Higher Technological Institute Mechanical Engineering Department

A Report on

Industrial Training ( Volkswagen service center )

Submitted by :

Name : Mustafa Amin Mohamed Mahfouze I.D : 20121441

Course code : ITR 102

Supervised By :

DR : Iman Ibrahim

August 2015

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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

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Abstract

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

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List of content :

ContentsCHPTER ( 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

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Introduction :..............................................................................................................................................................28

Fixation step :.............................................................................................................................................................28

3 - Painting..................................................................................................................................................................31

CHAPTER ( 5 )..................................................................................................................................................................34

SERVICES AFTER BUYING................................................................................................................................................34

1 – intrudction :..........................................................................................................................................................34

2 – types of this maintenance....................................................................................................................................34

A – oil change :.......................................................................................................................................................34

CHAPTER ( 6 )..................................................................................................................................................................38

Cautchouc service..........................................................................................................................................................38

1 – intrudction............................................................................................................................................................38

Basic Alignment Procedures.......................................................................................................................................38

Attach the Targets/Pods.............................................................................................................................................39

For outside rim mounting:..........................................................................................................................................39

Balance procedure......................................................................................................................................................41

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Table of figure

Figure 1: compare between volks logo...................................................................................11Figure 2: cranck shat...............................................................................................................15Figure 3: cams shaft................................................................................................................17Figure 4: fly wheel...................................................................................................................19Figure 5 :.................................................................................................................................20Figure 6 : connection rod (B.L)................................................................................................21Figure 7 : pro.diagnosis system..............................................................................................23Figure 8 : pro diagosis system 2..............................................................................................24Figure 9 : jop model................................................................................................................25Figure 10 : gear box................................................................................................................26Figure 11 : gear box jack.........................................................................................................27Figure 12 : bored control unit.................................................................................................28Figure 13 : engine sling...........................................................................................................29Figure 14 : instal engin sling...................................................................................................29Figure 15 : displacement motor..............................................................................................29Figure 16 :dameged piston from motor..................................................................................29Figure 17 : processing of cleaning motor................................................................................30Figure 18 : new piston installtion............................................................................................31Figure 19 : torqe hand............................................................................................................31Figure 20 : model of analogize................................................................................................33Figure 21 : car welding...........................................................................................................33Figure 22 : fixation hydro device.............................................................................................34Figure 23 : types of gage........................................................................................................35Figure 24 : softing of car.........................................................................................................35Figure 25 : embrey car body...................................................................................................36Figure 26 : painting furnans....................................................................................................36Figure 27 :coloring codin system............................................................................................37Figure 28 : types of painting...................................................................................................37Figure 29 : covering the car process.......................................................................................38

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Figure 30 : painting car proess................................................................................................38Figure 31 : car lever................................................................................................................40Figure 32 : dissemble the togge of oil.....................................................................................40Figure 33 : empting oil progress.............................................................................................41Figure 34 : removing old filter oil process...............................................................................42Figure 35 : putting new filtter process....................................................................................42Figure 36 : adiing oil...............................................................................................................43Figure 37 : car lever................................................................................................................44Figure 38 : the pods are atteched to the wheel......................................................................46Figure 39 : balancing machine................................................................................................47Figure 40 : fixation the tire on the device...............................................................................47Figure 41 : sensor edge angle.................................................................................................48

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CHPTER ( 1 )Introduction to Volkswagen company

Figure 1: compare between volks logo

Company HistoryVolkswagen was originally founded in 1937 and operated by the German trade union, the

German Labor Front. Volkswagen was headquartered in Wolfsburg, Germany. The project’s

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

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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-Through-Joy" 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 Volkswagen's

stock to the German public, successfully denationalizing it. Twelve years later, the Beetle

bettered the longstanding worldwide manufacturing record of 15 million automobiles. With

the Beetle's design comparatively unchanged since 1935, sales grew lazy in the early 1970s.

