TECHNICAL REPORT

ON
STUDENT’S INDUSTRIAL WORK EXPERIENCE SCHEME
(S.I.W.E.S).

UNDERTAKING AT
SUNFRI GARAGE
PLOT 110, OYADIRAN ESTATE SABO, YABA, LAGOS STATE.

BY
IDOWU FABRICS OLUWASEUN
F/ND/22/3440024

DEPARTMENT OF MECHANICAL ENGINEERING

SCHOOL OF ENGINEERING
YABA COLLEGE OF TECHNOLOGY, LAGOS.

FROM FEBRUARY TO MAY 2024.

 CERTIFICATION
This is to certify that this Student Industrial Work Experience Scheme report was carried
out by IDOWU FABRICS OLUWASEUN (F/ND/22/3440024), in the department of
Mechanical Engineering, school of Engineering, Yaba college of Technology, Yaba, Lagos
State.

……………………………………………………....... ………………………………………………
(Supervisor) Date

………………………………………………....... …………………………………………………
(H.O.D) Date

ABSTRACT

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This Industrial training report presents the experience garnered during my 16 weeks of
industrial training undertaken at SANFRI GARAGE.
My training was on the diagnosis, repairs, maintenance in Automobile vehicles ranging
from cars, SUVs, light trucks and pick ups.
During this period, I acquired practical knowledge on how to repair, replace and install
some mechanical parts and systems also assisted in providing the units the functionality
they need.

ACKNOWLEDGEMENTS

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My appreciation goes to God almighty, through his help that made me to choose
mechanical engineering as my discipline.
To paraphrase an actor who just won an Emmy, “there are so many people to thank”.
However, I will like to thank the Industrial Training Fund ITF for their foresight in putting
this program to place and also to the Mechanical Engineering department, in my school
YABA COLLEGE OF TECHNOLOGY, for providing the platform on which was engaged in the
training.
I want to say a big thank you to my industrial based MD/CEO. Didonu Sunday Owolabi
and the technicians in my unit Mr. Afolabi Tunde, Mr. Mathew Sunday, Mr. Rasheeed
Toheeb, Mr.Alani Rasheed and Mr. Akeju Sulimon, who helped with solutions to my
numerous questions.
I am grateful to SANFRI GARAGE for providing with the opportunity to be exposed to
engineering services to the automobile industry.
I also want to thank my mother she encouraged me all through my Industrial Training
period and also appreciate boss who taught me the basics in automobile repair work and
my dad for their effort to ensure I get a placement, also for their moral and financial
support.
Finally to my Institution based supervisor, for his advice and support, to my other friends
and colleague. I say thank you all. Am highly grateful.

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 TABLE OF CONTENT
Title Page
Abstract................................................................................................................................
.......2
Acknowledgements..............................................................................................................
........3
Table of
Content..........................................................................................................................4
List of
tables................................................................................................................................5
List of
Figures ............................................................................................................................6
CHAPTER 1
INTRODUCTION TO TRAINING PROGRAM
1.1 Purpose of
Training.....................................................................................................7
1.2
Background.................................................................................................................
7
1.3 Objectives of (S.I.W.E.S) …….……………………………………………………………...8
1.5 Name and location of the
company………………………………………………………...8
CHAPTER 2
DESCRIPTION OF THE ESTABLISHMENT
2.0 Establishment profile………………………………………………………………………...9
2.1 Establishment corporate goal………………………………………………………………..9
2.2 The establishment scope of
work…………………………………………………………...9
CHAPTER 3
THE TRAINING PROGRAM
3.0 Description of work done …………… ……..……………..……………………………...11
3.1 Automotive mechanical systems and parts ………………………….…….….
………….11

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 3.11 Engine…………………….………...……………………………………………………..11
3.12 Most common sensors…………………………………………………………………….12
3.13 Lubricating system……..………………………………………………………………….13
3.14 Cooling system…..………………………… ……………………………………………..14
3.15 Transmission system…….. ……………………………………………………………….15
3.16 Braking system…………………………………………………………………………….15
3.17 Fuel system………...………………………………………………………………………16
3.18 Fuel nozzles system………… ………………………………………………………….17
3.19 Ignition system…………………………………………………………………………….17
3.20 Suspension system………...………………………………………………………………18
3.21 Steering system…………………………………………………………………………….19
CHAPTER 4
REPAIR AND MAINTENANCE PROCESSES
4.10 Safety information …………………………… ……… ……………… ………………...20
4.11 Tools required………………………………………………… …………………………..20
4.20 The instrument cluster…………………………………………………………………….20
4.30 Troubleshooting engines……………… ……………………………………………….21
4.31 Emission system…………………………………………………………………………..22
4.32 Engine cooling system…………………………………………………………………….22
4.33 Exhaust system…………………………………………………………………………….23

4.34 Filters and fluids…………………………………………………………………………..24

4.35 Brake problems…………………………………………………………………………….24
4.36 Suspension issues………………………………………………………………………….26
4.37 Six step approach…………………………………………………………….……………27
CHAPTER 5
SUMMARY, CONCLUSION AND RECOMMENDATION
5.1 Summary of
activities................................................................................................28
5.2 Conclusion……………………………………………………………………………….....28
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 5.3
Recommendation......................................................................................................2
8
5.4 Challenges encountered during training
period...........................................................29
REFERENCES...................................................................................................30
LIST OF FIGURES
Figure. 3.11. Four strokes cycle process
Figure. 3.13. Lubricating system
Figure. 3.14. Cooling system
Figure. 3.15. Transmission system
Figure. 3.16a & 3.16b Braking system
Figure. 3.17. Fuel system
Figure. 3.19. Ignition system
Figure. 3.20. Suspension system
Figure. 3.21. Steering system
Figure. 4.11. Tools required
Figure. 4.31. A/c system

