transmission refers to the whole drive train, including clutch, gearbox, prop shaft,
differential, and final drive shafts.
Components of power train

► Clutch
► Gear box
► Propeller shaft
► Differential
► Wheel
A clutch or torque convector is a mechanism designed to disconnect and reconnect driving and
driven members. It is a device which enable one rotary drive shaft to be coupled to another shaft,
either when both the shafts are stationary or when there is retentive motion between them. The needs
of the clutch seems mainly from the characteristics of the turning effort developed by the engine over
it is lower speed range. Also the clutch disconnected the engine from the transmission to change the
gear.
The main function of the clutch the clutch enables smooth transmission of the rotary motion of the engine
cracks shaft to stationary It provide positive linkage for transmitting the maximum engine torque at high
speed of the vehicles It is the friction type coupling that transmitting power between the driving member and
driven member.

The main components of clutch

Driving member uses a pressure plate assembly and the fly wheel both are bolted together such that
the assembly rotates at the speed of the engine.

Driven member consists of disc or plate assembly clutch shaft.

Operating member is consisted of release bearing, release lever, foot pedal, linkage and spring with
adjuster.
 2.9 Automotive electrical system
Batteries is a rechargeable that is used to start a motor vehicle. Its main purpose is to provide an
electric current to the electric-powered starting motor, which in tum starts the chemically-powered
internal combustion engine that actually propels the vehicle. Once the engine is running, power for the
car's electrical systems is still supplied by the battery, with the alternator charging the battery as
demands increase or decrease.

Components:
Negative plate
Positive plate
Container

Electrolyte (battery acid)

Battery maintenance
► Always wear eye protection and safety gloves.
► Inspect the case and terminals for physical damage.
► Check the electrolyte level or indicator eye.

► Clean the battery terminal connections

Starting System
The starting system uses battery power and an electric motor to tum the engine crankshaft for
engine starting. The starter motor is a low voltage direct current motor, which converts electrical
energy from the storage battery in to mechanical energy. The IC engines are not capable of starting by
it, but they require external power to crank it and help it to start. Among the various means available,
automobile now use:

Electrical cranking system

Manual cranking system
Hydraulic cranking system

The starter motor used in automobiles is incorporates a magnetic switch that shifts a rotating gear in to
and out of mesh with the ring gear around the circumference of the flywheel.

The major components of the starter motor

is a device used to rotate (crank) an internal-combustion engine so as to initiate the engine's
operation under its own power. Starters can be electric, pneumatic, or hydraulic. The starter can also
be another internal-combustion engine in the case, for instance, of very large engines, or diesel
engines in agricultural or excavation applications.

1. Main Housing (yoke)

2. Overrunning clutch
3. Armature
4. Field coils
5. Brushes
6. Solenoid
 Magnetic Switch it consists of a hold in and pull in coil, a return spring a plunger and other
components. It is activated by the magnetic forces generated in the coil and carries the following
functions, It pushes the pinion gear to mesh with the ring gear It serves as a relay allowing heavy
current to pass from the battery to the starter motor.

Starter Housing it is a heavy cylinder machined case that holds the starting motor assembly. Steel
pole shoes are securely attached to the inner surface by screws the pole shoes hold the field coils in
place inside the housing. The field coils are connected to a terminal and are insulated from the
housing.

Field Coils the electrical current from the magnetic switch flows thoroughly the field coils which
generates the magnetic field required to rotate the armature.

Brushes the brushes are pressed against the segments of the armature commentator by the brush
springs and allow the current to pass from the field coils to the armature.

Armature the armature which is the revolving component of the motor consists of armature core
armature coils, commutator, etc. It revolves as a result of the interaction between the magnetic fields
generated by the armature coils and field coils.

Commutator End Frame the commutator end of the housing and supports the commentator end of
the armature in a bushing. In many starter motors the commutator end frame also supports the brushes.

Drive Housing the drive housing supports the driving end of the armature shaft and also contains the
mounting flange by which the starting motor is attached to the engine.

