TECHNICAL REPORT

ON

STUDENTS INDUSTRIAL WORK EXPERIENCE SCHEME

(SIWES)

UNDERTAKEN AT

AUTOTEL AUTOMOTIVE SOLUTION

WRITTEN BY

OLAIGBE OLAJIDE IBRAHIM

(MEE/15/2929)
SUBMITTED TO

THE DEPARTMENT OF MECHANICAL ENGINEERING,

FACULTY OF ENGINEERING
FEDERAL UNIVERSITY OYE-EKITI, IKOLE CAMPUS.

IN PARTIAL FULFILLMENT OF THE REQUIREMENT FOR THE AWARD OF

BACHELOR OF ENGINEERING (B.ENG) DEGREE IN MECHANICAL
ENGINEERING.

JANUARY, 2020.

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 ACKNOWLEDGEMENTS

I give the almighty God all glory and honor for granting me the opportunity to be an intern at

Autotel Automotive Solution Car Care, Samonda Ibadan, and a reputable organization where I

was given the opportunity to improve myself in all ramifications. I am very opportune to have

worked alongside wonderful people during the course of my student industrial work experience

scheme who made my stay in the company very insightful and interesting.

I am using this opportunity to also appreciate my family: my dad, my two sisters, for supporting

me in all ways they could, especially emotionally, throughout my stay in Autotel Automotive

Solutions.

I also appreciate my Industry based supervisors, Engineer Mathew, Engineer Monday, Engineer

Oriyomi amongst others for dedicating their time to ensuring that I understood properly, the

things I am meant to learn as an intern in Autotel Automotive Solutions, Samonda, Ibadan.

My sincerest gratitude goes to FEDERAL UNIVERSITY OF OYE-EKITI and SIWES for

providing this platform and to my departmental SIWES coordinator.

Finally, I want to appreciate my fellow interns in Autotel Automotive Solutions for making my

stay a delight. I see this opportunity as a big step in my growth as an engineer and I would ensure

that I use the knowledge and skills I gained and acquired in the best possible way I can.

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 DEDICATION

This Project is dedicated firstly to God Almighty and secondly to the whole Faculty of

Engineering (FUOYE) for the priviledge and the Opportunity given to me to undergo this

Industrial Training

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 ABSTRACT

The importance of vehicles is an issue that cannot be overemphasized as the daily routine of

most individuals entails the interaction with vehicles to go about businesses and move people

and goods from one place to another. This implies that with the breakdown of vehicles, our lives

and businesses tend to experience a noticeable amount of stress compared to what it was before

the breakdown. This brings up the issue and ultimately the business of automotive maintenance

and repair. With the possibility of a breakdown on one’s mind, the menacing topic of automotive

maintenance cannot be taken with levity.

This usually comes in form of questions like when should a car be serviced? How are brake pads

fixed or removed? How often should a service operation be done on a vehicle? How can

problems be easily detected in a vehicle? Is it possible to detect faults in a vehicle by using a

computer?

This technical report on the Students in Work Experience Scheme (SIWES) exercise undertaken

at Autotel Automotive Solutions, attempts to answer these questions using everyday language. In

cases where a seemingly clear answer is not available, this report hopes to shed more light and at

least create a clearer picture in the mind of the reader.

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 TABLE OF CONTENTS
ACKNOWLEDGEMENTS.............................................................................................................1
ABSTRACT....................................................................................................................................3
CHAPTER ONE..............................................................................................................................7
STUDENTS’ INDUSTRIAL WORK EXPERIENCE SCHEME (SIWES)...................................7
1.0 Introduction.......................................................................................................................7
1.1 Background of SIWES......................................................................................................7
1.2 Objectives of SIWES........................................................................................................9
1.3 Bodies Involved In the Management of SIWES...............................................................9
1.4 Problems of SIWES........................................................................................................10
CHAPTER TWO...........................................................................................................................11
BACKGROUND OF COMPANY/ORGANIZATION................................................................11
2.1 History of Autotel Automotive Solutions.......................................................................11
2.1.1 Vision Statement......................................................................................................12
2.1.2 Mission Statement...................................................................................................13
2.1.3 Strategy....................................................................................................................13
2.1. Product Portfolio......................................................................................................14
2.2 Organization Structure.....................................................................................................15
2.4 Company Policy and Terms of Service…………………………………………….……

16

2.5 Services Offered by the Company……………………………………………………….17

CHAPTER THREE………………………………………………………………………………

18

THE TRAINING PROGRAM......................................................................................................18

3.0 Introduction.....................................................................................................................18
3.1 The Definitive Tools Used In an Automobile Workshop …………………………….18

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 3.1.1 Basic Tools .....................................................................................................................19
3.1.1.1 Wrenches(Set)........................................................................................................19
3.1.1.2 Ratchets and Sockets................................................................................................19
3.1.1.3 Screwdriver.…………………………………………………………………… 20

3.1.1.4 Plier…………………………………………………………………………….21

3.1.1.5 Hammer………………………………………………………………………...22

3.1.1.6 Multimeter……………………………………………………………………….22

3.1.1.7 Jack………………………………………………………………………………23

3.1.1.8 Jack Stand……………………………………………………………………….24

3.1.1.9 Ramp……………………………………………………………………………24

3.1.1.10 Oil Filter Wrench………………………………………………………………25

3.1.2 Intermediate Tools.........................................................................................................26