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 CHAPTER 1
INTRODUCTION TO TRAINING PROGRAM
1.0 PURPOSE OF TRAINING
The Student Industrial Work Experience Scheme (SIWES) was initiated in 1973 by the
Industrial Training Fund (ITF). This was to update practical knowledge of students in the
Universities, Polytechnics and Colleges of Technology. It was aimed at bridging the gab
between the theoretical knowledge acquired in classes and technical knowledge in the
industry by providing students with the opportunities to apply their educational
knowledge in real work situations.
Over the years, SIWES has contributed immensely to building the common pool of
technical and allied skills available in the Nigeria economy which are needed for the
nations industrial development.
Furthermore, the place and relevance of SIWES is underscored by the fact that the
scheme contributes to improving the quality of technical skills generally available in the
pool from which employers source technical manpower
Its gives student the opportunity to blend the theoretical knowledge acquired in the
classroom and with practical hands on application of knowledge required to perform
work in the industry. Also it prepares students for employment and makes the transition
from school to the world of work easier after graduation.
1.2 BACKGROUND
The Students Industrial Work Experience Scheme (SIWES) is a program initiated by the
Industrial Training Fund (ITF) under the Federal Government of General Yakubu Gowon
through decree No. 47 of 1971. Its primary objective is to cultivate indigenous skilled
manpower to meet the demands of the economy. The program was established in 1973
by the ITF to address the challenge of inadequate practical skills among Nigerian
graduates from tertiary institutions, particularly in preparation for employment in
industries. ITF collaborates with various bodies including the Nigerian University
Commission (NUC), the National Board for Technical Education (NBTE), and the National
Commission for Colleges of Education (NCCE), as well as employers and higher
institutions to ensure the effective implementation of the scheme. Currently, the funding

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and oversight of the SIWES program are managed by ITF. Tertiary institutions play a
crucial role in facilitating the program by assisting students in securing placements in
industries, providing supervision, and assessing students during their training. The
beneficiaries of the program are undergraduates from faculties such as agriculture,
engineering, environmental science, basic medical sciences, pure and applied sciences.
The duration of the program is four months for students of polytechnics and colleges of
education, and six months for university students. SIWES offers students exposure to
industry-specific skills essential for a seamless transition from academic studies to the
professional world. It provides opportunities for students to familiarize themselves with
machinery and equipment not readily available within educational institutions. By
integrating classroom studies with hands-on work experiences, SIWES promotes
experiential learning, preparing students for their future careers. Successful completion
of internships within the SIWES framework fosters an experiential learning process that
not only enhances career readiness but also cultivates leadership skills necessary for
future professional roles. However, the effectiveness of the SIWES experience may vary
depending on factors such as the individual student, the nature of the work assignment,
and the quality of supervision and mentorship provided. Therefore, it is crucial for
internship positions to include specific written learning objectives to ensure the
comprehensive development of leadership skills.
 OPERRATION: The ITF, the coordinating agencies (NUC, NCCE, NBTE) employers of
labour and the institutions.
 FUNDING: The federal government of Nigeria funds the scheme.
 BENEFICIARIES: Undergraduate students of the following; Medical Sciences,
Engineering, Technology, Environmental, Science Education, Agriculture and Pure
and Applied Sciences.
 DURATION: For polytechnics and colleges of education SIWES runs for 4 months
while in universities it runs for 6 months.
1.3 OBJECTIVES OF SIWES
Specifically, the objectives of the students industrial work experience scheme are:  To
make the transition from the university to the world of work easier and thus enhance
students’ contact for later job placement.
 To provide an avenue for students in Nigeria universities to acquire industrial skills
and experience in their course of study.
 To enlist and strengthen employers’ involvement in the entire educational process
of preparing university graduate for employment in industry.
 To expose students to work methods and techniques in handling equipment and
machinery that may not be available in the universities.
 To prepare students for the work situation they are likely to meet after graduation.
1.5 NAME AND LOCATION OF THE COMPANY
I undertook my SIWES at SUNFRI GARAGE which is located at Plot 110, oyadiran estate,
sabo, yaba, lagos state.

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 CHAPTER 2
DESCRIPTION OF THE ESTABLISHMENT
2.0 ESTABLISHMENT PROFILE
SANFRI GARAGE is an indigenous establishment that deals with passenger and light
goods vehicles such cars, station wagon, jeep, bus, truck and pick up of various brands.
It is equipped with the latest technology available in developed parts of the world. The
establishment was founded by its CEO/MD. Didonu Sunday OwolabI.
2.1 ESTABLISMENT CORPORATE GOAL
SANFRI GARAGE goal to our clients is to fix your vehicle to the proper working condition
in a clean and professional environment, so that you are happy and satisfied with the
service that was performed. We also want you to have the trust and confidence in us that
you are being treated honestly and fairly. Also to have the freedom to approach us at any
time with any questions or concerns with the service that you are receiving. The goal to
my employees is to provide them with the bet working conditions possible with the
proper tools and equipment to repair our client vehicles. This in turn gives them the
privilege to associate with happy, satisfied and dedicated clients. Also, for the employees
to have the freedom to input on how to better improve the working conditions to better
service our clients.
2.2 THE ESTABLISHMENT SCOPE OF WORK
In the area of specialization SANFRI GARAGE has the capacity of providing the following
services
1. Sales
2. Service and Maintenance
3. Body and Paint job
4. Provision of authentic spare parts for vehicles
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SANFRI GARAGE is made up of four (4) major departments,
1. Sales department
2. Service and Maintenance department
3. Spare parts department
4. Body and Paint department.

