Automobile Report Sample
Automobile Report Sample
Automobile Report Sample
ON
UNDERTAKEN AT
LAFIA, NIGERIA.
SUBMITTED TO
COLLEGE OF ENGINEERING
BY
(16/37320/UE)
DECEMBER, 2020.
ABSTRACT
This report discusses the technical skills gained during the training period and
justifying the relevance of the scheme in equipping students with the needed
technical competence to thrive in the real world.
ACKNOWLEDGEMENT
I will like to start by thanking the Industrial Training Fund for their foresight in
putting this program to place and also to the Mechanical Engineering
department, Federal University of agriculture Makurdi, for providing the
platform on which I was engaged in the training.
My profound gratitude goes to my mother siblings and friends for their support
to ensure I get a placement, also for their moral and financial support. I am
grateful to them.
CHAPTER ONE
1.0. INTRODUCTION
Duration-- Four months for polytechnics and colleges of education and six
months for the universities
To set and control by the standard of excellence and effectiveness in and after
direct training of professionals, technicians, technologist and entrepreneurs
using best of breed training techniques and modern technology as well as highly
motivated competent staffs for rapid industrialization and economic
development of Nigeria. As a way of achieving that vision and mission the
scheme was initiated with the below aims and objectives.
Nasarawa state polytechnic Lafia was established in the year 2000 by the first
executive governor of the state Alhaji Dr. Abdullahi Adamu taking effect in
2001. The first rector is Malam Musa, followed by Dr. Mustipher Onuku,
followed by Mr. Michael Mamma.
On 12 April 2020 the governor of Nasarawa state appointed Dr. Ruth Jeriko as
the acting rector of the polytechnic.
a) National diploma
b) Ordinary diploma
c) Certificate course
d) HND program.
The state government intention in establishing the POLYTECHNIC predicted
on her desire for scientific, technological and professional education in the state.
This is spelt out in the objectives of the polytechnic as contained in that
Nasarawa State Polytechnic law, 2000.
The works department is where all the polytechnic's machines and equipment
and are sent for repair, maintenance and service. The WD consist of six
workshops namely;
2.5. SAFETY
The store or workshop must be suited to the purposes task. Decisions as to what
taste are appropriate for each situation were made by the supervisor.
Solid, liquid or gaseous substances, equipment and fittings may all be stored.
Corrosion or damage of container may cause product leakage, which can
contaminate surfaces below, create slip hazard and may react to ignite a fire or
fume hazard. Other items may have a limited shelf life, and become more
hazardous as they age.
2.6. HAZARD
Shelving must be secured and never overload. Ensure that freestanding shelves
and cupboards are secured to walls.
Materials used for workshop activities should be held at the work area in
appropriate quantities. Bulk storage at the work are is usually unnecessary and
contribute to congestion of work area.
Slips and Falls: Workers should be provided with non-slip foot wear and
proper training in safety procedures to avoid resulting injuries such as
musculoskeletal pain.
Falling Objects: Injuries from falling object may occur when items are not
properly positioned while stationary or not restrained while being moved.
Workers should be trained in appropriate placement and proper techniques for
transporting items such as the use of restraints.
Chemical Burn/Exposure: Chemical burn and exposure accident occur when
the chemicals are not properly contained and labelled with then chemical's name
and subsequent handling procedure.
Improper Lifting: Back spine and limb injuries may occur overtime as poor
lifting techniques resulting from lack of proper training and supervision take
their toll on the worker's body. Workers need to know how to use supportive
equipment and use correct techniques when lifting to avoid this type of injury.
Inspect the ladder: It should have non-skid feet, straight side rails, no visible
damage, and even spacing between the rungs.
Use stepladders safely: Stepladders should fully unfold with the braces locked.
Workers shouldn’t stand on the top step of a stepladder.
Watch out for electrical hazards: Don’t overload circuits, run cords under rugs,
use indoor extension cords outdoors, or forget to turn off the lights on indoor
trees when you go out or go to bed.
Be a team player: it is not advisable to work alone. Get help when carrying
heavy loads, have someone hold ladders steady for you, and share the driving so
that you don’t have to drive when you are drowsy.
