A TECHNICAL REPORT
ON THE
STUDENTS IN WORK EXPERIENCE SCHEME (SIWES)
UNDERTAKEN AT
GENAIS AUTO COMPANY
54/56, SALVATION BUS STOP, OPEBI ROAD, OPEBI, LAGOS
COMPILED AND SUBMITTED
BY
OYEWOLE, David Olatunde
MEE/08/3547
TO
THE MECHANICAL ENGINEERING DEPARTMENT
FEDERAL UNIVERSITY OF TECHNOLOGY, AKURE
IN PARTIAL FULFILMENT OF THE REQUIREMENTS FOR THE AWARD OF
A BACHELOR’S DEGREE IN MECHANICAL ENGINEERING
DECEMBER, 2012
1
Certification
This is to certify that this report is based on the knowledge and skills gained by me,
OYEWOLE, David Olatunde during my months of Industrial Training experience at
Genais Auto Company located at 54/56, salvation bus stop, Opebi road, Opebi, Lagos
State, Nigeria.
……………………………………
OYEWOLE, David Olatunde
(MEE/08/3547)
Signature and Date
…………………………………………
Mr Felix Vinyo
Technical Director
Signature and date
2
Dedication
In loving memory,
OYEWOLE, Johnson Adebayo
Till we meet to part no more
You will forever live in my heart.
3
Acknowledgement
All glory to God for a successful Industrial Training exercise. Special thanks to the
management and staff of Genais Auto Company for giving me a chance to see first-hand, and
engage in the practical aspects of my course of study.
My profound gratitude goes to my parents, Mr and Mrs Oyewole, and my siblings for
believing in me, for the love, care and support given in cash and kind. Even though it has not
been easy on your finances, still you have decided to give me a chance at every necessary
junction of my life. May God bless you and cause you to increase on every side.
Also, my heartfelt appreciation goes to the Head of Department (past and present),
Lecturers, Technologists, Technicians, and the non-academic staff of the Mechanical
Engineering Department of the Federal University of Technology, Akure. The immense manhours invested into us, in and out of class as students, shall yield wonderful fruits to the benefit
of humanity in Jesus’ name. I pray that the Almighty God increase you in all directions. God
bless you.
I say a big thank you to my dearie, Chi, for standing by me through the trying times. I
won’t fail to appreciate my roommate, Okatahi Joe, and my housemates in Hinterland III, Elijah
Adeoye, Lanre and Ope (The Dadas), and to the countless others I won’t be able to mention due
to time and space constraints. My heartfelt prayer for us is that God will lift us all to the peak
points in our lives in Jesus’ name.
Lastly, to the innumerable people who are not mentioned here, not because of their
insignificance, but due to time and space limitations, thank you for being there for me even when
it was inconvenient. I pray for you that you will always matter where it matters in Jesus’ name.
Amen. God bless us all.
4
Table of Contents
Certification ..................................................................................................................................... 2
Dedication ....................................................................................................................................... 3
Acknowledgement ........................................................................................................................... 4
List of Tables ................................................................................................................................... 7
List of Figures ................................................................................................................................. 8
Abstract ........................................................................................................................................... 9
1.
2.
3.
4.
INTRODUCTION ................................................................................................................. 10
1.1
Historical background of Genais Auto Company........................................................... 10
1.2
Location .......................................................................................................................... 10
1.3
Organisational Structure of the Company ...................................................................... 10
1.4
Company Policy and Terms of Service .......................................................................... 11
1.5
Services offered by the Company ................................................................................... 12
OIL SERVICE....................................................................................................................... 13
2.1
Service tools ................................................................................................................... 14
2.2
Service Procedure ........................................................................................................... 15
2.3
Maintenance of service equipment ................................................................................. 16
COMPUTER DIAGNOSIS................................................................................................... 17
3.1
Error Codes ..................................................................................................................... 18
3.2
Diagnostic Devices ......................................................................................................... 19
3.2.1
On-board Diagnostic tools (OBD) .......................................................................... 19
3.2.2
PC-based Diagnostic tools ...................................................................................... 20
3.3
Diagnosis Procedure ....................................................................................................... 20
3.4
Maintenance of Diagnostic Devices ............................................................................... 21
GENERAL REPAIRS ........................................................................................................... 22
4.1
Engine repairs and replacement ...................................................................................... 22
4.2
Brake pad replacement ................................................................................................... 24
5
4.3
5.
Shock absorber replacement ........................................................................................... 25
CONCLUSION AND RECOMMENDATION .................................................................... 27
5.1
Conclusion ...................................................................................................................... 27
