A TECHNICAL REPORT

ON

STUDENTS’ INDUSTRIAL WORK EXPERIENCE SCHEME (SIWES)

UNDERTAKEN AT

NASARAWA STATE POLYTECHNIC.

LAFIA, NIGERIA.

SUBMITTED TO

THE DEPARTMENT OF MECHANICAL ENGINEERING

COLLEGE OF ENGINEERING

FEDERAL UNIVERSITY OF AGRICULTURE MAKURDI, NIGERIA

IN PARTIAL FULFILMENT OF THE REQUIREMENTS FOR THE

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

BY

NKWO, GODWIN UDO

(16/37320/UE)

DECEMBER, 2020.
ABSTRACT

This Industrial training report presents the experience gained during my 6

months of industrial training undertaken at Nasarawa State Polytechnic Lafia.
My training was mainly on vehicle repair and engine reconditioning that is
overhauling and maintenance. During this period, I acquired practical
knowledge on how to recondition inline engines of multiple cylinders. I learnt
how to repair, replace and install some mechanical parts. I also learnt
installation of some electrical car accessories and 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 the needed
technical competence to thrive in the real world.
ACKNOWLEDGEMENT

My sincere appreciation goes to God almighty, through the help of my Mother

who made me achieve my dream of studying mechanical engineering as my
discipline.

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.

I want to extend my gratitude to my industrial base supervisors, Engr Mike, Mr

Friday, Mr Jang and all the technicians in the various workshops who helped
with solutions to my unending questions.

I am grateful to the department of works, Nasarawa State Polytechnic for

providing me with the opportunity to be exposed to different engines of
vehicles.

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

SIWES (student industrial work experience scheme) was established by ITF in

1973 to solve the problem of lack of adequate practical skills preparatory for
employment in industries by Nigerian graduates of tertiary institutions.

The scheme introduces students to industry-based necessity and skills for a

smooth transition from the classroom to labour market. It affords student of
tertiary institutions the opportunity of being exposed and familiarized to the
needed experience on handling machinery and equipment which a usually not
available in the educational institutions.

Participation in industrial training is a well-known education strategy.

Classroom studies are integrated with learning through hands-on work
experience on a field related to the student's academic major and career goals.
Successful internships foster an experiential learning process that not only
promotes career preparation but provides opportunities for students to develop
skills needed to become leaders in their profession.

One of the fundamental goals is SIWES is to help students integrate leadership

development into the experiential learning process. Students are expected to
learn and develop basic non-profit leadership skills through a mentoring
relationship with innovative non-profit leaders.

The industrial training experience helps to encourage students to actively

engaged in non-profit management as a professional career objective. However,
the effectiveness of the SIWES experience will have varying outcomes based
upon individual student, the work assignments. It is vital that each internship
position description includes specific written learning objectives to ensure
leadership skills development is. Incorporated. Participation in SIWES have
become a necessity precondition for the award of Diploma and Degree
certification in specific disciplines on most institutions of higher learning in the
country, in accordance with the education policy of government.

Operators--The ITF, the coordinating agencies (NUC, NCCE, NBTE),

employers of labour and the institutions.

Funding--The federal government of Nigeria.

Beneficiaries--Undergraduate students and f the following: Agriculture,

Engineering, Technology, Environment, Science, education, medical science
and pure and applied sciences.

Duration-- Four months for polytechnics and colleges of education and six
months for the universities

1.1. MISSION OF INDUSTRIAL TRAINING FUND

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.

1.2. OBJECTIVES OD SIWES

The following are some of the objectives of SIWES.

i. SIWES will provide students the opportunity to test their interest in a

particular career before permanent commitments are made.
ii. SIWES students will develop skills and techniques directly applicable to
their career.
iii. SIWES students will develop skills in the application of theory to
 practical work situations.
iv. SIWES will aid students in adjusting from college to full-time
employment.
v. SIWES will provide students the opportunity to develop attitudes
conductive to effective interpersonal relationship.
vi. SIWES will increase a student sense of responsibility.
vii. SIWES will prepare students to enter into full-time employment in their
area of specialization upon graduation.
viii. SIWES students will acquire good work habit.
ix. SIWES students will develop employment record/references that will
enhance employment opportunity.
x. SIWES will provide students the opportunity to understand informal
organizational interrelationships.
xi. SIWES will reduce dropouts.
xii. SIWES will be able to develop a draft agency of project budget and will
able to identify method of obtaining revenue to support the budget.
 CHAPTER TWO

For my industrial work experience program, I secured placement with the

department of works Nasarawa State Polytechnic Lafia which is located at
OMBI 1 Lafia, Nasarawa State. I was posted to Auto workshop section of the
department of works.