Volkswagen reboundedwith the introduction of sportier models such as the Rabbit and

later, the Golf. In 1998, the company began selling the vastly advertised "New Beetle"

although still continuing production of its predecessor. After nearly 70 years and more than

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21 million units produced, the last original Beetle rolled off the line in Puebla,Mexico, on

July 30, 2003.

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)

Brazil: Anchieta (Gol, Polo, Fox), Curitiba (Golf, Fox)

South Africa: Uitenhage (Polo, Golf, Jetta)

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Component of car 1 - Mechanically parts

2 – body parts

3 – interment parts

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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 :

A / crank shat

Figure 2: cranck shat

is a mechanical part able to perform a conversion between reciprocating motion and

rotational motion. In a reciprocating engine, it translates reciprocating motion of the piston

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into rotational motion; whereas in a reciprocating compressor, it converts the rotational

motion into reciprocating motion.

In order to do the conversion between two motions, the crankshaft has "crank throws" or

"crankpins", additional bearing surfaces whose axis is offset from that of the crank, to which

the "big ends" of the connecting rods from each cylinder attach.

It is typically connected to a flywheel to reduce the pulsation characteristic of the four-

stroke cycle, and sometimes a torsional or vibrational damper at the opposite end, to

reduce the torsional vibrations often caused along the length of the crankshaft by the

cylinders farthest from the output end acting on the torsional elasticity of the metal.

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B / cams shaft

Figure 3: cams shaft

Camshafts can be made out of several types of material. These include:

Chilled iron castings: this is a good choice for high volume production. A chilled iron

camshaft has a resistance against wear because the camshaft lobes have been chilled,

generally making them harder. When making chilled iron castings, other elements are added

to the iron before casting to make the material more suitable for its application.

Billet Steel: When a high quality camshaft is required, engine builders and camshaft

manufacturers choose to make the camshaft from steel billet. This method is also used for

low volume production. This is a much more time consuming process, and is generally more

expensive than other methods. However the finished product is far superior.

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When making the camshaft, CNC lathes, CNC milling machines and CNC camshaft grinders

will be used. Different types of steel bar can be used, one example being EN40b. When

manufacturing a camshaft from EN40b, the camshaft will also be heat treated via gas

nitriding, which changes the micro-structure of the material. It gives a surface hardness of

55-60 HRC. These types of camshafts can be used in high-performance engines.

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c/ Fly wheel

Figure 4: fly wheel

A flywheel is a rotating mechanical device that is used to store rotational energy. Flywheels

have a an inertia called the moment of inertia and thus resist changes in rotational to their

speed just as the mass (inertia) of a vehicle resists its acceleration. The amount of energy

stored in a flywheel is proportional to the square of its rotational speed. Energy is

transferred to a flywheel by the application of a torque to it, thereby increasing its

rotational speed, and hence its stored energy. Conversely, a flywheel releases stored energy

by applying torque to a mechanical load, thereby decreasing the flywheel's rotational

speed.c/ fly wheel

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D / piston

Figure 5 : piston

is a component of reciprocating engines, reciprocating pumps, gas compressors and pneumatic cylinders, among other similar mechanisms. It is the moving component that is contained by a cylinder and is made gas-tight by piston rings. In an engine, its purpose is to transfer force from expanding gas in the cylinder to the crankshaft via a piston rod and/or connecting rod. In a pump, the function is reversed and force is transferred from the crankshaft to the piston for the purpose of compressing or ejecting the fluid in the cylinder. In some engines, the piston also acts as a valve by covering and uncovering ports in the cylinder wall.

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E/ connection rod ( B.L)

Figure 6 : connection rod (B.L)

In a reciprocating piston engine, the connecting rod or conrod connects the piston to the crank or crankshaft. Together with the crank, they form a simple mechanism that converts reciprocating motion into rotating motion.

Connecting rods may also convert rotating motion into reciprocating motion. Historically, before the development of engines, they were first used in this way.

As a connecting rod is rigid, it may transmit either a push or a pull and so the rod may rotate the crank through both halves of a revolution, i.e. piston pushing and piston pulling. Earlier mechanisms, such as chains, could only pull. In a few two-stroke engines, the connecting rod is only required to push.