5.2
Recommendation ............................................................................................................ 27
REFERENCES .............................................................................................................................. 28
6
List of Tables
Table 3.0
Digits in third place holders and their interpretations as related to the Powertrain.
7
List of Figures
Figure 1.0
Organisational chart of Genais Auto Company
Figure 2.0
Some service tools and service materials
Figure 2.1
Removal of Oil filter with an oil filter remover during a service operation
Figure 3.0
An On-board Diagnostic (OBD-II) scanner, Genisys, in use
Figure 3.1
an On-board diagnostic (OBD) scanner
Figure 3.2
A PC-based diagnostic tool in use
Figure 4.0
A 4-cylinder gasoline-combusting, spark-ignition engine undergoing repairs
Figure 4.1
A hydraulic jack used for general repairs
Figure 4.2
An engine block
8
Abstract
The importance of vehicles is an issue that cannot be overemphasized as the daily routine
of most individuals entails the interaction with vehicles to go about businesses and move people
and goods from one place to another. This implies that with the breakdown of vehicles, our lives
and businesses tend to experience a noticeable amount of stress compared to what it was before
the breakdown. This brings up the issue and ultimately the business of automotive maintenance
and repair. With the possibility of a breakdown on one’s mind, the menacing topic of automotive
maintenance cannot be taken with levity.
This usually comes in form of questions like when should a car be serviced? How are
brake pads fixed or removed? How often should a service operation be done on a vehicle? How
can problems be easily detected in a vehicle? Is it possible to detect faults in a vehicle by using a
computer?
This technical report on the Students In Work Experience Scheme (SIWES) exercise
undertaken at Genais Auto Company, attempts to answer these questions using everyday
language. In cases where a seemingly clear answer is not available, this report hopes to shed
more light and at least create a clearer picture in the mind of the reader.
9
CHAPTER ONE
1.
INTRODUCTION
1.1
Historical background of Genais Auto Company
Genais Auto Garage (also called Genais Auto Company,) was set up in 1998 by the
CEO, George Umo. Starting on a rather low budget, it has grown over time to be a highly
sophisticated service centre laced with the responsibility of making sure that today’s automobiles
with their computers on-board, stay functional.
From staff strength of four at its inception to twenty in 2007, its professional composition
has increased. The CEO being a seasoned engineer with great passion for the automobile, has not
stopped at his quest to acquire the best in diagnostic equipment and qualified staff in order to
give customers’ vehicles the best of care and all round protection from break downs.
1.2
Location
Genais Auto Company is situated in the city of Lagos, the nation’s commercial capital, at
54/56, Salvation bus stop, Opebi road, Ikeja, Lagos State. This choice location gives the
company the much needed positioning for its clientele base as it opens the company to customers
from the Lagos mainland and the Lagos Island.
1.3
Organisational Structure of the Company
Fig. 1.0 Organisational chart of Genais Auto Company
10
The figure above (Fig. 1.0) shows the organisational structure of the company. With a
staff strength of twenty (interns not included), the company is jointly run by the Chief Executive
Officer, Mr George Umo, who also acts as the Managing Director and Mr Felix Vinyo, the
technical director.
1.4
Company Policy and Terms of Service
As part of the company’s policy and terms of service, every vehicle that gets admitted for
a service is subjected to vehicle inventory or vehicle check. Vehicle inventory is the intensive
examination of a vehicle that comes to the auto garage for a service, which may be any of the
following: vehicle service, engine repairs and replacement, body works, etc. It is a way in which
the company ascertains the integrity of a vehicle that comes into the garage for any job. In this
exercise, all parts and sections of the vehicle are checked and their conditions, whether working
or bad are noted and recorded.
The vehicle inventory is done in triplicates- a white copy which is the customer’s copy; a
blue copy which is kept at the administrative office on which the items used and/or replaced in
the course of the repairs are noted, and a pink copy which is kept at the garage shop for future
reference.
To execute a vehicle inventory, the first thing to be done is to fill in the date and time of
the vehicle’s arrival. This is followed by details of the vehicle such as the manufacturer, the
vehicle model, the year of production, the engine type, the mileage of the vehicle, the registration
number and the chassis number.
The next thing after this is to take the customer’s details; the vehicle owner’s name and
telephone number, e-mail address, and home or office address (whichever the customer wishes to
give). After the customer’s details, the complaints of the customer are noted. These range from
common problems such as brake pad replacements, oil service, etc. to more complex ones like
faulty transmission systems, vehicle height calibration, etc.
After taking details of the vehicle, the customer and the complaints, the vehicle inventory
exercise goes into full swing. The things checked range from the fuel level to side mirrors, door
openers (inner and outer), door panels, window winds, windows, carpets, latches (hood, fuel and
trunk latches), the lights (headlights, parking lights, signal lights, etc.), tyres, rim size, tools, etc..
The inventory is concluded by attaching the name of the executant and date. The customer is
then given the document to append his name and signature in agreement with the information
therein.
11
As part of the company’s policy, a new intern is required to stay at this exercise for a
minimum of two weeks. This is to enable the intern to fully grasp the importance of the exercise.
The advantage of vehicle inventory is that in the advent of any claims of damages by a client, the
inventory done on such vehicle can be easily accessed and checked to confirm the integrity of
the customer’s claims and in most cases exonerate the company of such damage claims.
1.5
Services offered by the Company
The services offered by the company include:

Oil or Lube service,

Computer diagnosis,

Body works,

Engine repair and replacement, and

General repairs.
The different services offered at Genais Auto Company are discussed in detail in
subsequent chapters.
12
CHAPTER TWO
2.
OIL SERVICE
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 usually
specified by the vehicle’s manufacturer in a service schedule and some modern cars display the
due date for the next service electronically on the instrument panel.
At Genais Auto Company, the vehicle service is carried out in the pit. The pit is a
compartment dug into the ground over which the vehicle will be parked. This location is ideal
because it creates the necessary space required by the mechanic to conveniently inspect the
underside of the vehicle and to drain the spent engine oil from the engine sump since it is located
at the downside of the engine. In cases where the pits have been occupied by other vehicles, the
service operation takes place at the vehicle lift. After service, the vehicle and engine are cleaned
and released to the customer.
The completed services are recorded electronically on a database by the service centre
upon the completion of each service. However, with recent customer demands, customer service
records can now be printed from the database.
At the completion of the vehicle service procedure, the engine and the vehicle body is
cleaned thoroughly so as to rid it of greasy and oily stains that might have come about during the
service.
Maintenance tasks during a vehicle service include;

Engine oil replacement

Oil filter replacement

Replacement of air filter

Cleaning/Replacement of spark plugs

Level check and refilling of brake fluid

Level check and refilling of power steering fluid

Level check and refilling of automatic transmission fluid

Inspection and replacement of the timing belt, if needed

Inspection of condition of the tyres
Other parts in the vehicle that are also checked and advised upon include the following:

Battery

Engine components, etc.
13
Fig 2.0 Some service tools and service materials
The necessary tools and materials are shown in the fig. 2.0. The tools required for a
service operation include sets of sockets, spanners, screwdrivers, ratchets, extension bars and the
T-bar. Necessary materials for a service operation include engine oil, motor flush, oil filter, and
oil supplement.
2.1
Service tools
Some of the tools used for a typical service exercise are highlighted below:

Mechanical jack (hydraulic or electric),

Axle stand,

Funnel,

Set of sockets,

Set of spanners,

Ratchet and extensions, etc.
Hydraulic jack: A mechanical jack is a device which lifts heavy equipment. It works on the
principle of pressure transmission. Mechanical jacks are usually rated for a maximum lifting
capacity. A hydraulic jack uses a fluid, which is incompressible, that is forced into a cylinder by
a pump plunger. Oil is used since it is self-lubricating and stable. In the case of electric lifts,
electrical power is required. The electric lift used at Genais Auto Company has a maximum
lifting capacity of 4100kg. The jack is used in lifting the vehicle in order to create enough
clearance for work to be done underneath it.
14
Axle stand: Axle stands are tripod-shaped bodies used in keeping a suspended vehicle parked
while work is being done underneath it. After lifting the vehicle to the desired height using a
mechanical jack, it is used to keep the vehicle at that height. It is much safer as the risk of failure
of a hydraulic jack is greatly reduced.
Set of spanners: The set of spanners contains spanners of various sizes. The spanners are used
to loosen the guiding nuts of the protector covering the underside of the vehicle, especially when
the protector is hindering access to the engine sump. Other nuts and/or bolts that need to be
removed to access the oil sump can also be removed with the spanners.
Ratchet: A ratchet is a mechanical device that allows continuous linear or rotary motion in only
one direction while preventing motion in the opposite direction. A ratchet makes it easy to
loosen nuts since it eliminates the stress caused by using a spanner.
2.2
Service Procedure
A sample service exercise at Genais Auto Company is described below:
Location: In the pit, the electric lift or on the ground using manual hydraulic jacks.
Required tools: Ratchet, Extensions, Sockets, Oil filter remover, T-nut remover, air blower and
gun
Necessary Items: Engine oil, Oil flush, Oil supplement, Oil filter, Fuel treatment and Air filter
(if necessary)
Procedure:
1. Pour the Oil flush into the engine. This removes every trace of sludge formed in the
engine. The amount of flush required varies with the engine type. For four and six
cylinder engines, a can of flush is adequate but engines with more cylinders require two
cans of flush.
2. Start the engine and leave it running for some minutes (recommended time, 20 minutes)
so that all the sludge present will dissolve completely into the engine oil.
3. If the underside of the engine has a protector shielding the engine sump, remove it.
4. With the aid of the T-nut remover and the appropriate socket, remove the retaining bolts
of the engine sump to drain the oil. Drain the spent engine oil.
5. Use the Oil filter remover to remove the Oil filter.
6. Replace the retaining bolt in position to prevent oil leaks.
7. Replace the Oil filter with a new one.
15
8. Pour the new engine oil and the Oil supplement into the engine. The volume of Engine
oil and oil supplement used is a function of the engine’s capacity.
9. Check the Engine oil level. Ensure it is filled to the maximum level.
10. Remove the Air filter from the air cleaner in the engine. Blow off the dust particles
trapped in it with the aid of the Air blower and gun. Replace the Air filter.
11. Check the level of the engine fluids such as brake fluid, power steering fluid and
transmission fluid.
12. When the fuel is to be supplied, add the Fuel treatment. This reduces the fuel
consumption rate and the rate of emissions of waste gases.
13. Clean the engine and body of the vehicle to rid it of any oily or greasy stains.
The vehicle is then ready to leave the garage.
Fig. 2.1
2.3
Removal of Oil filter with an oil filter remover during a service operation
Maintenance of service equipment
The tools are kept in a dry place free from humidity in the store. For tools that require
special fluids for proper functioning, such as the hydraulic jack, the fluid level is checked from
time to time and refilled when necessary. Other tools that have special storage compartments
such as ratchets, sockets and spanners are properly cleaned and replaced immediately after use.
Tools like the axle stands used in the suspension of vehicles while work is done underneath them
are kept in the store far from open space in order to prevent them from rainfall, which will
ultimately lead to corrosion.
16
CHAPTER THREE
3.
COMPUTER DIAGNOSIS
Computer diagnosis of a vehicle is the use of specially built computers called scanners,
to run certain tests on the vehicle in order to ascertain the working condition, detect errors and
faults in the engine and to sometimes (in the advent of error codes), clear errors from the vehicle
computer’s memory. Sometimes, a generic computer may also be used as a scanner if it is
connected to a scanner kit and the scanner’s software is installed on it. The computer is
connected to the vehicle’s master computer (precisely, through the Assembly Line Diagnostic
Link, ALDL) by a special cable via one of its universal serial bus ports (USB ports).
Popular scanning programs that run on computers include Abrites, VCDS, SDD, All
Data, etc. There are various types of scanners used in the automotive industry. These range from
on-board diagnostic scanners (OBD) to laptop computers. At inception, the company started with
an On-board diagnostic scanner but with latest innovations in the automotive industry, the firm
has evolved. Now armed with the latest technology in automobile diagnosis, more vehicle brands
can now be easily diagnosed and repaired.
To run the diagnosis, the scanner or computer is plugged into the Assembly Line
Diagnostic Link (ALDL). The engine is turned to the ON position via the key and the prompts
displayed on the screen of the scanner are followed. The scanner then presents results in codes