ABOUT THE INSTITUTION

2.1. BRIEF HISTORY OF NASARAWA STATE POLYTECHNIC.

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.

The institution has five colleges such as:

a) College of science and technology

b) College of general studies and pre-ND
c) College of administration
d) College of arts
e) College of engineering
The institution offers different program such as:

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.

2.2. OBJECTIVES OF THE POLYTECHNIC

 To produce men and women of different endeavors who are imaginative,

practical, creative, humble and dedicated to the service of humanity.
 To strive for excellence in education through acceptable curricular,
designed to produce diplomates who are morally and academically sound.
 To endeavor to expose students to such educational standard and program
in technical skills that are designed to improve their certification
advantage.
 To provide opportunity for all our students to be able to appreciate the
benefit of technology in all its complexity.
 To encourage meaningful interaction between stuff and students both in-
house and externally.
2.3. ABOUT WORKS DEPARTMENT

Works services department is an engineering outfit of the polytechnic

committed to the following:

 Maintenance and upkeep of public building and furniture.

 Maintenance and upkeep of residential building and furniture.
 Maintenance and upkeep of roads and drains in the polytechnic.
 Maintenance, upkeep, and beautification of the school environment.
 Provision of water, electricity and communication service and also their
upkeep and maintenance.
 Maintenance and upkeep of plants and equipment.
  Maintenance and repair of polytechnic vehicle include cars, lorries,
tractors crane and other road vehicles
 Maintenance and repair of electronic and other equipment used in
teaching laboratories of the polytechnic.

Fig 2.1. works department hierarchical chart.

2.4. WORKS DEPARTMENT (WD)

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;

1. Car repair and maintenance

2. Electricals
3. Engine reconditions
4. Generator reconditions
5. Welding
6. Plumbing
Each of these workshops have a supervisor Foreman and some technicians.
The following are the two (2) scheduled section of the department where I
carried out my industrial training (I.T).

a. Car repair and maintenance workshop

b. Engine recondition workshop.

2.5. SAFETY

Safety is a fundamental factor to consider in any engineering organization or

business to reduce the risk of accident. During my I.T it is necessary that it was
adhere to strictly.

2.5.1. WORKS DEPARTMENT SAFETY RULES.

The following are safety rules to be adhered to at works department:

 All workshops and stores must be under the direct control of a

supervisor, who is responsible for ensuring they are maintained and used
in a safe and healthy manner. Only those authorized to do so may enter or
work in the workshop or stores, and must comply with the requirements
of the supervisor whilst I that area.
 All persons using workshop and stores should apply good housekeeping
practices, wear appropriate clothing and foot wear, and use the workshop
and store only for the intended purpose.
 A tidy work place makes it easier to spot and avoid hazards and does not
interfere with purpose and operation. Good housekeeping is essential to
workshop safety, management, and the time allotted to a job must include
cleaning up afterwards. This applies to both individual and shared areas.
 Personal items, food, drinks, or cigarettes are not to be taken into
workshop and store, unless a clean work-free area has been set aside for
this purpose. Where necessary, lockers should be provided and used.
 All workers should be properly dressed in safety attire that is unique to
 each workshop.

Fig. 2.2. Workshop wear auto repair workshop.

2.5.2. SAFE STORAGE

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

A hazard is an agent which has the potential to cause harm to a vulnerable

target. "Hazard' can also mean risk as the two words are often used
interchangeably. However, in terms of risk assessment, they are two very
separate terms. Risk is defined as the probability that exposure to hazard will
lead to a negative consequence or a hazard poses no risk if there is no exposure
that hazard. Hazard is simply an accident waiting to happen.

