ABSTRACT

This Industrial training report presents the experience garnered during my 6 months of industrial
training

undertaken at Jaja & Bros Mechanical works, 14b Industry Road, Port Harcourt.

My training was on the diagnosis, repairs, programming and maintenance of automobile vehicles

ranging from SUVs, sedan, coupe, wagon, hybrid/electric and light trucks.

During this period, I acquired practical knowledge on how to diagnose, repair, replace and install some

mechanical parts and systems and I also assisted in providing the units the functionality they need.

This report discusses the technical skills gained during the training period and justifying the relevance of

the scheme in equipping students with needed technical competence to thrive in the real world.
 ACKNOWLEGDEMENTS

My appreciation goes to God almighty, through the help of the Holy Spirit 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 for their foresight in putting this program to place and also to

the Mechanical Engineering department, federal University Otuoke, for providing the platform on which
was engaged in the training.

I want to say a big thank you to my industrial based supervisor, ENGR WUGAH GOODLUCK JAJA for his
vital encouragement, support and guidance in my learning process throughout training period at here,
and for giving me the opportunity to experience and undergo training in this company and the
technician in my unit, Mr. Oscar, Mr. Chima, Mr. Collins, and Mr. Femi who helped with solutions to my
numerous questions.

I am grateful to Jaja & Bros Mechanical works for providing with the opportunity to be exposed to

engineering services in the automobile industry.

I want to thank my mother for the encouragement she gave me throughout the Industrial Training
period and also my sisters and her family [mr &mrs Peter Adodo], for accommodating me and treating
me like a king in his place during this period, and also for their financial support.
 TABLE OF CONTENT

Title Page

Abstract………………………………………………………………………………….1

Acknowledgements……………………………………………………………………...2

Table of Content…………………………………………………………………………3-5

List of tables……………………………………………………………………………..5

List of Figures…………………………………………………………….......................5-6

Chapter 1

Introduction to Training program

1.1 Purpose of Training………………………………………………………………7

1.2 Company’s Profile…….....….……………………................................................7

1.3 The Establishment’s Cooperate Goal...…………………………………………...8

1.4 The Establishment’s Scope of Work……………………………………………...8

1.5 Organizational Structure………………………………………………………….9

1.6 Work Flow in the Service Station………………………………………………...10

Chapter 2

The Training Program

2.0 Description of Work done………………………………………………………..11

2.1 Automotive Mechanical System…………………………………………………11

2.2 Engine………………………………………………………………………………………..11

2.3 Lubrication System…………………………………………………………………….14

2.4 Cooling System……………………………..………………………………………..…14

2.5 Transmission………………………,………,…………………………………………..16

2.6 Braking System……………………………,,…………………………..…………..…17

2.7 Fuel System…………………………………,,……………………………………...…18

2.8 Suspension System…………………….…………………………………………..,19

2.9 Steering System…………………………..…………………………………….......21

Chapter 3
Repair and Maintenance Processes

3.0 Safety Measures and Information………………………………………………….23

3.1 Tools Required…………….………………………………………………………24

3.2 Trouble Shooting Engine…….……………………………………………………25

3.3 Emission System………………………………………………………………….27

3.4 Engine Cooling System……………………………………………………….......28

3.5 Exhaust System………………………………………………………………........29

3.6 Filters and Fluid……………………………………………………………………30

3.7 Brake Problems……………………………………………………………….........32

3.8 Suspension Issues………………………………………………………………….34

3.9 Ride Control Module………………………………………………………………35

3.10 Transmission problems…………………………………………………………….38

3.11 Sensors…………………………………………………………………………….40

3.12 Spark Plugs………………………………………………………………………..45

3.13 Fuel Injector……………………………………………………………………….46

3.14 Cylinder Head Gasket……………………………………………………………..48

3.15 Hybrid Electric Vehicles………………………………………………………….48

3.16 Six Step Approach…………………………………………………………………49

Chapter 4

On-Board Diagnostics (OBD) System

4.1 What is OBD?............................................................................................................71

4.2 OBD-II Codes Explained…………………………………………………………...73

4.3 Launch X431 IV Scanner…………………………………………………………...74

Chapter 5

Observations and Contributions

5.0 Observations……………………………………………………………………75

5.1 Contributions…………………………………………………………………....75

Chapter 6

Conclusion and Recommendation

6.0 Conclusion…………………………………………………………………….76

6.1 Recommendation………………………………………………………………76

6.2 Challenges encountered during training period……………………………….76

References…………………………………………………………………………….77

SIWES TECHNICAL REPORT

 LIST OF TABLE

Table 1: Injector Problems

LIST OF FIGURES

Figure 1.0: Organization Structure

Figure 1.1: Service Work Flow

Figure 2.0: Mounting a new Engine

Figure 2.1: Four Stroke Cylinder

Figure 2.2: Typical cylinder arrangement

Figure 2.3: Lubricating system

Figure 2.4: Cooling system

Figure 2.5: Transmission system

Figure 2.6: Brake system

Figure 2.7: Fuel System

Figure 2.8.0: Suspension system

Figure 2.8.1: Shock Absorber;