which represent faults and errors the scanner has detected in the vehicle.
Fig 3.0 An On-board Diagnostic (OBD-II) scanner, Genisys, in use
17
3.1
Error Codes
Error codes are alphanumeric representations of the faults detected by the scanner in a
vehicle. Each error code on a scanner starts with one of the following letters:
1. B: faults related to the body
2. C: faults related to or stemming from the chassis.
3. U: faults originating from the network of the vehicle’s components.
4. P: faults stemming from the Powertrain.
The letter is followed by four digits that correspond to a specific error. The first digit is
used by the automaker for specialty codes while the second digit represents specific problems.
The last two digits indicate a subsection in the area with the detected problem. The error
codes can be checked on the automaker’s website depending on the type of scanner used. Some
scanner software provides diagnostic wizards that display interpretations for the codes and
possible scenarios for fixing problems.
The number 0 in the second place holder is a generic code shared by all automakers but
some manufacturers use a specific code, so the number 1 may appear. The third place holder
determines the area of the problem.
Table 3.0
Digits in third place holders and their interpretations as related to the Powertrain.
Code
0.
Interpretation
Fuel and Air metering and Auxiliary Emissions Control
1.
Fuel or air problem
2.
Fault in injector circuit
3.
Ignition problem or engine misfiring
4.
Auxiliary Emissions Control problem
5.
Vehicle speed or idle control problem
6.
Computer or output circuit problem
7.
Transmission related problem
8.
Transmission related problem
The third and fourth digits of the diagnostic report further identify the subsection of the
malfunctioning system. Generally, the error codes that appear from the diagnostic report vary by
vehicle make and manufacturer preference.
18
An example of an error code could be P0122. This error code can be interpreted as
follows; Throttle Position Sensor/Switch A Circuit Low Input. This code means that the car’s
computer has detected a fault connected to the powertrain that the TPS (Throttle Position Sensor)
is reporting too low a voltage. On some vehicles that lower limit is 0.17 – 0.20 volts.
Some scanners can monitor Mass Air Flow (MAF) and engine revolutions per minute
(RPM) or determine if the car will pass an emissions inspection. When done with the diagnosis
and repairs, the errors are cleared and any associated warning lights such as Check Engine Light,
Tyre Pressure light are turned off.
Computer diagnosis is very efficient because it saves time since it reduces the workload
and time taken to humanly test the components one after the other, which may lead to the
jeopardy of the components.
3.2
Diagnostic Devices
The tools and devices used during a diagnosis operation are referred to as diagnostic
devices. The devices used during a diagnosis at Genais Auto Company range from specially built
On-board diagnostic (OBD-II) scanners to laptop computers. The diagnostic softwares that run
on computers are referred to as PC-based diagnostic tools.
3.2.1 On-board Diagnostic tools (OBD)
OBD is an automotive term referring to a vehicle’s self-diagnostic and reporting
capability. OBD systems give the vehicle owner or a repair technician access to state of health
information for various vehicle sub-systems. The OBD scanner used at Genais Auto Company is
an OBD2 type scanner.
Fig. 3.1 an On-board diagnostic (OBD) scanner
19
3.2.2 PC-based Diagnostic tools
Some specially designed diagnostic softwares also run on computers. Such diagnostic
softwares are referred to as PC-based diagnostic tools. Examples of such softwares used at
Genais Auto Company include All Data™, Abrites™, SDD™, VCDS™, etc.
Fig. 3.2 A PC-based diagnostic tool in use
3.3
Diagnosis Procedure
A typical computer diagnosis exercise on a vehicle at Genais Auto Company is described
below:
Required tools/devices: On-board diagnostic scanner or a laptop with PC-based diagnostic
software, an OBD or USB connector.
Procedure:
1. With the vehicle engine in its OFF mode, plug the OBD scanner or laptop computer to
the Assembly Line Diagnostic Link (ALDL) via the OBD or USB connector.
2. If the device being used is a multi-platform device, i.e. runs on various vehicles, select
the manufacturer, year of vehicle manufacture, model of the vehicle, engine type, and all
other relevant information as required by the diagnostic device.
3. Turn the ignition to the ON mode.
4. Follow the prompts on the screen to initiate the diagnosis.
5. When the diagnosis is complete, take note of the error codes.
6. Turn off the ignition, and the scanner.
7. Clear the screen and turn the scanner off. Repeat steps 3 to 5. This helps to remove wrong
errors from the scan results hereby giving better results.
8. When done, clear the screen, and turn off the engine ignition and turn off the scanner.
20
3.4
Maintenance of Diagnostic Devices
The diagnostic devices are kept in their special storage packs so as not to hamper their
safety. The laptop computers used in diagnosis are always kept charged so that in the case of
power failure, diagnosis can still be run on their battery power. It is also ensured that the laptops
are free from malicious software and spyware. For the PC-based softwares, it is ensured that new
updates are downloaded and installed when available.
21
CHAPTER FOUR
4.
GENERAL REPAIRS
A general repair as implied in this chapter refers to repairs and replacements done on any
parts of the vehicle with the exception of the vehicle body. Repair and replacement services done
at Genais Auto Company include suspension repairs such as brake pad replacements, shock
absorber replacement, stabilizer linkage replacement, stabilizer bushing replacement, etc.
Some of the repairs I served as an assistant in include:
4.1