3.1.2.1 Wire Terminal Crimper…………………………………………………………26

3.1.2.2 Wire Connectors (set)…………………………………………………………26

3.1.2.3 Torque Wrench……………………………………………………………….,, 27

3.1.2.4 Wrecking Bar………………………………………………………………….28

3.1.2.5 Rolling Tool Chest…………………………………………………………….28

3.1.2.6 OBD2 Scanner………………………………………………………………..29

3.1.2.7 OBD2 Scanner…………………………………………………………………29

3.1.3 Advanced Tools.......................................................................................................30

3.1.3.1 Air Compressor........................................................................................................30
3.1.3.2 Tire Inflator with Gauge…………………………………………………………31

3.1.3.3 Impact Sockets………………………………………………………………….31

3.1.3.4 Radiator Pressure Tester (Kit)…………………………………………………32

3.1.3.5 Auto data……………………………………………………………………….32

3.2 OIL SERVICE …………………………………………………………………………………………………………………………… 33

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3.3 Service tools………………………………………………………………………….35

3.4 Service Procedure…………………………………………………………………………..36

3.5 Maintenance of service equipment…………………………………………………………..38

3.6 GENERAL REPAIRS……………………………………………………………………….38

3.61 Engine repairs and replacement…………………………………………………………….39

3.6.2 Brake pad replacement………………………………………………………….41

3.6.3 Shock absorber replacement……………………………………………………..42

CHAPTER FOUR.........................................................................................................................46
CONCLUSION AND RECOMMENDATION............................................................................46
5.0 Conclusion......................................................................................................................46
5.1 Recommendation............................................................................................................47
REFERENCES..............................................................................................................................48

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 CERTIFICATION
This is to certify that this report is based on the knowledge and skills gained by me, OLAIGBE

OLAJIDE IBRAHIM during my months of Industrial Training experience at Autotel Automotive

Solutions located at Shop 15, NCWS Complex, beside Lighthouse Church, Samonda, Ibadan,

Oyo State, Nigeria.

……………………………………

OLAIGBE OLAJIDE IBRAHIM

(MEE/15/292)

Signature and Date

…………………………………………

Mr. Monday

Technical Director

Signature and date

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 CHAPTER ONE

STUDENTS’ INDUSTRIAL WORK EXPERIENCE SCHEME (SIWES)

1.0 Introduction

The Students Industrial Work Experience Scheme (SIWES) is the accepted skills training

program, which forms part of the approved minimum academic standard in the various degree

program, for all Nigerian Universities. It is an effort to bridge the gap between theory and

practice of engineering and technology, sciences, agriculture, medical, management and other

professional educational program in Nigerian Tertiary Institutions. Prior to the establishment of

the scheme, there was a growing concern among our industrialist that graduates of higher

learning institutions lacked adequate practical background studies preparatory for employment in

the industries. It is against this background that the rationale for initializing and designing the

scheme was hinged. Consequently, the scheme affords students the opportunity of familiarizing

and exposing themselves to the needed experienced in handling equipment and machinery that

are usually not available in their institution. The SIWES prepares students for labor markets. It

has become an innovative phenomenon in human resources development and training in Nigeria.

It is aimed at exposing students to machines and equipment, professional work methods and

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ways of safe guarding the work areas, workers in industries, and other organizations. The

minimum duration of the SIWES for engineering and technology program is 24 week (6

months).The scheme is a tripartite program, involving the students, the universities and the

industry (employers of labor). It is funded by the Federal Government of Nigeria and jointly

coordinated by the Industrial Training Fund (ITF) and the National Universities Commission

(NUC).

1.1 Background of SIWES

In the earlier stage of science and technology education in Nigeria, students were graduating

from their respective institutions without any technical knowledge or working experience. It was

in this view that students undergoing science and technology related courses were mandated for

students in different institution in view of widening their horizons so as to enable them have

technical knowledge or working experience before graduating from their various institutions.

The Student Industrial Work Experience Scheme (SIWES) was established by the Industrial

Training Fund (ITF) in 1973 to enable students of tertiary institution have technical knowledge

of industrial work base on their course of study before the completion of their program in their

respective institutions. The scheme was designed to expose students to industrial environment

and enable them develop occupational competencies so that they can readily contribute their

quota to national economic and technological development after graduation. The major

background behind the embankment of students in SIWES was to expose them to the industrial

environment and enable them develop occupational competencies so that they can readily

contribute their quota to national economic and technological development after graduation. The

major benefit accruing to students who participate conscientiously in Students Industrial Work

Experience Scheme (SIWES) are the skills and competencies they acquire. The relevant

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production skills remain a part of the recipients of industrial training as life-long assets which

cannot be taken away from them. This is because the knowledge and skills acquired through

training are internalized and become relevant when required to perform jobs or functions.

By integrating leadership development activities into the Industrial Training experience, we hope

to encourage students to actively engage in non-profit management as a professional career

objective. However, the effectiveness of the SIWES experience will have varying outcomes

based upon the individual student, the work assignment, and the supervisor/mentor requirements.

It is vital that each internship position description includes specific, written learning objectives to

ensure leadership skill development is incorporated.

Participation in SIWES has become a necessary pre-condition for the award of Diploma and

Degree certificates in specific disciplines in most institutions of higher learning in the country, in

accordance with the education policy of government. (Judith NSE, 2014)

Operators - The ITF, the coordinating agencies (NUC, NCCE, NBTE), employers of labour and

the institutions.

Funding - The Federal Government of Nigeria

Beneficiaries - Undergraduate students of the following: Agriculture, Engineering, Technology,

Environmental, Science, Education, Medical Science and Pure and Applied Sciences.

Duration - Four months for Polytechnics and Colleges of Education, and Six months for the

Universities.

