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THE UNIVERSITY OF ZAMBIA

SCHOOL OF ENGINEERING

DEPARTMENT OF MECHANICAL ENGINNERING

INDUSTRIAL TRAINING REPORT

At: TOYOTA ZAMBIA

Period from: 19/12/2011 to 20/01/2012

By:

Student Name: Chilufya Mubanga B.

Student ID Number: 29031800

Course Code: EG

Submitted to: Mr S. S. Virdy

2012

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LIST OF FIGURES

Figure page

1: Long Chassis Service Jack and Jack Stand…………………………………….........5

1: Car Lifts……………………………………………………………………………………6

2: 22-re engine lubrication system…………………………………………………………7

3: lubrication system operation…………………………………………………………….7

4: remove oil filter……………………………………………………………………………9

5: check engine oil level…………………………………………………………………….9

6: rear brakes assembly. 2WD and 4WD………………………………………………..10

7: front brakes components……………………………………………………………….10

8: check brake pad thickness……………………………………………………………..11

9: remove the brakes……………………………………………………………………..11

10: brake pads………………………………………………………………………………11

11: install pad support plates………………………………………………………………11

12: install new pads………………………………………………………………………...11

13: install calliper……………………………………………………………………………12

14: rear brake components………………………………………………………………..12

15: check brake shoe lining………………………………………………………………..12

16: check the brake drum for scoring…………………………………………………….13

17: clutch unit components………………………………………………………………..13

18: remove clutch cover……………………………………………………………………13

19: remove the fork and boot……………………………………………………………...14

20: install disk on the flywheel…………………………………………………………….14

21: install clutch cover……………………………………………………………………...14

22: apply grease…………………………………………………………………………….14

23: install boot, fork…………………………………………………………………………14

24: double wishbone type suspension used in front suspension………………………15

25: front shock absorber components…………………………………………………….15

26: stabilizer components…………………………………………………………………..16

27: rear shock absorber components……………………………………………………..17

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CONTENTS

Contents page

1. SUMMARY…………………………………………………………………….............4

2. INTRODUCTION...........................................................................................4

3. COMPANY PROFILE………………………………………………………………....4

4. MACHINERY…………………………………………………………………..............4

4.1 HYDRAULIC JACKS……………………………………………………………....4

5. MAIN ACTIVITIES…………………………………………………………….............6

5.1 LUBRICATION SYSTEM…………………………………………………............6

5.1.1 DESCRIPTION ………………………………………………………….......6

5.1.2 OPERATION…………………………………………………………...........7

5.1.3 OIL AND FILTER REPLACEMENT…………………………………….....8

5.2 BRAKE PADS AND BRAKE SHOES……………………………………………9

5.2.1 GENERAL DESCRIPTION…………………………………………………9

5.2.2 FRONT BRAKE……………………………………………………………...9

5.2.3 BRAKE PADS REPLACEMENT…………………………………………..10

5.2.4 REAR BRAKES…………………………………………………………......10

5.2.5 INSPECTION OF REAR BRAKE LININGS AND DRUMS……………..12

5.3 CLUTCH UNIT ……………………………………………………………………..13

5.3.1 COMPONENTS……………………………………………………………..13

5.3.2 CLUTCH UNIT REMOVAL…………………………………………………13

5.3.3 CLUTCH UNIT INSTALLATION…………………………………………...14

5.4 SUSPENSION……………………………………………………………………..15

5.4.1 FRONT SUSPENSION 2WD………………………………………...........15

5.4.2 FRONT SHOCK ABSORBER…………………………………………......15

5.4.3 FRONT SHOCK ABSORBER REMOVAL………………………………..16

5.4.4 SHOCK ABSORBER INSPECTION………………………………...........16

5.4.5 FRONT SHOCK ABSORBER INSTALLATION………………………....16

5.5 STABILIZER BAR…………………………………………………………….......16

5.5.1 COMPONENTS……………………………………………………………..16

5.5.2 STABILIZER BAR REMOVAL……………………………………………..16

5.5.3 STABILIZER BAR INSTALLATION……………………………………….17

5.6 REAR SHOCK ABSORBER……………………………………………………..17

5.6.1 COMPONENTS……………………………………………………………..17

5.6.2 SHOCK ABSORBER REMOVAL…………………………………………17

5.6.3 INSPECT SHOCK ABSORBER…………………………………………..18

5.6.4 INSTALL REAR SHOCK ABSORBER…………………………………...18

6. CONCLUSION....................................................................................................19

7. APPENDIX A………………………………………………………………………….19

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1. SUMMARY

