A TECHNICAL REPORT ON STUDENTS’
WORK EXPERIENCE PROGRAM (SWEP)
COMPILED BY,
ADE-ONOJOBI OMOKEHINDE AYOMIKUN
LCU/UG/21/20604
300 LEVEL
CONDUCTED AT:
GUANGZHOU AUTOMOBILE GROUP CO.LTD (GAC
MOTORS), PLOT 3&4 WEMCO ROAD OGBA, IKEJA,
LAGOS NIGERIA.
PROGRAM COMPLETED AT: GAC MOTORS (AFTER SALES
BRANCH) KM15, IKORODU ROAD, BY FAMAD (BATA),
OJOTA, LAGOS, NIGERIA.
SUBMITTED TO:
DEPARTMENT OF MECHANICAL ENGINEERING,
FACULTY OF ENGINEERING
LEAD CITY UNIVERSITY, IBADAN NIGERIA.
SEPTEMBER 2023
1
122, OGUNRUN ELETU ROAD,
MOWE, OGUN STATE.
FRIDAY, SEPTEMBER 22, 2023.
THE HEAD OF DEPARTMENT,
MECHANICAL ENGINEERING,
LEAD CITY UNIVERSITY,
IBADAN, OYO STATE.
DEAR SIR,
REPORT SUBMISSION LETTER
I, Ade-onojobi Kehinde Ayomikun, A 300 level student of the department of
Mechanical Engineering with matriculation number LCU/UG/21/20604, Write
this letter to notify the department of the completion of my two month long
Industrial Training (SWEP), for the 2022/2023 academic session. The program
commenced on Thursday, July 20, 2023, and ended on Friday, September 22,
2023.
I am turning am turning in this submission letter along with it, my industrial
training report and logbook. I hope my work report is examined and reviewed
favorably.
Yours’ faithfully,
Ade-onojobi Kehinde
2
CERTIFICATION
I, Ade-onojobi Omokehinde Ayomikun, A 300 level student of the department
of mechanical engineering, Lead city University, Ibadan, Oyo state, With the
matriculation number LCU/UG/21/20604; Hereby certify that this Technical
Report on students’ Work Experience Programme (SWEP) was written by
myself.
……………………..
...……………..
Level Adviser
Signature & Date
…………………….
…………………
Head of department
Signature & Date
3
ACKNOWLEDGMENT
To begin, I give all the glory to God almighty for his guidance, help, provision
and protection throughout the duration of the Industrial training program.
I am eternally grateful to my parents, Mr. & Mrs. Ade-onojobi for their
steadfast support, care, sponsorship and guidance throughout the program. They
served as a major source of motivation towards immersing myself fully into the
program.
I also want to express a heartfelt thank you to my line manager during this
program, Engineer Sunny Abiri, the various engineers, organizational staff and
fellow industrial training students for their acceptance, understanding, care and
clarity in explaining technical situations and imparting knowledge to me during
this program
I also extend a profound appreciation to my level advisor, to my Dr Olumide
Towoju and equally to all respective lecturers in the department of mechanical
engineering for providing myself and my fellow departmental mates with the
opportunity and academic tools to ensure we could compete beyond the four
walls of this institution.
As the saying goes, “It takes a village to raise a child”; And for all your
respective efforts towards our growth during this period; I thank you all and I
am indeed grateful.
4
ABSTRACT
This report is a comprehensive summary of the work experience gained during
my two-month industrial training program at Guangzhou Automobile Group
(GAC MOTORS).
My training was based on the assembling of GAC Motors car models (GS3,
GS4, GA4, GS8)
Over the course of the industrial training program, I acquired practical
knowledge on automobile assembly, maintenance, repair and servicing.
This knowledge will be highlighted in terms of the main body of the work
report. The contents of this report majorly consist of knowledge acquired
directly from the work experience. However, some references were made to
fully buttress certain sections of the work report.
This report discusses the technical skills gained during the training period and
justifying the relevance of the scheme in equipping students with needed
technical competence to thrive in the real world.
