Higher Technological Institute

Mechanical

ngineering Department

A Report on
Industrial Training ( Volkswagen service center )
Submitted by :
Name : Mustafa Amin Mohamed Mahfouze

.D : 20121441
Course code : ITR 102
Supervised By :
DR : Iman Ibrahim

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August 2015
Acknowledge
Special tahnks to :
DR Iman who subervised our training along this course
All doctors and engineering who provided to us a lot information in this field
All tecnicns and engineering at the center specialy ENG: Ahmed sheriff El-znaty

Abstract
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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 :

Contents
CHPTER ( 1 )................................................................................................................................ 8
Introduction to Volkswagen company.......................................................................................... 8
Company History...................................................................................................................... 8
Main Models :......................................................................................................................... 10
Component of car.................................................................................................................. 11
Mechanicaly parts :................................................................................................................ 12
Motor.................................................................................................................................. 12
A / crank shat...................................................................................................................... 12
B / cams shaft

.........................................14

c/ Fly wheel......................................................................................................................... 16
D / piston............................................................................................................................ 17
E/ connection rod ( B.L)....................................................................................................... 18
Volkes maintenance types :................................................................................................... 19
1 mechanically maintenance........................................................................................... 19
2 Body and painting maintenance....................................................................................19
3 after buying service....................................................................................................... 19
4- genral service................................................................................................................. 19
CHAPTER ( 2 )............................................................................................................................ 20
Mechanically Maintenance........................................................................................................ 20
Introduction :.......................................................................................................................... 20
2 detecting the problem...................................................................................................... 22
3 fixation steps.................................................................................................................... 22
A ) Gear box fixiation.......................................................................................................... 23
B ) full fixation.................................................................................................................... 25
chapter ( 3 ).............................................................................................................................. 28
Body And Painting..................................................................................................................... 28
Introduction :.......................................................................................................................... 28
Fixation step :......................................................................................................................... 28
3 - Painting............................................................................................................................. 31
CHAPTER ( 5 )............................................................................................................................ 34
SERVICES AFTER BUYING.......................................................................................................... 34
1 intrudction :...................................................................................................................... 34
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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

Table of figure
Figure 1: compare between volks logo.....................................................11
Figure 2: cranck shat...............................................................................15
Figure 3: cams shaft................................................................................17
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4: fly wheel...................................................................................19
5 :................................................................................................. 20
6 : connection rod (B.L).................................................................21
7 : pro.diagnosis system...............................................................23
8 : pro diagosis system 2..............................................................24
9 : jop model................................................................................. 25
10 : gear box................................................................................. 26
11 : gear box jack.........................................................................27
12 : bored control unit..................................................................28
13 : engine sling...........................................................................29
14 : instal engin sling....................................................................29
15 : displacement motor...............................................................29
16 :dameged piston from motor...................................................29
17 : processing of cleaning motor.................................................30
18 : new piston installtion.............................................................31
19 : torqe hand.............................................................................31
20 : model of analogize.................................................................33
21 : car welding............................................................................33
22 : fixation hydro device.............................................................34
23 : types of gage.........................................................................35
24 : softing of car.......................................................................... 35
25 : embrey car body....................................................................36
26 : painting furnans.....................................................................36
27 :coloring codin system.............................................................37
28 : types of painting....................................................................37
29 : covering the car process........................................................38
30 : painting car proess................................................................38
31 : car lever................................................................................. 40
32 : dissemble the togge of oil......................................................40
33 : empting oil progress..............................................................41
34 : removing old filter oil process................................................42
35 : putting new filtter process.....................................................42
36 : adiing oil................................................................................43
37 : car lever................................................................................. 44
38 : the pods are atteched to the wheel.......................................46
39 : balancing machine.................................................................47
40 : fixation the tire on the device................................................47
41 : sensor edge angle..................................................................48

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CHPTER ( 1 )
Introduction to Volkswagen company

Figure 1: compare between volks logo

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Company History
Volkswagen was originally founded in 1937 and operated by the German trade
union, the German Labor Front. Volkswagen was headquartered in Wolfsburg,
Germany. The projects objective was the development and mass production of
a reasonably priced yet still speedy automobile that could sell for less than
1,000 Reich marks (approximately $140 at the time). Known as
Volkswagenwerk, or "The People's Car Company" at the time, to provide the
design for this "people's car," the German Labor Front called in the Austrian
automotive engineer Ferdinand Porsche.
However, shortly after the KdF (Kraft-durch-Freude)-Wagen ("Strength-ThroughJoy" car) was presented for the first time at the Berlin Motor Show in 1939,
World War II began, and Volkswagen ceased production. After the war ended,
with the plant in ruins, the Allies would make Volkswagen the center of their
attempts to revive the German auto industry. In 1959, the advertising agency
Doyle Dane Bernbach launched an innovative campaign, naming the car the
"Beetle" and turning its miniature size as a distinct advantage to consumers.
Over the next several years, Volkswagen became the top-selling auto import in
the United States. In 1960, the German government vended 60 percent of
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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 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)
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Brazil: Anchieta (Gol, Polo, Fox), Curitiba (Golf, Fox)

South Africa: Uitenhage (Polo, Golf, Jetta)

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 :

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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 into rotational motion; whereas in a
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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

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consuming process, and is generally more expensive than other methods.