This is a (5) weeks report of my Industrial training at Toyota Zambia for the partial

fulfilment of the requirements for the award of The Bachelor of Engineering degree at

The University of Zambia.

The report outlines the activities carried out while working at the Toyota Service

Station, the details of these activities, tools and equipment used, precautions taken

and the experience obtained.

During the course of the training, I was assigned to work at Toyota Service Station

under the supervision of a Professional Technician. The work mainly involved

maintenance service of Toyota vehicles. A minimum of three vehicles were serviced

at each bay and the maintenance services were classified according to service

required, see appendix B.

2. INTRODUCTION

This report covers the general overview of the industrial training experience obtained

during the work period at Toyota Zambia in Lusaka. The work involved maintenance

services of Toyota vehicles such as, Toyota Hilux, Toyota Land Cruiser and Toyota

Hiace, at Toyota Service Station.

3. COMPANY PROFILE

Toyota Zambia is a leading motor dealer in Zambia. It is situated in Lusaka along

Cairo Road, north end. The company aim to build into the preferred supplier to the

Zambian automotive market, providing reliable and well supported value for money

products and services, through a well-trained and highly motivated team, using

modern facilities, technology, systems and equipment, generating profitable growth

and enhanced stakeholder confidence through innovative and ethical business

strategies, whilst positively participating in the development of Zambia

4. MACHINERY

4.1 HYDRAULIC JACKS AND HYDRAULIC LIFTS

A Jack is a mechanical device used to raise or otherwise exert a force on an object

too heavy to deal with by hand. Hydraulic Jacks use the principle of hydraulics.

Hydraulics is application of fluid mechanics to engineering devices involving liquids,

usually water or oil. Hydraulics deals with such problems as the flow of fluids through

pipes or in open channels, the design of storage dams, pumps, and water turbines,

and with other devices for the control or use of liquids, such as nozzles, valves, jets,

and flow-meters. Two of the most important applications of hydraulics are in the

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design of hydraulic actuators and hydraulic presses; these are based on Pascal's

law, which states that the pressure exerted on a liquid is the same in all directions.

Because force equals pressure multiplied by area, forces can be greatly amplified by

having liquid enclosed between two movable pistons of different area. If, for

instance, one piston has a unit area of 1 and the other a unit area of 10, a unit force

of 1 applied to the smaller piston, corresponding to a pressure of 1 per unit area will

result in a force of 10 per unit area on the larger piston. This mechanical advantage

can be used in such hydraulic actuators as Jacks.

A common example A hydraulic jack is a car Jack, which is used to elevate the end

of a car by a system of ratchets, gears, and screws. A hydraulic Jack makes use of

Pistons and liquids in order to raise weights. Hydraulic Jacks and lifts are used for

raising vehicles in service stations and for lifting heavy loads in the construction

industry.

The following are the types of hydraulic Jacks and lifts that were used when

servicing vehicles at Toyota Zambia.

Figure 1 Long Chassis Service Jack and Jack Stand.

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Figure 2: Car Lifts

5. MAIN ACTIVITIES

During the whole course of attachment the main activities involved basic mechanical

maintenance services, full mechanical maintenance services and repairs. Basic

mechanical services involve replacing engine oil and oil filter, air filter inspection or

replacement, and inspection or replacement of brake pads and brake shoes. Full

mechanical services involved the above operations and include replacement of

transmission oil, fuel filter and inspection or replacement of drive belts. The repairs

involved inspecting and changing shock absorbers, stabiliser bushes, clutch

overhaul, and ball joints replacements.