2.6.1. Managing Hazards

Stored items should be periodically reviewed to rationalize their storage and

dispose of obsolete items. Effective stock rotation should be employed to
identify items that are of no use or not required and items that are deteriorating.

Materials must be stored in such a way to avoid spillage, leakage, breakage or

falls.

Shelving must be secured and never overload. Ensure that freestanding shelves
and cupboards are secured to walls.

Materials should be stored in appropriate containers. Rigid containers must be

used instead of flimsy cardboard boxes or cartons.

All substances must be clearly labelled to avoid confusion or inadvertent

contact with incomparable substances. When reusing containers, remove or
obscure the old label after cleaning the container.

Heavy or awkward items should be stored below shoulder height or at knee

height to avoid bending or excessive reaching when reaching them.

Segregation in storage must be practiced for incompatible materials. Flaming

materials or substances must be stored within a flammable store, which is
suitably constructed, marked and located.

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.

Whenever possible, a clean-bench policy should be adopted, with all items

returned to their designated storage location on completion of a task. This
requires suitable and sufficient shelves, cupboards, wall hanging and space to be
available.

2.6.2. Emergency Procedures

In case of a Procedure Hazardous substance spillage, leakage, escape or

exposure. Follow the guidance on the material safety data sheets. Major liquid
escape. Contain and avoid entry into drains where possible and safe to do so. If
hazardous substance is released, follow departmental evacuation drill and notify
the local council if substance enter the drain. Major gas escape. Follow
departmental evacuation drill, and warm those adjacent and downward. Fire
Follow departmental evacuation drill.

2.6.3. Industrial Accident

An accident, also known as unintentional injury, is an undesirable, incident and

unplanned event that could have been prevented had circumstances leading up
to the accident been recognized, and acted upon, prior to its occurrence.
Industrial accidents are severe mishaps that result in injuries to people and
damage to properties or the environment. Some common industrial accidents
are as follows:

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.

Industrial accidents occur when there is a failure to follow proper procedures,

including taking shortcut, improper handling of materials misuse of equipment,
fatigue and over-confidence about abilities. These accidents also occur when
thorough training and emphasis on safety techniques and procedure are not
accentuated and adhere to though vigilant supervision.

2.6.4. HOLIDAY SAFETY

As the Christmas holiday approach, employees tend to deal with more

distractions than usual. Planning dinners, hosting out of town family members,
purchasing gift and figuring out the logistics of other festive activities can easily
cause people's mind to wander when they are at work. From a health and safety
perspective, it is worth considering how these issues affect all's workers on the
floor, on-site, on road or at home.

Some holiday safety includes:

Make sure vehicles are in good repair:  Encourage workers to be especially

aware of safety-critical devices like headlights and taillights, turn signals,
brakes, tires, and the horn.
Drive carefully: The four most dangerous driving behaviors are speeding,
aggressive driving, inattention, and drowsiness.

Avoid drinking and driving: Encourage workers to protect themselves, their

families, and other drivers and their families. Driving under the influence—even
a little—seriously impairs a person’s ability to drive safely and greatly increases
the risk of an accident.

Inspect the ladder:  It should have non-skid feet, straight side rails, no visible
damage, and even spacing between the rungs.

Avoid under extending:  Employees should be sure the top of an extension

ladder clears the level of the roof by at least 3 feet so they can get on and off
safely. Also, they should set the ladder’s feet at least one quarter of the vertical
distance from the wall—for example, if they’re climbing onto a 12-foot roof,
the ladder feet should be at least 3 feet from the wall’s base.

Avoid overextending:  Workers should be careful not to overreach, which could

cause the ladder to become unbalanced. Instead of reaching out too far, it’s best
to get down and move the ladder.

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.

2.7.1. Basic Auto workshop Rules

The following are rules in the auto workshop I was posted to:

 Never work alone.

