Professional Documents
Culture Documents
A Report On: Higher Technological Institute Mechanical Engineering Department
A Report On: Higher Technological Institute Mechanical Engineering Department
A Report On: Higher Technological Institute Mechanical Engineering Department
Mechanical
ngineering Department
A Report on
Industrial Training ( Volkswagen service center )
Submitted by :
Name : Mustafa Amin Mohamed Mahfouze
.D : 20121441
Course code : ITR 102
Supervised By :
DR : Iman Ibrahim
1 | Page
August 2015
Acknowledge
Special tahnks to :
DR Iman who subervised our training along this course
All doctors and engineering who provided to us a lot information in this field
All tecnicns and engineering at the center specialy ENG: Ahmed sheriff El-znaty
Abstract
2 | Page
This report is going to handle whit service which Volkis service center specially
Oboor branch presented it and How they try to fix the problem at no time with
very high quality
This services consists of main components like : Mechanical service , after
buying services , body and paint service and others whish handle it at this
report
3 | Page
List of content :
Contents
CHPTER ( 1 )................................................................................................................................ 8
Introduction to Volkswagen company.......................................................................................... 8
Company History...................................................................................................................... 8
Main Models :......................................................................................................................... 10
Component of car.................................................................................................................. 11
Mechanicaly parts :................................................................................................................ 12
Motor.................................................................................................................................. 12
A / crank shat...................................................................................................................... 12
B / cams shaft
.........................................14
c/ Fly wheel......................................................................................................................... 16
D / piston............................................................................................................................ 17
E/ connection rod ( B.L)....................................................................................................... 18
Volkes maintenance types :................................................................................................... 19
1 mechanically maintenance........................................................................................... 19
2 Body and painting maintenance....................................................................................19
3 after buying service....................................................................................................... 19
4- genral service................................................................................................................. 19
CHAPTER ( 2 )............................................................................................................................ 20
Mechanically Maintenance........................................................................................................ 20
Introduction :.......................................................................................................................... 20
2 detecting the problem...................................................................................................... 22
3 fixation steps.................................................................................................................... 22
A ) Gear box fixiation.......................................................................................................... 23
B ) full fixation.................................................................................................................... 25
chapter ( 3 ).............................................................................................................................. 28
Body And Painting..................................................................................................................... 28
Introduction :.......................................................................................................................... 28
Fixation step :......................................................................................................................... 28
3 - Painting............................................................................................................................. 31
CHAPTER ( 5 )............................................................................................................................ 34
SERVICES AFTER BUYING.......................................................................................................... 34
1 intrudction :...................................................................................................................... 34
4 | Page
Table of figure
Figure 1: compare between volks logo.....................................................11
Figure 2: cranck shat...............................................................................15
Figure 3: cams shaft................................................................................17
5 | Page
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
4: fly wheel...................................................................................19
5 :................................................................................................. 20
6 : connection rod (B.L).................................................................21
7 : pro.diagnosis system...............................................................23
8 : pro diagosis system 2..............................................................24
9 : jop model................................................................................. 25
10 : gear box................................................................................. 26
11 : gear box jack.........................................................................27
12 : bored control unit..................................................................28
13 : engine sling...........................................................................29
14 : instal engin sling....................................................................29
15 : displacement motor...............................................................29
16 :dameged piston from motor...................................................29
17 : processing of cleaning motor.................................................30
18 : new piston installtion.............................................................31
19 : torqe hand.............................................................................31
20 : model of analogize.................................................................33
21 : car welding............................................................................33
22 : fixation hydro device.............................................................34
23 : types of gage.........................................................................35
24 : softing of car.......................................................................... 35
25 : embrey car body....................................................................36
26 : painting furnans.....................................................................36
27 :coloring codin system.............................................................37
28 : types of painting....................................................................37
29 : covering the car process........................................................38
30 : painting car proess................................................................38
31 : car lever................................................................................. 40
32 : dissemble the togge of oil......................................................40
33 : empting oil progress..............................................................41
34 : removing old filter oil process................................................42
35 : putting new filtter process.....................................................42
36 : adiing oil................................................................................43
37 : car lever................................................................................. 44
38 : the pods are atteched to the wheel.......................................46
39 : balancing machine.................................................................47
40 : fixation the tire on the device................................................47
41 : sensor edge angle..................................................................48
6 | Page
7 | Page
CHPTER ( 1 )
Introduction to Volkswagen company
8 | Page
Company History
Volkswagen was originally founded in 1937 and operated by the German trade
union, the German Labor Front. Volkswagen was headquartered in Wolfsburg,
Germany. The projects objective was the development and mass production of
a reasonably priced yet still speedy automobile that could sell for less than
1,000 Reich marks (approximately $140 at the time). Known as
Volkswagenwerk, or "The People's Car Company" at the time, to provide the
design for this "people's car," the German Labor Front called in the Austrian
automotive engineer Ferdinand Porsche.
However, shortly after the KdF (Kraft-durch-Freude)-Wagen ("Strength-ThroughJoy" car) was presented for the first time at the Berlin Motor Show in 1939,
World War II began, and Volkswagen ceased production. After the war ended,
with the plant in ruins, the Allies would make Volkswagen the center of their
attempts to revive the German auto industry. In 1959, the advertising agency
Doyle Dane Bernbach launched an innovative campaign, naming the car the
"Beetle" and turning its miniature size as a distinct advantage to consumers.