Working principle of the starter

Basic starting System of the ignition switch energizes the solenoid then solenoid energizes the
starting motor. The starting system uses battery power and an electric motor to tum the engine
crankshaft for engine starting. When the automatic lock mesh with the gear in to the starter and the
power is short whether directly or indirectly the rotor crank the engine and the engine get a power then
the automatic backs in to its position. It also has connection negative terminal to the ground and
positive terminal to the power source.

Starter clutch during cranking

The rotating armature tires to force the clutch housing to which it is splinted to rotate faster than
the Inner race which is combined with the pinion gear. The clutch rollers are forced to roll towards the
narrow section between the clutch housing and the inner race until they jam as a result the rollers
transfer the rotational moment of the clutch housing to the inner race and to the pinion gear.

Charging system
o Recharges the battery after cranking.
o Supplies the car's electricity when the engine is running.
o Provides an output voltage slightly higher than the battery voltage.
 o Changes the output to meet varying loads.
Charging system components
Alternator generator that uses mechanical power to produce electricity.
Voltage regulator controls the output voltage of the alternator.

Alternator drive belt links the engine crankshaft pulley with the alternator pulley and drives
the alternator.

Charge Indicator informs driver of the charging system condition.

Battery: provides current to initially energize the alternator field stabilizes the alternator
output.

Alternator
Pulley Mechanical energy is transferred from the engine to the alternator by the grooved drive belt
on a pulley arrangement. Through electromagnetic induction , the alternator changes this mechanical
energy into electrical energy. The alternating current generated is converted into direct current by the
rectifier, a set of diodes which allow current to pass in only one direction. It consists of a spinning set
of electrical windings called rotor, a stationary set of windings called stator, a rectifier assembly, a set
of brushes to maintain electrical contact with the rotor.

1. Alternator Housing
2. Rotor
3. Stator
4. IC regulator
5. Rectifier diode
6. Fan and Pulley assembly

Alternator Housing
The housing usually made up of two pieces of die-cast aluminum. Aluminum is used because it is
non-magnetic, light weight material that provides good heat dissipation.

Stator Assembly
The stator is clamped between the front and the rear housing. A number of steel stampings are
riveted together to form its frame. The stator contains 3 sets of wire that have many loops each and are
evenly distributed to form a three phase system. On some systems, the wires are connected to each
other at one end and are connected to a rectifier assembly on the other end. On other systems, the wire
is connected to each other end to end, and at each of the three connection points, there is also a
connection to the rectifier.

Rotor Assembly
The rotor assembly consists of a rotor shaft, a winding around an iron core, two pole pieces, and
slip rings. The rotor is pressed into the core. Six - fingered, malleable, iron pole pieces are pressed on
to the shaft against each end of the winding core. A slip ring assembly is pressed on to the rear end of
the rotor shaft and connected to the two ends of the two windings.
Rectifier Assembly
The rectifier assembly consists of six diodes mounted either in the rear housing or in a separate
small housing called rectifier bridge. Three of the diodes are connected to ground, and three are
mounted in an insulator.

IC Regulator

Regulates the charging voltage that the alternator produces, keeping it between 13.5-14.5 volts to
protect the electrical component through the vehicle.

Ignition system
► Tums a spark ignition engine on and off

► Operates on battery or alternator voltage.

► Creates a high voltage arc at the spark plug
► Distributes high voltage to each spark plug in the correct sequence.
► Times the spark.

Basic ignition system

► Changes battery voltage to a very high voltage
► Sends the high voltage to the spark plugs

Components of ignition system

► Battery
► Ignition switch
► Ignition coil

Ignition Coil Windings

Primary: several hundred turns of heavy wire wrapped around or near the secondary windings.
Secondary: several thousand turns of fine wire located inside or near primary windings
Iron core: concentrates the magnetic field.

Ignition timing
► Spark timing
► How early or late the spark plugs fire in relation to piston position

► Changes with speed, load, and temperature

Engine firing order

► Sequence in which the spark plugs fire.
► Firing order information is used when installing plug wires, installing a distributor, setting
ignition timing, and performing other tasks.