Note that the maintenance services carried out were based on the maintenance

schedule and it is the schedule which describe whether basic or full service

operation should be carried out. See Appendix B.

The main types of vehicles operated on were; Toyota Hilux, Toyota Land Cruiser,

and Toyota Land Cruiser Prado.

The general maintenance operations carried out are outlined below.

5.1 LUBRICATION SYSTEM

5.1.1 DESCRIPTION

A fully pressurized, fully filtered lubrication system is used in 22-re engine.

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Figure 3: 22-re engine lubrication system

5.1.2 OPERATION

Figure 4: lubrication system operation

A pressure feeding lubrication system has been adopted to supply oil to the moving parts of this engine. The lubrication system consists of an oil pan, oil pump and oil filter, etc. The oil circuit is shown in the illustration above. Oil from the oil pan is pumped up by the oil pump. After it passes through the oil filter, it is fed through the various oil holes in the crankshaft and cylinder block. After passing through the cylinder block and

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performing its lubricating function, the oil is returned by gravity to the oil pan. A dipstick on the side of the oil pump body is provided to check the oil level.

OIL PUMP The oil pumps up oil from the oil pan and sends it under pressure to the various parts of the engine. An oil strainer is mounted in front of the inlet to the oil pump to remove impurities. The oil pump itself is an internal gear pump, which uses a drive gear and driven gear inside the pump body. When the drive gear rotates, the driven gear rotates in the same direction. The space between the two gears changes when both, gears rotate. Oil is drawn in when this space widens, and is discharged when the space becomes narrow.

OIL PRESSURE REGULATOR (RELIEF VALVE) At high engine speeds, the oil pump supplies more oil to each part than is necessary. For this reason, an oil pressure regulator which works to prevent an oversupply of oil is installed on the oil pump. During normal oil supply, a coil spring and valve keep the bypass closed, but when too much oil is being supplied, the pressures become extremely high, overpowering the force of the spring and opening the valve. This allows the excess oil to flow through the relief valve and return to the oil pan.

OIL FILTER The oil filter is a full flow type with a paper filter element and built−in relief valve. Particles of metal from wear, airborne dirt, carbon and other impurities can get in the oil during use and could cause accelerated wear or seizing if allowed to circulate through the engine. The oil filter, integrated into the oil line, removes these impurities as the oil passes through it. The filter is mounted outside the engine to simplify replacement of the filter element. A relief valve is also included ahead of the filter element to relieve the high oil pressure in case the filter element becomes clogged with impurities. The relief valve opens when the oil pressure overpowers the force of the spring. Oil passing through the relief valve bypasses the oil filter and flows directly into the main oil hole in the engine. 5.1.3 OIL AND FILTER REPLACEMENT

CAUTION: - Prolonged and repeated contact with mineral oil will result in the removal of

natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer.

- Adequate means of skin protection and washing facilities should be provided. - Care should be taken, therefore, when changing engine oil, to minimize the

frequency and length of time your skin is exposed to used engine oil. - Protective clothing and gloves that cannot be penetrated by oil should be

worn. Wash your skin thoroughly with soap and water, or use waterless hand cleaner, to remove any used engine oil. Do not use gasoline, thinners, or solvents.

- In order to preserve the environment used oil and used oil filters must be disposed of only at designated disposal sites.