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TABLE OF CONTENT
TITLE PAGE……………………………………………………………………………………………….….1
REPORT SUBMISSION LETTER………………………………………………………………………….…2
CERTIFICATION……………………………………………………………………………………………...3
ACKNOWLEDGMENT……………………………………………………………………………………….4
ABSTRACT……………………………………………………………………………………………………5
TABLE OF CONTENT………………………………………………………………………………......……6
CHAPTER ONE: INTRODUCTION
1.1 OVERVIEW OF STUDENTS’ WORK EXPERIENCE PROGRAM (SWEP)…………………………7
1.2 INFORMATION ON PLACE OF ATTACHMENT…………………………………………………….8
1.3 SUMMARY OF WORKS CARRIED OUT………………………………………………………….….9
CHAPTER TWO: WORKSHOP PRACTICES
2.1 EQUIPMENTS USED IN CARRYING OUT ACTIVITIES…………………………………………….10
2.2 SAFETY IN THE WORKSHOP……………………………………………………………………….….18
CHAPTER THREE: STUDENTS’ WORK EXPERIENCE
3.1 PRODUCTION AT OGBA BRANCH…………………………………………………………………….20
3.2 ASSEMBLY OF SEMI-KNOCKED DOWN (SKD) AUTOMOBILES………………………………......26
3.2.1 INSTALLATION (WIRING HARNESS) ……………………………………………………………….27
3.2.2 COUPLING, MOUNTING AND INSTALLATION OF GS3 ENGINE AND SUSPENSION
SYSTEM………………………………………………………………………………………………………...31
3.2.3 EXHAUST SYSTEM INSTALLATION………………………………………………………………….33
CHAPTER FOUR: SERVICING, MAINTENANCE AND REPAIR AT OJOTA
BRANCH
4.1 SERVICING OF A VEHICLE……………………………………………………………………………….36
4.2 CHANGING SUSPENSION SYSTEM……………………………………………………………………...38
4.3 PROBLEMS ENCOUNTERED AT BOTH PLANTS & SOLUTIONS…………………………………….40
CHAPTER FIVE: CONCLUSION AND RECOMMENDATION
5.0 CONCLUSION…………….……………………………………………………………………………….42
5.1 RECOMMENDATION…………………………………………………………………………………….42
5.2 REFERENCES………………………………………………………………………………………………42
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4.3 LIST OF FIGURES
Figure 1.1……… Organizational chart of Guangzhou Automobile Group Ogba
Figure3.1………………………………………. showing plant production cycle
Figure 3.1.1…………………………….... Showing plant A workflow process
Figure 3.2.1.1: …………………………………………..wire harness schematic
Figure 3.2.1.2 ……………………………………………………Vehicle Model
Figure3.2.1.2 ……………………………………………………. Left Headlamp
Figure 3.2.1.4 ……………………………………………………. Plug Insertion
Figure 3.2.1.3……………………………………………………. Type Of Plug
Fig 4.2.1………………………………………. Automobile Suspension System
4.4 LIST OF PLATES
Plate 3.1…………………………. SKD vehicles reaching the end of trimline
Plate 3.1……………….. SKD mounted on chassis frame for engine installation
Plate 3.1…………………………………………… Tire frame brow installation
Plate 3.2.2.1……………………………………………….. Engine steering rack
Plate3.2.2.2……………………………………………………… Engine Casing
Plate 3.2.2.3……………….Engine being hoisted up for mounting on scissor lift
Plate 3.2.2.4 ………………………… Vehicle Engine mounted on scissor lift
Plate 3.2.2.5………………………………. Mounted engine set for installation
Plate 3.2.3.1 ……………Suspended SKD awaiting suspension parts installation
Plate 3.2.3.2 ………………………………………. Tire frame brow installation
Plate 3.2.3.3.. Assembled SKD automobiles engaged in fluid filling on final line
Plate 4.1.1………………………. Changing transmission fluid during servicing
Plate 4.1.2…………………. Oil sump pan housing old engine oil and oil filter
Plate 4.1.3………………………………………………. Used oil filter removed
Plate 4.2.1………………………………………….Suspension System Changed
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CHAPTER ONE: INTRODUCTION
OVERVIEW OF STUDENTS’ WORK EXPERIENCE
PROGRAM (SWEP)
The student work experience program is a skill training program designed to
provide students with practical exposure to real-world work environments.
It prepares students for the industrial work situation they are likely to meet after
graduation; Usually the program helps bridge the gap between theory and
practice, specifically in engineering it helps engineering students get exposed to
machines and equipment, professional work methods, techniques in handling
equipment and machinery that may not be available in their universities and
ways of safeguarding the work areas and workers in industries.
These programs help students apply classroom knowledge, build skills, and
explore potential careers. They can also lead to networking opportunities and
job offers after graduation.
The students’ work experience program is a skill acquision program which is
geared towards technological development of the nation. It takes place within
12 weeks (3 months) at a stretch.
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1.2 INFORMATION ON PLACE OF
ATTACHMENT
Guangzhou Automobile Group (GAC MOTORS) is a large state-owned
automobile group, A subsidiary of CIG Motors, focusing on the manufacture of
automobiles and motorcycles; And it covers both upstream industries (vehicle
R&D and auto parts) and downstream industries (trade service, finance,
insurance, leasing and logistics for automobiles).