2.10 Engine diagnostics

2.5.1 Some Diagnostic Techniques
Visual Checks:
 Oil level and condition
Coolant level and condition
Oil leaks

Engine Smoke: The color of engine exhaust smoke can indicate what engine problem might exist.
Black Smoke exhaust: Caused by incomplete combustion due to a lack of air or fault in injection
system that could cause excessive amounts of fuel in the cylinders.
White Smoke exhaust: The most common causes of white exhaust smoke are:

► Inoperative glow plugs

► Low engine compression
► Incorrect injector spray
► A coolant leak into the combustion chamber
Blue Smoke exhaust: Usually due to oil consumption caused by worn piston rings, scored cylinder walls, or
defective valve stem seals.

Engine over heating problem

Leakage in cooling system Blocked passage ways

A failing or defective water pump effectiveness (increased stopping distance).

A faulty thermostat A faulty radiator

A loose belt Worn out hose

 Alternator Testing ety
gloves.
I tried to observe about
Inspect
alternator which is an electrical
the case
machine it is used to generate
and
electrical DC voltage after the
termina
engine start its work and to charge
ls for
the battery, and also the voltage
physica
uses for general purpose of the
l
vehicles and machineries in order
damage
to activate allover electrical source
.Check
that needs. It alsohas armature,
the
alternator, body, IC regulator, electrol
electrical pins, rotor, brush, etc. yte
Battery maintenance level or
► A
indicato

► l
r eye.

► w ► Clean the battery terminal connections.

a
Ignition switch problems
y
Can prevent the solenoid from working normally.
s
w ► Contacts can wear or bum.
e ► Open circuit causes no-crank condition.
a
r
► Short circuit causes the engine to crank all the
e time
y Ignition System Diagnosing
e Visual Inspection:
p ► Check all spark plug wires for proper routing.
r
o ► Check that all spark plug wires are securely
t attached to the spark plugs and to the distributor
e cap or ignition coil.
►
c Remove the distributor cap and carefully check
►
t
the cap and distributor rotor for faults. Remove
i
the spark plugs and check for excessive wear or
o
other visible faults. Replace ifneeded.
n
a Starting system problem
n Battery problem:
d
► Loose battery connection
s
a ► Corroded battery terminal
f ► Dead battery
 Solenoid problems: Can
cause slow cranking, no
► The large disc-shaped contact can bum and
pit.
►
cranking, or keep the starter
cranking after Windings can open or short.
engine start-up. Starter motor testing
I have seen starter motor which is a type of electrical machine that have an automatic key that is
connected to the negative and positive terminal of the battery and have gears that can mesh with the
engine crank shaft. It also connected to the key by electrical installation and used to start the engine or
to crank the engine, and have rotor, stator, automatic lock, gear, etc.

Charging
system testVisual Inspection

► Loose battery cables

► Damaged battery case
► Corroded terminals
► Belt tension and condition
► Low electrolyte ► Wiring condition
2.5.2 Repair, modify and replacing of parts
There are numerous parts that are required for repaired and replacement, but is
dependent on the state of the vehicle. If the part exists in the store, it will be delivered
to the mechanic, and replaced inplace of the defected parts. Most parts of a vehicle are
repairable during service, with the exception ofparts that have been blown up or
otherwise completely destroyed. For Parts that require repair or modification send to
the machine shop. In the machine shop there are three professionals, who work hand
in hand with the mechanic. Parts are calibrated to determine the magnitude of damage.

Repaired or modified of the above services are done by the machinist based on
mechanic's recommendation. And they may be modifying parts of vehicle or
machineries as the need and necessary of those parts. There are another works
which are doing in these work shop which are available to the enterprise
construction work, and to the construction smooth working performance. Repairing
of tire, brakes, cleaning of pars, gearing, are done in these work shop.

2.6 How good I have been in performing my tasks During my internship

program
I work my tasks in enthusiasm, as well as my supervisor is such a sincere man
when I ask a question he answered courteously. This internship program helped me to
improve my practical skills,leadership skills, upgrading interpersonal and
communication skills and best of all how to work with peoples peacefully. During the
duration of the internship I have been practicing some electrical and mechanical tasks
mentioned before like:
► Maintenance of breaking system
► Replace filters and shock absorber
► Repair and replace lighting system
► Testing and Maintenance of charging system
► Testing and maintenance of starter motor
During performing my work task, some employers had good practical skills so,
when we ask theemployers about something part they share about that thing clearly
and I have got good things from my hosting organization.