The following tasks were performed to replace Engine oil and oil filter

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Figure 5: remove oil filter

Figure 6": check engine oil level

5.2 BRAKE PADS AND BRAKE SHOES:

5.2.1 GENERAL DESCRIPTION

1. Care must be taken to replace each part properly as it could affect the performance of the brake system and result in a driving hazard. Replace the parts with parts of the same part number or equivalent. 2. It is very important to keep parts and the area clean when repairing the brake system. The service brakes consist of a foot brake which changes rotational energy to thermal energy to slow down the vehicle while it is being driven and a parking brake to keep the vehicle from moving while it is parked. 5.2.2 OPERATION

FOOT BRAKE When the brake pedal is depressed, a vacuum builds up in the booster which amplifies the pedal force, pressing on the piston in the master cylinder. The piston movement raises the hydraulic pressure in the cylinder. This hydraulic pressure is then applied to each respective brake cylinder and wheel cylinder, and acts to press the brake pads and shoes against the rotating discs and drum. The resulting friction converts the rotational energy to thermal energy, slowing down the vehicle.

PARKING BRAKE

1. DRAIN ENGINE OIL

(a) Remove the oil filter cap.

(b) Remove the oil dipstick.

(c) Remove the oil drain plug and drain the oil into a

container.

2. REPLACE OIL FILTER

(a) Using SST, remove the oil filter (located on right side

of the engine block)

(b) Clean the filter contact surface on the filter mounting.

(c) Lubricate the filter rubber gasket with engine oil.

Tighten the filter by hand until the gasket contacts the

seat of the filter mounting. Then using SST, give it an

additional 3/4 turn to seat the filter.

3. FILL WITH ENGINE OIL

(a) Clean and install the oil drain plug with a new gasket.

(b) Fill the engine with new oil, API grade SG multi grade, fuel

efficient and recommended viscosity oil.

4. START ENGINE AND CHECK FOR LEAKS

5. RECHECK ENGINE OIL LEVEL

Recheck the engine oil level and refill as necessary.

HINT: Insert the oil dipstick with the curved tip pointed toward

the engine.

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When the parking brake lever is pulled, the parking brake shoe lever is pulled via the parking brake wire. This causes the shoe strut to push the front shoe, which expands and is pressed against the parking brake drum. If the parking brake lever continues to be pulled, the contact point of the parking brake shoe lever and shoe strut then becomes the fulcrum so that the parking brake shoe lever causes the parking brake shoe to expand. This results in the parking brake drum being locked by the right shoe and left shoe.

Figure 7: rear brakes assembly. 2WD and 4WD.

5.2.3 FRONT BRAKE.

Figure 8: front brakes components.

5.2.4 BRAKE PADS REPLACEMENT

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The following procedure was carried out during brake pads replacement.

Figure 9: check brake pad thickness

Figure10: remove the brakes

Figure 11: brake pads

Figure 12: install pad support plates

Figure 13: install new pads

1. REMOVE FRONT WHEEL

2. INSPECT PAD LINING

THICKNESS

Check the pad thickness through the

calliper inspection hole and replace pads

if not within specification.

Minimum thickness: 1.0mm

4. REMOVE FOLLOWING PARTS:

(a) 2 brake pads

(b) 4 anti−squeal shims

(c) 2 pad wear indicator plates

(d) 4 pad support plates

5. CHECK DISC THICKNESS AND

RUNOUT

6. INSTALL PAD SUPPORT

PLATES

7. INSTALL NEW PADS

(a) Install a pad wear indicator plate to the pad.

(b) Install the 2 anti−squeal shims to each pad.

HINT: Apply disc brake grease to both side of the

inner anti−squeal shim.

(c) Install the 2 pads so that the wear indicator

plate is facing underneath.

3. LIFT UP CALIPER

(a) Remove the sliding sub pin from the torque

plate.

(b) Lift up the calliper and suspend it, making

sure the hose is not stretched.

HINT: Do not disconnect the brake hose.

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Figure 14: install caliper

5.2.5 REAR BRAKES

Figure 15: rear brake components

5.2.6 INSPECTION OF REAR BRAKE LININGS AND DRUMS

Figure 16: check brake shoe lining

8. INSTALL CALIPER

(a) Draw out a small amount of brake fluid from the

reservoir.

