A TECHNICAL REPORT ON THE STUDENTS

INDUSTRIAL WORK EXPERIENCE SCHEME (SIWES)

UNDERTAKEN AT

SEE AUTO MECHANIC WORKSHOP, BENIN CITY.

BY

OGBEIDE FRED

(Matriculation Number: ENG/MEC/20002011)

THE DEPARTMENT OF MECHANICAL ENGINEERING

FACULTY OF ENGINEERING

EDO STATE UNIVERSITY UZAIRUE

SUBMITTED IN PARTIAL FUFILLMENT OF THE AWARD OF

BACHELOR OF ENGINEERING (B.ENG) DEGREE IN
MECHANICAL ENGINEERING

FROM

MARCH TO OCTOBER 2024

 ABSTRACT

This Industrial training report presents the experience gained during my 6 months

of industrial training undertaken at See Auto Mechanic Workshop, Airport Road,

Benin City. My training was on the diagnosis, repairs, maintenance in automobile

vehicles ranging from cars, SUVs, light trucks and pick ups. During this period, I

acquired practical knowledge on how to repair, replace and install some

mechanical parts and systems also assisted in providing the units the functionality

they need. This report discusses the technical skills gained during the training

period and justifying the relevance of the scheme in equipping students with

needed technical competence to thrive in the real world

 DEDICATION

This report is dedicated to Almighty God for His mercy and grace upon my life

during my industrial training at See Auto Mechanic Workshop and who has made

the completion of this report possible

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

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

 ACKNOWLEDGEMENT

My sincere appreciation and gratitude goes to the management and staffs of the
Department of Mechanical Engineering, Edo State University Uzairue. To the
entire staff and management of See Auto Workshop, I would love to express my
heartfelt gratitude. My appreciation goes to See Auto Workshop. Mr. Elias
IBRAHIM and Mr. Owobamiduro, Oluwatobi for their great encouragement and
support for this six months IT.
 CERTIFICATION

This is to certify that this work was carried out by me OGBEIDE FRED Matric

number: ENG/MEC/20002011 at SEE AUTO WORKSHOP for the duration of 6

months has been duly completed has required by the Industrial Training Fund

(ITF) and Department of Mechanical Engineering, EDO STATE UNIVERSITY

UZAIRUE Auchi, Nigeria

___________________________ ____________________________

Supervisor Date

____________________________ ___________________________

Head of Department Date

TABLE OF CONTENTS

Title page

ABSTRACT ii

DEDICATION iii

ACKNOWLEDGEMENT iv

CERTIFICATION v

TABLE OF CONTENTS vi

1.0 INTRODUCTION

1.1 Background
1.2 Objectives

2.0 DESCRIPTION OF THE ESTABLISHMENT OF ATTACHMENT

2.1 Location and Brief history of establishment

2.2 Objectives of establishment

2.3 Organizational Structure

2.4 The various departments and sections in the establishment

2.5 Description of workdone

3.0 SAFETY PRACTICES AND PRECAUTIONS IN THE WORKSHOP

3.1 Safety Practices

3.2 Safety Precautions in the Workshop

3.3 Equipment used and their functions

3,4 What is Automobile?