Over the next several years, Volkswagen became the top-selling auto import in
the United States. In 1960, the German government vended 60 percent of
9 | Page
Main Models :
Germany: Wolfsburg (Golf, Tiguan, Touran), Emden (Passat), Zwickau (Golf,
Passat), Dresden (Phaeton).
Belgium: Brussels (Polo, Golf)
Spain: Pamplona (Polo)
Portugal: Palmela (Eos, Sharan)
Slovakia: Bratislava (Up, Polo, Touareg)
Mexico: Puebla (Jetta, New Beetle)
10 | P a g e
Component of car
1 - Mechanically parts
2 body parts
3 interment parts
11 | P a g e
Mechanicaly parts :
Motor
This is the most important part in the car due to it is responsible of move the
car but it consist of many parts :
12 | P a g e
A / crank shat
14 | P a g e
B / cams shaft
15 | P a g e
16 | P a g e
c/ Fly wheel
17 | P a g e
D / piston
Figure 5 : piston
18 | P a g e
19 | P a g e
4- genral service
Like caoutchouc service and angle fixation and
stabilization
20 | P a g e
CHAPTER ( 2 )
Mechanically Maintenance
Introduction :
At this chapter we detail exposed to the mechanically parts and mainly problem
of it
1 devises used to inspection
21 | P a g e
This devises are used to established the car after maintenance and another
mainly purpose to detect the problems of cars
3 fixation steps
Firstly tecnicas start to take the jop and see whts is the part which has the
problem and get to ix it
Mainly problem aat oboor branch were gear box problem or another motor
problem
23 | P a g e
get gear box out from the car by remove all fixation point at the base of
2 basically autmamic gear box consist of normal manuly gear box and whish
called meca parts
3 if the gang of disk and cylinder are damged the tecnicans take the jop ang
go to bring the new parts from store
24 | P a g e
B ) full fixation
This type used when mainly parts on the motor likr piston and BL or crank
shaft are damaged
At this stage all motor are removed and replaced by another one
Steps to remove and replace parts :
25 | P a g e
1 firstly we should remove motor from the car by using some equipment
like
Figure
2 start to get out the damged parts from the motor at the special room
26 | P a g e
27 | P a g e
chapter ( 3 )
Body And Painting
Introduction :
28 | P a g e
2 after that starting fix but if and only if the damage doesnt
reaches to 70% percentage of damages that percentage which suit to
refix the part except that replace part with another new one
3 if the damage part was at bottom of car our bones of it and cause remove
part of it at this case we should use which called smart welding
4 I the part is normaly damge we depend the normaly steps which are :
A straightnes the body from damge
It where many typ of hydrolic gange which used into bodu fixation level
30 | P a g e
That gage works on air pressure to fixation the car from the end to make it
straigt
31 | P a g e
3 - Painting
After all that the painting operation are came but it has some prpear :
1 get the car into the furns at the 81 c
32 | P a g e
4 start to cover all parts o car except the part wanted to be paint
33 | P a g e
6 after painting the car holding while and start to paint it with polish
7 washing the car after holding about 15 minuts
CHAPTER ( 5 )
SERVICES AFTER BUYING
1 intrudction :
37 | P a g e
CHAPTER ( 6 )
Cautchouc service
1 intrudction
38 | P a g e
To avoid personal injury or damage to property, follow the rack/lift manufacturers operating and
.safety procedures
.Raise the alignment lift, then lower the lift onto its mechanical stops .8
Place the transmission in neutral and release the parking brake just before beginning the Vehicle .9
.Positioning process
Attach the Targets/Pods
The targets/pods are attached to the wheels using the wheel clamps. The targets go on the front
.wheels, the measuring pods on the rear
There are several methods of attachment depending on the wheel lip configuration. The integrated
claws provide the versatility needed to grab virtually any wheel. The claws can be rotated to adjust
.for different wheel configurations
Claws may have sharp edges. To avoid personal injury, use caution when working with wheel
.clamps
.The clamps should be installed in a straight-up vertical manner (knob at the top)
Use the mounting method that provides the greatest security to keep the target from falling off the
wheel. Most wheels can be grabbed from the outside-in by placing the claws between the bead of
the tire and the outside edge of the rim. Others can be mounted on the inside of the rim such as with
.steel wheels
:For outside rim mounting
.Extend the clamp to a size slightly larger than the rim by turning the knob .1
Place the upper claws on the outside of the top of the rim. Push the claws in between the tire bead .2
and the rim. It may be necessary to pop the upper clamp bracket with the palm of your hand to
.seat well. Note that it is not necessary for the clamp to be mounted perfectly vertical on the wheel
.Tighten the clamp by turning the knob clockwise until the lower claws engage the rim .3
Push the lower claws into place. Again, it may be necessary to pop them in further for security. .4
.Continue tightening the knob until secure
Test the security by pulling outwards on the clamp. If it comes off easily, reattach the clamp or .5
.select an alternative mounting method
40 | P a g e
Balance procedure
41 | P a g e
42 | P a g e
The machine determine the amount of Wight need to install and the
correct place on tire edge
43 | P a g e
Coclusion :
44 | P a g e
From all the past information we learn about how the car
maintnenanse at the service center and the level which all type of maintenance
take
Recommendation
45 | P a g e
References :
1- wikipedia
2- 2 automotive reference
3- Some of online website about car maintenance
46 | P a g e
47 | P a g e