2.7. AUTOMOTIVE MAINTENANCE SAFETY
Automobile are big and heavy with lot off mechanical moving parts. In the right
environment, a vehicle can be repaired and maintained safely and effectively.
However, in the wrong environment repairing a vehicle can be dangerous.
The following are rules in the auto workshop I was posted to:
We always wear safety goggles for eye protection. Vehicle repair involve the
use of many types of duet, which splatter, and eye contact should be avoided.
Do not wear ties or any loose hanging clothing. Do not pony tail down or leave
any loose strand of hair. Bundle your hair up if it is long. Do not wear necklace,
rings, or other jewellery. Ideally, the best clothing for performing automotive
maintenance and repair is a mechanic jumpsuit. It is durable, comfortable, there
are pockets for tools and there is nothing loose that can get caught and pulled
into a moving part.
Hazardous chemicals scan includes gasoline, oil, coolant and other vehicle
fluids. Avoid contact with eye and mouth. If you ever have contact with eyes
then flush with cool water for several minutes. Some car fluids can be acidic,
such as battery fluid. If you ever start to feel burning, then flush with cool water
for several minutes, if burning continues then seek medical attention.
Proper clean up materials include shop, rags and "oil dri", which is simply kitty
litter without the fragrance. When a spill occurs, enough "oil dri" is sprayed
over the spill to absorb the entire spill. Then swept with a broom and dustpan
and throw it away. Avoid clutter in work space that can act as fall Hazards. We
also clean up tools after work is finished.
Fig 2.4. Image of oil dri.
The owner's manual will specify where the lifting points are for a specific
vehicle. Often vehicles have their lifting points marked on the running board or
rocker panel. There are a couple of disastrous events that can happen during an
attempt to raise a vehicle without using the proper lifting points. The weight of
the car pressing down and the jack pressing up against can damage the body of
the vehicle. Or worse, the jack could tip or slide while a person is underneath
the vehicle.
Fig 2.5. An illustration, which demonstrates vehicle lift, points for a sample
vehicle.
Any vehicle that has a frame can be lifted by the frame. When the front is lifted,
the jack is usually placed under the axle of it has a solid axle. If it doesn't have a
solid axle, then it should be lifted by the factory recommended lift points.
Vehicles are always placed on firm, level ground. If the ground is not level, then
the car may roll and tilt the jack. A jack or jack stand can also slip out or fail to
hold the vehicle in an elevated position when the ground is not firm.
A jack is used to raise the vehicle ether by hydraulic pumping or hand cranking.
A jack stand is used to keep the vehicle elevated and has a firm square base.
There are different types of Jacks and jack stands. One type of jack that people
are mostly familiar with is the one that is included with the spare Tyre kit. This
is to be used only for changing the Tyre and it is not sufficient for changing
tyres often. It has a four-point rectangular base. This is Nita's stable as a square
base.
A mechanic shop may have industrial Jack or hydraulic lifts. This can be used
to raise the vehicle and keep it elevated. These lifts can raise the entire vehicle
at the same time. When lifting the entire vehicle, the center of gravity is
positioned evenly with the lifting hoist arms. This is evident when a vehicle is
lifted and all the tyres lift off the ground at the same time. Most vehicles are
front heavy due to the engine block. However, many work trucks are balanced
to have their center of gravity in the middle.
Fig 2.7. Hydraulic lifts with hoist arms that raise the vehicle on its lifting points.
3.1.2. Socket Set and Wrenches: These have two different measurement
systems. One is metric system and one is SAE (or Standard). The metric system
has measurements in millimetres (mm). SAE has measurements in inches or
fractions of inches (1/4, 5/16, etc.). Wrenches often have an open end and an
opposite box end.
Fig 3.2a. Image of socket patched wrench
Fig 3.2b. These wrenches have an open end and a box end
3.1.3. Oil Filter Wrench: It has a prying mechanism like other wrenches but
one end has a belt that wraps around the object being unscrewed, which is much
bigger in diameter than the regular bolts and hex-head screws that other
wrenches are used for.
3.1.5. Jacks: These are used to lift the vehicle. Some are rotate by hand. Other
higher-end jacks are pumped. Some are hydraulic.