 Wear eye protection.
 Avoid loose clothing or hair.
 Stay clear of moving parts of a running vehicle.
 Beware of hazardous chemicals and keep a flushing station nearby for
eye and skin.
 Keep proper clean up materials in case of an accidental spill.
 Don't mix your work space with other cluttering materials such as home
storage, garden tools and other objects that are not task related.
 Never go under a vehicle that is elevated improperly (the jack to change
the Tyre is not sufficient, use jack stand to support the Jack).
 Know where the fire extinguisher is and have a planned exit route. The
fire extinguisher should be kept in working order and in a place with easy
access.
 Keep an emergency response number handy and posted clearly where
others can see it.
 Consult vehicle's manual for specific safety rules regarding that vehicle.
2.7.2. Proper Clothing and Hair.

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.

Fig 2.3 image of Safety goggles.

2.7.3. Avoid Slips, Falls and Hazardous Chemicals.

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.

2.7.4. PROPER LIFTING POINTS

A motor vehicle is a 4000+ pound piece of machinery that could fall on an

individual. Never go under a vehicle that is not elevated properly. If the vehicle
is elevated properly then there shouldn't be any problem. Vehicles should only
be lifted at their proper lifting points. The proper lifting points on a vehicle are
the locations on the vehicle where the jack is placed to lift the vehicle and
where the jack stands are placed to keep the vehicle elevated. Lifting points are
different on every vehicle.

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.

Fig 2.6. Hydraulic jack with hand pump mechanism.

When minor repairs are being performed such as changing a Tyre, it is

permissible to raise just one corner of the vehicle, or the front or the rear. The
vehicle is first raised with a Jack and then placed on Jack stand. The vehicle is
equally balanced on the jack stands.

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.

2.7.5. EMERGENCY PREPAREDNESS AND RESPONSE

In an emergency, preparedness and a quick response can save a life. Although it

is relatively rear, a fire can occur when working on motor vehicle. Some fluid is
flammable. They can combust with excess heat or when a faulty electrical wire
creates a spark.

We keep a working fire extinguisher in an accessible place. All shop workers

know where the fire extinguisher is. An ABC or "tri-class" fire extinguisher is
appropriate for auto repair workshop. Also plan for an emergency escape if a
fire becomes uncontrollable. An emergency response number posted clearly
where everyone can see it. A first aid kit handy for minor injuries like
superficial cuts and scratches. A flushing station nearby for any vehicle fluid
contact with eyes and mouth or with skin of the fluid is acidic.
3.0 CAR REPAIRS AND MAINTENANCE WORKSHOP

3.1. Introduction to Tools Used by Auto Mechanics

A tool is a mechanical device or equipment used in a profession or a piece of

software used to develop software intended to make a task easier. A commercial
mechanic’s shop usually has industry-standard tools, such as; a torque wrench,
hydraulic lifts, pneumatic (air operated) tools and electronic devices that
connect with the vehicle’s computer to receive diagnostics. The most common
tools in a mechanic’s set include the following:

3.1.1. Flashlight: A flashlight is one of the most-used tools in an auto repair

shop. It helps the mechanic to see anywhere for visual inspection, maintenance
and repair.

Fig 3.1. Image of flash light or Torch light

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.

3.1.4. Screwdrivers: Two types of screwdriver used in mechanic’s shop are

Phillips head (the Cross-Section looks like a cross or plus sign) and flat tipped
(or slotted).when using screwdrivers, it important to match the size of the
screwdriver head with screw. Also stripping the head of the screw should be
avoided (this can occur when you firmly turn this screwdriver against the head
of screw continually and the screw never rotates).

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. 3.7. Image of Hydraulic Jack

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.

3.1.7. Pry Bar:

This can occasionally be used to tension a belt

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.

Fig 3.11. Image of Hammer

3.1.9. Test Light:

This is used to test fuses

Fig 3.12. Image of Test Light

3.1.10. Funnel

This is used to fill vehicle fluids

Fig 3.13. Image of Funnel for Car fluids

3.1.11. Drain Pan

Used to collect vehicle fluids when changing fluids and filters or flushing
systems.

