CHAPTER ONE

INTRODUCTION

1.1 HISTORY AND BACKGROUND OF SIWES

The word “SIWES” is common to Tertiary Institutions which run courses that involve

Industrial Training programs. The Student Industrial Work Experience Scheme (SIWES) is a

skills training program designed to expose and prepare students of universities and other

Tertiary Institutions for the Industrial Work situation they are likely to meet after graduation.

It is also a planned and structured program based on stated and specific career objectives

which are geared towards developing the occupational competencies of participants (Mafe,

2009). Currently, participation in SIWES has become a compulsory graduation requirement

for all Nigerian university students offering certain courses like the Sciences, Agriculture,

Medical Sciences (including Nursing), Engineering and Technology, Management and

Information and Communication Technology and other professional educational Programs

and Disciplines in the Nigerian Tertiary Institutions, essential to the technological and

economic development of Nigeria and in accordance to the Education Policy of the

Government.

Before its establishment, Industrialists and other Employers of labour were concerned that

graduates of Nigerian Higher Institutions were deficient in practical background training

preparatory for employment in the industries. The Employers were of the judgment that the

theoretical education going on in Higher Institutions was not responsive to the needs of the

employers of labour. It was in agreement to this that SIWES was initiated and designed in

1973 by the Industrial Training Fund, with the funding solely borne by the Federal

Government (Adali I. A. 2017) and jointly coordinated by the National Universities

Commission (NUC); to acquaint students with the skills of handling employers’ equipment.

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The Student Industrial Work Experience Scheme (SIWES) was established by the Industrial

Trust Fund (ITF) under decree 47 of 1971 as amended in 1990. The policy statement No.1 of

the Fund published in 1973 inserted a clause dealing with the practical skills, to solve the

problem of inadequate practical skills preparatory for employment in industries by Nigerian

graduates of Tertiary Institutions. The scheme is a skill training program designed to expose

and prepare students of Universities, Polytechnics Colleges of Technology, and Colleges of

Education for the Industrial Work situation they are likely to meet after graduation. The

scheme also allows students to make connections and networks, exposing and getting them

familiar with the needed experience in handling equipment and machinery that are not

available in their institution.

The Industrial Training Fund (ITF), as a federal parastatal, was charged with the

responsibility of promoting and encouraging the acquisition of skills in industry and

commerce to generate indigenous trained manpower sufficient to meet the needs of the

economy.

1.2 AIMS AND OBJECTIVES OF SIWES

The SIWES is a Tripartite Program involving the Student, The High Institution, and the

Employer of Labor. It is aimed at exposing students to machines and equipment, professional

work methods, and ways of safeguarding the work areas and workers in industries, offices,

laboratories, hospitals, and other organizations (James-Rugu 2013).

The objectives of the SIWES are to:

a) Provide students with an opportunity to apply their knowledge in real work

situations thereby bridging the gap between theory and practical.

b) Expose students to work methods and techniques in handling equipment and

machinery that may not be available in the universities.

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 c) Prepare students for the industrial work situation they are likely to meet after

graduation.

d) Provide an avenue for students in institutions of higher learning to acquire

industrial skills and experience in their course of study, which is restricted to

engineering and technology, environmental studies and other courses that may be

approved.

e) Make the transition from school to the world of work easier, and enhance students’

contacts for later job placement.

f) Enlist and strengthen employers’ involvement in the entire educational process and

prepare students for employment in industry and commerce (James-Rugu, 2013).

The Scheme has contributed positively to the growth and development of the Nigerian

economy through improved quality of skilled manpower, closer ties between the tertiary

institutions and the industries and increase of output of the Nigerian Labor force.

According to the NUC, SIWES is the recognized and accepted training program, which is

part of the approved Minimum Academic Standard in the various degree programs for all

Nigerian Universities with the major target of bridging the existing gap between theory and

practice by making it possible for students to get themselves exposed to 'real and actual jobs'

scenarios and environments after graduation.

1.3 THE COMPANY

1.3.1 THE COMPANY’S PROFILE

Fix-It Automobile Works (or simply Fix-It), is a modern automobile service and repairing

company established in the year 2008 somewhere along Rukuba Road before it was

permanently moved to where it is now_ opposite first car wash, Rukuba Road, Jos, Plateau

State, Nigeria. The company is an indigenous establishment owned by two brothers: Mr

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Kayode James and Mr Folirunshola James, with a staff strength of approximately 20, with

high skills and experience. Fix-It deals with all kinds of Asian and German cars such as

Mercedes, Toyota, Audi, BMW, Honda, and even American cars like Ford. Though not

equipped with the latest technology available in developed countries, however, with some of

its modern facilities, equipment, machines, and tools required to meet up with the 21 st-century

automobile repair, it had been carrying out correct servicing, maintenance, and repairs of cars

in its environment.

Its first branch started operating officially in the year 2020 at Plot 1189 Gudu District, Gudu,

Abuja (where I was attached).

1.3.2 THE COMPANY'S GOAL

The goal of Fix-It is to Fix the vehicle of their customer to the proper working condition

cleanly and professionally. Because of the priority set on the happiness and satisfaction of the

customer, at Fix-It you don't have to worry, your car will be fixed! There is a liberty given to

clients to approach the company with any concerns about services offered to them. This is

because clients' trust is of great importance in the business of offering honest services.

Its goal is to also provide the employers with the best working conditions and supervision to

repair their client's vehicles. This in turn gives rise to an association of the clients with the

employees.