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1.2 Objectives of SIWES

The Industrial Training Funds policy Document No. 1 of 1973 which established SIWES

outlined the objectives of the scheme. The objectives are to:

(i) Provide an avenue for students in higher institutions of learning to acquire industrial

skills and experiences during their course of study.

(ii) Prepare students for industrial work situations that they are likely to meet after

graduation.

Expose students to work methods and techniques in handling equipment

and machinery that may not be available in their institutions.

(iii) Make the transition from school to the world of work easier and enhance

students’ contacts for later job placements.

(iv) Provide students with the opportunities to apply their educational knowledge in real

work situations, thereby bridging the gap between theory and practice.

(v) Enlist and strengthen employers’ involvement in the entire educational process and

prepare students for employment in Industry and Commerce (Information and

Guideline for SIWES, 2002).

1.3 Bodies Involved In the Management of SIWES

The bodies involved are: The Federal Government, Industrial Training Fund (ITF). Other

supervising agents are: National University Commission (NUC), National Board for Technical

Education (NBTE) and National Council for Colleges of Education (NCE). The functions of

these agencies above include among others to:

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 (i) Ensure adequate funding of the scheme.

(ii) Establish SIWES and accredit SIWES unit in the approved institutions.

(iii) Formulate policies and guideline for participating bodies and institutions as well as

appointing SIWES coordinators and supporting staff.

(iv) Supervise students at their places of attachment and sign their lob-book and IT forms.

(v) Vet and process student’s log-book and forward same to ITF Area office.

(vi) Ensure payment of allowances for the students and supervisors. Therefore the success

or otherwise of the SIWES depends on the efficiency of the Ministries, ITF,

Institutions, Employers of labor and the general public involved in articulation and

management of the program. Thus the evaluation of SIWES in tertiary institutions in

meeting up with the needs for the establishment of the program is necessary.

1.4 Problems of SIWES

This scheme like any other is faced with certain challenges which include:

(i) Inability to provide good supervision for those on the industrial training fund (ITF).

(ii) Inadequate and improper financing of the training.

(iii) Inabilities of the office to find and place student in an establishment that will help

student gain the technical know-how.

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 CHAPTER TWO

2. INTRODUCTION

2.1 Historical background of Autotel Automotive Solutions Company

Autotel Automotive Solutions was set up in 1998 by the Engr. Mathew Adewunmi Starting on a

rather low budget, it has grown over time to be a highly sophisticated service centre laced with the

responsibility of making sure that today’s automobiles with their computers on-board, stay

functional.

From staff strength of four at its inception to twenty in 2007, its professional composition has

increased. The founder being a seasoned engineer with great passion for the automobile, has not

stopped at his quest to acquire the best in diagnostic equipment and qualified staff in order to give

customers’ vehicles the best of care and all round protection from break downs.

2.2 Location

Autotel Automotive Solutions is situated in the city of Ibadan, the nation’s commercial capital, at

Shop 15, NCWS Complex, beside Light House Church Samonda, Ibadan, Oyo State. This choice

location gives the company the much needed positioning for its clientele base as it opens the

company to customers from the every part of Ibadan.

2.3 Organizational Structure of the Company

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The figure above (Fig. 1.0) shows the organizational structure of the company. With a staff

strength of twenty (interns not included), the company is jointly run by the Founder, Engr.

Mathew Adewunmi, who also acts as the Managing Director and Mr. Monday, the technical

director.

2.4 Company Policy and Terms of Service

As part of the company’s policy and terms of service, every vehicle that gets admitted for a

service is subjected to vehicle inventory or vehicle check. Vehicle inventory is the intensive

examination of a vehicle that comes to the auto garage for a service, which may be any of the

following: vehicle service, engine repairs and replacement, body works, etc. It is a way in which

the company ascertains the integrity of a vehicle that comes into the garage for any job. In this

exercise, all parts and sections of the vehicle are checked and their conditions, whether working

or bad are noted and recorded.

The vehicle inventory is done in triplicates- a white copy which is the customer’s copy; a blue

copy which is kept at the administrative office on which the items used and/or replaced in the

course of the repairs are noted, and a pink copy which is kept at the garage shop for future

reference.

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To execute a vehicle inventory, the first thing to be done is to fill in the date and time of the

vehicle’s arrival. This is followed by details of the vehicle such as the manufacturer, the vehicle

model, the year of production, the engine type, the mileage of the vehicle, the registration

number and the chassis number.

The next thing after this is to take the customer’s details; the vehicle owner’s name and

telephone number, e-mail address, and home or office address (whichever the customer wishes to

give). After the customer’s details, the complaints of the customer are noted. These range from

common problems such as brake pad replacements, oil service, etc. to more complex ones like

faulty transmission systems, vehicle height calibration, etc.

After taking details of the vehicle, the customer and the complaints, the vehicle inventory

exercise goes into full swing. The things checked range from the fuel level to side mirrors, door

openers (inner and outer), door panels, window winds, windows, carpets, latches (hood, fuel and

trunk latches), the lights (headlights, parking lights, signal lights, etc.), tyres, rim size, tools, etc..

The inventory is concluded by attaching the name of the executant and date. The customer is

then given the document to append his name and signature in agreement with the information

therein.

As part of the company’s policy, a new intern is required to stay at this exercise for a minimum of

two weeks. This is to enable the intern to fully grasp the importance of the exercise. The advantage

of vehicle inventory is that in the advent of any claims of damages by a client, the inventory done on

such vehicle can be easily accessed and checked to confirm the integrity of the customer’s claims and

in most cases exonerate the company of such damage claims.