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Volkes maintenance types :

1 – mechanically maintenance This type presented to us the mechanical problem at motor

or another part of car and the wright way to fix it

2 – Body and painting maintenance It represent the body of cars and problem of body due to

accident and crushes and how to back it to original shape

3 – after buying service This type of service represented changing oil and oils filter and

other that we handle it with details later

4- genral service Like caoutchouc service and angle fixation and stabilization

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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

Figure 7 : pro.diagnosis system

Firstly car is diagnosed by an engineer using a special device by which he connects it to the electronic or engine control unit (ECU) so it reads all sensors states and determine any bugs and issues in the car

A test plan, which can be used to test the following Sensors, actuators and the mechatronic unit during operation is contained, such as;

Sensors:

E438 Tiptronic switch in steering wheel to shift up

E439 Tiptronic switch in steering wheel to shift down

G182 Gearbox input speed sender

G270 Gearbox hydraulic pressure sender

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Figure 8 : pro diagosis system 2

This devises are used to established the car after maintenance and another mainly purpose to detect the problems of cars

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2 – detecting the problem After inspection and firstly look on the car it takes which called jop and transport to the engineer on charge who presented it to the suitable technicians

Figure 9 : jop model

3 – fixation stepsFirstly 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

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A ) Gear box fixiation

Figure 10 : gear box

Gear box is responsabla for speed of car and to change it whit suitable speed of us it were tow types of it manual and autmamic fixation of it be at many steps :

1- get gear box out from the car by remove all fixation point at the base of motor and

remove the tow copline from

Figure 11 : gear box jack

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

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4 – at the installion of the new gear box we should take care of :

a- Reading of A1 – A2 – B1 –B2 – k – Mall this reading were detacted after putting the small egg and the larfe one , that helped us by using some eqution to detected the suitable glp with suitable thickness

5 – after installion of new parts of gear box now turn to establish it by at device by familiarizing it on anew system by digoniis devise

Figure 12 : bored control unit

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B ) full fixationThis 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 oneSteps to remove and replace parts :1 – firstly we should remove motor from the car by using some equipment like

Figure 14 : instal engin sling

Figure 15 : displacement motor

2 – start to get out the damged parts from the motor at the special room

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Figure 13 : engine sling

Figure 16 :dameged piston from motor

3 – clean and put anew parts in motor

Figure 17 : processing of cleaning motor

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Figure 18 : new piston installtion

3 – if we change the piston it were some important cnosenrd should take with us :a- We should keeping the numbering o pistons and put all of it at the suit number b- During the attaching the piston we shold take care of moment which linking with it

the suitable moment as we know to ataach the piston is 40 N that represent

Figure 19 : torqe hand

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chapter ( 3 )

Body And Painting

Introduction : At this chapter we handle with body problem and the way to fit it

Fixation step :1 – firstly it must happen whis called analogize by standred model of it

Figure 20 : model of analogize

2 – after that starting fix but if and only if the damage doesn’t reaches to 70% percentage of damages that percentage which suit to refix the part except that replace part with another new one

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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

Figure 21 : car welding

4 – I the part is normaly damge we depend the normaly steps which are :

A – straightnes the body from damge

Figure 22 : fixation hydro device

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It where many typ of hydrolic gange which used into bodu fixation level

Figure 23 : types of gage

That gage works on air pressure to fixation the car from the end to make it straigt

B – soften the body

Figure 24 : softing of car

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C – Embrey car body

Figure 25 : embrey car body

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

Figure 26 : painting furnans

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2 – get the code numper of color o the car rom computer

Figure 27 :coloring codin system

3 – calculate the countity of it

Figure 28 : types of painting

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4 – start to cover all parts o car except the part wanted to be paint

Figure 29 : covering the car process

5 – start to paint the car

Figure 30 : painting car proess

6 – after painting the car holding while and start to paint it with polish

7 – washing the car after holding about 15 minuts

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CHAPTER ( 5 )