Fig 3.1.4. Image of Draining Oil

3.1.12. Tyre Pressure Gauge

Used to measure the tyre pressure

Fig 3.15. Image of Tyre pressure gauge

3.1.13. Battery Tester

Used to check the battery to see if it is charged

Fig 3.16. Image of Battery tester

3.1.14. Computer Scanner

Connects to the vehicle’s computer to receive diagnostic trouble codes (DTCs)

Fig 3.17. Image of Auto Scanner which receives DTC from vehicle’s computer

3.2. GENERAL MAINTENANCE

Maintenance refers to some actions performed to keep some machine or system

functioning or in service. General maintenance is one of the most applicable for
the average person to care for his or her own vehicle. During my I.T, vehicle
owner’s manual, vehicle fluids, fuses, belts, hoses, vehicle light and air filter
were some of the areas practised measure of general maintenance.

3.2.1. Vehicle Owner’s Manual

All vehicles are different and the owned manual for each make and model is the
most useful e reference for maintenance and repair of that specific vehicle.
Despite the fact that, it can often look surface, vehicle owners should become
familiar and comfortable with the owner’s manual. Almost any topic regarding
the vehicle’s maintenance can be found in the index.

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.

3.2.2. Vehicle Fluids

Vehicle fluids include; brake fluid, engine oil, coolant, power steering fluid,
windshield water fluid, transmission fluid and battery fluid.

3.2.2.1. Brake 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.

Fig 3.18. A brake fluid reservoir

3.2.2.2. Engine Oil

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.

We follow these steps to check oil level;

 The engine was turned off

 Dipstick was removed

 End of dipstick was wiped off with a rag

 Dipstick was put back in

 Dipstick was taken out to look at the level at the tip

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.

Fig 3.19 Oil dipstick and oil level on a dipstick

During my Industrial Training, there was a case where oil mixed with oil.
3.2.2.3. Draining Engine Oil

Apparatus

 Allen key, wrench to remove drain plug (box end or socket)

 Oil filter wrench.

 Oil drain pan.

 Funnel.

 Latex gloves

 Jack and Jack stand or ramps.

Procedure

 Type and amount of oil needed was checked.

 Oil filter, wrenches and other supplies were brought together.

 Vehicle was prepared by warming for at least 1 minute.

 Oil filter and drain plug were located.

 Oil was drained

 Drain plug was tightened

 Oil filter was changed.

 New oil was added

 Oil level was checked

3.2.2.4. Coolant

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.

Fig 3.20. Coolant, notice the green coolant image

A low coolant level indicates a positive leak, which should be investigate

3.2.2.5. Power steering Fluid

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

3.2.2.6. Wind shield Washer Fluid

There may be a clear reservoir or dipstick for windshield washer fluid.

3.2.2.7. Transmission Fluid:

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

3.2.2.8. Battery Fluid and Terminals

A battery is a device that produces stored electricity; it may have several

primary or secondary cells arranged in parallel or series. Most modern vehicles
do not have clear batteries. Any corrosion or sign of leaks around the battery are
indications of a problem. Corrosion can be a green or elite powdery substance.
If corrosion is present, the battery may need to be replaced or there could be a
problem with the charging system. If the battery fluid is low, only distilled
water is used to fill it. Is advisable to add acid to a battery. The present of
corrosion indicates a problem that should be addressed. However, as a
temporary fix, corrosion is cleansed off to get the car started.

Apparatus

 Garden hose

 Mixture of baking soda and water

 Wire brush or scrapper.

 Procedure

 Garden hose was used to rinse off corrosion

 Battery terminals were disconnected, starting with negative terminal first,

then the positive terminal.

 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.

 The terminals were rinsed with more water.

 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.

Violet ----- 3Amp

Pink ----- 4Amp

Orange ----- 5Amp

Red ----- 10Amp

 Blue ----- 15Amp

Yellow----- 20Amp

Clear ----- 25Amp

Green ----- 30Amp

Orange ----- 40Amp

Fig. 3.23. Image of blade fuses used in modern vehicle

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.

3.2.4. Belts and Hoses

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.

Fig. 3.24. Image of power steering indicating belt hoses

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.

3.2.5. Vehicle Lighting

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.

3.2.6. Air Filter

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.

Fig. 3.26. Image of air filter

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

3.2.7.1. Wear Bar

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.