2.7 Challenges faced me while performing my tasks and Measures I

have taken in order toovercome challenges
There are few challenges that faced us during our stay in the company are :
► Many mechanics call spare parts of the auto motives by other language such
as Italy so, it isdifficult to understand at the first time.
► Due to there is lack of safety materials; no safety materials were taken for
intern students

► Some engine manual was the oldest and is not written in common languages.
 Measures I have taken in order to overcome challenges In order to
overcome challenges faced me while performing my internship are:
► I made close relationship with each mechanic and electrician of the company to
get full the
information about old engine and other machine.

► I bought by my self-safety materials

► Follow the company's official rule to gate something.

2.3 Challenges we have faced while performing our work task

The main challenges we have faced while we were performing our work task are: -

1. Lack of working clothes and shoes.

2. Technicians were considered us; we are outstanding automotive professional men.
3. Our hand got injured many times because we were not experienced on handling the
tools.
4. It takes time to know the mechanics and work efficiently with them.
5. Because of the work really needs high energy it was difficult for the first month.
6. We were supposed to wear mask because of covid 19 so, it didn't allow us to
work comfortably due to the humidity and inability to breath freely.
2.4 Measurements taken to overcome challenges

1. We tried to buy our own from the market.

2. Apparently share our experience with the technicians.

3. We try to handle the tools carefully as much as possible.

4. We try to be watchful while they are performing tasks.

5. Doing physical exercise in the weekend.

6. We try to buy masks that are light weight and breathable.

3. Over all benefits I gained from internship

This internship training is very important for Ethiopia. It generate skill full generation to create
the new technology on the future. This internship is used to solve the problems and to make
the project. To know how to change theoretical knowledge in to practical. From this internship
improve the following things.
 3.1 Improving practical skill
In spending our internship in Marathon motors for a semester provides me the opportunity to
gain practical skill on work experience that i just can’t get by attending in the class room. This
internship training is very important for Ethiopia. It generate skill full generation to create new
technology on the future and It gives the chance to use my theoretical knowledge on the real
world. It is a great chance to prove the work of my qualification and to show my performance
in real world and getting experience in the real working environment is a great way to build
confidence.
Here is some other skill i develop in my internship period :-
 I have seen the real practical world and understood the work flow and interaction
between different levels of the organization.

 I try to operate machines

 I have developed working on heavy machines without fear and the ability of to
maintaining machines.

 I understand the working mechanism and the required materials of machines found in
the workshop.
 I also improved my sociability with the employs to adapt the working environment

3.2 Improving Theoretical knowledge

Everything that i learned in school are not there in the company. However, I have got a lot of
knowledge that upgraded what i have been learned in the campus. The following are practically
noticed, that i learned in the campus.
 breaking system, axle shaft, and bearing

 Fastening: - like bolting, riveting and welding (electrical art, metal inert gas and
oxygen)

 Thread, screw, gear, and differential

 Combustion process, crank shaft, connecting rod, and cylinder

 Lubrication system: like different type of oil and greases

 cooling of engine: like oil, coolant water and air (for radiator)
 3.3 Improving my interpersonal communication Skill
When I was joined to the first time in MOENCO, it was very hard to communicate with the
compound because of the rule and the regulation of the staff, working language, age variation
But after a week later it was become fine for communicating with workers and applying the
rule and the regulation of the industry and reach in to the common agreement with workers and
I begins exchanging life sharing experience. In the case of internship training communication
skill is the core thing. As we know, for different person have different behavior. In our working
area, there are different workers with their different behavior. So that, this was one of the
problem that i have been faced, but i decided to have a confidence to communicate them. I
started by greeting and asking question about a vehicle. This situation make them tired of that
is asking question about the vehicle and machineries every day. So , we planned something,
that keep the continuity of our relation, since the workers are not much aged .we started raising
ideas and try to have fun by talking about ladies ,jokes ,football and other stuffs which , helped
us to get a nice feedback and they started to share their knowledge.