Fig 3.8. spare tire kit with a spare tire, lug wrench and tire jack. The tire jack is
already placed under the lifting point and partially cranked.
3.1.6. Jack Stands: These are used to keep the vehicle elevated after it has been
raised with the jack. They have a wide square base and come to an apex where
the car rest on.
Fig 3.9. Two Jack stands; the lever shown on the stands is not used to raise the
vehicle but stands to keep the vehicle raised.
3.1.8. Hammer:
This can be any type of hammer and it is used on occasion, such as when
freeing a stuck drum or rotor from its hub.
3.1.10. Funnel
Used to collect vehicle fluids when changing fluids and filters or flushing
systems.
Fig 3.17. Image of Auto Scanner which receives DTC from vehicle’s computer
The owner’s manual has a maintenance chart. The chart includes; the oil, rotate
tires, replace air filter, inspect fuel cap (transmission fluid) and other
maintenance issues. Vehicles may have different maintenance requirements at
30, 000 miles, 90, 000 miles, 150, 000 miles and at other intervals as indicated
specifically in the owner’s manual.
Vehicle fluids include; brake fluid, engine oil, coolant, power steering fluid,
windshield water fluid, transmission fluid and battery fluid.
On most vehicles, the reservoir for brake fluid is clear. You can check the fluid
without removing the cap. There are markings on the reservoir that indicate the
minimum and maximum level. It is important to ensure that the level is between
those two marks. This fluid should never need to be topped off during
maintenance. Low fluid is an indication of a problem.
Engine oil is checked each time the vehicle is refuelled. Most engines, but not
all, have a dipstick to indicate the oil level. Typically, the handle is yellow.
The stick has marks on it. The “add” mark typically indicates one quart low.
This is a sign that there is a leakage and need repairs.
During my Industrial Training, there was a case where oil mixed with oil.
3.2.2.3. Draining Engine Oil
Apparatus
Funnel.
Latex gloves
Procedure
A fluid agent (gas or liquid) that produce cooling, especially one use to cool a
system by transferring heat away from one part to another. The best time to
check the coolant, is in the morning before the car is driven. Opening the
radiator cap while the engine is still hot can shoot a six-foot geyser into the air
and burn any skin it contacts.
There may be a clear reservoir for power steering fluid. If there is, then, it can
be checked the same way as the brake fluid. If it is not, then, it will have a
dipstick. Low power steering fluid is an indication of a leak and it should be
investigated. At a point, the driver may also notice change in steering
performance.
Fig. 3.21. Image of power steering reservoir
Some vehicles have a dipstick, but many new vehicles do not have one. In some
vehicle, one has to go underneath the vehicle to check this fluid. If the fluid is
low, then, there is a leak and it should be investigated. The fluid should also be
red. If the fluid is black and/or has a burnt smell, then, there is a problem with
the transmission.
Fig. 3.22 Image of new transmission fluid
Apparatus
Garden hose
A mixture of baking soda and water was used to rinse off terminals and
battery post.
Wire brush or scrapper was used to clean the inside terminals and battery
post.
Battery posts were reattached, starting with the positive terminal first,
then the negative.
3.2.3. Fuses
A fuse is a device that can interrupt the flow of electric current when it is
overloaded. Fuse can be in anywhere in the vehicle. The owner’s manual is
consulted to locate the fuse boxes in a particular vehicle. Modern vehicle use
blade type fuses. Initially, the plastic and colour-coded part of the fuse is seen.
The colour-coding system for fuses has been used since 1980 and is universal,
indicating the amperage of the fuses.
Yellow----- 20Amp
An easier and faster way to test fuses is with a testing light since the fuses do
not have to be removed. The testing light looks like an electric screwdriver with
a pointed tip. The wire end of the pointing light must be grounded to a clean and
unpainted metal surface of the vehicle. If a place cannot be found on the
vehicle’s body, then the negative terminal of the battery is alternatively used as
ground. The point of the testing light is placed on the metal contacts of the fuse.
Upon contact, the display indicate that the fuse is still good.
During my I.T., there was a case when a belt squeals after starting the engine
and while driving, this indicates a problem with belt tension. Most modern
vehicles have automatic belt tensioners, which keep the belt at the appropriate
tension. Checking the belt tension varies by make and model. It was observed
that modern vehicles only have one belt for all accessories of the engine (i.e.
power steering, air, water pump conditioning and alternator).