GAC Motors has 3 major branches in Lagos, Nigeria: focusing on Production,
sales and maintenance or repair. Located at Ogba, Victoria Island & Ojota,
respectively.
The production plant situated at Ogba focuses on the general production of
semi-knock down automobiles which is where I chose to begin the crucial part
of the work experience program before concluding at the Aftersales section
located at Ojota, Lagos State. This section deals with the servicing, maintenance
and repair of automobiles.
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Fig 1.1 : Organizational chart of Guangzhou Automobile Group Ogba
1.3 SUMMARY OF WORKS CARRIED OUT
1. Semi-Knocked Down Automobile Assembly:




Wiring harness fitting
Coupling the engine
Mounting the engine onto the vehicle chassis
Fitting of suspension components
 Bleeding of plant generator engine
2. Servicing, Repair and maintenance:
1. Servicing:







Drain of engine oil
Drain of transmission fluid
Change of oil filters
Change of fuel filter
Change, Cleaning of air filters
Checking and rotating the tires
Brake pad inspection and change
2. Repair:
 Panel Beating repair on crash vehicle
 Suspension system change
 Bleeding of brake system
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CHAPTER TWO: WORKSHOP PRACTICES
2.1 EQUIPMENT USED IN CARRYING OUT
ACTIVITIES
1. Semi knock Down Assembly
Equipment
Operation Carried
out
Provides compressed
Industrial Air
pneumatic power to a
Compressor
range of pneumatic tools
used in performing
various operations in the
workshop.
Pneumatic Guns
Battery powered
Electric Motor
Guns
Powered by cool
compressed air
generated by the air
compressor, air motor,
shafts and clutch Used to
carry out tightening and
loosening of nuts-andbolts operations of
various sizes and torque
values.
(Note: Bolt head size
determines size of
Socket to be used.)
Battery powered electric
motor guns used to carry
out various torque
operations involving
nuts and bolts.
11
Image
Electric Drill
Corded power drills
rated in watts, used for
making round holes or
driving fasteners. It is
fitted with a bit, either a
drill or driver chuck.
Power Angle
Grinder
Used to grind metal and
cut through marginally
stuck threaded bolts in
engine/gear sitting
bracket. It achieves this
through the use of
abrasive grinding discs
that come in a range of
materials, like,
aluminum, diamondtipped and carbide discs.
Used to tighten nuts and
bolts to a predetermined
torque value.
Torque Wrench
Combination
Spanner
(Metric Size (mm):
17/19, 22/24, 14/12)
Double ended tools and
serve the functions of
two spanners at once.
Ring end used to hold
nut in place when
electric motor gun is
used to loosen the bolt.
Adjustable
Spanner/Wrench
Open ended wrench with
a moveable jaw. Used to
grip fasteners, such as
nuts and bolts of all
sizes due to its moveable
jaw.
Operation carried out on
transfer lifts during
maintenance.
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Transfer Lifts
Tap And Die
Utilizing guide sensors
to detect proximity of
vehicle chassis to each
other; The transfer lifts
transport each s-k-d
frame from one point in
the production line to the
other.
E.g., Trimline to
Underbody section etc.
Taps and dies are
tools used to create
screw threads both
internal and external.
A tap is used to cut
internal threads in a
nut, Dies are used to
cut external threads
in a bolt.
During production
both were utilized in
increasing internal
thread width or
deepening thread
holes to allow proper
fitting of bolts.
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Battery Powered
Battery Powered
Engine Positioning engine positioning
scissor lift is used
Scissor Lift
during engine
installation procedure
for mounting and
transportation of the
engine to installation
section. Also, to
ensure flexible
movement in order to
professionally install
the engine and gear
sitting and fasten the
brackets.
Utilizing air pressure
Pneumatic Air
generated by the
Blow Gun
compressor it is used to
perform maintenance on
various workshop
equipment’s by blowing
air through tight crevices
to remove dirt and
otherwise particles that
can cause damage to the
equipment’s.
Attached to a socket at
Torque Wrench
Extensions/Wrench one end and a ratchet on
the other end of the
extensions
extension.
Used to aid access hard
to reach nuts and bolts,
used to gain distance
needed to reach a
predetermined torque
value.
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Torque Socket
(Metric Size: Mm)
Used to torque bolts to
the correct torque
values.
Sockets vary in size I.e.,
17, 19, 21 etc.
3-In-1 Fluid Filling Used in dispensing
coolant, brake fluid and
Machine
petrol into the vehicle
before transporting the
vehicle into plant B for
quality testing.