ORGANIZATION STRUCTURE

CEO/MD

SENIOR JUNIOR
SPARE PARTS SALES & TRADING MAINTENANCE & BODY WORK & MAINTENANCE &
STORE KEEPER MANAGER SERVICES PAINT TECHNICIAN SERVICE
TECHNICIANS TECHNICIAN

WORK FLOW IN THE SERVICE SECTION

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 SERVICE
CUSTOMER
ADVISOR

SERVICE STORE
ADVISOR MANAGEMENT

WORKSHOP
TECHNICIAN

CHAPTER 3
THE TRAINING PROGRAM
3.0 DESCRIPTION OF WORKDONE
During my stay in SANFRI GARAGE, I was assigned to the service and maintenance
department as a Diagnosis/ Mechanical Technician. Job duties in the department includes
Keep equipment available for use, inspecting and testing vehicles; completing preventive
maintenance such as engine tune-ups, oil changes, replacing filters, and suspension
system.
Maintain vehicle functional condition by listening to operator complaints; conducting
inspections, repairing engine failures, repairing mechanical systems malfunctions;
replacing parts and components. Verifies vehicle serviceability by conducting, test
drives; adjusting controls and systems.
3.1 AUTOMOTIVE MECHANICAL SYSTEMS AND PARTS
3.11 ENGINE
Internal combustion engines run on a
mixture of fuel and air, the core of the
engine is the cylinder, with the piston moving up and down inside the cylinder and this
takes place in a four strokes process, which are intake, compression, Power and Exhaust
(see in fig:3.11).
The piston moves down on the intake stroke, the intake valve is open and the fuel air
mixture is admitted into the cylinder
Figure. 3.11.
and the piston moves up during the
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compression with stroke both valves are closed, compresses the trapped fuel air mixture
that was brought during the intake stroke, thereafter the spark plug fires, igniting the
compressed air-fuel mixture which produces a powerful expansion of the vapor which is
used to drive the crankshaft and this is the power stroke.
Finally, during the exhaust stroke, where the piston is at the bottom of the cylinder the
exhaust valve opens to allow the burned gas to be expelled to the exhaust system.
Engine Types
The majority of engines in motor vehicles today are four stroke, spark ignition internal
combustion engines, there are several engine types which are identified by the number
of cylinders and the way the cylinders are laid. Straight line cylinders have their cylinders
in row while the “V” arrangement uses two banks of cylinders side-by-side and its
commonly used in V-6, V-8 configurations. Some automobile engine parts include;
Spark plug: The spark plug supplies the spark that ignites the air/fuel mixture so that
combustion can occur. The spark must happen at just the right moment for this to work
Properly.
Valves: The intake and exhaust valves open at the proper time to let in air and fuel and
to let out exhaust.
Piston: Piston is a cylindrical piece of metal that moves up and down inside the cylinder.
Piston rings: Piston rings provide a sliding seal between the outer edge of the piston
and the inner edge of the cylinder, the rings serves two purposes.
 They prevent the fuel/air mixture and the exhaust in the chamber from leaking into
the sump during compression and combustion,
 They keep oil in the sump from leaking into the combustion area where it would be
burn and lost.
Connecting rod: The connecting rod connects the piston to the crankshaft, it rotates at
both ends so that its angle can change as the piston moves and the crankshaft rotates.
Crankshaft: The crankshaft turns the piston reciprocating motion in the cylinder into
circular motion.
Sump (oil pan): The sump surrounds the crankshaft. It contains some amount of oil,
which collects in the bottom of the sump.
Camshaft: The camshaft in an internal combustion engine makes it possible for the
engine valve to open and close, the asymmetrical lobes of the camshaft correspond to
the engine valves.
3.12 MOST COMMON SENSORS
1. Speed Sensor: Measures vehicle speed and sends signals to the Engine Control Unit
(ECU). Used for speedometer, cruise control, and traction control.

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2. Oxygen Sensor: Monitors exhaust gas oxygen levels, indicating engine efficiency.
Helps the ECU adjust fuel injection for optimal combustion.
3. Coolant Temperature Sensor: Measures engine coolant temperature, ensuring
optimal operating range. Prevents overheating and engine damage.
4. Air Temperature Sensor: Monitors ambient air temperature, influencing fuel
injection and ignition timing.
5. Fuel Level Sensor: Measures fuel level in the tank, displaying it on the dashboard.
6. Fuel Pressure Sensor: Monitors fuel pressure in the fuel rail, ensuring proper fuel
injection.
7. Manifold Absolute Pressure (MAP) Sensor: Measures intake manifold pressure,
helping the ECU adjust fuel injection and ignition timing.
8. Throttle Position Sensor (TPS): Monitors throttle pedal position, controlling fuel
injection and ignition timing.
9. Crankshaft Position Sensor (CKP): Measures crankshaft rotation, determining
engine speed and position.
10. Camshaft Position Sensor (CMP): Monitors camshaft rotation, synchronizing fuel
injection and ignition timing.
11. Knock Sensor (KS): Detects engine knocking or pinging, adjusting ignition timing
to prevent damage.
12. Vehicle Speed Sensor (VSS): Measures vehicle speed, controlling transmission
shifting and braking.
13. Tire Pressure Monitoring System (TPMS) Sensor: Monitors tire pressure,
warning of under inflation.
14. Rearview Camera Sensor: Provides video feed for rearview cameras, enhancing
safety.
15. GPS Sensor: Provides location and velocity data for navigation and vehicle tracking.
These sensors work together to ensure efficient, safe, and comfortable vehicle operation.
Modern vehicles rely heavily on sensor data to optimize performance, fuel efficiency, and
safety features.
3.13 LUBRICATING SYSTEM
Oil is the life-blood of the engine. An engine running without oil will last about as long as
human without blood. Oil is pumped to all the moving parts of the engine by and oil
pump. The oil pump is mounted at the bottom of the engine in the oil pan and is
connected by a gear to either the crankshaft or camshaft. This way, when the engine is
running the pump is pumping simultaneously. There is usually an oil pressure sensor
near the oil pump that monitors pressure and sends this information to a warning light
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 Figure. 3.13. on the dash board