At our workshop, belts were checked by visual inspection and touch for signs of
cracking, fraying or glazing. Glazing means, the drive surface of the belt will be
shining.
Hoses were also checked visually and by touching for signs of cracking,
swelling or leaks. When the vehicle is cool, then the hose is squeezed to check
for softness. If there is any variation from hose to hose within the same vehicle,
then that indicate a problem.
While lighting includes instrument panel lighting, warning indicator lights, left
and right turn signals, brake lights, hazard lights, headlights and tail lights, front
marker lights, the licence plate light and lights for the cab and truck.
Fig. 3.25. Image of brake light
During my I.T., when we check vehicle brake light, two people are involved for
inspection. One person presses the brake pedal while the other person checks
the rear of the vehicle to make sure all the brake lights are illuminating.
An air filter removes dust from the air that passes through it. The air filter is
removed and inspected for visual signs of dirt and debris.
Any dirt in the engine can cause engine wear and eventually lead to engine
failure. We inspect the air filter with every oil change and it is changed as
needed.
3.2.7. TYRES
The wear bar is a horizontal bar moulded into the tyre between the treads. The
wear bar indicates safe tread depth. It is usually about 1/16 of an inch measured
from the valley of the tread, but not as high as the tread itself when the tyre is
new. As the tread wears down, the wear bar becomes more visible. When the
tread is even with the wear bar the tyres should be changed.
In order to obtain the greatest mileage from a set of new tyres, it is necessary to
change them around at intervals of about 3000 miles for rear drive vehicles and
2000 miles for front drive vehicles during its useful life.
Apparatus
A spare tyre
A jack
Procedure
Remove the spare tyre and tools from the vehicle. Fig. 3.28{Image of
changing tyre}
Use wheel chocks to block wheels opposite of the wheel you are
changing.
Loosen the lug nuts before lifting the vehicle, but do not remove.
Pump or crank the jack to lift the vehicle, using the proper lift point.
Torque the lug nut (tighten them as much as possible after the vehicle has
been lowered.
Working principle
Apparatus
Procedure
Engine Reconditioning
Brake pedal.
Fluid Reservoir
Fluid Lines
Brake pads
Brake drum
Rotor (disc)
Brake lining
Piston
Calliper.
Master Cylinder.
Vacuum Booster
Apparatus
Six-point wrench
Replacement pads
Allen keys
Hammer
Clamp
Procedures
The vehicle’s wheel is removed and supported with a jack stand. This is
done by losing the wheel nuts.
Unbolt the calliper and remove it as a single unit, tied up with wire or
cord so that it doesn’t get damage.
Brake pads are inspected for wear or damage. The groove in the middle
serves as an indicator for wear. If the groove is nearly gone, the pads are
changed.
The calliper is inspected for any damage and replaced if need be. The
brake disc was also inspected for minimum rotor thickness, groove or
damage.
Put the wheel back on, being sure to tighten all lug bolts.
Pulling stopping
1. Loss of brake Oil soaked brake drum/ Check and replace wheel
efficiency liner. cylinder/liner
Or
Or
Or
Replace
Defective wheel
cylinder
Or
Replace.
Loose
Or Replace
The petrol engine (also known as a spark ignition engine), refers to internal
combustion engines, generally petrol engines where the combustion process of
the air-fuel mixture is ignited by a spark from a spark plug. Spark ignition
engines may be either two-stroke or four-stoke. A four-stroke spark-ignition
engine is an Otto engine. It consists of the following four strokes: intake stroke,
compression stroke, expansion stroke or power stroke and exhaust stroke. SI
engines are the most widely used type of engine, they are high speed engines
due to their light weight and homogeneous combustion.
Fig. 3.30 {Image of 2TR Model Hilux Engine}
An engine consists of several small and large parts and some of them deteriorate
faster than one and another. When it starts showing signs of failing to perform,
or it break down, there comes the need of engine recondition. When such
engines are sent into the workshop, we thoroughly analyse the engine to
determine which pares should be replaced with the new ones to give a new life
to the engine. While engine reconditioning includes some activities, initially,
the entire engine will require disassembly, and each part will need to be
cleaned. This allows us to make an accurate assessment of each individual part,
which in turn allows for a list of part that will need to be re-machined, replaced
or manufactured. Very important, the crank will need to be thoroughly cleaned,
checked for cracks and turned to an acceptable operating standard.