1.3.3 THE COMPANY’S SCOPE OF SERVICE

Fix-It has the capacity of offering the following services:

 Service and Maintenance

 Diagnosis and Programming

 General Repair and Overhaul

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  Consultancy and Road Worthiness

Fix-It can also link you up to other companies who are good in works like; Upholstery, Body-

Work, Painting, and Sales of authentic Vehicle Parts etc.

1.3.4 HIERARCHICAL STRUCTURE

BOSS

DRIVER
TECHNOLOGIST ADMINISTRATIVE

MECHANIC ELECTRICIAN SECRETARY

CASHIER
SENIOR MECHANIC

STORE KEEPER
JUNIOR MECHANIC

TRAINEE

1.3.5 ORGANIZATIONAL STRUCTURE

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 HEAD

ADMINISTRATIVE WORKSHOP DEPARTMENTS

STORE MECHANICAL/ ELECTRICAL

KEEPER
AUTOMOTIVE
CIRCUITRY
SECRETARY
SERVICE/
MAINTENANCE DIAGNOSIS

CASHIER
REPAIRS AND PROGRAMMING
OVERHAUL

1.3.6 WORKFLOW

SECRETARY CUSTOMER

TESTS DIAGNOSIS

DEPARTMENT

Some of the Fix-It customers include:

 Private Individuals

 Soldiers,

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 Other Institutions

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 CHAPTER 2
MATERIALS AND METHODS: REVIEW OF TRAINING PROGRAM

2.1 DESCRIPTION OF WORK DONE

Fix-It is a modern Automobile Workshop in Jos. With some of its modern facilities and

highly experienced staff, it has been offering standard repairs and maintenance of vehicles

across different clients ranging from private to commercial owners. It is well known for

producing good workers. As a prospective Mechanical Engineer, I chose Fix-it with the

vision of having a broad understanding of automobile repairs and services.

During my 26 weeks IT period at Fix-It, I was attached to the Mechanical/Automotive

Department as a Trainee. I had a small opportunity to learn the basics of scanning a car using

Figure 2.1: Engine Installation of Ford Ranger

a STAR (System Troubleshoot Automatic Read-out) Scanner, in the Electrical Department

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(Diagnosis Section). Job responsibilities in the Mechanical Department include: keeping

equipment and tools available for use, lifting and supporting cars, completing preventive

maintenance such as oil replacement, replacing filters, removal and replacement or rotation of

tires, changing worn-out brake pads, replacing worn-out shock absorbers and springs (using a

clamp), injector nozzles servicing (using the choke cleaner), replacing spark plugs, diagnoses,

participating in engine and transmission overhaul, etc.

2.2 SAFETY PRECAUTIONS

Safety means the condition of being protected from or unlikely to cause danger, risk or

injury. It entails workers’ safety. The purpose of safety is to control risks by reducing or

eliminating them. It also aims to reduce the rate of failures and

if the failure does occur, it is not life-threatening. Safety

usually begins at the early start of any work.

The common workshop accidents which include slips, spills,

burns, hit, etc. are largely caused by poor manual handling of

tools, machines and equipment. Though machines and

Figure 2.2: A Cover-all
equipment can be regarded as sources of danger, however,

about 98% of accidents could be avoided easily provided due to precautions taken well in

time. A very familiar slogan goes on to say that accidents do not just happen but are caused

due to the failure of one element or the other, and the most unfortunate factor is the human

element. The major causes of accidents include; unsafe working positions, improper defective

tools or their improper use and act, etc.

Elementary Workshop Safety Precautions at Fix-It include:

 Never work underneath a vehicle unless it has been properly supported

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  Be sure the engine temperature is down before beginning any work, the engine

manifold, radiator, and exhaust system could be hot and cause burns.

 Never place the hand tools or other objects near the engine, the moving parts could

cause injury to a person or the engine itself.

 Always disconnect the battery when working on electrical systems even when the

vehicle is off.

 Don’t litre the ground with oil but empty all condemned oils into the Drum for

condemned oils.

2.3 TOOLS, MACHINES, EQUIPMENT AND DEVICES

Working in the mechanical

Figuredepartment
2.3: Basicrequires experience,and
Tools, Equipment training and the right tools. The
Devices
tools help you to carry out primary assignments. Without them, the repair is impossible.

However, funny enough, I later discovered that physical strength and its right application is a

requirement in carrying out jobs. Of course, the maintenance and repairs require tools, but

one might have to use some simple concepts of machines, levers, mechanical advantage,

moments, couple, twisting force application etc.

The mechanic cannot perform almost all his jobs without the following tools:

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 1. Wrench:

A wrench (or spanner) is used to exert a twisting force on bolt heads, nuts, and studs. The

best wrench is made of Chrome Vanadium Steel because of its lightweight and high strength.

The size of any wrench used on bolt heads or nuts is determined by the size of the opening

between the jaws of the wrench; which is also the same as the diameter of the Hex-nut and

other types of nut and bolt heads measured across opposite flats. There are many types of

wrenches. Each type is designed for a specific use. Some wrenches used in areas of primary

work assignment include open-end wrench, box wrench, combination wrench, socket wrench

(which has a handle, extensions), adjustable wrench, Allen and Bristol, etc.

Safety Rules for Wrench

There are a few basic rules that you should keep in mind when using spanners. They are as

follows

 Always use a spanner that fits the nut or bolts properly.

 Keep spanners clean and free from oil. Otherwise, they may slip, resulting in possible

serious injury to you or damage to the work.

 Do not increase the leverage of a spanner by placing a pipe over the handle. Increased

leverage may damage the spanner or the work.