2. Servicing, Repair and Maintenance
Equipment
Operation
Carried Out
Oil filter
wrench
Used to properly
take out or insert
used oil filter
from the vehicle’s
engine during oil
change in
servicing.
“Tee” socket
spanner
Is a hand tool
used for
tightening or
loosening
fasteners of
different sizes
such as “nuts”
and “bolts”
Image
15
Hydraulic jack
Used to lift
vehicles during
maintenance &
repair.
Screwdriver
Used for turning
screws to either
tighten or loosen
them.
Electric Drill
Corded power
drills rated in
watts, used for
making round
holes or driving
fasteners. It is
fitted with a bit,
either a drill or
driver chuck.
Attached to a
socket at one end
and a ratchet on
the other end of
the extension.
Used to aid
access hard to
reach nuts and
bolts, used to gain
distance needed
to reach a
predetermined
torque value.
Extensions
16
Used to loosen
Lug Wrench &
lug nuts on
socket
vehicle tires
through the
application of
torque.
Industrial air
compressor
Oil Filter
Mallet
Provides
compressed
pneumatic power
to a range of
pneumatic tools
used in
performing
various
operations in the
workshop.
Crucial
component in an
internal
combustion
engine that helps
remove
contaminants and
impurities from
the engine oil,
ensuring the oil
remains clean and
effective in
lubricating and
protecting the
engine.
Subject to change
during servicing.
Used to shape
and repair metal
panels on a
vehicle during
panel beating
work.
17
Sandpaper
Auto
Exterior
Repair
Machine
Used in
smoothening new
brake pads in
order to aid
friction.
Kit containing
tools used for
repairing minor
scratches and
blemishes on a
vehicle.
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2.2 SAFETY IN THE WORKSHOP
Safety is simply the condition of being protected from danger, risk or injury,
before you attempt any practical work in a workshop, you must understand the
basic safety rules. These rules will keep you and others safe in the workshop.
Remember workshop safety is everyone’s responsibility.
Some of the important safety practices i was introduced to over the course
of the training programme include:
1. QUALITY AND PROCESS DISCIPLINE
 Employees should carefully study assembly drawings and
engineering tables, and strictly follow the process documents for
on-site assembly and quality confirmation.
 Employees should carefully do a good job in the spot check of
tools to ensure the accuracy of tools meets the requirements.
 Before the operation, employees should carefully confirm the
installation location of parts before loading, and do not accept
defective products and defective product vehicles.
 During the operation, employees should not have bad actions, such
as: irregular posture of using wind wrenches, jumping on or off the
car body.
 During the operation, employees should strictly implement the
process documents to ensure the quality of assembly.
 During the assembly process, employees should give feedback and
record in time if they find defects in the upper process or the
position.
2. CLOTHING, LABOR PROTECTION AND SAFETY
 When entering the workshop, you should wear work shoes and
caps (I.e., Protective boots and Protective Helmets).
19
 Gloves Must be worn when carrying out assembly work, and
watches with metal bracelets cannot be worn. Helmets must be
worn under the vehicle and cabin work, and work caps are worn
for other positions.
 Dangerous auxiliary materials such as gasoline and ace should
be kept and locked, and the key should be kept by a special
person.
 The power supply and equipment of the workshop shall be the
responsibility of the designated person in charge, and if the
person in charge is not there, it should be entrusted to others.
3. ON-SITE
 Employees should keep the work site clean, and if they find
paper, parts packaging bags and other objects that obviously
affect 5s on the floor of the workshop, they should be dealt with
immediately.
 Employees should care for their tools, use them correctly, and
keep them well to prevent their loss. Do not leave parts, tools,
etc. on the car.
 Do not make loud noises, fights or chases in the workshop.
 Do not sleep in the workshop.
 Do not use mobile phones in the workshop.
 Only take the green channel in the workshop.
 Do not place beverage bottles, fruits, etc. on the parts rack and
workbench.
NOTE: Green channel refers to regions in the workshop which is permissible
for casual walk as it does not interfere with production nor does being their lead
to potential accident.
20
CHAPTER THREE: STUDENTS’ WORK
EXPERIENCE
3.1 PRODUCTION AT OGBA BRANCH
Situated at plot 3&4 wemco road Ogba, ikeja, Lagos state. Guangzhou
Automobile Group (GAC MOTORS) Ogba is a standard automobile production
plant that specializes in the assembly and mass production of semi-knocked
down (SKD) automobile models such as the GS3, GA4, New/Old GS8 etc.