2.5 Services offered by the Company

The services offered by the company include:

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 Oil or Lube service,

 Computer diagnosis,

 Body works,

 Engine repair and replacement, and

 General repairs

The different services offered at Autotel Automotive Solutions are discussed in detail in

subsequent chapters.

CHAPTER THREE

THE TRAINING PROGRAM

3.0 Introduction

The Students’ Industrial Work Experience Scheme is a great opportunity to know an

organization better than simply reading company literature. A lot was learnt as a career

consciousness was built that would complement my degree certificate. It also creates an

awareness of what to expect after graduation.

Below is a list of ideas:

• Theory: skillful application of theories learnt at school was very evident as courses such as

EEG 351 (Electro Mechanical Devices and Machine), EEG 411 (Control Theory) and all other

courses played tremendous role for easy understanding of practical work.

• Practical Experience: A lot was experienced when drawings were converted to live machines

and other repair works which looked impossible were corrected. The practical experience

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provided me with an appreciation of the fundamental role of function, time, cost, reliability,

safety, widened knowledge and environmental impact of engineering processes.

• Management of Engineering works: managing projects here include supervising workers,

exposure to business environment and technology from a societal perspective. These processes

may form a chain structure from Planning (identifying requirements, developing concept etc.) to

Scheduling (interactions, constraints, resources allocation etc.) to Budgeting (identifying labor,

materials, overheads etc.) to Supervision (leadership and professional conduct, team motivation,

technology etc.).

• Social Implication of Engineering: engineering works have social consequences to the

environment which may be positive and/ or negative; while not every activity will have direct or

immediate consequences to the society.

3.1The Definitive Tools Used In an Automobile Workshop

There are three different groups of tools, from Basic tools, the ones you need to start

doing any jobs in your car, passing by Intermediate tools, more specific sets of tools that will

allow you to jump into more complex repairs, to Advanced tools, the ones the Professionals use

for very specific cases and situations.

BASIC TOOLS INTERMEDIATE TOOLS ADVANCED TOOLS

1. Wrenches (Set 21. Wire Terminal Crimper 41. Air Compressor

2. Ratchet and Sockets (Set) 22. Wire Terminals (set) 42. Tire Inflator with Gauge
3. Screwdrivers 23. Torque Wrench 43. Impact Wrench
4. Pliers 24. Wrecking Bar 44. Impact Sockets
5. Hammer 25. Rolling Tool Chest 45. Digital Caliper

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 6. Multimeter 26. Breaker Bar 46. Female Torx Set
7. Jack 27. Molding Removal Tool 47. Radiator Pressure Tester
Set (Kit)
8. Jack Stands 28. Car Creeper 48. Under hood LED Light
9. Ramps 29. OBD2 Scanner 49. Jump Starter
10. Oil Filter Wrench 30. Service Manual 50. Brake Caliper Wind Back
Tool (kit)
11. Oil Dripping Pan 31. Brake Bleeder & 51. Cylinder Compression
Vacuum Pump Tester
12. Funnel 32. Circlip Pliers 52. Cylinder Piston Rings
Compressor (kit)
13. Assorted 33. Hose Clamp Pliers 53. Bearing Adapter Kit
14. Scissors 34. Pry Bars 54. Laser Thermometer
15. Electrical Tape 35. Flexible Magnet Pickup 55. Machinist Vise
16. Hex Wrench (Set) 36. Socket Adapters 56. Rethreading Set
17.  LED Headlamp 37. Cordless Drill 57. Heat Gun
18. Brake Cleaner Spray 38. Angle Grinder 58. Rotary Tool Kit
19. Mechanic Gloves 39. Torx Wrench (Set) 59. Wi-Fi Video Scope
20. Hand Cleaner 40. Ignition Spark Tester 60. Auto data

3.1.1 BASIC TOOLS

1. Wrenches (Set)

These are the quintessential tools for any home mechanic or car enthusiast that wants to do basic

maintenance and fix the vast majority of minor problems in his or her car. The most essential

tool from this list, the wrench. This is a must in any tool box. We recommend in investing in

chrome-vanadium alloy tools as they will last you for a lifetime. If you have to decide between

metric and standard wrenches, go for metric. Is good to have both but we very very rarely use

our standard sets. In metric, they go from 6mm up to any crazy size you may think about.

Usually, having up to 21-24mm is fine.

2. Ratchet and Sockets (Set)

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There are three different sizes of ratchets: ¼” (small), ⅜” (medium), and ½” (large).  There are

sets with all three, two like the one in the picture or just one size. With sockets of all kinds, or

just the basic ones. Some sets come with ratchets AND wrenches... Try and get yourself at least a

big and a small ratchet set with the basic sockets as those are the ones you'll use the most.

Ratchets allow you to work with freedom, speed and accuracy. One of the best possible

investments for your tool box. Socket-wise, you want to have from 6mm up to 24mm and

perhaps a single 32mm.

3. Screwdrivers

A nice set of screwdrivers is one of the basics of any well-assorted toolbox. There are shapes

galore although the most common are: Flat, Phillips, Allen and Torx. If faced with an uncommon

kind of screw, you can always check this extensive list and see what the kind of screwdriver that

you need is. Most ratchet sets include a few different screwdriver heads with the most common

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shapes and sizes. Consider getting at least some stubbed ones, great for working in reduced

spaces, and some regular length ones.