 Provide some containers or cases for all spanners. Return them to the case after each

job. This saves time and trouble and aids the selection of tools for the next job. Most

important, it eliminates the possibility of leaving them where they can cause injury to

a person or damage to equipment or loss of the spanner.

 Determine which way a nut should be turned before trying to loosen it. Most nuts are

turned counterclockwise for removal. This may seem obvious, but even experienced

people have been observed twisting at the spanner in the tightening direction

(clockwise) when they wanted to loosen the nut.

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I learnt to be familiar with spanners and their rules, and it helped me select the best spanner

fit for the type of work I am about to do and I am doing.

2. Pliers:

Pliers are made in many styles and sizes and are sued to perform many different

operations. They are used for cutting purposes as well as holding and gripping small

articles in situations where it may be inconvenient or impossible to use hands. The several

kinds of pliers used include slip-joint, spanner pliers, side-cutting and nose pliers.

Important Rules for Using Pliers

 Do not make pliers work beyond their capacity.

 Do not use pliers to turn nuts bolt because it can damage the nut or bolt. Pliers MUST

NOT be substituted for spanners.

3. Striking tools:

A hammer is a popular tool used to apply a striking force. You can’t remove the tie rod end,

some ball joints and some lower arms except by hitting heavily with the hammer.

4. Lifting equipment:

Most automobile repair activities will require the use of some kind of lifting equipment

whether modern or traditional. They are relevant for lifting and lowering and supporting

loads such as the engine, the vehicle and so many others. Lifting accessories like chains,

hooks, eyebolts and rope slings may be used, to attach the load to lifting equipment,

providing a link between the two.

The lifting equipment used includes the crane, jack, pits and supports. A stopper is placed

properly by the tires to prevent unwanted movement of the car.

5. Scanner:

The STAR (System Troubleshoot Automatic Read-out) scanner is used to scan and diagnose

faults in the car. The scanner scans all the electrical-related parts of the car like the Power

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Train, Transmission, SRS, ABS, Chassis, and so many others. It displays troubleshoot codes

for the faults discovered.

NOTE: the scanner doesn’t scan the mechanical related parts of the car like the suspension,

etc., and the troubleshoot codes it presents are to just give the mechanic a hint of where the

problem lies.

6. Screwdrivers:

A screwdriver is one of the most basic hand tools used for removing screws. The tiny

screwdriver is used for “tiny” jobs. Proper use of the screwdriver prevents blurring (that’s

like, too worn) the slot and reduces the force required to hold the driver in the slot.

2.4 THEORETICAL OVERVIEW OF MECHANICAL/AUTOMOTIVE SYSTEMS

2.4.1 THE ENGINE

The engine is the powerhouse of the car. It generates power from the combustion of

compressed air and fuel in a contained cylinder. The heat produced through the combustion is

converted to drive the car and other components attached to the crankshaft pulley by a drive

belt. Fuel and air are the lifeblood of the engine. As such, the more efficient an engine can

utilize fuel and air, the more power it will produce.

Again, the more cylinders there are, the more

pistons are combusting the fuel/air mixture and

therefore more mechanical energy would be

generated to power the car.

There are many engine types that are identified by

the number of cylinders and the way the cylinders

are laid. Of the various Mercedes engines, I have

come to know about include: 272 engines (for C300), 274 engines (a 4 in-line Turbocharged

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Figure 2.4: Engine Configurations
engine for GLC and C300), 276 engines (a V6 engine for E350, C300, GLK, R-Class,), 113

engines (a V8 engine for ML), 278 engines (a V8 engine for G-Wagon, CLS, and GL450),

and so on. Other engines include the 2TR (a 4 in-line engine for Toyota Hilux), 2ZR (for

Toyota Camry), the Bentley W12, and so on.

Engine parts include the engine block (a casting containing all the parts), engine top (which

contains the valves and the camshafts), head gasket (which seals the engine block and top

together), the pistons, crankshaft, oil sump, and the rest.

In producing power, a 4-stroke engine should pass through 4 different strokes to complete

one cycle. These are Intake, Compression, Power and Exhaust strokes. Air enters the engine

through the air manifold and fuel is injected in vaporized form by the fuel injectors into the

cylinders (the combustion chambers) as the engine begins its intake stroke. Due to the intake

force, the piston moves down and the intake valve(s) closes for the piston to compress the

fuel/air mixture by the upward movement of the piston. When the piston reaches the top, the

mixture is ignited by a spark plug to cause a powerful expansion of the gas, which pushes the

piston downward with great force against the crankshaft. Finally, during the exhaust stroke,

when the piston is at the bottom of the cylinder the exhaust valve opens to allow the exhaust

to be expelled to the exhaust system.

The cycle goes over and over and again, very fast, keeping the engine running and producing

power in the order of 1342, as it is for 4 in-line cylinder cars.

2.4.2 THE COOLING SYSTEM

The cooling system comes into play as it is very essential to remove the heat generated from

the engine during operation to avoid engine overheating. The typical system consists of the

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water pump, thermostat, radiator (and fan), coolant (which acts as an antifreeze and corrosion

resistor) and water, hoses and even exhaust system.