SERVICES AFTER BUYING

1 – intrudction : AT THIS PART WE HANDLE WITH periodic maintenance that th client should do after excating time

2 – types of this maintenance

A – oil change :

It recommented to change oil after 10,000 KM to save the motor rom damge

Steps of oil change :

1 – first get the car on the lever

Figure 31 : car lever

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2 – dissemble the toggle of oil

Figure 32 : dissemble the togge of oil

3 – hold on to empty all dirty oil rom the motor

Figure 33 : empting oil progress

4 – bind the toggle of oil finaly

5 – get the car down

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6 – desimmpe the filtter of oil

Figure 34 : removing old filter oil process

7 – bind the new filter

Figure 35 : putting new filtter process

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8 – put the new oil

Figure 36 : adiing oil

9 –wash the car

10 – start on the car

11- establishe it with the new reading at the system

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CHAPTER ( 6 )

Cautchouc service

1 – intrudction At this part we see the problem of tires from pressure of it to stability

Figure 37 : car lever

Basic Alignment ProceduresPositioning the Vehicle on the LiftProper vehicle positioning on the alignment lift is an important step for safety and accuracy.

1 .Make sure the front turntable and rear slip plate locking pins are in place.NOTE: Steps 2 - 5 are recommended to make sure the front tires are placed in the center of the turntables.NOTE: If an optional drive-on camera aid is available proceed to step 2, if not available skip to step 3.

2 .From the Home Screen click on the “Rack Drive-on Aid” icon located on the upper tool-bar. View the screen while positioning the vehicle.

3 .Drive the vehicle onto the alignment lift and stop just before the turntables. Take care to insure the vehicle is centered on the runways.

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4 .Place the vehicle in park (or in gear on a standard transmission), turn the ignition off, and set the parking brake on. Place wheel chocks behind the tires to prevent rolling.Failure to use the wheel chocks can allow the vehicle to roll off the rack/lift.

5 .Position the turntables as needed to insure the tires will be centered.6 .Drive the vehicle forward onto the center of the turntables.

Alternative Method: This method extends turntable life due to relief of load and stresses encountered when the brakes are applied (or acceleration on a FWD vehicle).

7 .Place the vehicle in neutral, release the parking brake, and pull or push the vehicle forward onto the turntables. Reposition the wheel chocks, place the vehicle in park, and reapply the parking brake.To avoid personal injury or damage to property, follow the rack/lift manufacturer’s operating and safety procedures.

8 .Raise the alignment lift, then lower the lift onto its mechanical stops.9 .Place the transmission in neutral and release the parking brake just before beginning the

Vehicle Positioning process.

Attach the Targets/PodsThe 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:

1 .Extend the clamp to a size slightly larger than the rim by turning the knob.2 .Place the upper claws on the outside of the top of the rim. Push the claws in between the

tire bead 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.

3 .Tighten the clamp by turning the knob clockwise until the lower claws engage the rim.

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4 .Push the lower claws into place. Again, it may be necessary to pop them in further for security. Continue tightening the knob until secure.

5 .Test the security by pulling outwards on the clamp. If it comes off easily, reattach the clamp or select an alternative mounting method.

Figure 38 : the pods are atteched to the wheel

.Wheel balance machine

Figure 39 : balancing machine

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Balance procedure

Install the tire on wheel balance machine

Figure 40 : fixation the tire on the device

Use sensor on the edge of tire to measure diameter of tire

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Figure 41 : sensor edge angle

Figure 42 : reading of device

get off the cover of the machine on the wheel to turn it

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Figure 43 : the tire turn on machine

The machine determine the amount of Wight need to install and the correct place on tire edge

Figure 44 : instruction from device

check again the tire

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Figure 45 : checking the tire

Coclusion :

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

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Recommendation

It is recommended to increase the period of the course to achieve the max benefit and gain the experience which qualifies us to the work after graduate

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References :

1- wikipedia 2- 2 – automotive reference3- Some of online website about car maintenance

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