Figure 2.8.2: Ball Joint

Figure 2.8.3: Stabilizer Bar

Figure 2.9: Steering system

Figure 2.10: Rack pinion system

Figure 3.1: Safety Equipment

Figure 3.2: Tools required

Figure 3.3.0: Engine Belt System

Figure 3.3.1: Hose

Figure 3.4: Emission System

Figure 3.5: Exhaust System

Figure 3.6: Oxygen Sensor

Figure 3.7.1: Oil Filter

Figure 3.7.2: Air Filter

SIWES TECHNICAL REPORT

6

Figure 3.7.3: Transmission Filter and Paper Gasket

Figure 3.8: Anti-Lock Brake System (ABS)

Figure 3.9: Stabilizer Bar Bushings

Figure 3.10: Suspension Spring

Figure 3.11: Air Spring

Figure 3.12: Valve Body

Figure 3.13.0: Speed Sensor

Figure 3.13.1: MAF Sensor

Figure 3.13.2: VSS Sensor

Figure 3.13.3: Evaporator Sensor

Figure 3.13.4: Oil Pressure Sensor

Figure 3.13.5: Throttle Body Temperature Sensor

Figure 3.13.6: Spark Plug

Figure 3.14: Injector

Figure 3.15: Hybrid Electric Vehicle Schematic

Figure 3.16: Hybrid Battery Pack

Figure 3.17: Hybrid Pair Change

Figure 4.1: OBD-II

Figure 4.2: Launch Scanner

 CHAPTER 1

INTRODUCTION TO TRAINING PROGRAM

1.1 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 gap 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 nation’s 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 industry easier after graduation.

I undertook my SIWES at AUTOGENIUS ROYAL MOTORS which is located at 56 Urubi, behind

Okada house, Benin City from APRIL to SEPTEMBER 2015.

1.2 COMPANY’S PROFILE

Autogenius Royal Motors located at 56, Urubi road, behind Okada house, Benin City is an indigenous

establishment that deals with passenger and light goods vehicles such as SUVs, wagon, van, sedan,

coupe, truck, hybrid and pick-up of various brands and models. Though not equipped with the latest

technology available in developed parts of the world, however with its equipment and tools it has been

carrying out proper diagnosis, servicing and maintenance of customer’s vehicle.

The establishment was founded in 2004 by its current Chairman/CEO (Mr. Ogieva Kingsley) it has a

staff strength of approximately 15. Some of its trained personnel have gone to establish their own

mechanical firm.

The organization is mostly known for their computerized approach to diagnosing various automatic cars
ranging from 1995 till date, Engine Control Unit (ECU) and Powertrain Control Module (PCM, usually
called the ‘brainbox’) tuning and programming. They also do key programming and alarm installation

on vehicles as well as Transmission Control Module (TCM)

1.3 ESTABLISMENT’S CORPORATE GOAL

Autogenius Royal Motors 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 best working conditions possible with the proper

tools and equipment to repair our client’s vehicles. This in turn gives them the privilege to associate with

happy, satisfied and dedicated clients. Also, for the trainee to have the freedom to input on how to
better

improve the working conditions to offer better service to our clients.

1.4 THE ESTABLISHMENT SCOPE OF WORK

In the area of specialization, Autogenius Royal Motors has the capacity of providing the following

services

1. Diagnosis

2. Auto Repair

3. Service and Maintenance

4. Key Programming and other programming

Autogenius Royal Motors is made up of two (3) major departments/units,

1. Repair, Servicing and Maintenance Department

2. Diagnosis and Programming Department

3. Air Conditioning and Electrical Department

About Repair, Servicing and Maintenance department: This unit is trusted with the overall

responsibility of caring out all actions which have the objective of retaining or restoring an item in or to

a state in which it can perform its required function. The actions include the combination of all technical
and corresponding administrative, managerial, and supervision actions. It also includes performing

routine actions which keep the device in working order (known as scheduled maintenance) or prevent

trouble from arising (preventive maintenance).

About Diagnosis and Programming Department: This unit carry out On-Board Diagnosis

test, the first step to diagnosing modern automobiles troubles, using an OBD-II scan tool to get the fault

codes or Diagnostic Trouble Codes (DTC). Reprogramming and flashing of the Engine Control Unit

(ECU) as well as erasing false DTCs.

About Air Conditioning and Electrical Department: This unit deals with the installation, maintenance and
servicing the systems that controls air quality, temperature, humidity inside the car as well as all
electrical work in the car.

1.5 ORGANIZATION STRUCTURE