While the exhaust pipe and oil work hard to remove heat, the engine still gets heated. But

when the engine is cranked, the water pump, which is bolted to the engine is driven by the

crankshaft pulley via a drive belt, starts to pump the coolant around the engine coolant

passages. During the circulation, the coolant and water surely absorb the heat produced by the

engine and flow toward the radiator inlet. However, the thermostat regulates the coolant until

it reaches an alarming temperature of 180ºF (90ºC). At this instance, the fan is actuated by a

thermostatic switch once the coolant flow passes the thermostat, to enter the radiator. The fan

enhances hot air removal by forced convection. The coolant reaches the lower part of the

radiator with its temperature considerably reduced. The water is then circulated again and
Figure 2.5: The Schematic of the Cooling System
continuously through the engine to maintain an optimal operating temperature and prevent

the engine from overheating.

The radiator is a very important part of a car. It can be quickly located under the bonnet as the

largest component at the front of the car, usually near the engine. Its job is to serve as a heat

exchange medium for water, air, and oils.

2.4.3 THE BRAKING SYSTEM

The fundamental concept of a vehicle’s braking system is simple – the car is in motion and it

needs to stop. The brake disc and drum are the most used braking systems in cars. A typical

brake system consists of the brake disc or drum, calliper assembly, and brake pads or linings.

The calliper is connected to the master cylinder vis hoses that convey brake fluid through the

system.

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On depressing the brake pedal, the brake fluid in the master cylinder is forced out through the

brake lines to the calliper assembly. The pressurized fluid pushes the pistons in the calliper

which in turn pushes the attached brake pads or brake linings against the surface of the disc

or wall of the drum, thus slowing down the rotation of the wheel.

The Anti-lock Braking System (ABS)

The antilock braking system control module is a microprocessor that runs diagnostic checks

of a vehicle's ABS. It processes information from wheel-speed sensors and the hydraulic

brake system to determine when to release braking pressure at a wheel that's about to lock up

and start skidding. The ABS prevents skidding when braking and stability control intervenes

to prevent skids even when the brakes aren't applied.

2.4.4 THE TRANSMISSION SYSTEM

The gearbox, otherwise known as the transmission is that part of the car containing the train

of differential gears and to which the gear lever is connected for switching between gears.

The gearbox is needed to maintain the cruise speed of the car without any disturbance to the

car’s performance.

A car transmission can either be Manual or Automatic. Most cars in the workshop operate on

the Automatic Transmission. It is called Automatic Trans because its transmission gearing at

different levels is done automatically without any assistance from drivers; while manual cars

have the gear lever and the clutch pedal to be used when switching gear levels at different

conditions by the driver. The basic gear positions of an Automatic Transmission are the Park

(P), Drive (D), Reverse (R), and Neutral (N). The Manual Transmission has more gear

positions than the Automatic Transmission.

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You will hear of these terms pertaining Automatic Transmissions:

a. The Valves and the Valve Body

b. Selector and the Selector Switch

c. VGS (Variable Gear-ratio Steering) and TCU (Transmission Control Unit)

The Valves and Valve Body

It serves as the heart and brain of the

transmission. It acts as the control centre of

the transmission. It contains a maze of

channels and passages that direct the

transmission fluid through valves to control

the various clutches… that change gear levels.

The TCU and VGS

Figure 2.6: The Valve Body
The TCU and VGS work together in order to control the automatic transmission with the help

of sensors form the vehicle and data from the Engine Control Unit (ECU), to calculate how

and when to change gears, for efficient performance, and shift quality.

2.4.5 THE EXHAUST SYSTEM

The typical system consists of an exhaust manifold, the catalytic converter, oxygen sensor,

and the muffler. The exhaust manifold collects gases from the multiple cylinders into one

pipe. The exhaust flow passes the catalytic converter which traps toxic chemicals in the

exhaust and then out through the muffler which reduces the engine noise. The oxygen sensors

are mounted along the exhaust system to monitor the level of oxygen in the exhaust gases in

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order to maintain efficient engine operation (through fuel/air regulation) and to monitor the

catalytic converter operation.

2.4.6 THE FUEL SYSTEM

The fuel system stores and delivers the fuel the engine needs to run. The fuel system consists

of the fuel tank, the fuel pump (which has the job of building up a fuel pressure enough to

open the tiny injects of the fuel injectors), the nozzle injectors, the pressure regulator (which

monitors the fuel pulse-weight), the fuel rail, the fuel filter and the canister (which traps

displaced fuel vapour and prevents them from entering the atmosphere, and channels it to the

engine to be burnt).

The Fuel Gauge Sender Unit

In the fuel tank is a fuel gauge sender unit. It is attached to the fuel pump assembly and is

Figure 2.7: The Fuel Gauge Sender Unit

made up of three components (the float, the metal rod/arm, and the variable resistor) which

work together to measure the fuel level and relay the information to the fuel gauge display on

the dashboard. The float floats on top of the fuel in the tank. It is connected to a thin metal

road to a contact inside a variable resistor. The resistor adjusts to the amount of resistance

voltage encountered by sliding a wiper over a resistive element. The wiper is connected to the

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fuel gauge by a wire to an electric device which communicates with the fuel gauge on the

dashboard display.

2.4.7 THE SUSPENSION SYSTEM

The vehicle suspension is the term used to refer to the system of springs, shock absorbers,

and linkages and other components that connect the car to its wheels and allow relative

motion between the two. The basic principles of the suspension system are to reduce road

vibrations from being transmitted to the various components of the vehicle as such keeping

occupants comfortable and reasonably well isolated from bad noises, bumps, vibrations and

road-shock etc. The suspension is also meant to maintain the stability of the vehicle as such

contributing to the car's road-wheel handling and driving quality, and protecting the vehicle

and/or any load from damage and wear.