(b) Press in piston with a hammer handle or an

equivalent.

HINT: Always change the pad on one wheel at a time as

there is a possibility of the opposite piston flying out.

(c) Insert the calliper carefully so that the boot is not

wedged.

(d) Install and torque the sliding sub pin.

(a) Check the lining –to-drum contact

condition and lining wear. Minimum

lining thickness: 1.0 mm

Brake Drum

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Figure 17: check the brake drum for scoring

5.3 CLUTCH UNIT

5.3.1 COMPONENTS

Figure 18: clutch unit components

5.3.2 CLUTCH UNIT REMOVAL The following procedure was carried out during clutch overhaul.

Figure 19: remove clutch cover

(b) Check the brake drum for scoring or wear.

Maximum drum inside diameter: 2WD 256.0mm,

4WD 297.0mm.

(c) Clean the brake parts with a damp cloth

1. REMOVE TRANSMISSION FROM ENGINE.

HINT: Do not drain the transmission oil.

2. REMOVECLUTCH COVER AND DISC

(a) Place match marks on the clutch cover and flywheel.

(b) Loosen the set bolt one turn at a time until spring

tension is released.

(c) Remove the set bolts and pull off the clutch cover and

disk. Do not drop the clutch disc.

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Figure 20: remove the fork and boot

5.3.3 CLUTCH UNIT INSTALLATION

Figure 21: install disk on the flywheel

Figure 22: install clutch cover

Figure 23: apply grease

Figure 24: install boot, fork

3. REMOVE BOOT, RELEASE BEARING AND

FORK FROM

TRANSMISSION

(a) Remove the retaining clip pull off the bearing.

(b) Remove the fork and boot.

1. INSTALL DISC ON FLYWHEEL Using SST, install the disc on the

flywheel.

2. INSTALL CLUTCH COVER

(a) Align the match marks on the clutch cover and

flywheel.

(b) Torque the bolts on the clutch cover in the order

shown.

HINT: Temporarily tighten the No.1 and No.2

bolts.

3. APPLY GREASE

(a) Apply molybdenum disulphide lithium base grease to

the following parts:

Release fork and hub contact point

Release fork and push rod contact point

Release fork pivot point

Clutch disc spline

(b) Apply MP grease to the front of the release bearing.

4. INSTALL BOOT, FORK, HUB AND BEARING

ON TRANSMISSION

5. INSTALL TRANSMISSION

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5.4 SUSPENSION

5.4.1 FRONT SUSPENSION 2WD

Figure 25: double wishbone type suspension used in front suspension

5.4.2 FRONT SHOCK ABSORBER

5.4.2.1 FRONT SHOCK ABSORBER COMPONENTS

Figure 26: front shock absorber components

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5.4.3 FRONT SHOCK ABSORBER REMOVAL

Jack up vehicle and remove front wheel remove shock absorber. Remove the 2 bolts and disconnect the shock absorber lower from the lower suspension arm. Hold the shock absorber, and remove the set nut, retainer, cushion and shock absorber. 5.4.4 SHOCK ABSORBER INSPECTION Compress and extend the shock absorber piston rod and check that there is no abnormal resistance or unusual operation sounds. If there is any abnormality, the shock absorber is replaced with a new one. 5.4.5 FRONT SHOCK ABSORBER INSTALLATION Install the following parts: Cushion and Retainers. Then install the shock absorber upper to the frame and connect the shock absorber lower to the lower suspension arm. Install the cushion and retainers with a new nut. Install the front wheel and lower the vehicle.