The connecting rod will need to be tested for their straightness and cylinder
heads, cylinder head reconditioning involves disassembly and cleaning
surfacing, regarding the valve angles and seats, knurling or replacing the guides,
installing new valve seals and checking the spring. The goal of cylinder head
reconditioning, is to allow for more efficient flow of air. The cylinder is bored
and finished. The final step in engine reconditioning is testing. Once individual
part has been cleaned reconditioned and, in some cases, replaced the engine will
be carefully reassemble and put to a test stand and tested multiple times.
Components assessment
An experienced engineer was assigned to the aged faculty Hilux 2TR Toyota
engine assisted by other technicians and i. we will start by disassembling the
engine down, part by part, keeping meticulous record of parts and location. At
this stage, an initial visual inspection is completed.
In order to get all the used oil, foreign bodies and lubricant out of the parts, we
used premium motor spirit to wash after removing of carbon from those parts.
3.3.1.3. Component Assessment
The engineer will now inspect the components for cracks, wear and tear. Some
components require machining or replacement.
These has to do with assembling the engine parts,. In this step, we replace all
the parts that need to be replaced.
After rebuilding the engine on the ground, it is lifted with a block chain pulley
and installed on the vehicle’s engine seating. Thereafter, the vehicle is turned on
and put to test for an extended period of time.
3.3.2.1. Introduction
A cylinder head is usually located on the top of the engine block. It serves as a
housing for components such as the intake and exhaust valves, springs and
lifters and the combustion chamber. The passages in the cylinder head allow air
and fuel to flow inside the cylinder while permitting the exhaust gasses to flow
out of it. The passages are otherwise called ports or tracts.
The cylinder head also channels the coolant into the engine block, thereby
cooling down the engine components. Good engine performance depends on
valve condition. Worn guides or stems and burned or badly seated valves allow
gas to escape under compression, resulting in poor starting and loss of power.
The cylinder head uses a gasket that aid to prevent water or oil from leaving
into the combustion chambers.
3.3.2.2. Cylinder Head Reconditioning
Apparatus
v. Gaskets
vii. Hammer
x. Wire brush
Procedure:
i. When a job arrives and inspections are done, a job order is used to
determine what to be done on the job.
ii. The cylinder head assemble was supported firmly on a suitable bench or
work surface.
iii. All existing part were removed including the inlet and exhaust manifold,
rocker arm, valve, valve keeper, oil seal, valve spring and the other valve
assembly.
iv. The cylinder head was cleaned from the old gasket gum, the sludge, the
carbon build up and any remaining deposits settled on the cylinder head.
v. The cylinder head was the inspected to check for any cracks and also to
see if the valve seats have burns cracks or pit.
vi. Check for wear and tear on the camshaft that we check to see if the
camshaft is within the manufacturer’s specification by using a micro-
meter screw gauge or a vennier calliper using specification gotten from
the service manual.
vii. The face of the cylinder head is polished using size 20 sand paper.
viii. If the valves are to be replaced, the new valves are grinded (each lapped
into their respective seats to ensure a gas-tight seal) by hand using a valve-
grinding tool and valve-grinding paste ( a coarse grinding paste was used at
first, followed by a fine paste). The sucker on the grinding tool was attached
to the valve face.
ix. Rub a thin film of grinding paste around the chamfered edge of the valve
head and insert valve fully into its guide.
x. Ground each valve into its seat by rotating the grinding tool back and
forth between the palms, pressing the tool and valve into the valve’s seat
at the same time.
xi. After a couple of minutes of continuous grinding, raise the valve off its
seat, revolve about 30 digress, then grinding process continued for some
minutes.
xii. Grinding procedure was repeated with the valve position altered
periodically until both the valve-head flange, and the valve seat has an
even matte-grey appearance with no pitting or other blemishes, which
indicate that the valve and seat are making good contact all the way
round.