Shock absorbers are hydraulic devices designed to absorb and damp shock impulses while

driving. They keep the vehicle’s tires in contact with the road surface and control the

unwanted motion of the vehicle by absorbing shocks and blows of wheels, suspension and car

body.

The suspension coil springs are designed to provide a safe and comfortable ride while also

providing additional ground clearance and vibration damping.

2.4.8 STEERING SYSTEM

The direction of motion of a motor vehicle is controlled as desired by the help of the steering

system. When the driver turns the steering wheel, a shaft from the steering column turns a

steering gear. The steering gear moves the tie rod that connects to the front wheels. The tie

rod moves the front wheels right or left.

2.4.9 SENSORS

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Sensors are used in cars to serve as input devices; they react to the environment (remote

sensing) and make diagnosis and faults detection easy. Common sensors include:

a. Oxygen Sensors (or O2 Sensors): they sense the amount of oxygen in the vehicle’s

exhaust. The readings from the sensors are sent as input to the ECU to regulated the

amount of fuel-air ratio in the engine. They are found along the exhaust system.

b. Mass Air Flow (MAF) Sensor: it records the amount of air coming into the engine

and regulates the amount of fuel needed to offset it. It found along the air hose

between the air filer and the actuator.

c. Crank Angle Position Sensor: it is popularly referred to as the “starting sensor”. Its

common location is above the flywheel. This sensor monitors the position or

rotational speed of the crankshaft. This information is used by the ECU to control the

ignition system, the timing, and other engine parameters like the fuel injection and

strokes. Without this sensor the car won’t start!

d. Brake Pad Wear Sensor: it monitors the wear of brake pads. When the pads are

worn to a low level, these sensors give alert for replacement.

e. Vehicle Speed Sensor (VSS): it is responsible for sending a signal to the car’s

computer that tells it how fast the car is traveling. The speed is displayed on the

speedometer on the dashboard.

f. Thermostat: it serves as a temperature sensor and one-way-valve at the same time,

in the cooling system. It monitors the flow of coolant flow in the engine until in

reaches an alarming temperature of 180ºF where it can now allow the hot fluid to

flow pass it to the radiator and then actuate the fan via a thermostatic switch.

g. Camshaft Sensor: it is found above the camshaft gear teeth. It determines the

position of the camshaft as it relates to the crankshaft. This data is then sent to the

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 Powertrain Control Module (PCM) for use with fuel injection and/or ignition system

control

h. Knock Sensor: it is bolted to the engine block to pick up vibrations and abnormal

sounds from the combustion chamber. The information obtained is used by the ECU

to adjust combustion timing to the correct one and thus avoiding knocking (an

inappropriately timed, unplanned, or secondary combustion within the combustion

chamber).

Figure 2.8: Sensors

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 CHAPTER THREE
RESULTS AND ANALYSIS: THE REPAIR AND MAINTENANCE PROCESS

The mechanical systems in automobiles are little complex and some of the problems may

need to be worked on at the workshop.

3.1 ENGINE PROBLEMS AND OVERHAUL

There are many problems that don't only decrease engine efficiency but can knock down your

engine. Overhaul is the opening of the engine to detect and repair engine problems.

Figure 3.1 Engine Overhaul

But however, on a properly running engine, the following engine problems will be within

tolerance:

a. Bad fuel mix: the engine is getting insufficient air or fuel due to clogged air passages,

as well as failure of fuel system or injectors, and impurities in fuel.

b. Lack of compression: worn-out piston rings; valves are sealed poorly due to bent

valves or accumulation of carbon; warpage cylinder top; breakdown of top gasket.

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 c. Lubrication: incorrect oil gauge level; failure to service oil; and use of improper

engine oil.

d. Overheating: warpage top; breakdown of top gasket; and cooling system failure.

e. Misfiring: failed fuel system and ignition; bad fuel/air mixture; worn-out spark plugs;

wrong ignition timing; incorrect engine timing; and bad ignition coils;

f. Drive Belt breakdown

g. Engine will not start

3.1.1 Timing Chain

The simple concept of timing is to have the camshaft and crankshaft to work timely together

and correctly so as the piston and valves will not jamb. It the timing chain that keeps the

crankshaft and camshaft mechanically synchronized, which in turn opens and closes the

valves. For the engine to work at its best, the fuel/air mixture in each cylinder must fire just

timely with the spark plugs. The common causes of timing jump are timing chain stretch

(wear) and faulty adjuster. If the timing is off, damage can occur; a destructive contact of the

valves and piston might occur, misfiring is sure and engine vibration due to rough idling.

Figure 3.2: Blown Piston Head

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 Setting the Timing

To set the timing is not an easy task. You’ll have to dissemble the engine chain cover in order

to gain access to the dampers, the timing chain and adjusters. The faulty adjuster can be

replaced from there. But to set the timing for Mercedes, the crankshaft pulley is turned with a

27mm diameter spanner with its angle 45º mark directly set in line to its proper mark on the

engine block. The front end can now be removed and the markings on the chains and gears

teeth be used to set the timing.

3.1.2 Drive Belt

It is single continuous rubber belt whose function is to transmit power from the engine

crankshaft to several accessories – the alternator, power steering pump, air-conditioner,

compressor, water pump, turbo (in cars with supercharger), and fan (in some cars). Routine

maintenance of the timing belt must be ensured because as little it may be, its breakdown can

disappoint you.

The factors that determine the replacement of the drive belt include the length of use, work

tensioner, loosen/worn belt and cut of the belt (this can cause sudden engine knock).