4. Pliers

Most jobs will require you to use some kind of pliers. From brake jobs to removing small electric

connectors, pliers are a must. From wire cutting to working on reduced spaces with long nosed

pliers keeping some of this will come in handy. Get at the very least some regulars and wire

cutting ones. Adding a Jaw plier that adjusts to a lot of different sizes will be quite helpful too.

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5. Hammer

Things get stuck with dirt, grease and rust, and sometimes a good whack with a hammer is all it

takes for that rotor or that ball joint to come off. Especially when we work in brakes and

suspension, things tend to get really hard. Look for a nice rubber handlebar to ensure good grip.

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6. Multimeter

The essential tool for electrical diagnosis and troubleshooting, the multimeter. It will allow you

to measure Voltage, Resistance and Amperage (make sure you buy one multimeter that can read

Amps) extremely useful to check batteries, fuses, work on car audio... an absolute must. They

range from cheap and inexpensive to extremely high expensive. We advise you to buy something

of decent quality as you will give this tool a lot of use.

7. Jack

Although not every car job will require you to lift the car up, there are many cases where doing

so will speed up the process. Hydraulic Jacks are lifting tools only and are not meant to be used

to secure the car up. For that purpose, make sure to always use jack stands. Good jacks can be a

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bit pricey so you may want to use the mechanical jack that comes with your car as a substitute

and maybe ramps.

8. Jack Stands

One of the essential tools needed for auto mechanic work are jack stands. To safely secure a

lifted car, mechanic jack stands are a must. Consider getting at least a couple of them and to

make sure that they withstand at least 2-3 tons of weight.

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9. Ramps

Ramps are extremely useful to work comfortably on your car. They lift the car up in a secure

way and even the most inexpensive one will do fine. Space wise they are bulkier than jack

stands. The only counterpart vs jack stands is that they do not allow movement of the wheels, so

whilst they are great for jobs such as an oil change, to do brake or suspension jobs using ramps

isn't possible.

10. Oil Filter Wrench

Doing an oil change is perhaps one of the simplest, most money-saving operations we can

conduct in our own cars. Oil filters tend to get really stiff and is usually borderline impossible to

remove them by hand. There are loads of different tools for this purpose although we believe

adjustable zip wrenches as the one on the picture and 3 Jaw wrenches are the most efficient for

the job.

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3.1.2 INTERMEDIATE TOOLS

In the following section of this auto mechanics tools list, you will find a mix of upgrades, tools

that are more specific for certain jobs and others that although simple, we know aren't as

"essential" as the first ones listed before.

1. Wire Terminal Crimper

If you conduct some extended electric repair, you will most likely have to change a few dozen

wire terminals. Having a terminal crimper will allow you to get those terminals nicely fitted to

the wire with a nice, professional end.

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2. Wire Connectors (set)

These are the terminals we were talking about. Terminals tend to get corroded by external

agents. Some may cause malfunction of component.

When you conduct a reparation in some component and take out relays and connectors and

sensors... sometimes you notice some terminals are gone. A smart thing to do is to quickly

replace them with a healthy one. A box of assorted terminals is usually just a few bucks and will

come very handy when you need it.

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3. Torque Wrench

Looks like a simple ratchet but it isn't. This tool will allow you to tighten bolts at exactly the

specified torque given by the manufacturer. 

This is a matter of special relevance when we conduct operations inside the engine or the

transmission gear. Really convenient to use when tightening spark plugs as nothing ruins a day

faster than a spark plug that strip the threads inside the engine block.

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4. Wrecking Bar

I'll tell you who, overly-attached ball joints and shock absorbers heads. Man they love to stay

together. Luckily for us we can get a big badass bar in between, if we get some nice leverage

point, and get them off each other and keep working on that clutch... 

5. Rolling Tool Chest

Tools start to add up and when you notice you have your trunk full of mini boxes with small sets

of wrenches, screwdrivers, fuses... on your garage you have a messy table full of expensive tools

and it starts to get a bit chaotic and hard to find everything when you need it. If your tool

collection starts to look good and you want to keep it nicely organized, you may want to get

yourself a tool chest. Notice that some are quite inexpensive and that sometimes you will find

deals of fully equipped tool chests so have a look at that if you have some budget and you

haven't yet got any tools.

6. OBD2 Scanner

Troubleshooting gets so much easy with an OBD2 Scanner. Back in the day this tools did only

read codes and they cost a fortune. Luckily for us, in 2019 good OBD2 scanners can be found at

around a hundred dollars with engine and ABS code read, scan and erase. 

Some are brand-specific, some are "read only" and some can do it all, just like the software used

at authorized dealerships. We advise you to do your research when you purchase one of this

tools. In my opinion, every automobile workshop should get a #80,000 code reader, or a full

blown scanner that will not only tell you what trouble code you have, but what it means, how to

fix it, allow you to test parts in your car, etc. Cars from 1996 onwards incorporate OBD2.

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7. Socket Adapters

Sometimes you have the socket that you need but the ratchet won't fit in the space you

have. Sometimes the only socket that fits is from the small ratchet and the torque isn't enough for

you to move it. Here is where socket adapters come into play.

3.1.3 ADVANCED TOOLS

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The following selection of tools comprises power tools, total upgrades such as air compressed

systems and some very job-specific tool kits that will allow you to conduct every job ever

possible on a car.

1. Air Compressor

Setting an air compressed system empowers you to conduct heavy duty jobs with minimal effort,

maximizing the outputs of your job. This should be a one-off investment, if you treat it well.

Consider getting only the best air compressor for the money you have and then you can gradually

build your air powered tool selection gradually.