Engine repairs, overhaul and replacement,

Brake pad replacement,

Shock absorber repair and replacement, etc.
Engine repairs and replacement
The Engine is the component of any vehicle that takes the chemical energy in the fuel
and converts it through a series of processes into useful mechanical energy so as to generate
sufficient power to propel the vehicle. The engine acts as the powerhouse of the vehicle.
Automobile engines come in various designs, sizes and configurations. The structure on which
other components of the engine are attached to is called the Engine block. The engine also
supplies the necessary drive needed by the generator, the air-conditioning compressor and the
power steering pump.
Automobile engines can be classified in various ways. These range from the method of
ignition to fuel type used, number of cylinders, piston arrangement, method of mixture
preparation, method of ignition, etc. The most common type of engine found in vehicles is the
gasoline-burning, liquid-cooled, spark-ignition, four stroke, and multi-cylinder engine. It has the
intake and exhaust valves in the cylinder head, and electronically controlled ignition and fuel
injection system.
The most popular automobile engine is the one based on the constant volume process
also called the Otto cycle. The process was named after the individual that first proposed such a
design, Nicolas August Otto, a German engineer in 1876. Though his proposed design has seen
various adjustments through time, it still remains the foundation for gasoline-combusting, sparkignition four stroke engines.
22
Fig. 4.0 A 4-cylinder gasoline-combusting, spark-ignition engine undergoing repairs
Common engine repairs done at Genais Auto Company include engine overhaul,
camshaft replacement, piston replacement, etc. In cases where the engine has been confirmed to
be in a really bad condition, customers are advised to get a new engine instead.
Engine replacement exercises usually start with the removal of the hood (bonnet) as it
may hinder the proper removal of the engine. Once the bonnet is removed, the engine is carefully
detached from the transmission system. Then the engine is unseated from its seat and every
component that might hinder its easy removal. The engine is lifted out of the vehicle with the aid
of a special hydraulic jack with a maximum lifting capacity of 3 tons.
To overhaul an engine, the engine is removed from its position and dismantled to its
components. The components are then properly cleaned to remove dirt and greasy particles that
may hinder the proper functioning of the engine. Reasons for overhauling an engine range from
having too much sludge in the engine to having water in some areas where it is not desired. The
overhauling process is a labour intensive exercise since it requires valuable man-hours for it to
be done effectively.
Sometimes, an engine repair may simply be the repair of components attached to the
engine like the alternator, water-pump, power steering pump and the air-conditioning system’s
compressor. At other times, engine repairs may simply be the properly welding of the engine
block in the advent of a fracture.
23
4.2
Brake pad replacement
The brake system is a very important subsection of the suspensions system of an
automobile. Without the brakes in the vehicle, it automatically becomes a weapon of destruction
because it won’t be able to stop when it is needed to do so. To achieve this mission, the brake
system comes with a wide range of components like the brake drum, brake piston, brake
callipers, and most important of all, the brake pads. Often times, brake pads get used up and need
to be replaced. The procedure for a brake pad removal exercise at the company is described
below.
Replacement of brake pads
Location: in the workshop
Required tools: Wheel spanner, Hydraulic jack, Tyre chock, Set of sockets, Set of spanners, etc.
Necessary items: new brake pads
Procedure:
1. Using tyre chocks, keep the vehicle stationary.
2. With the aid of the wheel spanner, slack the wheel nuts keeping the tyre in place.
3. Elevate the vehicle to a convenient height using the hydraulic jack, to allow enough space
for the removal of the tyres.
4. Loosen the tyre nuts completely and remove the tyres.
5. The wheel is now exposed. With the aid of ratchets and necessary sockets, remove the
bolts and screws guiding the brake calliper.
6. Lift the calliper and carefully remove one of the brake pads to be replaced.
7. With one of the pair left, carefully pull the calliper so as to press the brake piston against
the brake drum. This enables it to return to its original position before the brake pads
were reduced.
8. With the piston in its position, remove the remaining brake pad.
9. Fit the new pair of brake pads to the brake calliper.
10. Ensure the brake pads are properly fitted.
11. Return the brake calliper to its position and tighten the guiding bolts and nuts.