Furthermore, you might hear squeaking noise from under the bonnet during start-up or car

operation.

Installing Drive Belt of Volks Wagen (Tiguan)

Without assistance, I found it very confusing to install the drive belt, but with assistance I

found the drive belt replacement one of the easiest assignments in the workshop. Below is

simple summary of the whole process.

Wrapping the belt around the grooved pulleys, with the smooth parts against the smooth

tensioner pulley, I started by wrapping the belt around the crankshaft pulley, then around the

A/C compressor and under the smooth tensioner pulley. I held the final loop close to the

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alternator pulley. Placing a 17mm diameter spanner over the bolt end to release the tensioner

arm and carefully slipped the last loop of the new belt over the alternator pulley at the top

corner of the engine. Worn out rollers and adjusters can be replaced also before the belt

installation.

This is basic principle I used to install the drive belt of Mercedes, Bentley W12, Toyota and

other cars. Insofar as the replacement of the drive belt is easy, care must be taken in order to

install it correctly.

3.1.3 Overheating

This is a common issue in almost all cars. Most engines are designed to operate within a

normal temperature range of about 195ºF to 220oF. A relatively constant temperature is

essential for proper emissions control, good fuel economy, and engine performance. But

problems can arise which can cause the engine to run hotter outside its heat and pressure

capacities. This is called Overheating.

The major causes of overheating are failure of the cooling system; blown head gasket, and

warpage of cylinder top. The head gasket is required to seal the cylinder head and the engine

block, but when it gets blown, gases known as blow-by gases from the combustion chamber

escape into the cooling system – causing an increase in thermal pressure, hindering proper

water circulation, leading to bubbling in the radiator cavity and finally rapid engine

overheating. Leakage in the radiator and hoses, faulty thermostat, faulty radiator fan, low

coolant/water lever and faulty water pump and can also cause overheating.

Rectifying overheating

Driving the car outside the engine’s heat and pressure capacities can warpage the cylinder top

and damage engine internal parts. When faced with overheating problems, I learned how to

offer the following replacements:

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 i. All components of the cooling system like the water pump, radiator, hoses, and

thermostat, which are inspected and found faulty are replaced for new ones or fairly

used ones.

ii. The blown head gasket is replaced properly with necessary application of gasket glue.

iii. Always check the engine coolant/water level. If you have to keep topping off the

coolant, that’s an indication of a leak that should be taken care of before it becomes a

major one.

3.1.4 Misfiring

Engine misfire occurs when one of the cylinders in the engine fails to fire properly. A

misfiring cylinder in a 4 in-line engine can result to 25% engine power loss; performance

suffers along with fuel economy, emissions and idle quality.

Since the requirements for combustion are fuel, air, and spark, if any of these is faulty, the car

would misfire. The faults might be loss of spark due to bad spark plugs or ignition coil;

clogged fuel injector nozzles; clogged air passage; and a timing which is off can also cause

misfiring.

Rectifying Engine Misfiring

We have the car scanned first in order to obtain the fault codes. Faulty codes with P, B, or C

means it’s a Powertrain, Body, or Chassis related problem etc... The faults and cleared and re-

scanned again. Persisting faults give a hint of where the problem lies.

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 Figure 3.3: Replacing dead Spark Plugs for 272 (V6) Engine
I learnt how to gauge spark plugs using the 0.08mm diameter feeler gauge and to correctly

replace the spark plugs using either the 14mm or 16mm diameter plug spanner; how to verify

a bad ignition coil; and how to service the fuel injector nozzles using a choke cleaner. The

clogged air filter is changed for a new one or the debris blown-off using an air blower.

3.1.5 Lubrication

In engines, there are parts which move against each other, and this friction wastes otherwise

useful power by converting the Kinetic Energy (K.E) to heat energy. This heat wears away

those parts. Lubrication is the process of using lubricants in order to allow smooth continuous

operation of the car; clean and remove heat from moving parts; and prevent excess stress or

seizures of bearings. Lubrication is required for correct operating mechanical parts such as

the pistons, camshaft, crankshaft, bearings, transmissions, etc. Oil is the life-blood of the

engine and it is pumped from the oil sump to all the moving parts of the engine by an oil

pump.

Engine Oil Service

This means oil replacement. An oil change is one of the most vital aspects of vehicle

maintenance, since without it the oil in the car can become dirty and cause serious damage to

27
the engine. New engine oil is amber in color but gets black and dirty from dirt and other

particles that enter the engine as well as extremely small metal particles.

When it comes to auto-maintenance, there is no service that your vehicle will need as

frequent as an oil replacement. In replacing the oil, the following procedures are safely

carried out in order to successfully and correctly change oil:

1. I ensured that the car well supported or driven onto a pit with a wheel chock (wedge)

safely placed behind the rear wheel(s). This is to allow all of the old oil to drain down.

2. I locate the drain plug from the oil sump and loose it, in order to drain the old oil into

a pan. I re-install the plug when draining has stopped.

3. I removed the oil filter using a filter spanner and replace a new one with proper

sealing.

4. I finally poured in the new oil and ensured that it is gauged using a dip stock to check

the level.

After replacing motor oil, the next thing to do is to “reset the service setting”. This is done in

order to know the next time the driver would need to change motor oil again.

3.2 BRAKING SYSTEM PROBLEMS

Failure of the braking system is very dangerous because it means that you can't stop the

accelerating car! Brake problems usually indicate the need for certain repairs or replacement

of parts. The brake pad wear sensor gives warning signs regarding brake pad wear. A hard-to

press-pedal, grinding sounds of worn-out brake disc, and vibrations in the pedal are all signs

that something is wrong with the brake system.