Fig. 3.27. Image of tyre showing wear bar

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.

3.2.7.2. Changing Tyres Around

Apparatus

 A spare tyre

 A jack

 A wheel wrench with extension bar

 A wheel chock (to stop car rolling when it is jacked up)

  Vehicle handbook

Procedure

 It was ensured that the vehicle was on a level ground

 Apply the parking brake.

 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.

 Remove the lug nuts.

 Remove the flat/worn-out tyre.

 Place the spare tyre.

 Lower the vehicle.

 Torque the lug nut (tighten them as much as possible after the vehicle has
been lowered.

 Replace the tools in the appropriate location for future use.

3.2.8. BRAKE SYSTEM MAINTENANCE

Brakes are one of the most important components in a vehicle as good

performance includes good brakes, also, the faster a vehicle move the same
amount of stopping power is needed to reduce that speed.
A brake is a mechanical device that absorbs energy from a moving system. It is
used to slow or stop a moving vehicle, which is mostly achieved by means of
friction.

 Working principle

 component of the braking system

 Installation of brake pads and shoes

 Apparatus

 Procedure

 Common brake troubleshooting

 Engine Reconditioning

3.2.8.1. Working Principal

Brake works on the principle of friction. When a moving element is brought

into contact with a stationary element, the motion of the moving element is
affected. This is due to the frictional force, which acts in opposite direction of
the motion and converts the kinetic energy into heat energy. It is a mechanical
device that absorbs energy from a moving system.
Fig. 3.29. Image of basic brake system

3.2.8.2. Components used in Brake System

 Brake pedal.

 Fluid Reservoir

 Fluid Lines

 Brake pads

 Brake drum

 Rotor (disc)

 Brake lining

 Piston

 Calliper.

 Master Cylinder.

 Vacuum Booster

3.2.8.3. Installation of Brake Pads and Shoes

Apparatus

 Six-point wrench

 Replacement pads

 Jack and jack stands

 Strong wire brush (sand paper)

 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.

 Compress the brake piston with the use of a C-clamp

 Brake calliper is reinstalled.

 Put the wheel back on, being sure to tighten all lug bolts.

 The procedure is repeated for the other wheels.

 The vehicle is tested-driven for the following brake system concerns.

 Noise during driving and braking

 Pulsation during stopping

 Pulling stopping

 False ABS activation

 3.2.8.4. Common Brake System Troubleshooting:

S/N PROBLEM PROBABLE CAUSE REMEDY

1. Loss of brake Oil soaked brake drum/ Check and replace wheel
efficiency liner. cylinder/liner

Or

Worn out brake lining Replace

Or

Defective master Service/Replace

cylinder

2 Brake binding Brake shoe retracting Replace

spring weak

Or
Replace
Defective wheel
cylinder

3 Brake As in binding with Replace

prolonged usage

4 Brake judder Wrong brake Adjust

adjustment

Or
Replace.
Loose

5 Vehicle pulling to Improper adjustment of Adjust

one side
 lining

Or Replace

Oil or grease settled on

liners

6 Hand brake Stretching of operating Replace

ineffective cable

7 Excessive loss of Leaking master cylinder Service / Replace

brake fluid or wheel cylinder or
hose joints

8 Excessive air Defective master Replace

bubble cylinder

3.3. ENGINE RECONDITIONING

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}

Engine reconditioning is the maintenance of a used engine to enhance its

performance and efficiency and hopefully extends its lifespan. When a vehicle
engine is being reconditioned, it is completely taken apart, every piece is
inspected and whatever piece shows appreciable wear is reconditioned to its
original shape and dimensions or replaced with a new one.

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.

3.3.1. Engine Reconditioning Process

The engine reconditioning process includes various steps, which are:-

 Strip down and analysis

 Engine cleaning and decarbonisation

 Components assessment

 The engine re-build

 Installation and testing

3.3.1.1. Strip Down and Analysis

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.

3.3.1.2. Engine Cleaning and Decarbonisation

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.

3.3.1.4. Engine Rebuild

These has to do with assembling the engine parts,. In this step, we replace all
the parts that need to be replaced.