(this features is found in modern cars as it might be in your car), when the ignition key is turned
on, fig 3.13 .but before the car is started the oil light should light, indicating that there is
no oil pressure yet, but also letting you know that the warning system is working.
3.14 COOLING SYSTEM
A car engine produces enormous amount of heat when it is running, and must be cooled
continuously to avoid engine damage, generally this is done by circulating coolant liquid
usually water mixed with an antifreeze solution through special passages.
How the cooling system work
Actually there are two types of cooling system found on motor vehicles: liquid cooled and
air cooled. Air cooled engines are found on a few older cars, but for most part,
automobiles and trucks use liquid cooling
systems and that is what this write up will
concentrate on subsequently. The cooling
system is made up of the passages inside
the engine block and heads, water pump to
circulate the coolant, a thermostat to control
the temperature of the coolant, a radiator
cap to control the pressure inside the
system, and a plumbing consisting of
interconnecting hoses to transfer the coolant
from the engine to the radiator and also to
the car heater system where hot coolant is
used to warm up the vehicle interior on a
cold day. A cooling system works by sending a liquid coolant through passages in the
engine block and heads. As the coolant flows through these passages, it picks up the
heated fluid then makes its way through a rubber hose to the radiator in the front of the
car. As it flows through the thin tubes in the radiator, the hot liquid is cooled by the air
stream entering the engine compartment from the grill in front of the car.
Figure. 3.14.
Once the fluid is cooled, it returns to the engine to absorb, ore heat. The
water pump has the job of keeping the fluid moving through this system of plumbing and
hidden passages. In order to prevent the coolant from boiling, the cooling system is
designed to be pressurized, under pressure the boiling point of coolant is raised
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considerably. However, too much pressure will cause hose and other parts to burst, so a
system is needed to relieve pressure if it exceeds a certain point and this is job of
radiator cap.
3.15 TRANSMISSION SYSTEM
A car transmission is simply the assembly of parts, including the gears and the propeller
shaft that transmit the power from the engine to the axle. There are two types of
transmission which is Automatic and Manual Transmission.

Figure. 3.15.

3.16 BRAKING SYSTEM

An automatic braking system is a group of mechanical, electronic and hydraulic
activated components which use friction/ heat to stop a moving vehicle.
How the automotive Braking System works:
When the brake pedal is depressed the pressure on the brake pedal moves a piston in
the master cylinder, forcing the brake fluid
from the master cylinder through the brake
lines and flexible hoses to the calipers and
wheel cylinders. The force applied to the
brake pedal produces a proportional force on
each of the pistons. The calipers and wheel
cylinders contain pistons, which are
connected to a disc brake pad or brake shoe.
Each output piston pushes the attached
friction material against the surface of the
rotor or wall of the brake drum, thus slowing
Figure. 3.16a
down the rotation of the wheel. When the
pressure on the pedal is released, the pads
and shoes return to their release positions. This action forces the brake fluid back
through the flexible hose and tubing to the master cylinder.
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Component of Automotive Braking System
Brake Disc: brake disc are comprised of a disc or rotor, a caliper assembly, disc brake
pads and the wheel bearings and hardware necessary to mount the components on the
here it is created through hydraulic lines to the vehicle. The caliper is connected to the
master cylinder through tubes, hoses and valves that conduct brake fluid through the
system.
Brake Drum: brake drums are comprised of a drum and backing plate, a hub or axle
assembly, brake shoes, wheel cylinder, wheel bearings and hardware necessary to
mount these components on the vehicle. The wheel cylinder is connected to the master
cylinder through tubes, hoses and valves that conduct brake fluid through the system.
Brake Fluid: Brake fluid is a type of hydraulic fluid used in brake applications for

Figure. 3.16b

automobiles and light trucks. It is used to transfer force under pressure from where it is
created through hydraulic lines to the braking mechanism near the wheels. Braking
applications produce a lot of heat so brake fluid must have a high boiling point to remain
effective and must not freeze under operating conditions.
3.17 FUEL SYSTEM
The fuel system is critical in storing and delivering the gasoline or diesel fuel your engine
needs to run. Think of it as your vascular system, with a heart (fuel pump), veins (fuel
lines) and kidneys (filter). A failure in any of these fuel system component has the same
devastating effects as in your body.
Component of the fuel system
Fuel tank: basically a holding tank for your fuel. When you fill up at a gas station the
gas travels down the filter tube and into the tank. In the tank there is a sending unit
which tells the gas gauge how much gas is in the tank. Some fuel thank houses the fuel
pump and has more emissions controls to prevent vapors leaking into the gas.

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 Fuel pump: on newer cars the fuel
pump is usually installed in the fuel
tank. Older cars have the fuel pump
attached to the engine or on the
frame rail between the tank and the
engine. If the pump is in the tank or
the frame rail then it id electric and is
driven by your car battery. Fuel
pumps mounted to the engine use
the motion of the engine to pump the
fuel, most often being driven by the
camshaft, but sometimes the
crankshaft.
Fuel filter: clean fuel is critical to
engine life and performance. Fuel
injectors and carburetors have tiny
Figure. 3.17.
openings which clog easily so
filtering the fuel is a necessity. Filters can be before or after the fuel pump. They are
most often made from a paper element, but can be stainless steel or synthetic material
and are designed to be disposable in most cases. Some performance fuel filters will have
washable mesh, which eliminated the need for replacement.
3.18 FUEL NOZZLES SYSTEM
Fuel nozzles, also known as fuel injectors, are components of an engine's fuel system.
They are responsible for spraying fuel into the engine's cylinders at the right time, in the
right amount, and at the right pressure.
3.19 IGNITION SYSTEM
The ignition system is responsible for generating the spark or heat needed to ignite the
fuel in the engine's cylinders. The main components of the ignition system are:
 Battery
 Ignition Coil
 Distributor Cap (in older engines)
 Spark Plugs
 Engine Control Unit (ECU)
How it works:
1. The battery provides power to the ignition coil.
2. The ignition coil generates a high voltage spark.
3. The spark is delivered to the distributor cap (in
older engines) or directly to the spark plugs.

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4. The spark plugs ignite the fuel in the engine's cylinders.
5. The ECU controls the ignition timing and ensures the correct spark is delivered.