3.5 Who is an Automobile Engineer?

3.6 Purpose of Automobile Maintenance

4.0 Overview of work carried out and experience gained

4.1 Automobile Servicing

4.1.1 Purpose of Automobile Servicing

4.1.2 How Automobile Servicing is carried out

4.2 Automobile Engine

4.2.1 Description of an Automobile Engine

4.2.2 Lubrication/ Cooling system

4.2.3 Ignition system

4.2.4 Emission system

4.3 Driveline/ Drive train, Power transmission and Running system

4.3.1 Clutch system

4.3.2 Transmission system

4.3.3 Suspension system

4.3.4 Steering system

4.3.5 Braking system

4.4 Automobile Electrical system

4.4.1 Starting system

4.4.2 Charging system

4.5 Repair and Maintenance process

4.5.1 Electrical Safety information

4.5.2 Tools required

4.5.3 Problems that affect the Electrical system and solutions

4.6 Troubleshooting of Automobile and Car Diagnostic Test

4.6.1 Troubleshooting of Automobile

4.6.2 Car Diagnostic Test

5.0 Summary, Conclusion and Recommendations

5.1 Summary and Problems encountered during the program

5.2 Conclusion

5.3 Recommendation
1.0 INTRODUCTION

1.1 Background

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

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

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

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

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

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

See Auto Mechanic Workshop which is located at Airport Road, Benin City. Is an
indigenous establishment that deals with passenger and light goods vehicles such cars, station
wagon, jeep, bus, truck and pick up. Though not equipped with the latest technology available
in developed parts of the world, however with its equipment and tools it had been carrying out
proper servicing and maintenance of customer’s vehicle. The establishment was founded in
2009 by its current Chairman/CEO (Mr. Olokode Olaleye) it has a staff strength of
approximately 20.

2.1 Location and Brief history of establishment

See Auto Mechanic Workshop which is located at Airport Road, Benin City. See Auto
Workshop was established in 2009. It was established by Olokode Olaleye, who is an
automobile engineer with the aim of having a company being the foremost automobile
technical support company whose services are likened to what is obtainable in the international
world and to provide solution to automobile problems by using standard technique and
modern equipments.

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

2.2 Objectives of establishment

See Auto Mechanic Workshop goal to our clients is to fix your vehicle to the proper
working condition in a clean and professional environment, so that you are happy and satisfied
with the service that was performed. We also want you to have the trust and confidence in us
that you are being treated honestly and fairly. Also to have the freedom to approach us at any
time with any questions or concerns with the service that you are receiving. The goal to my
employees is to provide them with the bet working conditions possible with the proper tools
and equipment to repair our client’s vehicles. This in turn gives them the privilege to associate
with happy, satisfied and dedicated clients. Also, for the employees to have the freedom to
input on how to better improve the working conditions to better service our clients.
2.3 Organizational Structure

DirCector

Manager

Engineer 1 Engineer 2

2.4 Company departments:

In the area of specialization Special Gift Technical Services has the capacity of providing the
following services

1. Sales

2. Service and Maintenance

3. Panel Beater

4. Provision of authentic spare parts for vehicles

Sections in the company

1. Mechanical workshop

2. Welding

3. Vulcanizing

4. Electrical section
2.5 DESCRIPTION OF WORK DONE
During my stay in See Auto Mechanic Workshop, I was assigned to the service and
maintenance department as a Diagnosis/Mechanical Technician. Job duties in the department
includes; Keep equipment available for use, inspecting and testing vehicles; completing
preventive maintenance such as engine tune-ups, oil changes, replacing filters, wheel balancing.
Maintaining vehicle functional condition by listening to operator complaints; conducting
inspections, repairing engine failures, repairing mechanical systems malfunctions; replacing
parts and components. Verifies vehicle serviceability by conducting, test drives; adjusting
controls and systems.

3.0 SAFETY PRACTICES AND PRECAUTIONS IN THE WORKSHOP

3.1 SAFETY PRACTICES

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

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

 Ignorance
 Over-confidence
 Carelessness
 Poor maintenance of equipment and engineering facilities
 Poor working condition/environment
 Tiredness
 Lack of protective devices
 Unsuitable clothing
3.2 SAFETY PRECAUTIONS IN THE WORKSHOP

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

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

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

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

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

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

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

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

3.5 Who is an automobile engineer

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

3.6Purpose of automobile maintenance

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

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

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

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

4.0 OVERVIEW OF WORK CARRIED OUT AND EXPERIENCE GAINED

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

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

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

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

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

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

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

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

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

4.1 Automobile Servicing

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

4.1.2 How automobile servicing is carried out

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

4.2 AUTOMOBILE ENGINE

4.2.1 Description of Automobile Engine
Internal combustion engines run on a mixture of fuel and air, the core of the engine is the
cylinder, with the piston moving up and down inside the cylinder and this takes place in a four
stroke process, which are intake, compression, Power and Exhaust. The piston moves down on
the intake stroke, the intake valve is open and the fuel air mixture is admitted into the cylinder,
and the piston moves up during the compression with stroke both valves are closed,
compresses the trapped fuel air mixture that was brought during the intake stroke, thereafter
the spark plug fires, igniting the compressed airfuel mixture which produces a powerful
expansion of the vapor which is used to drive the crankshaft and this is the power stroke.
Finally during the exhaust stroke, where the piston is at the bottom of the cylinder the exhaust
valve opens to allow the burned gas to be expelled to the exhaust system.