However the finished product is far superior.
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 microstructure 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

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
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Figure 9 : jop model

3 fixation steps
Firstly tecnicas start to take the jop and see whts is the part which has the
problem and get to ix it
Mainly problem aat oboor branch were gear box problem or another motor
problem

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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 M
all 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

B ) full fixation
This type used when mainly parts on the motor likr piston and BL or crank
shaft are damaged
At this stage all motor are removed and replaced by another one
Steps to remove and replace parts :
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1 firstly we should remove motor from the car by using some equipment
like

Figure 13 : engine sling

Figure

14 : instal engin sling

Figure 15 : displacement motor

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

Figure 16 :dameged piston from motor

3 clean and put anew parts in motor

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Figure 17 : processing of cleaning motor

Figure 18 : new piston installtion

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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

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

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Figure 20 : model of analogize

2 after that starting fix but if and only if the damage doesnt
reaches to 70% percentage of damages that percentage which suit to
refix the part except that replace part with another new one
3 if the damage part was at bottom of car our bones of it and cause remove
part of it at this case we should use which called smart welding

Figure 21 : car welding

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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

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

Figure 23 : types of gage

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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

C Embrey car body

Figure 25 : embrey car body

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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

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

Figure 27 :coloring codin system

3 calculate the countity of it

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Figure 28 : types of painting

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

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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

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
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Steps of oil change :

1 first get the car on the lever

Figure 31 : car lever

2 dissemble the toggle of oil

Figure 32 : dissemble the togge of oil

3 hold on to empty all dirty oil rom the motor

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Figure 33 : empting oil progress

4 bind the toggle of oil finaly

5 get the car down

6 desimmpe the filtter of oil

Figure 34 : removing old filter oil process

7 bind the new filter

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Figure 35 : putting new filtter process

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

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Figure 37 : car lever

Basic Alignment Procedures

Positioning the Vehicle on the Lift

.Proper vehicle positioning on the alignment lift is an important step for safety and accuracy
.Make sure the front turntable and rear slip plate locking pins are in place .1
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
From the Home Screen click on the Rack Drive-on Aid icon located on the upper tool-bar. View .2
.the screen while positioning the vehicle
Drive the vehicle onto the alignment lift and stop just before the turntables. Take care to insure .3
.the vehicle is centered on the runways
Place the vehicle in park (or in gear on a standard transmission), turn the ignition off, and set the .4
.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
.Position the turntables as needed to insure the tires will be centered .5
.Drive the vehicle forward onto the center of the turntables .6
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)
Place the vehicle in neutral, release the parking brake, and pull or push the vehicle forward onto .7
the turntables. Reposition the wheel chocks, place the vehicle in park, and reapply the parking
.brake
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To avoid personal injury or damage to property, follow the rack/lift manufacturers operating and
.safety procedures
.Raise the alignment lift, then lower the lift onto its mechanical stops .8
Place the transmission in neutral and release the parking brake just before beginning the Vehicle .9
.Positioning process
Attach the Targets/Pods

The targets/pods are attached to the wheels using the wheel clamps. The targets go on the front
.wheels, the measuring pods on the rear
There are several methods of attachment depending on the wheel lip configuration. The integrated
claws provide the versatility needed to grab virtually any wheel. The claws can be rotated to adjust
.for different wheel configurations
Claws may have sharp edges. To avoid personal injury, use caution when working with wheel
.clamps
.The clamps should be installed in a straight-up vertical manner (knob at the top)
Use the mounting method that provides the greatest security to keep the target from falling off the
wheel. Most wheels can be grabbed from the outside-in by placing the claws between the bead of
the tire and the outside edge of the rim. Others can be mounted on the inside of the rim such as with
.steel wheels
:For outside rim mounting

.Extend the clamp to a size slightly larger than the rim by turning the knob .1
Place the upper claws on the outside of the top of the rim. Push the claws in between the tire bead .2
and the rim. It may be necessary to pop the upper clamp bracket with the palm of your hand to
.seat well. Note that it is not necessary for the clamp to be mounted perfectly vertical on the wheel
.Tighten the clamp by turning the knob clockwise until the lower claws engage the rim .3
Push the lower claws into place. Again, it may be necessary to pop them in further for security. .4
.Continue tightening the knob until secure
Test the security by pulling outwards on the clamp. If it comes off easily, reattach the clamp or .5
.select an alternative mounting method

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Figure 38 : the pods are atteched to the wheel

Wheel balance machine

Figure 39 : balancing machine

Balance procedure

Install the tire on wheel balance machine

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Figure 40 : fixation the tire on the device

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

Figure 41 : sensor edge angle

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Figure 42 : reading of device

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

Figure 43 : the tire turn on machine

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

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Figure 44 : instruction from device

check again the tire

Figure 45 : checking the tire

Coclusion :
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From all the past information we learn about how the car
maintnenanse at the service center and the level which all type of maintenance
take

Recommendation

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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

References :
1- wikipedia
2- 2 automotive reference
3- Some of online website about car maintenance

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