The day’s activities begin at 7:45am with an assembly comprising of hired staff
(i.e., panel beaters, painters, forklift operators, Plant A assembly staff, Quality
personnel), IT students and organizational staff (I.e., General Manager, Line
managers, Quality process & aftersales staff/engineers) addressing the day’s
work, assembly/production targets, welfare issues of the staff etc.; Production
begins at 8:00am with which everyone proceeds to their designated assembly
zone to begin the day’s work.
Working hours run from 8:00am-5pm from Monday-Friday, 10:00am-3:00pm
on Saturdays.
The plant is divided into 3 zones, Plant A (SKD Assembly Unit), Plant B
(Quality Workshop) and Storage/ Warehouse.
Plant A
Plant B
Storage
Fig3.1: showing plant production cycle
21
1. Plant A (Assembly Unit):
Production begins in plant A otherwise known as the assembly
unit; it is divided into 3 assembly zones which are:
 The trimline
 Underbody/Chassis Line Section
 Final Line
a. The Trimline: This is the first stage of assembly where semiknocked down (SKD) automobiles are brought onto the line
through:
 Alignment stage: Hoisting of vehicle to conveyor line
(Hoist line lifts up to 2 tonnes).
Offloading occurs simultaneously.
The following processes are then implemented:
 Scanning of SKD bar code, assigning of vehicle
identification number and production number to
indicate entry into production plant and start of
assembly on that vehicle.
 Headlamp Installation
 Multimedia & Wiring Harness Installation
Plate 3.1: SKD vehicles reaching the end of
trimline
22
Upon Reaching the end of the conveyor belt, each
vehicle is transferred to the underbody section
through the use of transfer lifts.
b. Underbody Section: This is the secondary stage
of assembly, divided into 3 sections namely:
 Engine Mounting Section: This unit
deals with the removal of engines from
their casing, coupling of engine parts,
mounting of engine on scissor lift for
installation.
 Engine Installation: This unit deals with
the installation of each engine (by
vehicle identification number) and the
installation of the suspension system.
Plate 3.1: SKD mounted on chassis
frame for engine installation.
 Suspension Parts Installation: This unit
deals with the installation of the vehicles
exhaust system, stabilizer linkage,
Intermediate propeller shaft (Model
Dependent).
 Bumper Installation and Tire Fitting:
This unit deals with the installation of
front, rear bumpers and tires.
23
Plate 3.1: Tire frame brow installation
Equipment Used: Exact battery powered
gun (8mm socket)
Proceeding from the underbody section; Each
vehicle is then transported to the final line via
transfer lifts.
c. Final Line: This is the final stage of assembly where each
vehicle is positioned on the conveyor line whereby the
following processes are carried out on it:
 Fluid Filling: This is the process by which Brake Fluid,
coolant (Antifreeze), refrigerant and petrol are put into
the vehicle before quality testing begins.
 Steering & Steer Board Installation: The final line unit
begin the installation of the steering board and steering
components.
 Seat Clipping & Installation
24
TrimLine
Underbody
Final line
Fig 3.1.1 : Showing plant A workflow process
Upon the completion of assembly, each model is then moved over to plant B for
quality testing.
The following are quality testing procedures:
 Speed Testing: Done through the use of sensor pads and a system to
ensure the assembled automobile can reach the maximum allowed speed
without breakdown.
 Weight Testing: Carried out through the use of weight sensor pads and a
system to ensure the assembled automobile reaches the desired weight
class.
 Dark Room: A steel structured room designed to gauge the luminous
intensity of each assembled vehicle model.
 Sound Room: A steel structured room designed to gauge the automobiles
sound system level/intensity.
 Rain Room: Designed to test for leakage spots/cracks/defects in the
assembled automobile through constant spray of water from multiple
directions akin to rain.
 Track Test: Each automobile is then put through a series of tracks
resembling various terrains in order to assess each vehicle’s performance
and handling characteristics.
25
After completing each procedure and ascertaining the quality of each
vehicle they are then parked into storage and put up for sale.
Defects are recorded and taken to plant B for repair.
Data for the days work is then compiled on an excel spreadsheet and sent
into the company’s database.
This concludes the production process at Ogba branch
26
3.2 PROJECT 1: ASSEMBLY OF SEMI-KNOCKED DOWN
(SKD) AUTOMOBILES
What is a semi-knocked down vehicle?
A knock-down kit is a collection of parts required to assemble a product. The
parts are typically manufactured in one country or region, then exported to
another country or region for final assembly.
A semi-knocked-down automobile (SKD) is an automobile that has been
partially assembled in the country of origin and exported whole to the
destination market.
Before assembly begins; Organizational staff from both plants are called to go
over vehicle model process cards to ensure a thorough understanding of each
assembly process to ascertain quality and reduce potential errors/defects.
a.