2. Tire Inflator with Gauge

The most basic air compressed tool, the tire inflator. This is a must buy as soon as you get your

compressor. It will allow you to have your tire pressure always spot on. Make sure to buy one

with a gauge that reads at least up to 8 bar or 100 PSI.

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3. Impact Sockets

Regular sockets aren't made for use on air compressed tools. They will break rather easily since

they aren't designed to withstand the impacts this tools produce.

4. Radiator Pressure Tester (Kit)

This tool allows easy testing for leakage in radiator system and quick change of coolant. By

pressurizing the system and being able to control it via the gauge, we can check for sustained

pressure or lack thereof to diagnose a failing coolant circuit.

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5. Auto data

Auto data is a software (although now they have turned for a full-cloud version and CD versions

are discontinued) that contains technical information on over 40.000 different vehicles. From

wiring diagrams, timing belt diagrams, torque values for parts, to component testing and just so

much more. This is the ultimate tool for professionals.

3.2 OIL SERVICE

A motor vehicle service is a series of maintenance procedures carried out at a set time interval or

after the vehicle has travelled a certain distance. The service intervals are usually specified by the

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vehicle’s manufacturer in a service schedule and some modern cars display the due date for the

next service electronically on the instrument panel.

At Autotel Automotive Solutions, the vehicle service is carried out in the pit. The pit is a

compartment dug into the ground over which the vehicle will be parked. This location is ideal

because it creates the necessary space required by the mechanic to conveniently inspect the

underside of the vehicle and to drain the spent engine oil from the engine sump since it is located

at the downside of the engine. In cases where the pits have been occupied by other vehicles, the

service operation takes place at the vehicle lift. After service, the vehicle and engine are cleaned

and released to the customer.

The completed services are recorded electronically on a database by the service centre upon the

completion of each service. However, with recent customer demands, customer service records

can now be printed from the database.

At the completion of the vehicle service procedure, the engine and the vehicle body is cleaned

thoroughly so as to rid it of greasy and oily stains that might have come about during the service.

Maintenance tasks during a vehicle service include;

 Engine oil replacement

 Oil filter replacement

 Replacement of air filter

 Cleaning/Replacement of spark plugs

 Level check and refilling of brake fluid

 Level check and refilling of power steering fluid

 Level check and refilling of automatic transmission fluid

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 Inspection and replacement of the timing belt, if needed

 Inspection of condition of the tyres

Other parts in the vehicle that are also checked and advised upon include the following:

 Battery

 Engine components, etc.

Fig 3.2 some service tools and service materials

The necessary tools and materials are shown in the fig. 2.0. The tools required for a service operation

include sets of sockets, spanners, screwdrivers, ratchets, extension bars and the T-bar. Necessary

materials for a service operation include engine oil, motor flush, oil filter, and oil supplement.

3.3 Service tools

Some of the tools used for a typical service exercise are highlighted below:

 Mechanical jack (hydraulic or electric),

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 Axle stand,

 Funnel,

 Set of sockets,

 Set of spanners,

 Ratchet and extensions, etc.

Hydraulic jack: A mechanical jack is a device which lifts heavy equipment. It works on the

principle of pressure transmission. Mechanical jacks are usually rated for a maximum lifting

capacity. A hydraulic jack uses a fluid, which is incompressible, that is forced into a cylinder by a

pump plunger. Oil is used since it is self-lubricating and stable. In the case of electric lifts, electrical

power is required. The electric lift used at Autotel Automotive Solutions has a maximum lifting

capacity of 4100kg. The jack is used in lifting the vehicle in order to create enough clearance for

work to be done underneath it.

Axle stand: Axle stands are tripod-shaped bodies used in keeping a suspended vehicle parked while

work is being done underneath it. After lifting the vehicle to the desired height using a mechanical

jack, it is used to keep the vehicle at that height. It is much safer as the risk of failure of a hydraulic

jack is greatly reduced.

Set of spanners: The set of spanners contains spanners of various sizes. The spanners are used to

loosen the guiding nuts of the protector covering the underside of the vehicle, especially when the

protector is hindering access to the engine sump. Other nuts and/or bolts that need to be removed to

access the oil sump can also be removed with the spanners.

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Ratchet: A ratchet is a mechanical device that allows continuous linear or rotary motion in only one

direction while preventing motion in the opposite direction. A ratchet makes it easy to loosen nuts

since it eliminates the stress caused by using a spanner.

3.3 Service Procedure

A sample service exercise at Autotel Automotive Solutions is described below:

Location: In the pit, the electric lift or on the ground using manual hydraulic jacks. Required tools:

Ratchet, Extensions, Sockets, Oil filter remover, T-nut remover, air blower and gun Necessary

Items: Engine oil, Oil flush, Oil supplement, Oil filter, Fuel treatment and Air filter (if necessary)

Procedure:

1. Pour the Oil flush into the engine. This removes every trace of sludge formed in the engine. The

amount of flush required varies with the engine type. For four and six cylinder engines, a can of flush

is adequate but engines with more cylinders require two cans of flush.

2. Start the engine and leave it running for some minutes (recommended time, 20 minutes) so that all

the sludge present will dissolve completely into the engine oil.

3. If the underside of the engine has a protector shielding the engine sump, remove it.

4. With the aid of the T-nut remover and the appropriate socket, remove the retaining bolts of the

engine sump to drain the oil. Drain the spent engine oil.

5. Use the Oil filter remover to remove the Oil filter.

6. Replace the retaining bolt in position to prevent oil leaks.

7. Replace the Oil filter with a new one.

8. Pour the new engine oil and the Oil supplement into the engine. The volume of Engine oil and oil

supplement used is a function of the engine’s capacity.