3.20 SUSPENSION SYSTEM

Suspension is the term given to the system of shock absorbers and linkages that connect
a car to its wheels. The suspension system has two basic functions: 1) to keep the car’s
wheels in firm contact with the road to provide the traction and 2) to provide a
comfortable ride for the passengers and isolate them from road noise, bumps and
vibrations.
Component of the suspension system
The basic components of a suspension system are as follows:

Figure. 3.20.

 Control Arms and Bushing: holds the steering knuckle, bearing support, or axle
housing in position, as the wheel moves up and down. The outer end of the control
arm has a ball joint and inner end has bushings. Vehicles, having control arm on
the rear suspensions may have bushings at both ends. The control arm bushing act
as bearings, which allows the control arm to move up and down the shaft bolted to
the frame or suspension unit.
 Shock Absorbers and Struts: shock absorbers are necessary because springs do
not settle down fast enough. After the spring has been compressed and released. It
continues to shorten and lengthen for a time, such spring action on a vehicle would
produce a very bumpy and uncomfortable ride. It would also be dangerous
because a bouncing wheel makes the vehicle difficult to control; therefore a
dampening device is needed to control the spring.
 Ball Joints: the ball joints are connections that allow limited rotation in every
direction and support the weight of the vehicle. They are used at the outer ends of
the control arm where arms attach to the steering knuckle. In operation, the

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 swiveling action of the ball joints allows the wheel and steering knuckle to be
turned left or right and to move up and down with changes in road surface.
 Strut Rods: the strut road fastens to the outer end of the lower control arm and to
the frame. This prevents the control arm form swinging toward the rear or front of
the vehicle. The front of the strut rod has rubber bushings that soften the action of
the strut rod. These bushings allow a controlled amount of lower control arm
movement while allowing suspension to travel.
 Stabilizer bar: limits body roll of the vehicle during cornering
 Spring: supports the weight of the vehicle, permits the control ram and wheel to
move up and down, also helps in isolation of vibration.
3.21 STEERING SYSTEM
The direction of motion of a motor vehicle is controlled to a desired direction steering
system. When the driver turns the steering wheel, a shaft from the steering column turns
a steering gear. The steering gear moves tie rods that connect to the front wheels. The
tie rods move the front wheels to the vehicle right or left.
Today, there are two types of steering systems: 1) standard mechanical (reciprocating
ball) steering and 2) rack and pinion steering. The standard mechanical steering can be
either power-assisted or non-power. Rack and pinion is almost always power assisted,
although there are cases where it is not.
Standard mechanical (reciprocating ball) steering: The steering wheel is
connected to the steering box through the steering column. The steering box turns the
rotation of the steering wheel 90 degrees and, in the case of power steering, uses high-
pressure fluid to help actuate the
steering. The steering box has an arm
attached to the output shaft called the
pitman arm. This connects the
steering to the steering gear. The
pitman arm is connected to one end of
the center link (drag link). On the
other end of the center link is an idler
arm. Between the idler and pitman
arms, the drag link is supported in the
proper position to keep the left and
Figure. 3.21.
right wheels working together. The
inner tie rod ends are attached to each end of the center link and provide points for the
steering gear. From there it goes to the outer tie rod ends through an adjustment sleeve.
This sleeve joins the inner and outer tie rod ends together and allows for adjustment
when the front wheels are aligned. The outer tie rods ends are connected to the steering
knuckle that actually turns the front wheels. The steering knuckle has an upper and
lower ball joint on which it pivots and creates the geometry of the steering axis.
Rack and pinion steering: Rack and pinion steering, on the other hand, basically
combines the steering box and drag link into one unit. The steering wheel, through the
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steering column, is directly connected to the track. Inside the steering rack is a pinion
assembly that moves a toothed piston which in turn moves the steering gear. One end of
the inner tie rod ends is connected to each of this piston and the other end is connected
directly to the outer toe rod end. The inner tie rod end is actually threaded into the outer
tie rod end and can be rotated to make adjustments during a wheel alignment. The
advantage of rack and pinion steering is that it’s more precise than mechanical system.
By reducing the number of parts and pivot points, it can more accurately control wheel
direction, making the steering move responsive. The disadvantage of a rack and pinion
steering system is that it’s prone to leakage, requiring replacement of the steering rack
assembly. Components of steering system; Power Steering fluid reservoir, Power Steering
Pump, Rack and Pinion steering gear, Steering Wheel, Pitman Arm, Steering Box, Tie
rod/Track rod, Steering Column and Knuckle, Drag Link and Steering Shaft.

CHAPTER 4
REPAIR AND MAINTENANCE PROCESS
Mechanical systems in automobiles are a little complex and some problems, may need to
be serviced at the repaired shop.
4.10 SAFETY INFORMATION
Most accidents in servicing/mechanical repair involve slips, trips and falls or poor manual
handling. Other causes of incidents sometimes resulting in serious injury or death
include working under inadequately supported vehicles, incidents involving petrol and
vehicle movement. Keeping work areas free of clutter is an important, but often
overlooked, step in running a safe and productive workshop. Requiring appropriate
protective gear minimizes eye and finger lacerations, which are common auto body shop

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injuries. Shops should purchase appropriate eyewear, and make protective gloves
available to prevent cuts from glass, sheet metal or other jagged objects.
4.11 TOOLS REQUIRED

Figure. 4.11.