Engine Types
The majority of engines in motor vehicles today are four stroke, spark ignition internal
combustion engine. There are several engine types which are identified by the number of
cylinders and the way the cylinders are laid. Straight line cylinders have their cylinders in row
while the “V” arrangement uses two banks of cylinders side-by-side and its commonly used in
V-6, V-8 configurations
Some automobile engine parts include;
Spark plug
The spark plug supplies the spark that ignites the air/fuel mixture so that combustion can
occur. The spark must happen at just the right moment for this to work properly Valves The
intake and exhaust valves open at the proper time to let in air and fuel and to let out exhaust.
Piston
Piston is a cylindrical piece of metal that moves up and down inside the cylinder.
Piston rings
Piston rings provide a sliding seal between the outer edge of the piston and the inner edge of
the cylinder, the rings serves two purposes.
 They prevent the fuel/air mixture and the exhaust in the chamber from leaking into the sump
during compression and combustion,
 They keep oil in the sumo from leaking into the combustion area where it would be burn and
lost.
Connecting rod
The connecting rod connects the piston to the crankshaft, it rotates at both ends so that its
angle can change as the piston moves and the crankshaft rotates.
Crankshaft
The crankshaft turns the piston’s reciprocating motion in the cylinder into circular motion.
Sump (oil pan)
The sump surrounds the crankshaft. It contains some amount of oil, which collects in the
bottom of the sump.
Camshaft
The camshaft in an internal combustion engine makes it possible for the engine’s valve to
open and close, the asymmetrical lobes of the camshaft correspond to the engine valves

4.2.2 Lubrication/ Cooling system

Lubrication system
The lubrication system supplies engine oil to each engine part, creating a film of engine oil,
which reduces the effects of friction and wear by allowing engine parts to slide smoothly and
perform optimally.

There are many rotating and sliding parts in an engine. As the engine operates at high engine
speed, if these parts were not lubricated, a great amount of friction would occur, resulting in
wear and seizure. To keep the engine rotating smoothly, the friction on each part needs to be
minimized. Parts are;
a. Oil pump
b. Oil filter
c. Oil strainer
d. Oil cooler
I learnt that oil cooler helps to maintain lubrication properties when the engine oil rises above
100°C. If the temperature rises above 125°C however, engine oil lubrication properties will
deteriorate suddenly. Therefore, to maintain lubrication properties, some engines are equipped
with oil cooler. Normally, all of the oil flows into the oil cooler and then flows to each engine
part after it is cooled.

Cooling system
The cooling system is made up of the passages inside the engine block and heads, a water
pump to circulate the coolant, a thermostat to control the temperature of the coolant, a
radiator to cool the coolant, a radiator cap to control the pressure in the system, and some
plumbing consisting of interconnecting hoses to transfer the coolant from the engine to the
radiator and also car’s heater system where hot coolant is used to warm up the vehicle’s
interior on a cold day.
A cooling system works by sending a liquid coolant through passages in the engine block and
heads. As the coolant flows through the passages, it picks up heat from the engine. The heated
fluid then makes its way through a rubber hose to the radiator in the front of the vehicle. As it
flows through the thin tubes in the radiator, the hot liquid is cooled by the air stream entering
the engine component from the grill in front of the car. Once the fluid is cooled, it returns to
the engine to absorb more heat.
4.2.3 Ignition System
The three essential elements of a gasoline engine are: good air-fuel mixture, good
compression, and good spark.
The ignition system generates a powerful spark through proper ignition timing in order to ignite
the air-fuel mixture.
1. Powerful sparks: In the ignition system, sparks are generated between the electrodes of the
spark plugs to burn the air-fuel mixture. Because even air has electrical resistance, when it is
compressed highly, tens of thousands of volts must be generated to ensure the generation of
powerful sparks that can ignite the air-fuel mixture.
2. Proper ignition timing: The ignition system must provide proper ignition timing at all times to
accommodate the changes in engine speed and load.
3. Sufficient durability: The ignition system must be able to provide sufficient reliability to
withstand the vibrations and heat that are generated by the engine. The ignition system uses
the high voltage that is generated by the ignition coil to produce sparks, which ignite the air-
fuel mixture that has been compressed. The air-fuel mixture is compressed and burns in the
cylinder. This combustion generates the motive force of the engine.
Through self-induction and mutual induction, the coil generates the high voltage that is
necessary for ignition. The primary coil generates several hundred volts and the secondary coil
generates tens of thousands of volts.
The types of ignition systems are as follows:
1. Breaker points type
2. Transistorized type
3. Transistorized type with ESA (Electronic Spark Advance),
4. DIS (Direct Ignition System)
Instead of a distributor, this type employs multiple ignition coils to supply high voltage directly
to the spark plugs. The ignition timing is controlled by the ESA function of the engine ECU. This
system is predominant in recent gasoline engines
How to Inspect Ignition system:
1. Allow the engine to warm up and short the terminal TC and CG on DLC3. Read the blinking
pattern of the MIL(Malfunction Indicator Lamp)
2. Check spark: if there is no spark, then the engine will never start
Spark test
(1) Disconnect all injector connecters so that fuel cannot be injected.
(2) Remove the ignition coil (with igniter) and spark plug.
(3) Re-install the spark plug in the ignition coil.
(4) Connect the connectors with it, and ground the spark plug. Check that the spark plug
generates a spark when cranking at this condition. This test determines which cylinder does not
have a spark. NOTICE: Do not crank for the spark test over 5 - 10 seconds.