The Trimline: This is the first stage of assembly where semi-knocked
down (SKD) automobiles are brought onto the line through:
•
Alignment stage: Hoisting of vehicle to conveyor line (Hoist line lifts
up to 2 tonnes = 6000kg).
Offloading occurs simultaneously.
The following processes are then implemented:



Wire harness knitting/Installation
Head lamp installation
Multimedia Installation
27
3.2.1 Wiring Harness Knitting/Installation
The Purpose Of The Job:
Fixing and handling of wire harness for power and signal transmission of
electrical components.
Normal Job Status:
The clamps of the wiring harness should be firmly fixed and organized in a
regular position.
The Main Part Of Use Of The Harness:
Right floor wiring
harness
Left floor wiring
harness
Fig3.2.1.1: wire harness schematic (Source: GAC MOTORS
installation manual 2023)
28
PROCEDURE 1:
 Harness removal procedure:
1. Confirm the main points.
2. Handle harness properly before installation (If connector is
jammed during handling it will cause scratches to the car body or
break the plug).
3. Insert fastener properly.
4. Confirm insertion of hole of glue nail.
 Processing confirmation:
1. Is there distortion in the harness?
2. Have the nails come off?
3. Is there peeling off the harness nails?
3.2.1.2 Headlamp Installation:
The purpose of the job:
To connect the plug of the harness to ensure power is applied.
Normal Job Status:
The outer and inner terminals are in contact, and the jaws without the plug are
loose to ensure a reliable snapping state.
Fig 3.2.1.2 :Left
Headlamp
Fig 3.2.1.2 : Vehicle Model
29
(source: GAC
MOTORS installation manual 2023)
3.2.1.3 THE TYPE OF PLUG
Waterproof plug:
Waterproof filler
non-Waterproof plug:
Terminal case
Jaws
Pin
Wiring harness
Fig 3.2.1.3: Type Of Plug (source: GAC MOTORS installation
manual 2023)
Operational Points:
The plug should be inserted vertically into the terminal hole. Confirm its
plugged in place through sound and feel.
Do not force the terminal into the plug hole as hard press-in may cause damage
to the pins of the plug.
Confirmation of plug insertion:
•
Check for:
•
Bent inner plug terminal.
30
•
Mixing of foreign objects in plug
•
If the inner plug terminal has come off.
•
Is the combination carried out smoothly?
•
When pulling to confirm does it come off?
•
Is there a rebound force when the combined is pressed in again?
Insertion Of the Connector:
Stuck jaws
Insert straight into the shape
inner joints.
Regular plug mating of the outer and
Fig 3.2.1.4 : Plug Insertion (source: GAC MOTORS installation
manual 2023)
Upon Reaching the end of the conveyor belt, each vehicle is transferred to the
underbody section through the use of transfer lifts.
b.
Underbody Section: This is the secondary stage of assembly, divided
into 3 sections namely:
•
Engine Mounting Section: This unit deals with the removal of engines
from their casing, coupling of engine parts, mounting of engine on scissor lift
for installation.
•
Engine Installation: This unit deals with the installation of each engine
(by vehicle identification number) and the installation of the suspension system.
31
•
Suspension Parts Installation: This unit deals with the installation of
the vehicles exhaust system, stabilizer linkage, Intermediate propeller shaft
(Model Dependent).
•
Bumper Installation and Tire Fitting: This unit deals with the
installation of front, rear bumpers and tires.
3.2.2 ENGINE COUPLING, MOUNTING & INSTALLATION
Overview:
Car propulsion is provided by an engine or motor, usually an internal
combustion engine. Heat engines, like the internal combustion engine burns fuel
to create heat which is then used to do work. Pneumatic motors use compressed
air as well as steam engines.
Specific to an automobile, an I.C engine is a heat engine in that it converts
energy from the heat of burning gasoline into mechanical work, or torque which
is then applied to make the car move.
The practical guide of an I.C engine is the supply of air-fuel mixture is fed into
the cylinder where compression occurs and then burnt through the spark plugs
igniting it. This heat energy generated is then converted into mechanical work
as the high gas pressure generated forces the piston to move along its stroke in
the cylinder.
To enable usage of the piston movement the driving thrust of the piston is
transmitted by means of a connecting rod to a crankshaft which serves to
convert linear piston motion in the cylinder to a rotational crankshaft
movement.
 Procedure:
During the assembly of Semi-knocked down (SKD) automobile the engines
come in coupled albeit missing the steering rack
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Plate 3.2.2.1 : Engine steering rack
Plate3.2.2.2 : Engine Casing
The engine casing is then dismantled using an electric motor gun of socket size
10mm, 12/14 mm ring spanner, 17 mm ring spanner for central key bolt and the
hooks are attached at both brackets at equal positions to maintain balance and to
enable hoisting.