4.20 THE INSTRUMENT CLUSTER

The instrument cluster is the dashboard display that shows various lights and gauges to
indicate the vehicle's status. Here are the full details of the common lights that show on
the instrument cluster:
 Check Engine Light (CEL): Indicates a problem with the engine or emissions
system. Can be a steady or flashing light, depending on the severity of the issue.
 Service Engine Soon Light: Indicates a scheduled maintenance is due, such as
an oil change.
 Airbag Light: Indicates a problem with the airbag system or sensors.
 Anti-lock Braking System (ABS) Light: Indicates a problem with the ABS
system.
 Traction Control Light: Indicates the traction control system is engaged or
there's a problem with it.
 Electronic Stability Control (ESC) Light: Indicates the ESC system is engaged
or there's a problem with it.
 Battery Charge Light: Indicates a problem with the battery charging system.
 Oil Pressure Light: Indicates low oil pressure, which can cause engine damage.
 Coolant Temperature Light: Indicates the engine coolant temperature is too high.
 Door Ajar Light: Indicates a door is not closed properly.
 Seatbelt Reminder Light: Indicates a seatbelt is not fastened.
 Fog Light Indicator: Indicates the fog lights are turned on.
 High Beam Indicator: Indicates the high beams are turned on.
 Turn Signal Indicator: Indicates a turn signal is engaged.
 Hazard Light Indicator: Indicates the hazard lights are turned on.
 Brake Pad Wear Light: Indicates the brake pads need replacement.
 Tire Pressure Monitoring System (TPMS) Light: Indicates a tire is
underinflated.
 Lane Departure Warning (LDW) Light: Indicates the vehicle is drifting out of its
lane.
 Forward Collision Warning (FCW) Light: Indicates a potential collision is
detected.
 Blind Spot Monitoring (BSM) Light: Indicates a vehicle is in the blind spot.

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 Note that the exact lights and their meanings may vary depending on the vehicle
make and model. It's essential to consult the owner's manual or a repair manual for
specific information.
4.30 TROUBLESHOOTING ENGINES
BELTS AND HOSES
What is it?
Belts and hoses are essential to the cooling, air conditioning and charging systems, and
the engine. Don’t take these routine replacement intervals for granted because they can
break down and leave you stranded.
What does it do?
The timing belt keeps the crankshaft and camshaft mechanically synchronized to
maintain engine timing. Whether serpentine, V-belt or fan belt (the belts on the outside
of the engine), they all transmit power from the front of the engine to accessories that
need to be driven, such as the air conditioning, the charging system and fans. Radiator
and heater hoses carry coolant to and from the engine, radiator and heater core.
Typical Wear and Tear
Key items that affect the replacement interval for belts and hoses:
 Vehicle age
 Electrolytic corrosion
 Mileages
 Oil contamination
 Belt tension
 Failed hose clamps

Symptoms
 Squeaking noise from under the hood during start-up or operation
 Coolant leaks
 Dashboard light will illuminate
 A/C System may fail
 Engine overheating
 Smell of burnt rubber
4.31 EMISSION SYSTEM
Car emission system keeps the engine running cleanly and efficiently in all sorts of
operating conditions. A steady or flashing warning light on your vehicle dashboard
indicates a problem that is currently happening and may require immediate attention.
Failure to do so can reduce your gas mileage or cause your vehicle to pollute.

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What does it do?
Emission system controls the emissions, exhaust and pollutants (including gasoline
vapors escaping from the fuel tank), using an array of sensors, computerized engine
controls and the exhaust components. The emission system substantially reduces
harmful gases such as carbon monoxide (CO), unburned hydrocarbons (HC) and oxides of
nitrogen (NOx) and, by law, must be maintained in operating condition.
Typical Wear and Tear
Some factors affecting the emission system include:
 Driving and atmospheric conditions
 Mileage
 Vehicle age
 Type of spark plug electrode material
 Poor vehicle maintenance
 Poor quality fuel
 Damaged or worn sensors
 Dry-rotted or cracked vacuum hoses
4.32 ENGINE COOLING SYSTEM
What is it?
The engine cooling system affects your car’s overall dependability and engine longevity.
Cooling systems have advanced over the years with new coolant formulations and new
radiator designs and materials. If you suspect a problem with your cooling system, you
should check it immediately.
What does it do?
The key parts of the cooling system remove heat from the engine and automatic
transmission and dissipate heat to the air outside. The water pump circulates coolant
through the engine. The coolant absorbs heat and returns it to the radiator where heat is
dissipated. The thermostat regulates the coolant temperature to keep it consistent for
efficient engine operation.
Typical Wear and Tear
Factors that affect the replacement of cooling system parts include:
 Driving habits
 Operating conditions
 Type of vehicle
 Type of coolant
 Frequency of regular maintenance such as coolant changes
Symptoms
 Overheating
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  Sweet smell
 Leaks
 Repeatedly need to add fluid
4.33 EXHAUST SYSTEM
What is it?
Exhaust system has come a long way from the old days of exhaust pipes and mufflers.
Today, the exhaust system is safety and emissions control rolled into one. Have your
car’s exhaust system inspected regularly and check it immediately if you suspect any
problems.
What does it do?
The exhaust system routes dangerous exhaust gas from the engine out and away from
the car to keep from affecting the occupants. Next, the exhaust system reduces exhaust
noise from the engine. The catalytic converter reduces the level of harmful pollutants in
the exhaust. The oxygen sensors mounted in the exhaust system monitor the level of
oxygen in the exhaust gases to maintain efficient engine operation and to monitor the
converter’s operation.
Typical Wear and Tear
Maintain a safe car with regular exhaust system checks. Factors that affect replacement
requirements include:
 Driving habits (short trips take their toll on exhaust system life)
 Road conditions (salt, road spray, bumps)
 Vehicle type
 Age of exhaust system parts
Symptoms
 Loud noise
 Rattling noise when starting, accelerating or braking
 Drowsiness while driving
 Rotten eggs smell
4.34 FILTERS AND FLUIDS
What is it?
Filters are important to the longevity of your car and interior comfort. Maximize your car
investment by replacing filters regularly.
What does it do?
The oil filter traps contaminants, allowing the oil to flow through the engine unrestricted.
The fuel filter separates harmful contaminants that may cause problems with carburetors
or intricate fuel injectors. The air filter traps dirt particles, which can cause damage to