4.2.4 Emission System

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

4.3 Driveline/ Drive train, Power transmission and Running system

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

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

Clutch Troubleshooting and Overhaul

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

4.3.2 Transmission system

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

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

Transmission Troubleshooting and overhaul

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

sensors
(Various signals) Engine & ECT ECU
Vehicle speed sensor Counter gear speed sensor
Oil pump
Planetary
Torque converter gear unit
Automatic Transmission or transaxle with its parts.

4.3.3 Suspension system

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

It consists of the following principal components:

1. Springs: Neutralize the shocks from the road surface.
2. Shock absorbers (dampers): Acts to improve riding comfort by limiting the free oscillation of
the springs.
3. Stabilizer (sway bar or anti-roll bar): Prevents lateral swaying of the vehicle.
4. A linkage: Acts to hold the above components in place and to control the longitudinal and
lateral movements of the wheels.
Sprung Weight
The body is supported by springs. The weight of the body, etc., which is supported by
springs is called the sprung weight. On the other hand, the wheels and axles, and other parts of
the automobile which are not supported by springs, make up the unsprung weight. It is
generally said that the greater the sprung weight of an automobile, the better the riding
comfort becomes, because, as the sprung weight is made larger, the tendency of the body to be
jolted decreases.

Types of Suspension and their characteristics

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

4.3.4 Steering system

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

4.3.5 Braking system

A brake system transmits force from a driver’s foot to the car’s brakes. The brake then
transmit the force to the tires and road, where the friction slows and stop the vehicle. Brakes
translate a push of a pedal to slowing down of the vehicle.
In order to decrease the speed of a running vehicle and bring it to a stop, it is necessary to
generate force to slow the rotation of the tires. The energy (kinetic energy) of the tires working
to rotate is converted into the heat of friction (thermal energy) by operating the brakes which
works to stop the rotation of the tires. Some of the terminologies are:

1. ABS (Anti-lock Brake System): An ABS is a brake control unit that uses a computer
 control to automatically prevent the tires from locking due to emergency braking. This
system raises the vehicle stability further and shortens the braking distance. Therefore,
the tires do not lock up and the steering wheel can be steered even when the brake is
depressed suddenly. The vehicle is kept in control, and can stop safely.
2. EBD(Electronic Brake force Distribution): braking force appropriate to the condition of
the vehicle is distributed among the front and rear wheels and left and right wheels
using the ABS brake hydraulic control unit.
3. BA (Brake Assist): The BA is a system that assists brake operation when drivers cannot
apply enough force on the brake pedal
4. TRC (Traction Control system)
Sometimes when the accelerator is depressed too much while starting off or accelerating
on slippery surfaces, etc., the excessive torque that is generated causes the drive wheels to
slip, causing the vehicle to lose the start-off/ acceleration ability and the steering control.
The brake hydraulic pressure control of drive wheel and the engine output control by the
fuel cut-off control lower the motive power when the accelerator pedal is depressed. Thus
the TRC ensures the vehicle start-off/ acceleration ability and steering control.
5. VSC (Vehicle Stability Control system)
While the ABS and TRC are mainly used to stabilize brake operation and accelerator
operation during braking and acceleration, the VSC ensures the “steering and direction
stability” of the vehicle. The system detects sudden steering and sideways slip on slippery
surfaces and then provides optimum control of the braking for each wheel and the engine
power to attenuate front wheel skid and rear wheel skid. The brake control method
(controlled wheels) for the various wheels differs depending on the model (FF, FR).
4.4 Automotive Electrical System
4.4.1 STARTING SYSTEM
Since the engine cannot be started by itself, external power is required to generate the
first combustion to start it. To start the engine, the starter rotates the crankshaft via the ring
gear. The starter is required to generate extremely large torque from the limited power from
the battery and should be compact and light as well. For this reason, a DC (direct current)
series motor* is used for the starter. To start the engine, the crankshaft has to rotate faster
than the minimum cranking speed. The minimum cranking speed required to start the engine
differs depending on the engine's construction and operating conditions, but it is generally 40
to 60 rpm for a gasoline engine and 80 to 100 rpm for a diesel engine.

Description of a Starter A Starter

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

4.4.2 CHARGING SYSTEM

Vehicle is equipped with many electrical devices to drive safely and comfortably. The
vehicle requires electricity not only while driving but also while it stops. Therefore, the vehicle
has a battery for a power supply and a charging system to generate electricity by the engine
running. The charging system supplies electricity to all the electrical devices and charges the
battery.
Charging system mainly consists of the following devices.
1. Alternator : While the engine is running, this generates a nearly equal amount of electricity
to operate the electric devices used for the vehicle and to charge the battery

The functions of alternator include:

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

2. Battery: This is a power source when the engine stops and it supplies electricity to the
electric devices to start the engine or when the alternator does not generate electricity.
However, electricity generated by the alternator is charged to the battery once the engine
starts running.

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

4.4.7 SENSORS AND ACTUATOR

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

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

4.5 Repair and Maintenance Processes

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

4.5.1 Electrical Safety Information

Working with the electrical system in a vehicle is generally quite safe. Automotive
electrical systems run at 12V, which does not pose a danger of shocks or electrocution.
However, many electrical components are easily damaged, so care should be taken when
handling them. Introducing incorrect voltages or currents can break many systems. One part of
the electrical system that is potentially dangerous is the high-voltage side of the ignition coil,
which should not be serviced while power is applied. Additionally, electric or hybrid-electric
vehicles use many high-voltage batteries and powertrains, which are dangerous and
potentially fatal if mishandled.
 4.5.2Tools Required
The simplest tool that can be used in electrical diagnosis is 12 volts test light.. This light can be
used to check if power is being received at any point in a circuit, which can be handy for simple
or quick tests. However, test lights do not provide very much information. A digital multimeter
have two probes that can be connected to a circuit to test voltage, amperage, resistance,
continuity, and more. Basic electrical and automotive tools, such as wire cutters, wrenches,
and screwdrivers, are used to service automotive electrical systems.

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

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

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

4.6 Troubleshooting of Automobile and Car Diagnostic Test

4.6.1 Troubleshooting of Automobile

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

component or the other. Like people, vehicle sometimes experience little hiccups and need a
bit of checkup and some extra attention to get back on track. The most important thing is to
first recognize the problem and then fix it with proper tools because the vehicle might have
been given symptoms like noises, shakes, bumps etc. Here are some common car troubles and
solutions.