3.2.1 Brake Pad Replacement:

To replace the brake pad of Mercedes, I do the following:

1. I ensured that the car well supported.

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 2. I locate the caliper bolts and loosed them with a 13mm diameter spanner.

3. I use a screw driver to bar (push) the piston inside in order allow free removal worn

pad and easy insertion of the new pad.

4. I insert the new pads properly and tie back the caliper bolts.

3.2.2 Bleeding:

When the car’s braking distance is increased or when you have to press more on the brake

pedal than usually had, it is an indication that the brake lines need to be bled. Also, after

working on ABS module, the brake lines are bled instantly. Bleeding the brake lines is a

fairly easy and simply process:

1. Locate the bleed valve/screw on the brake caliper assembly.

2. With cap of the master cylinder open, open the bleed valve with a spanner and drain

the trapped air out. Use a bottle to collect the brake fluid. Have someone push the

brake pedal repeatedly. The pressure created by the brake pedal will force the fluid

out of the cylinder and so also the air. I also ensure the fluid in the master cylinder is

maintained at maximum level.

3. Once the brake fluid starts coming out of the bleed valve as a constant stream, have

the brake pedal pushed twice (fully down), close the valve and you are done.

Worn out brake discs are taken to be machined (re-faced) or in bad situations are replaced for

new ones.

3.3 SUSPENSION ISSUES

The components that make up the suspension system are like combat troops serving on the

front lines always. The suspension components just like other components are subject to wear

and tear. The suspension is designed to work together so if one part fails, say the ball steering

linkage or ball joint, the other components’ performance would be affected without

immediate care can lead to further damage and needed repairs. The suspension is a very

29
important component when it comes to life safety, so you should never ignore signs of

problems with the suspension system

Suspension problems come with a number of symptoms that give a wake-up call to see a

mechanic. Many drivers become aware that it is time to investigate their vehicle's suspension

components when their car starts to behave abnormal. This can include such times when

strange sounds are heard, like clanking or knocking when driving over bumps. Constantly

correcting the steering wheel to assist the vehicle going straight is another abnormal

experience that require checks on the steering system as well.

During my training period I enjoined in the following general suspension repairs:

replacement of springs, ball joints, steering linkages, wheel bearings, arms, and bushings; re-

tightening loose parts; replacing bad tires, engine sittings, gearbox mount, and shock

absorbers. I learnt to make available the necessary tools required for suspension works. These

include: 18/19mm diameter spanner, T40 Allen Key, a hammer, 21/22/23mm spanner, 10mm

spanner, 16/17mm spanner, clamp (for shock springs), etc.

Finally, drivers are advised to always check the well-being of the suspension system of their

car. WHEN YOU FEEL ANYTHING, DO SOMETHING QUICKLY ABOUT IT.

3.4 TRANSMISSION PROBLEMS AND REPAIRS

Burnt fiction plates, worn out and dirty ATF (Automatic Transmission Fluid), slow or harsh

gear engagement/shifts into higher gears while driving are common transmission issues.

The Mercedes GL 450 gearbox (an automatic gearbox) was the first and last one I engaged in

its overhaul. The car was not 4MATIC, as such it wasn’t hard to remove the gearbox. At the

first instance, a knock sound has been heard while shifting between gears and it was

diagnosed to have burnt fiction plates. We had them replaced for good ones from another

30
fairly used gearbox. During the replacement, I tried to observe the orders of replacement: the

reverse (which happens to be the strongest of all) comes first, then the neutral, drive and

finally the park gear. But still yet, I couldn’t fully grab the gears and their replacement orders

that well, so I resolved to wait for another opportunity.

Yet, I learnt how to the special funnel to replace the ATF for new one.

Figure 3.4: Replacing Automatic Transmission Fluid (ATF)

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 CHAPTER FOUR

OBSERVATIONS, CONTRIBUTIONS AND CHALLENGES ENCOUNTERED

4.1 OBSERVATIONS

I first of all marked the difference between theory (in school environment) and practical (in

industries) and tried as much as possible to relate the two. The school environment impacts

the theoretical knowledge while the industries impacts the knowledge and experience of how

to put the knowledge acquired in the class room into practice.

I observed that neatness is a key attribute in the workshop even though the job is usually seen

as a dirty job, mechanics are always admonished to be as neat as possible in their dressing

and in carrying out their duties. Daily work routine has it that we sweep to keep the shop

clean and to also make the working environment oil free.

Communication is another important element in the successful execution of jobs; from among

personnel in a section to departments communication with other departments present in the

company and also customers with company's personnel. Lack of good flow of information

between workers results to most jobs returned. As such, I had to learn the Workshop

Language too! I got to understand most key concepts in my department of primary

assignment through communication by way of asking questions. I learnt how to identify the

various different tools, equipment and machines and their respective applications in the repair

of the various car systems.

At this stage it is important to state an organized approach to problem solving that I observed

(though certain steps are recursive). The six steps are:

1. Collect evidence;

2. Analyze evidence;

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 3. Locate the fault;

4. Find the cause of the fault and remedy it;

5. Rectify the fault (if different from 4);

6. Test the system to verify that repair is correct.

Safety is of great importance while working. It is the primary goal of every staff and

mechanic of Fix-It. Thus, safety instructions were always reiterated before starting any work.

I was urged to always take safety first. Although tools are machines are available for work,

the sixth sense and physical strength are required too!