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9. Check the Engine oil level. Ensure it is filled to the maximum level.

10. Remove the Air filter from the air cleaner in the engine. Blow off the dust particles trapped in it

with the aid of the Air blower and gun. Replace the Air filter.

11. Check the level of the engine fluids such as brake fluid, power steering fluid and transmission

fluid.

12. When the fuel is to be supplied, add the Fuel treatment. This reduces the fuel consumption rate

and the rate of emissions of waste gases.

13. Clean the engine and body of the vehicle to rid it of any oily or greasy stains.

The vehicle is then ready to leave the garage.

Fig. 3.3 Removal of Oil filter with an oil filter remover during a service operation

3.4 Maintenance of service equipment

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 The tools are kept in a dry place free from humidity in the store. For tools that require special

fluids for proper functioning, such as the hydraulic jack, the fluid level is checked from time to time

and refilled when necessary. Other tools that have special storage compartments such as ratchets,

sockets and spanners are properly cleaned and replaced immediately after use. Tools like the axle

stands used in the suspension of vehicles while work is done underneath them are kept in the store far

from open space in order to prevent them from rainfall, which will ultimately lead to corrosion.

3.5 GENERAL REPAIRS

A general repair as implied in this chapter refers to repairs and replacements done on any parts of

the vehicle with the exception of the vehicle body. Repair and replacement services done at

Autotel Automotive Solutions include suspension repairs such as brake pad replacements, shock

absorber replacement, stabilizer linkage replacement, stabilizer bushing replacement, etc.

Some of the repairs I served as an assistant in include:

 Engine repairs, overhaul and replacement,

 Brake pad replacement,

 Shock absorber repair and replacement, etc.

3.5.1 Engine repairs and replacement

The Engine is the component of any vehicle that takes the chemical energy in the fuel and

converts it through a series of processes into useful mechanical energy so as to generate

sufficient power to propel the vehicle. The engine acts as the powerhouse of the vehicle.

Automobile engines come in various designs, sizes and configurations. The structure on which

other components of the engine are attached to is called the Engine block. The engine also

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supplies the necessary drive needed by the generator, the air-conditioning compressor and the

power steering pump.

Automobile engines can be classified in various ways. These range from the method of ignition

to fuel type used, number of cylinders, piston arrangement, method of mixture preparation,

method of ignition, etc. The most common type of engine found in vehicles is the gasoline-

burning, liquid-cooled, spark-ignition, four stroke, and multi-cylinder engine. It has the intake

and exhaust valves in the cylinder head, and electronically controlled ignition and fuel injection

system.

The most popular automobile engine is the one based on the constant volume process also

called the Otto cycle. The process was named after the individual that first proposed such a

design, Nicolas August Otto, a German engineer in 1876. Though his proposed design has seen

various adjustments through time, it still remains the foundation for gasoline-combusting, spark-

ignition four stroke engines.

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 Fig. 3.5.1 A 4-cylinder gasoline-combusting, spark-ignition engine undergoing repairs

Common engine repairs done at Autotel Automotive Solution include engine overhaul, camshaft

replacement, piston replacement, etc. In cases where the engine has been confirmed to be in a

really bad condition, customers are advised to get a new engine instead.

Engine replacement exercises usually start with the removal of the hood (bonnet) as it may

hinder the proper removal of the engine. Once the bonnet is removed, the engine is carefully

detached from the transmission system. Then the engine is unseated from its seat and every

component that might hinder its easy removal. The engine is lifted out of the vehicle with the aid

of a special hydraulic jack with a maximum lifting capacity of 3 tons.

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To overhaul an engine, the engine is removed from its position and dismantled to its

components. The components are then properly cleaned to remove dirt and greasy particles that

may hinder the proper functioning of the engine. Reasons for overhauling an engine range from

having too much sludge in the engine to having water in some areas where it is not desired. The

overhauling process is a labor intensive exercise since it requires valuable man-hours for it to be

done effectively.

Sometimes, an engine repair may simply be the repair of components attached to the

engine like the alternator, water-pump, power steering pump and the air-conditioning system’s

compressor. At other times, engine repairs may simply be the properly welding of the engine

block in the advent of a fracture.

3.5.2 Brake pad replacement

The brake system is a very important subsection of the suspensions system of an automobile.

Without the brakes in the vehicle, it automatically becomes a weapon of destruction because it

won’t be able to stop when it is needed to do so. To achieve this mission, the brake system

comes with a wide range of components like the brake drum, brake piston, brake calipers, and

most important of all, the brake pads. Often times, brake pads get used up and need to be

replaced. The procedure for a brake pad removal exercise at the company is described below.

Replacement of brake pads

Location: in the workshop

Required tools: Wheel spanner, Hydraulic jack, Tyre chock, Set of sockets, Set of spanners, etc.

Necessary items: new brake pads

Procedure:

1. Using tyre chocks, keep the vehicle stationary.

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2. With the aid of the wheel spanner, slack the wheel nuts keeping the tyre in place.

3. Elevate the vehicle to a convenient height using the hydraulic jack, to allow enough space for

the removal of the tyres.

4. Loosen the tyre nuts completely and remove the tyres.

5. The wheel is now exposed. With the aid of ratchets and necessary sockets, remove the bolts

and screws guiding the brake calliper.

6. Lift the calliper and carefully remove one of the brake pads to be replaced.

7. With one of the pair left, carefully pull the calliper so as to press the brake piston against the

brake drum. This enables it to return to its original position before the brake pads were reduced.