5.5 STABILIZER BAR

5.5.1 STABILIZER COMPONENTS

Figure 27: stabilizer components

5.5.2 STABILIZER BAR REMOVAL

Jack up vehicle and remove front wheel and remove one torsion bar spring. Remove stabilizer bar from lower arms. Remove the nuts and cushions holding both sides of

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the stabilizer bar from the lower arms, and disconnect the stabilizer bar. Remove the 4 bolts, bushing, brackets and stabilizer bar. 5.5.3 STABILIZER BAR INSTALLATION

Place stabilizer bar to frame. Place the stabilizer bar in position and install both stabilizer bar bushings and brackets to the frame. Then finger tighten the bolts and connect stabilizer bar to lower arms. Connect the stabilizer bar on both sides to the lower arms with bolts, cushions and new nuts. Install the torsion bar spring then install front wheel and lower the vehicle.

5.6 REAR SHOCK ABSORBER

5.6.1 REAR SHOCK ABSORVER COMPONENTS

Figure 28: rear shock absorber components

5.6.2 SHOCK ABSORBER REMOVAL

Jack up vehicle and remove rear wheel. Jack up and support the body on stands. Lower the axle housing until the leaf spring tension is free, and keep it at this position. Remove the schock absorber.

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Figure 29: vehicle jacked up for shock absorber removal

5.6.3 INSPECT SHOCK ABSORBER

Compress and extend the shock absorber and check that there is no abnormal resistance or unusual operation sounds. If there is any abnormality, replace the shock absorber with a new one. 5.6.4 INSTALL REAR SHOCK ABSORBER

Connect the shock absorber to the frame with the bolt. Tighten the bolt. Connect the rear shock absorber lower to the spring seat with the bolt. Tighten the bolt then install rear wheels and lower the vehicle

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6. CONCLUSION

Working at Toyota Zambia Service Station was a worthwhile experience in that knowledge was gained in automobile mechanics. The various vehicle maintenance operations carried out gave insight to design features in automobile design. The machinery and new vehicle technologies, such as Hybrid Vehicle, were of great help in the sense that principles learnt in class, Thermodynamics, Dynamics, Material Science and Hydraulics, were seen applied in reality. Vehicle maintenance included the braking, lubricating, suspension, and cooling systems. The experience was appreciated, all the activities carried out were in application of mechanics in automobiles, which can help in understanding theories learnt in the pursuit of a Mechanical Engineering degree. 7. APPENDIX APPENDIX A ABBREVIATIONS USED

A/T Automatic Transmission

ATF Automatic Transmission Fluid

IN Intake (Main fold)

M/T Manual Transmission

SST Special Service Tools

STD Standard

2WD Two Wheel Drive Vehicles (4 * 2)

4WD Four Wheel Drive Vehicles (4*4)

APPENDIX B SERVICE REQUIRED A-SERVICE 5000/15000/25000/35000km 45000/55000/65000/75000km 1.5units

A-SERVICE Replace engine oil Replace engine oil filter Engine clean

B-SERVICE 10000/30000/50000/70000 90000/110000/130000km 2.5 units

B-SERVICE Replace engine oil Replace engine oil filter Replace fuel filter Engine clean

C-SERVICE 20000/60000/100000 140000/180000/220000km 3.7 units

C-SERVICE Replace engine oil Replace engine oil filter Replace sparkplugs (petrol) Replace fuel filter Replace air cleaner element(if necessary)

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Inspection of fan belt Engine clean Wheel alignment and balancing

MAJOR-SERVICE 40000/80000/120000/160000 200000 240000 280000km 6.7units

MAJOR-SERVICE Replace Engine Oil Replace Engine Oil Filter Replace Sparkplugs (Petrol) Replace Fuel Filter Replace Air Cleaner Element(If Necessary) Replace Brake Fluid Replace Wheel Bearing Grease Replace Transfer Case And Diff Fluid Replace Gear Box Oil Replace Brake Pads Replace Brake Shoes Replace Engine Coolant Replace Power Steering Oil Top- Up Battery Water Replace Atf Oil Wheel Alignment And Balancing Engine Clean

APPENDIX C

REFERENCES

1. 1994 Toyota Repair Manual. 2. R.K. Rajput, “Fluid Mechanics and Hydraulic Machines,” S. Chand &

Company Ltd. 3. http://toyotazambia.com.