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engine cylinders, walls, pistons and piston rings. The air filter also plays a role in keeping
contaminants off the airflow sensor (in fuel-injected cars). The cabin filter helps trap
pollen, bacteria and dust that may find their way into a car’s ventilation system.
Typical Wear and Tear
Filters are normal wear items that require regular checks and replacement.
4.35 BRAKE PROBLEMS
Brake problems usually indicate the need for certain repairs or replacement parts, so
here is a quick review of some common fixes:
 LOW BRAKE FLUID: This may be the result of worn disc brake pads, or it may
indicate a leak in the brake system. If the BRAKE WARNING LIGHT is also on, most
likely the problem is a leak (though the Brake Warning light may also come on if
the master cylinder reservoir has a fluid level sensor). Leaks are dangerous
because they can cause brake failure. The brake calipers, wheel cylinders, brake
hoses and lines, and master cylinder all need to be inspected. If a leak is found,
the defective component must be replaced. Your vehicle should NOT be driven until
the leak can be repaired.
 LOW BRAKE PEDAL: The brake pedal may be low if the shoe adjusters on rear
drum brakes are rusted or sticking and not compensating for normal lining wear.
Adjusting the rear drum brakes may restore a full pedal. But unless the adjusters
are cleaned or replaced the problem will return as the linings continue to wear.
Other causes include worn brake linings or a fluid leak.
 SPONGY OR SOFT BRAKE PEDAL: This is usually caused by air in the brake
system, either as a result of improper bleeding, fluid loss or a very low fluid level.
The cure is to bleed all of the brake lines using the sequence recommended for
your vehicle. Another possible cause is a rubber brake hose that is "ballooning"
when the brakes are applied.
 EXCESSIVE BRAKE PEDAL TRAVEL: Possible causes include worn brake linings
front or rear (or both), misadjusted drum brakes, or air in the brake lines. This can
be dangerous because the brake pedal may run out of travel before the brakes are
fully applied. Pumping the pedal when you apply the brakes usually helps, but you
need to diagnose and fix the problem.
 PEDAL SINKS TO FLOOR: This may occur while holding your foot on the brake
pedal at a stop light. If the pedal goes slowly down, it means the master cylinder is
not holding pressure. This is also a potentially dangerous condition because a worn
master cylinder or a leak in the hydraulic system may cause the brakes to fail.
 BRAKE PEDAL PULSATION: Indicates a warped brake rotor (one that is worn
unevenly). The rotor needs to be resurfaced or replaced. The faces of a rotor must
be parallel (within .0005 inch on most cars) and flat (no more than .003 inches of
run out as a general rule on most cars and trucks, but some cars cannot tolerate
any more than .0015 inches of run out). Excessive run out can be corrected by
resurfacing the rotors in place with an on-car brake lathe, or by installed special
tapered shims between the rotors and hub to correct the run out.
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  SCRAPING NOISE FROM BRAKES: Usually indicates metal-to-metal contact due
to worn out disc brake pads (or shoes on rear drum brakes). Your vehicle needs a
brake job now! In fact, it is overdue for a brake job. Your vehicle is also dangerous
to drive in this condition because it may take longer to stop. The rotors and/or
drums will likely have to be resurface or replaced because you waited too long to
replace the pads and shoes.
 BRAKE SQUEAL: Can be caused by vibrations between the disc brake pads and
caliper, or the pads and rotor. Harder semi-metallic brake pads tend to be noisier
than non asbestos (NOA) or ceramic brake pads. The noise can usually be
eliminated by replacing the old pads with new ones (ceramic pads are usually the
quietest, but may not be available for some applications because the vehicle
requires semi-metallic pads), and resurfacing or replacing the rotors. Installing
noise dampening shims behind the pads, spraying the rotors with some type of
aerosol brake noise control compound and/or applying a small amount of high
temperature brake grease (never ordinary grease) to the backs of the pads can
also help suppress noise. Also, if any pad mounting hardware such as shims or
anti-rattle clips are missing, these should be replaced
 BRAKE CHATTER: Can be caused by warped rotors or rotors that have been
improperly finished.
 GRABBY BRAKES Oil, grease or brake fluid on the brake pads will cause them to
slip and grab. This may create a jerky sensation when braking. The cure is to
inspect the pads for contamination, replace them if they have oil, grease or brake
fluid on them, and eliminate the cause of the contamination (such as replacing a
leaky brake caliper or curing a nearby oil/grease leak). Badly scored drums or
rotors can also cause uneven or grabby braking. Resurfacing may be needed.
 DRAGGING BRAKES: This can cause a steering pull and/or increased fuel
consumption. The constant drag will also accelerate brake wear and cause the
brakes to run hot (which can increase pedal effort and the risk of brake fade if the
brakes get too hot). Dragging brakes can be caused by weak or broken retracting
springs on drum brakes, a jammed or corroded disc brake caliper piston, a floating
caliper with badly corroded mounting pins or bushings (uneven pad wear between
the inner and outer pads is a clue here), overextended drum brake self-adjusters or
a sticky or frozen emergency brake cable.
 BRAKES PULL TO ONE SIDE: If your vehicle suddenly swerved to one side when
you apply the brakes, there is uneven braking side-to-side. This usually means one
front brake is not working properly. The pull will be toward the side with the good
brake (because it is doing all the work). Brake pull can be caused by brake fluid, oil
or grease on the brake pads, a stuck caliper, a blockage in the brake line to one of
the front calipers, or sometimes loose wheel bearings. A brake pull can also be
caused by different types/brands of brake pads side-to-side on the front brakes.
Different friction materials have different friction characteristics, so the brakes will
pull toward the side that generates the most friction.
 HARD BRAKE PEDAL: Lack of power assist may be due to low engine vacuum, a
leaky vacuum hose to the brake booster, or a defective brake booster. The booster