Plate 3.2.2.3:Engine being hoisted up for mounting on scissor
lift
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Plate 3.2.2.4 : Vehicle Engine mounted on scissor lift
 ENGINE INSTALLATION
PROCEDURE:
 After the engine has been mounted onto the scissor lift, it is then passed
to the engine mounting unit. Here, the engine is pushed under the
suspended automobile model with a scissor lift.
 The engine needs to be set very well into its various threaded bolt holes
before lifting the scissor lift.
 After setting in place, the technician climbs up the Ladder-Table to screw
in the engine seat, gear seat and screw in the bolts. There are 4 bolts of
21mm tightened to 200nm torque value
Plate 3.2.2.5 : Mounted engine set for installation
3.2.3 SUSPENSION PARTS INSTALLATION
Here, the tie-rod end, hub bolts, stabilizer linkage, catalytic converter,
exhaust gasket and silencer are fixed in and connection of radiator hose
occurs.
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Plate 3.2.3.1 : Suspended SKD awaiting suspension parts installation
 BUMPER INSTALLATION AND TIRE FITTING
Procedure:
 Fixing the front and back bumpers, side brow bumpers through the use of
an exact battery powered electric motor gun.
 Tire Fitting: Each tire lug bolt should be torqued to the appropriate value
(click) and in a kris cross manner.
Plate 3.2.3.2 : Tire frame brow installation
Equipment Used: Exact battery powered gun (8mm socket)
 FINAL LINE
This is the final stage of assembly where each vehicle is positioned on the
conveyor line whereby the following processes are carried out on it:
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•
Fluid Filling: This is the process by which Brake Fluid, radiator coolant
(Antifreeze), A/C refrigerant and petrol are put into the vehicle before
quality testing begins.
•
Steering & Steer Board Installation: The final line unit begin the
installation of the steering board/steer column and steering components.
•
Seat Clipping & Installation
Plate 3.2.3.3 : Assembled SKD automobiles engaged in fluid filling on final
line
After completing the processes, the automobile is then driven into plant B
for quality testing.
This concludes the assembly of SKD automobiles.
Note: Torque refers to a rotational or twisting effect of a force; Used in
assembly to bring bolts to the appropriate point in a threaded hole.
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CHAPTER 4: SERVICING, MAINTENANCE AND REPAIR
AT OJOTA BRANCH
Towards the end of my students’ work experience under (GAC MOTORS), I
was exposed to several ways of maintaining, servicing and repairing of cars and
some other important parts of a car at the ojota aftersales branch.
Some of the works we frequently did are:
4.1 SERVICING:
A motor vehicle service or tune-up is a series of maintenance procedures carried
out at a set time interval or after the vehicle has traveled a certain distance. The
service intervals are specified by the vehicle manufacturer in a service schedule
and some modern cars display the due date for the next service electronically
on the instrument panel. A tune-up should not be confused with engine tuning,
which is the modifying of an engine to perform better than the original
specification, rather than using maintenance to keep the engine running as it
should. Servicing involves the act of cleaning, checking, adjusting, or making
minor repairs to the car to ensure that it works properly.
Steps involved in servicing a vehicle:
1. Park the car on a leveled and spacious ground and make sure it is cool.
2. Jack up the vehicle on both sided around the front area and place a
wedge/support for safety purposes.
3. Use the correct size of spanner to loosen the drain plug connected to an oil
pan beneath the sump to drain the old oil from the engine
4. After oil drainage, fix the oil pan and screw back the drain plug.
5. Remove the oil filter using the oil filter wrench and change it.
6. Remove and change the air filter and fuel filter.
7. Pour fresh specified engine oil to replace the drained old oil.
8. Check and top water level in the radiator if needed.
9. Start the engine and run it for a minimum of 3minutes to ensure there is no
leakage of oil at the drain plug.
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Plate 4.1.1 Changing transmission fluid during servicing
Other additional operations include:
1. Replacement of the spark plugs
2. Checking the level and refilling brake fluid
3. Checking the level and refilling power steering fluid
4. Checking the level and refilling Automatic Transmission Fluid
5. Lubrication of some components or moving parts of the engine 6.
Inspecting and setting of the timing belt if needed
7. Checking of the tire condition.
8. Checking of coolant hoses
9. Inspection and replacement of timing belt or timing chain if needed
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Plate 4.1.2 Oil sump pan housing old engine oil
and oil filter
Plate 4.1.3: Used oil filter removed
4.2 CHANGING OF SUSPENSION SYSTEM
Suspension is the system of tires, tire air, springs, shock absorbers and linkages
that connects a vehicle to its wheels and allows relative motion between the
two. The suspension system affects an automobile's comfort, performance, and
safety.