1. Problem starting the car: The car will either takes a long time to start or the car won’t
start at all. There are number of reasons which can cause a car engine not to start, the
most common is when the battery is dead. Pay attention to the noise it makes when
turning the key. If the car is completely silent then it might be a problem with the
battery terminal cable connections, but if the car crank and did not start, then it might
be the spark plugs or fuel supply to the engine.
2. Engine overheating: When the engine is overheating, there may be smoke coming from
the bonnet or the needle on your engine temperature gauge may be through the roof.
Overheating can be caused by a few different factors. The simplest cause may be that
the car needs more coolant or the water in the radiator has dried. Yet depleted coolant
can be caused by bigger problem like leaks or faulty hoses, so always check for the
underlying cause before simply filling it up. Another common reason for overheating
may be when the radiator fan which keeps the engine cool is faulty, so check the fan
motor connection and fan thermostat.
3. Noisy brakes: The car will produce more unpleasant sound/ noise. There could be a
number of reasons for noisy brakes. It could be that the brake pads are loose, worn out,
or there may be brake dust inside the drum. If there is nothing wrong with the brake
pad then one can suspect it to be brake dust and brake dust can be extremely
dangerous if accidentally inhaled.
4. Uneven tyre wear: It may not be obvious that the car tyres are unevenly worn, but worn
out tyres can be dangerous due to their reduced grip on the road. The best way is to
jack up the car and inspect each tyre individually, noting whether there are any dips and
dents in the tyre tread. Rotate the tyres and have wheel alignment regularly and do
wheel balancing also.
5. Air conditioner not working: When the air conditioner is switch on and you notice that it
is just blowing room-temperature air around rather than cold air then it is faulty. The
most likely cause of this that there is no refrigerant left in the system. This could be
caused by a leak in the system somewhere which will have to be fixed before refilling
the refrigerant.

4.6.2 Car Diagnostic Test

Regular diagnostic tests can detect problems with the vehicle before they require
expensive repairs or total breakdown. Diagnostic tests can reveal problems within a
car’s engine, transmission, exhaust system, brakes and other major components and as
well as performance issues with the fuel injector, air flow and coolant, ignition coils, and
throttle.
Before emergence of car diagnostic tests, identifying problems was a time consuming
and expensive, especially considering car owners only brought their cars to mechanics
after a break down or severe malfunction. Using specialized software, car diagnostic
tools quickly and accurately point to problem areas in a car’s engine or elsewhere,
thanks to built-in processors, microchips and sensors. Now computerized car
components can detect problems long before they cause a breakdown. Diagnostic tools
can also check a car’s computer system for manufacturer notifications and stored
information about the car’s history, giving technicians a complete picture in order to
perform the best repair possible. You don’t have to wait for the check engine light to get
a car diagnostic test, if you hear or feel something is “off”, mechanics can use diagnostic
testing to uncover car problems. However, many technicians recommend taking car for
a diagnostic check at least once in a year, which will uncover minor problems that can’t
be seen or heard and that won’t trigger the check engine lights.
Skills acquired for effective diagnosing are as follow:
1. Use of appropriate ‘dedicated’ test equipment effectively.
2. Make effective use of wiring diagrams and use of instruction manuals effectively.
 3. Use multi-meters and other (non-dedicated) equipment effectively.
4. Interpretsymptoms of defective operation of a system and, by suitable processes, trace
the fault and its cause.
5. Work in a safe manner and avoid damage to sensitive electronic components.
6. Fit new units and make correct adjustments and calibrations.
7. Test the system, and the vehicle for correctness of performance.

5.0 SUMMARY, CONCLUSION AND RECOMMENDATION

5.1 Summary and Problems encountered during the program

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

5.2 Conclusion

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

Through my training I was able to appreciate my chosen course of study even more, because I
had the opportunity to blend the theoretical knowledge acquired from school with the practical
hands-on application of knowledge gained here to perform very important tasks that
contributed in a way to my productivity in the company. My training here has given me a
broader view to the importance and relevance of Automobile Technology in the immediate
society and the world as a whole, and making me to know that automobile is not only about the
mechanical aspect but also include the electrical/electronic aspect too, now look forward to
impacting the knowledge positively after graduation. I have also been able to improve my
communication and presentation skills and thereby developed good relationship with my fellow
colleagues at work. I have also been able to appreciate the connection between my course of
study and other disciplines in producing a successful result.
I suggest the continuation of orientating of students before starting the program to prepare
their minds towards the task ahead.

5.3 Recommendations

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

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

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

5.3.2 CHALLENGES ENCOUNTERED DURING PERIOD OF TRAINING

  I wasn’t allowed to drive cars after repair. I could not do active test using Diagnostic
machines on my own.

 And I was not allowed to go out to repair car. I was restricted to the workshop.

REFERENCES

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

2. Society of Automotive Engineers (1998). Automotive Engineering Handbook. Warren

dale, PA: Society of Automotive Engineers, Inc.

3. wikipedia.com/automobile/dictionary.