12. Replace the wheel in position and tighten the wheel nuts to keep it in place.
13. With the aid of the hydraulic jack, bring the vehicle down to ground level.
14. Tighten the wheel nuts again to ensure they are secured in place.
After the steps above, the exercise is complete and the vehicle is worthy to leave the
workshop.
24
4.3
Shock absorber replacement
The automobile frame and body are mounted on the front and rear axle not directly but
through the springs and shock absorbers. Without shock absorbers and springs the vehicle would
not be able to dampen the vibrations resulting from its motion.
Suspension is the term given to the system of springs, shock absorbers and linkages that
connects a vehicle to its wheels and allows relative motion between the two. Suspension systems
serve a dual purpose – contributing to the vehicle’s handling and braking for good active safety
and driving pleasure, and for keeping the vehicle occupants comfortable and reasonably well
isolated from road noise, bumps and vibrations. These goals are generally at odds, so the tuning
of suspensions involves finding the right compromise.
Suspension repairs at Genais Auto Company include the repairs of shock absorbers
(which usually entails the removal and replacement of shock absorber springs), stabilizer linkage
shafts, etc. A typical scenario involving the replacement of a shock absorber is described below;
Required tools: Hydraulic jack, Wheel spanner, Sets of spanners and sockets, Ratchet
Procedure:
1. Using tyre chocks, keep the vehicle stationary.
2. Slack the wheel nuts or bolts keeping the tyre of the respective shock absorber to be
replaced in place.
3. Elevate the vehicle to a convenient height using the hydraulic jack, to allow enough space
for the removal of the tyres.
4. Loosen the tyre nuts completely and remove the tyres.
5. If it’s located in the front part of the vehicle, open the hood to get access to where the top
of the shock absorber is screwed and/or bolted to.
6. With the aid of the necessary tools – Ratchet, Spanner or T-bar, loosen the guiding nuts
of the shock absorbers.
7. Repeat step 6 for the bottom mounting hook of the shock absorber.
8. Remove the old shock absorber and replace with the new one.
9. Fix it properly according to the guiding marks on it. These marks are guides to the proper
orientation of the shock absorbers.
10. Fix the bolts and/or nuts and tighten them to keep the shock absorber in place.
11. Fix the tyre, bolt them in place and reduce the vehicle’s elevation to ground level.
12. Tighten the tyre again to ensure they are not loose. The process is complete.
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Fig.4.1 a hydraulic jack used for general repairs
Fig. 4.2 An engine block
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5.
CONCLUSION AND RECOMMENDATION
5.1
Conclusion
Though the industrial training lasted just for some months, I learned quite a lot. I had the
privilege to participate as an assistant in a sizeable number of repairs and services. The
automotive maintenance industry is a rapidly evolving industry with a lot of potential, especially
in a developing nation like Nigeria due to the fact that a lot of vehicles moving around are based
on technological advancements that are way beyond the reach of the typical roadside mechanics.
This poses a threat to the survival of the local mechanic but also opens up a new world of
opportunities should he be willing to try them out.
5.2
Recommendation
Having participated and as a beneficiary of the Students In Work Experience Scheme
(SIWES), the following recommendations are prescribed;
1. The University community should invite and encourage corporate bodies and
organisations with seasoned professionals in relevant fields to hold seminars and
workshops that will enlighten the minds of the students to recent developments and
challenges in their discipline.
2. As a way of encouragement, lecturers should be provided with multimedia teaching aids
when and where necessary as this would help this students get a clearer picture of the
topics discussed in the classrooms.
3. Due to the nature of the nation’s economy, the students should be assisted in securing
attachment for their Industrial training period as this will eliminate the waste of time
encountered in searching for a place of attachment.
4. More practical classes should be held so as to further reduce the breach between the
classroom and the professional field. Also, more field trips and excursions should be
organised as this would encourage the students because the link between the classroom
and field work would be further emphasized.
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REFERENCES

Heywood, J. B. (1998), Internal Combustion Engine Fundamentals.

Top signs of Engine Trouble, http://howstuffworks.com/engine

On-board diagnostics, http://en.wikipedia.org/wiki/on-board_diagnostics
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