The suspension system suspends the automobile's body a short distance above
the ground and maintains the body at a relatively constant height to prevent it
from pitching, swaying, or leaning. In order to maintain effective acceleration,
braking, and cornering—the components of good handling—the suspension
system must also keep all four tires firmly in contact with the ground.
It is difficult to design a suspension system that provides both a smooth ride and
good handling characteristics. The typical family sedan has a relatively soft
suspension that promotes a smooth, comfortable ride but sacrifices some
acceleration, braking, and cornering capabilities. Conversely, the typical sports
car or utility vehicle has a firm suspension that assures good handling at the
expense of some riding comfort. The suspension systems at the front and rear of
the automobile are usually different from each other because these areas have
different suspension requirements.
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Fig 4.2.1: Automobile Suspension System
Steps involved in changing the suspension system:
1. Park the car on a leveled and spacious ground and make sure it is cool.
2. Jack up the vehicle on both sided around the front area vertically to a distance
above your head and place a wedge/support on the suspension system for safety
purposes.
3. Use the correct size of spanner, Torque wrench to loosen the stabilizer
linkage, lower control arms, shock absorber.
4. After defective part change, fix the various linkages and screw back
thoroughly to ascertain proper connection.
5. Start the engine and take the vehicle for a test drive to ensure there is no noise
coming from the suspension system.
Plate 4.2.1 :Suspension System Changed
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4.3 PROBLEMS ENCOUNTERED AT BOTH PLANTS &
SOLUTIONS
 FREE BRAKE PEDAL:
During servicing, A vehicle was reported to have a free brake pedal this is due
to lack of reliable pressure in the braking system caused by air in the brake
lines.
Diagnosis & Solution:
Pressure loss in braking system caused by air in the system; Solution rendered
was to bleed the brake system. This involves releasing air from the brakes.
The simple procedure involves forcing of fluid through brake lines and out
through a bleeder valve or bleeder screw. The fluid eliminates any air that may
be in the system. Bleeder screws and valves are fastened to wheel cylinder or
caliper. The bleeder must be cleaned. A drain hose is then connected from
bleeder to glass jar where the fluid coming out from bleeder valve is collected.
Bleeding involves repetition of procedure at each wheel to ensure complete
bleeding. Meanwhile, one person should also be assigned to top up the fluid
level in container over master cylinder to compensate for the fluid taken out
through valves. If top up is not continued, then there are chances of air bubbles
being developed in system which further delays the process.
 BROKEN STABILIZER LINKAGE BOLT
During assembly at the Ogba branch we had an increase in defective stabilizer
linkages from the suspension installation unit.
Diagnosis and Solution:
The technicians and personnel in the installation unit went above the assigned
torque value accidentally; Due to torquing before the bolt fit in properly.
Solution rendered was a change in approach to torquing; Bolts were to be
screwed in firmly by hand first before torquing.
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5.0 CONCLUSION
Following my Nine-week work experience programme at Guangzhou
Automobile Group, I have gained exposure of the different fault’s cars develop
especially when proper maintenance and care are not taken as well as the
various methods of solutions to tackle these problems, I possess a detailed
understanding to a large extent the various processes involved in automobile
assembly & production. During my 9 weeks training, I was also sensitized on
the importance of safety rules and regulations in a workshop and that it should
come first in any engineering environment. This training also gave me exposure
to other skilled individuals in the engineering field.
5.1 RECOMMENDATION
I recommend that the training duration be probably increased to allow enough
time for students to have a proper understanding on the manufacturing sector
and practical application of what they have been taught in their various lecture
halls. I also recommend Guangzhou Automobile Group for any engineering
student who wants to have an outstanding practical knowledge about
automobile and its system.
5.2 REFERENCES
https://en.m.wikipedia.org/wiki/Car_suspension
Ali Bokhari (2018). Car Brakes and Accelerators. Available at:
https://factschronicle.com/what-happens-to-the-car-if-brake-and-accelerator-arepressedat-thesame-time-15257.html
AK All Education (2020). Mechanical Brake System. Available at:
HTTPs://images.app.goo.gl/WuhN72p3DDTHB2Zr5
Semi Knock Down (SKD) Automobile Assembly: A Comprehensive Review; S. Jagadeesha,
H.S. Madhusudan, S.M. Shivaprakash (2019)
Guangzhou Automobile Group (GAC MOTORS) Installation Manual (2023)
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