3.3.1.5. Installation and Testing

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. CYLINDER HEAD

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

Fig.3.31. Image of Toyota Hilux head about to be reconditioned

Apparatus

i. Ratchet (big and small)

ii. Socket wrench (10mm, 12mm)

iii. Valve spring compressor

iv. Needle-nose pliers

v. Gaskets

vi. Blind flanges

vii. Hammer

viii. Paste and oil

ix. Two-wheel trolley

x. Wire brush

xi. Sand paper (smooth and course)

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.

Fig. 3.32. Image of grinding valves with hand palm

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.

xv. Clean engine oil is robbed on the new valve stem.

 xvi.The new ground valves were fitted to their respective positions in the
cylinder head.

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.

xxi. The valve cups were also replaced on all valves.

3.3.3. The ENGINE BLOCK ASSEMBLY

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 block was thoroughly cleaned

 With the aid of the liner installation tool, the new liners were installed in
the block.

Fig 3.33. Image of Sleeve Installation

 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 crankshaft was wiped with a clean cloth.

 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.

Fig. 3.34. Image of assembled engine

 The crankshaft was rotated to confirm free rotation of pistons in the liners
and to distribute the oil evenly over the surface.

 Replace the gasket

 Tighten the cylinder head nuts in order of removal using the appropriate
torque by a torque wrench

 Replace the cylinder head fittings

 Connect cable to dynamo and starting meter, connect electric horn

 Connect radiator hose to the engine sides and insert radiator.

 Connect I.T. cable to ignition system

 Connect fuel supply line

 Connect cable from battery

 Replace engine bonnet

  Fill radiator with water

 Insert lubricant (oil)

 The vehicle is put to a test multiple time

Fig 3.35. Image of complete engine rebuild

3.3.4. The Crankshaft

3.3.4.1. Introduction

The crankshaft is a mechanical part able to perform a conversion between

reciprocating motion and rotational motion. The crankshaft converts the
straight-line force from the piston and connecting rod into rotary force. It is
attached to the engine block by bearing caps and bearings that surround the
crankshaft journal. This design allows the crankshaft to rotate inside the bearing
with minimal friction.

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.

Fig. 3.36. Labelled parts of a crankshaft

3.3.4.2. Crankshaft Reconditioning

Reconditioning of the crankshafts can be done by grinding the journals (bearing

surface on the crankshaft for the connecting rod bearing and main bearings).
These grinding for 2TR VVTI Toyota Hilux Engine can be only be done four
times from standard t0 010. From 010 to 020 and from 020 to 030 and from 030
to 040. That is to say, if the crankshaft has been grounded four times, if the
journals worn again, that crankshaft will be thrown away, that is, it has to be
replaced with a new one. Before the grinding process, a straightness check is
done on the crankshaft.
Fig. 3.37. Image of crankshaft after cleaning

3.3.5. The Cooling System

3.3.5.1. Working Principle

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.

3.3.5.2. Component of Cooling System

The cooling system of Toyota coasta, Toyota Hilux and Honda accord set
consist of: -

 Water Pump: This is a cooling system component that is connected to

the fan shaft at the rear of the fan and is driven by belt.

 Radiator: This is another component of cooling system that contains the

coolant, which cool the coolant received from the engine. The radiator is
a heat exchanger used for heat dissipation. That is to transfer heat from
the hot coolant that flow through it to the air blown through it by the fan.
  Radiator Fan: This is a component between the radiator and the engine
that is responsible for the increase of air flow through the radiator and
blowing the ai over the outer surface of an engine.

 Radiator Hose: This component functions as channel through which

coolant or water flows through.

 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.

Fig. 3.38. Image of a cooling system

3.3.5.3. Visual Inspection of the Cooling System

i. Check coolant level in the cooling system.

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.

v. Check for broken hose and damaged fan blade.

3.3.5.4. Radiator Reconditioning

Apparatus

 Water pressure gun

 Water hoses

 Water pressure machine

 Detergent

 Soft nylon brush

Procedure

 Radiator was dissembled from the vehicle.

 The radiator was carried to the washing area.

 Detergent was poured into the water pressure machine.

 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.