8. With the piston in its position, remove the remaining brake pad.

9. Fit the new pair of brake pads to the brake calliper.

10. Ensure the brake pads are properly fitted.

11. Return the brake calliper to its position and tighten the guiding bolts and nuts.

12. Replace the wheel in position and tighten the wheel nuts to keep it in place.

13. With the aid of the hydraulic jack, bring the vehicle down to ground level.

14. Tighten the wheel nuts again to ensure they are secured in place.

After the steps above, the exercise is complete and the vehicle is worthy to leave the

workshop.

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3.5.3 Shock absorber replacement

The automobile frame and body are mounted on the front and rear axle not directly but through

the springs and shock absorbers. Without shock absorbers and springs the vehicle would not be

able to dampen the vibrations resulting from its motion.

Suspension is the term given to the system of springs, shock absorbers and linkages that connects

a vehicle to its wheels and allows relative motion between the two. Suspension systems serve a

dual purpose – contributing to the vehicle’s handling and braking for good active safety and

driving pleasure, and for keeping the vehicle occupants comfortable and reasonably well isolated

from road noise, bumps and vibrations. These goals are generally at odds, so the tuning of

suspensions involves finding the right compromise.

Suspension repairs at Autotel Automotive Solutions include the repairs of shock absorbers

(which usually entails the removal and replacement of shock absorber springs), stabilizer

linkage, shafts, etc. A typical scenario involving the replacement of a shock absorber is described

below;

Required tools: Hydraulic jack, Wheel spanner, Sets of spanners and sockets, Ratchet

Procedure:

1. Using tyre chocks, keep the vehicle stationary.

2. Slack the wheel nuts or bolts keeping the tyre of the respective shock absorber to be replaced

in place.

3. Elevate the vehicle to a convenient height using the hydraulic jack, to allow enough space for

the removal of the tyres.

4. Loosen the tyre nuts completely and remove the tyres.

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5. If it’s located in the front part of the vehicle, open the hood to get access to where the top of

the shock absorber is screwed and/or bolted to.

6. With the aid of the necessary tools – Ratchet, Spanner or T-bar, loosen the guiding nuts of the

shock absorbers.

7. Repeat step 6 for the bottom mounting hook of the shock absorber.

8. Remove the old shock absorber and replace with the new one.

9. Fix it properly according to the guiding marks on it. These marks are guides to the proper

orientation of the shock absorbers.

10. Fix the bolts and/or nuts and tighten them to keep the shock absorber in place.

11. Fix the tyre, bolt them in place and reduce the vehicle’s elevation to ground level.

12. Tighten the tyre again to ensure they are not loose. The process is complete.

Fig.3.5 a hydraulic jack used for general repairs

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 Fig. 3.5 An engine block

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 CHAPTER FOUR

4.0 CONCLUSION

In conclusion, after undergo Eighteen Weeks of Industrial Training, all the objectives of the

program are full-filled. I have learned lot of new things and have acquired sufficient exposure in

new area such as instrumentation, Mechanical and others. I also have a chance to relate all the

theories learned at university with real working life.

Basically the program was successfully completed whereby all the objectives highlighted by

Industrial Training Committee were achieved. I had the opportunity to integrate theory with

practice while completing the assignment and projects given by my supervisor. The integration

of the theoretical knowledge and the industry has enhanced better understanding on the subjects

that I have learned in the university, thus smoothen the learning process.

Moreover, the program was not only beneficial for me in term of technical or academic base but

I could also develop various skills. From this program, I had developed skills in work ethics,

communication and management skills. Since there are different levels of personnel, I had

experience in adapting to this kind of environment.

Autotel Automotive Solutions is an ideal place for Industrial Training Programme as the

experience and knowledge gained is the most valuable lesson which cannot be received in class.

The combination of technical and non-technical skills has provided an opportunity for the

student to prepare in working life culture.

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4.1 RECOMMENDATION

I use this means to make the following recommendations concerning the training of students in
Industrial Attachments;

(i) The University community should invite and encourage corporate bodies and

organisations with seasoned professionals in relevant fields to hold seminars and

workshops that will enlighten the minds of the students to recent developments and

challenges in their discipline. Allowances should be paid to students during their

program just like NYSC and not after. This would help them a great deal to handle

some financial problems during their training course.

(ii) Industrial Training Fund as a body responsible to federal Government should create

time to visit students on site to evaluate the success of the scheme.

(iii) Participations of various professional, regulatory and statutory bodies such as

COREN, NSE in the supervision of students.

(iv) Due to the nature of the nation’s economy, the students should be assisted in securing

attachment for their Industrial training period as this will eliminate the waste of time

encountered in searching for a place of attachment.

(v) More practical classes should be held so as to further reduce the breach between the

classroom and the professional field. Also, more field trips and excursions should be

organised as this would encourage the students because the link between the classroom

and field work would be further emphasized

REFERENCES

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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. SIWES. (2008). Retrieved January 2015, from ITF: http://odich.com/itfnig/siwes.php

4. Paul Dempsey. (November 5, 2007). 4th Edition: Troubleshooting and Repair of Diesel

Engines

5. wikipedia.com/automobile/dictionary

6. 1998 NAPA Institute of Automotive Technology. Introduction to OBD II

7. http://www.obd-codes.com/trouble_codes/

8. Charles Fayette Taylor, 1995, The Internal Combustion Engine in Theory and Practice:

Volume 1 & 2

9. Willard W. Pulkrabek: Engineering Fundamentals of the Internal Combustion Engine

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