Generally, i have developed communication skills through:

 Adaptation of those different workers

 sometimes our supervisor and us talked about the whole situation about the compound

3.4 Improving Team playing skills

Team playing skills are one of the basic requirements for the proper working of a good
company, regardless of its size and its service. A company with properly functioning dedicated
working team will always have a graph going up wards with different workers, working as
different team. However, they contribute to a single goal the progress of the company.
For the proper functioning of a team, each member must be sure of his mission, vision,
behavior, working style, and goal. They must personally and organizationally dedicate to the
team. Team members must believe in one another and must be ready to work hand to hand in
both adverse and favorable situation.
General skills such as; good communication skill, concentration, fast decision making, self-
confidence and a well being feeling are important for all team members engaged. So, in our
company any work or problems are accomplished with the co-operation of each other. Thus,
situation makes us to develop a team playing skill, since we were one of the members of them.
3.5. Improving leader ship skills
A leader is a person who has strong principles, courage and dedications to a clear vision.
Developing a power full vision, building strong team and bringing out the best in those you
lead are key facts to experience success as a leader. People follow their leaders because they
are representative of their believe . Those persons have to focuses on common benefits and
goals.
Leader ship is critical management; skill is being the ability to motive a group of people toward
a common goal. It shows the skill, as a manager must master to be successful and shows this
management skills build on each other to wards success .The leader person, first have to
eliminate fear and behave knowledge or an idea about what he going to do with a confidence.
A leader ship person must have a communication skill that helps him to persuade his follower.
In four month duration of the internship, we learn some skills and techniques of leader ship
.Among the skills we developed are ;how to decide a management carrier is appropriate for us
and how to get the train and develop large projects, how to lead, motive, inspire and encourage
workers, develop work ethics, values; like accountability , which is answerable to the decision
and acts we took and transparency , which is our openness of activities that we done to the
customers and works of the company.
we have observed that, during a meeting/a conference of, the branch and service manager
discuses about the work, food preparation in company for the workers, salaries and other
related agenda. During this time, the managers are listening the workers problems and complain
politely. The managers then negotiate with the workers about the problems politely, and decide
the solution with respect to a common benefit. The situation between them is like brothers and
every worker likes them. Clearly, we can see that, this is the result of how the managers treat
their workers. From these situations, we captured how lead a team or a people. Remember, the
creation of opponent/uprising is a result of bad leading system.

3.6. Improving Work ethics skills

If one have strong love to his work we call it, he has work ethics habit. Instruction to develop
strong work ethics are:-
 Arrive to work on time

 Eliminate or reduce absent

 Respect yourself, yours work and others with their work, in addition to these respect
other’s religion, race, language and customs.
  put a positive spin on negative comments, a positive attitude is crucial to have a strong
work ethics. Bring a fresh perspective to problems at work.

 be confident and self- motivated in your ability to handle job responsibility

 Honor your commitment, being independent and creates confidence in your working
capacity. Seek to serve the interests of the company’s goal, objectives and missions. Do
your part to create a productive place to work.

 The quality and quantity of work is a direct reflection of personal characters and
integrity.

 Respect what others contribute to the work environment. Concentrate on your job and
commitment to proactive attitude.

Work ethical employee is a key to productive. All of the employees have to disciplined and
ethical in their working environment. The employees can be considered as a work ethical when
they are:-
 Punctual

 Not absent

 Commitment for work

 Accountable and responsible for my work etc…

3.7. Improving Entrepreneurship skills

It is defined by their habit of innovation and redefines markets. It can be realized that when
someone engages or creates profitable job, which is/are significant for the society. From
entrepreneur principle, the following are some of them. Therefore, we have three alternations:-
 If you have enough money, even if you have neither talent nor profession, you can make
a business by employee those educated or talented persons. To do this first, you have
to study the most needed thing in the community, in the country, or in the world, that
are not or les available.

 If you are not educated/have no profession and money, you may have talent. Therefore,
you can start a business about your talent.