xiii. The valves are removed after grinding, cleaned and placed each in its
order of removal.
xiv.The cylinder head and combustion chambers and valve port were
thoroughly washed with premium motor spirit, to remove all traces of
grinding paste.
xvii. New oil seals were fit over the valve stems with care so as not to
damage the seal lips.
xviii. Valve springs and spring caps were placed in position over the
valve stem.
xix.The valve spring was compressed with a spring compressing tool until the
two split, tapered collets can be slipped into position between the spring
cap and the valve stem. The compressing tool was slowly released until
both collets are locking the spring cap and valve stem together.
xx. The compressing tool was removed and valve installation procedure
repeated on the remaining valves, in the order of removal.
3.3.3.1. Introduction
The engine block also known as the cylinder block is the biggest part of the
engine. It is made of cast iron and cast aluminium. The primary purpose of the
block is to house the cylinder {2TR-FE 2.7L Toyota Hilux Engine} (variable
valve tinning system) also where the pistons slide up and down. The block
assembly consist of the deck’, oil-galleries, water jacket, the engine liners,
pistons and connecting rods.
The Steps Used for Rebuilding 2TR-FE 2.7L Toyota Hilux Engine at
Engine Reconditioning Workshop Naspoly Lafia.
The engine block was turned upside down to position it for crankshaft
bedding.
The engine block and crankshaft were measured again to ensure the
crankshaft is not oversize.
The crank was picked up, oiled and installed resting on the engine block
bearing.
The position of the piston rings (compression, oil rings and retainer rings)
were confirmed.
The piston assembly was made up by installing the connecting rod using
a Gaugeon pin and pin retainer on both sides.
The connecting rod bearing were installed on both sides after plastic
gauging to ensure there is enough clearance. The clearance is 0.005inch.
Oil was applied on the connecting rod journals and bearings and bolts
torqued to 152 ibf.
The crankshaft was rotated to confirm free rotation of pistons in the liners
and to distribute the oil evenly over the surface.
Tighten the cylinder head nuts in order of removal using the appropriate
torque by a torque wrench
3.3.4.1. Introduction
The bearing caps are held to the engine block by two, four or six bolts
torque to specification. The main journals, connecting rod, journals snout (nose)
fly wheel, mounting flange, throws counterweight and web are the different
parts of the crankshaft. The crankshaft drives the flywheel, alternator, pump
power steering, crankshafts and sometimes the cooling fan.
The cooling system process of an engine starts from the radiator which contains
coolant that circulates through radiator hoses to other parts of the engine with
the help of water pump and returns the hot coolant through the hose from the
engine to the radiator and get cool with the help of radiator fans for further
circulation process from the radiator back to engine.
The cooling system of Toyota coasta, Toyota Hilux and Honda accord set
consist of: -
Radiator Coolant: This substance aids the cooling process in the cooling
system.
Radiator Cap: The component that covered the radiator, which prevent
the coolant from escaping into the atmosphere.
Thermostat: These regulate the amount of water that goes through the
radiator.
ii. Look for bent radiator fans. Ensure that air-flow through the radiator does
not have a restriction.
iii. Inspect the drive belt for the fan.
iv. Inspect pressure cap and the sealing surface for cap.
Apparatus
Water hoses
Detergent
Procedure
The radiator fins are brushed gently in the direction of the fin with soft
nylon brush.
The gun was used to rinse the radiator inside to outside using water
mixed with detergent.
CHAPTER FOUR
5.1. CHALLENGES
Traffic in Nasarawa town at closing hour was terrible so I got back home
at least 7pm every workday.
Most of our clients do not have their vehicle's instructions and manuals
booklets and this pose a lot of challenges when assembling as
manufacturer's specification on torque and pressure for that vehicle can't
be known.
Some technician slows down work so that they won’t be assign new once
these acts caused me to learn just little in electrical workshop.
Some of the workshop supervisor leave us at the mercy of the
technicians.
5.2. RECOMMENDATION
Base on my daily observation and participation, below are some conditions that
should be met to curb students’ discouragements and encourage interest and
hard work during the period of training.
5.3. CONCLUSION
I hereby in conclusion, state that the aims and objectives of SIWES was
achieved.