4.2 CONTRIBUTIONS

My contributions were shown in my work done and services offered as a trainee in the

automobile/mechanical department, which was basically general repairs, service and

maintenance. I was able to maximize the job efficiency and work output in my section

through running errands and participating in the little part of the job I could do and whichever

case, improved work output and job efficiency. I was able to elaborate the theoretical

working principles of some systems to the workers while working with them. It was very

interesting because they practically know how it works while I theoretical know how it

works! As such, in that sense, I tried correcting some workers on the correct names and

pronunciation of some mechanical parts and systems they have misunderstood and

misconstrued.

4.3 CHALLENGES ENCOUNTERED

In everything we do in life, there are limitations to the extent in which we can go and which

we desire to go. This practical and technical report is not an exception.

We accept that the scheme should be for the acquirement of practical skills needed by

undergraduates necessary for their field of study. Due to time impediments, I had to train

33
basically under one department at Fix-It_ the Mechanical/Automobile Department. During

my first days of training, prior to other challenges, I found it difficult to pick the right tools,

nuts and bolts etc., for particular work processes. Although due to perpetual observations and

experience, I overcame it. Another challenge was the inappropriate coordination of some of

the workers which sometimes creates an unfriendly environment for learning. I asked a lot of

questions about things I don’t know/understand. Some of which I got answered correctly,

while some I am let to do my own research. I wasn’t challenged by the workers when it

comes to respond to my questions; in fact, they urged me to ask. It is just that the nonchalant

behavior of some workers resulted to wrong explanations and conflict of answers from the

different staff.

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 CHAPTER FIVE
CONCLUSION AND RECOMMENDATION

5.1 CONCLUSION

My twenty-six (26) weeks SIWES at Fix-It Automobile Works as a SIWES student was a

huge success accompanied by a great time of skills acquisition and new knowledge. Through

the training, I appreciate my area of discipline even more, because I had the opportunity to

blend the theoretical knowledge acquired from the classroom with the practical work

application of knowledge gained here to perform very important tasks that contributed in a

way to my productivity in the company.

Among the many practical skills, I have learned include engine oil servicing; brake pad

replacement; alternator replacement; drive belt installation; how to participate in a successful

engine and gearbox overhaul and installation with other Mechanics; how to bleed the brake

lines; tire rotation; and so many others. As it is been exclaimed in the workshop, “are you not

a mechanic?”, I was challenged to reason deep while facing or solving any problem rather

than being fed by experienced mechanics on what to do. This impelled me enough to employ

all that I can, in order to solve the problem at hand. Indeed, personal experience is the best

teacher.

My training here has given me a wider view of the importance and relevance of Mechanical

Engineers in the immediate society and the world at large, as I now look forward to

impacting it positively after graduation. I have also been able to improve my communication

skills and thereby developed good relationships with my fellow colleagues at work and

expanded my connection/network.

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5.2 RECOMMENDATION

The SIWES scheme is such a crucial program in the training of the workforce for Nigeria,

that it must be vibrant, in providing the needed skills that form the basic objectives of the

scheme. I hereby recommend that:

1. All establishments that receive SIWES students should have expert professionals

specifically assigned to train SIWES students more thoroughly.

2. Regular supervision of the SIWES students can immensely increase the value of this

program in the eyes of the students.

3. Allowances and some form of financial assistance should be offered to students by the

establishment during their training. This would help them handle some financial

problems, motivate them to work harder, and achieve excellence in the scheme.

4. The government should provide a constitutional framework that would compel

establishments to accept a certain number of students yearly for the SIWES program.

5. Code of conduct for SIWES students should be encouraged.

36
 REFERENCES

Aiyeki Adolor-David (2016): Technical Report from University of Benin, Benin State

Nigeria

Automotive Industry Training Retail, Service and Repair AUR05 Learning & Assessment Resource

AURT210170, Inspect and Service Braking Systems.

Charles Fayette Taylor (1995) The Internal Combustion Engine in Theory and Practice: vol.
1 & 2.

Friday Abolorunke (2017): Technical Report from University of Benin, Benin State Nigeria

How To Write A Good & Presentable SIWES Report (2020).mhtml

http://www.obd-codes.com/trouble_codes/

NAPA (1998) Institute of Automotive Technology. Introduction to OBD II

Paul Dempsey. (November 5, 2007). 4th Edition: Troubleshooting and Repair of Diesel
Engines

SIWES. (2008). Retrieved January 2015, from ITF: http://odich.com/itfnig/siwes.ph

Society of Automotive Engineers (1998). Automotive Engineering Handbook. Warren dale,

PA: Society of Automotive Engineers, Inc.

Taylor, C. F.: The Internal Combustion Engine in Theory and Practice, vol. I, p. 506, MIT

Press,

wikipedia.com/automobile/dictionary

Willard W. Pulkrabek: Engineering Fundamentals of the Internal Combustion

Engine

37
 LIST OF FIGURES

Figure 2.1: Engine Installation of Ford Ranger

Figure 2.2: A Cover-all

Figure 2.3: Basic Tools, Equipment and Devices

Figure 2.4: Engine Configurations

Figure 2.5: The Schematic of the Cooling System

Figure 2.6: The Valve Body

Figure 2.7: The Fuel Gauge Sender Unit

Figure 2.8: Sensors

Figure 3.1: Engine Overhaul

Figure 3.2: Blown piston head

Figure 3.3: Replacing dead Spark Plugs for 272 (V6) Engine

Figure 3.4: Replacing Automatic Transmission Fluid (ATF)

38