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 is located between the master brake cylinder and firewall in the engine
compartment. Sometimes a faulty check valve will allow vacuum to bleed out of
the booster causing a hard pedal when the brakes are applied. This condition can
be diagnosed by starting the engine (to build vacuum), shutting it off, waiting four
or five minutes, then trying the brakes to see if there is power assist. No assist
means a new check valve is needed.
4.36 SUSPENSION ISSUES
Suspension components, including springs, shock absorbers (or struts on some vehicles),
anti-roll bars, control arms and other parts, are like combat troops serving on the front
lines: They take a pounding daily from pock-marked streets, railroad tracks, rain, snow,
road salt, gravel, all manner of dirt and grime, and the occasional piece of scrap metal or
other debris that drivers see too late to avoid. Under those conditions, just about any
suspension component can be damaged or worn out from years of abuse, resulting in a
number of symptoms and/or noises that should be your wakeup call to see a car doctor.
Here are some common issues vehicle owners are likely to encounter:
 Poor wheel alignment: The wheels have to be pointed in the right direction
(literally) and aligned for toe-in, camber and caster. If they aren’t, your steering
won’t be centered when you’re going straight and tire wear will increase. Wheels
get knocked out of alignment by potholes and curbs, but getting the wheels
aligned won’t fix damaged springs, controls arms or other parts that affect
alignment. When you buy new tires, it’s a good idea to have the alignment
checked so suspension issues don’t shorten tread life.
 Shock absorbers: They really should be called “dampers,” and when they wear
out you should notice more bouncing after a bump and a whole lot of shaking
going on over rough roads because they can’t keep the tires planted on the
pavement. Shocks contain fluid that dampens the bouncing, and once they start to
leak, performance will deteriorate.
 Springs: These are what hold the weight of the car, and as they wear they can
sag or break. If your car is on level ground but one corner is lower than the others,
that’s a sign of a damaged spring. You can measure the height of the corners to
confirm your visual cue. You might also hear clunking noises over bumps, and the
car may not corner with confidence because a damaged spring can’t control the
weight it’s supporting.
 Ball joints: These are pivot points that attach the suspension to the wheels, and
they absorb some of the shock from up-down movement and rotate as the steering
angle changes. You’ll know they need replacing when you can hear them
squeaking and creaking, especially when turning. You’ll know you waited too long if
a ball joint breaks and suspension parts are dragging on the pavement. A
mechanic can tell if they need replacing by the amount of wheel movement they
can force by hand or, in some cases, by wear indicators on the ball joints.
 Control arms: These are hinges that hold the wheels to the frame and connect
the steering to the wheels, so when you turn one the other responds. Lower control

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 arm bushings are more prone to wear out on front-wheel-drive cars than on rear-
wheel-drive cars. Bushings are rubber and/or metal parts that help absorb shock,
and when they wear they can cause ride and handling problems and accelerate tire
wear. So can a bent control arm. Signs of wear include clunks or rattles -- because
the wheels move back and forth in acceleration and braking – and loose, imprecise
steering.
4.37 SIX STEP APPROACH
At this stage it is important to emphasize the need to be methodical. A simple but
effective approach is diagnostic work know as six step approach. This six-step approach
maybe, recognized as an organized approach to problem solving in general. As quoted
here it may be seen that certain steps are recursive. That is to say it may be necessary
to previous steps as one proceeds to solution.
The six steps are:
1. Collect evidence;
2. Analyze evidence;
3. Locate the fault;
4. Find the cause of the fault and remedy it;
5. Rectify the fault (if different from 4) and Test the system to verify that repair is correct.

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 CHAPTER 5
WORK EXPEIENCE
(SUMMARY, RECOMMENDATION AND CONTRIBUTIONS)
5.1 SUMMARY OF ACTIVITIES
As a student my first observation was the cognition of the difference between the school
environment and the labor market, as it is a different ball game entirely.
I also observed that safety was paramount and it could easy be seen as the primary goal
of every staff of the company and not only the technicians. As safety equipment and
instructions were always put in place or made available at strategic locations within the
company. Work shop to the service desks to the customer care centers to the offices to
the receptions. Neatness was also a key attribute as even though the job is usually seen
as a dirty job, technicians were always admonished to be as neat as possible in their
dressing and in carrying out their duties. This was further encouraged by rewarding
technicians that could fully adhere to the hospitality shown to customers was of another
level as customers were treated with so much care and respect. From provision of free
breakfast and lunch, to a brief internal training, to free medical checkup the customers
were always made to feel at ease.
Communication played a vital role in the successful execution of jobs, from among
personnel section to departments communicating with other departments present in the
company and also customers with company’s personnel. Good flow of information was
required and as a result most jobs that were returned or problematic, come about as a
result of poor communication between parties.
5.2 CONCLUSION
My 16 weeks industrial attachment as a junior technician at SANFRI GARAGE was a huge
success and a great time of acquisition of knowledge and more skills. Through my
training I was able to appreciate my chosen course of study even more, because I had
the opportunity to blend the theoretical knowledge acquired from school with the
practical hands-on application of knowledge gained here to perform very important tasks
that contributed in a way to my productivity in the company. My training here has given
me a broader view to the importance and relevance of Mechanical Engineers in the
immediate society and the world as a whole, as I now look forward to impacting it
positively after graduation. I have also been able to improve my communication and
presentation skills and thereby developed good relationship with my fellow colleagues at
work. I have also been able to appreciate the connection between my course of study
and other disciplines in producing a successful result.
5.3 RECOMMENDATION;
To SIWES

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 They should assist students in getting placement in companies or industries related to
their course of study.
 Allowance paid to student should fit into the economic situation of the country.
TO THE INDUSTRY
 Students should be allowed to pass through all departments in the industry so as to
expand their scope of knowledge.
 Hospitality should be increased in the industry.
TO THE STUDENTS
 Students should co-operate and comply with all rules and regulation in the industry.
 Students should be well mannered so as not to tarnish the image of the school
5.4 CHALLENGES ENCOUNTERED DURING PERIOD OF TRAINING
My cost of transportation and I wasn’t allowed to drive cars after repair. So I could not do
active test using Diagnostic machine.

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REFERENCES
1. Taylor, C. F.: The Internal Combustion Engine in Theory and Practice, vol. I, p. 506, MIT
Press,
2. Society of Automotive Engineers (1998). Automotive Engineering Handbook. Warren
dale, PA:
Society of Automotive Engineers, Inc.
3. Whatsapp (Meta AI).
4. wikipedia.com/automobile/dictionary
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