 Clean water was streamed through the radiator outside-inside

 The water inside the radiator was emptied

 Fig. 3.39. Image of radiator washed with water gun

CHAPTER FOUR

4.0 SKILLS ACQUIRED:

During my industrial attachment I have learnt very importantly, that no matter

the importance or urgency of a job, Safety Comes First. And refusal I abide by
the laid down work life-saving rules can claim lives while the job will still be
there in the workshop. Most importantly at the cost of my industrial training I
can boast of being able to recondition 2TR vvti Toyota Hilux engine and Toyota
coastal bus cylinder head with no assistance from the technicians that taught me
in NSPL. I also acquired the following skills.

1. Self Confidence: In the first month of my I.T, I was able to show.my

ability in handling tools. A skill I got when I was at a roadside mechanic
workshop at New Garage Wadata. I was able to make the technicians see
that these was not my first time and my confidence helped because more
work was given to me within a short time of my arrival.
2. Open mindedness and flexibility: I realized that as an engineer I must
be willing to learn new things because the world is fast changing and new
 innovation, designs are coming up.
3. Team Work: Most times, we work in groups. I have learnt to work as a
team, how to relate my ideas about a problem on ground and to engage
myself in the work while relating with co-worker and employer.
4. Assembly And Disassembly: At the cost of my I.T, I have learnt that
during disassembly of engine or vehicle's suspension, I should mark and
label each components and during assembly, retightening using the right
toque specification only by so doing will the work go with ease and less
challenge.
5. Problem Solving Skill: During the 24 weeks period of my industrial
training, I have come to know that engineers are problem solvers and
analytical thinkers and that to be a good engineer, I must be able to think
and apply various techniques to solve problems. In the middle of my
industrial training experience, I was privileged to be among those
selected to go to Calabar to fix a Toyota coasta bus whose engine failed in
the course of an excursion due to lack oil circulation to the cylinder head.
On arrival to where the vehicle was parked, we checked the oil level,
replaced oil filter, changed engine oil and tried to run the engine but we
still have the same result. Together we thought of possible ways to fix the
fault so I suggested that the engine should be run without the valve cover.
At this point it was discovered that the pores on the oil supply tube were
clogged. Carburetor flush was used to remove dirt. Lastly, the engine was
put to test successfully. The engineer in charge gave us #1000 each for
feeding and also express how impressed he was with my work. We also
serviced the vehicle we used for the journey, changed the engine oil and
oil filter. We return to the workshop at about 5pm the following day.
 CHAPTER FIVE
5.0. CHALLENGES, RECOMMENDATION AND CONCLUTION

5.1. CHALLENGES

The industrial training program exposed me to a practical world of engineering

from planning and job acquisition to job completion. Some of the major
challenges I encountered in the course of the training include:

 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.

 Wages department could not approve my allowance till date.

 I encountered Language barrier as most of the supervisors and technicians

were fluent with Hausa than English and explanations were mostly done
in Hausa language. Hence, the need for and interpreter.

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.

 The institution should be actively involved in helping students secure

placements for their industrial training program especially in
establishments that are relevant to their course of study.

 I would recommend that COREN should reduce the duration of

classroom studies for engineering and if possible 500L (final year) should
be dedicated to practical and industrial work experience in order to enrich
the practical knowledge we acquire from the university.

 Every organization in the country should be compelled to accept students

for the training.
  I would also want the Nigeria University Commission place supervisors
in each state to ensure that the students undergoing training are properly
supervised. Throughout my training, no external supervisor came.

 Students or trainees should learn to comport themselves well in these

companies so as not to send a bad signal which may discourage such
company from taking or accepting future SIWES students.

5.3. CONCLUSION

The SIWES program was indeed an intriguing experience as daily it exposed

the practical aspects of class lectures and examinations. I had experience of
engineering management and approaches taken towards solving all manner of
problems and improving productivity with minimized losses. This has gone a
long way to boost my confidence, technical and practical know-how in my
discipline. Through this program I got to see and use some unheard machines
equipment such as ... and other common workshop tools.

I hereby in conclusion, state that the aims and objectives of SIWES was
achieved.