KULLIYAH OF ENGINEERING

EIT REPORT

INTERNATIONAL ISLAMIC UNIVERSITY MALAYSIA

MUHAMAD AZMIR BIN ALI@MOHAMAD

ENGINEERING INDUSTRIAL TRAINING

AT

ANGAHMA ENTERPRISE

6 JUNE 2016 – 26 AUGUST 2016

MUHAMAD AZMIR BIN ALI@MOHAMAD

AUTOMOTIVE

1310629

AUTOMOTIVE ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

2016
2016
 ACKNOWLEDGEMENT

Alhamdulillah, firstly I express my gratitude to Allah s.w.t. for giving me

opportunity to write this report regarding my industrial training which started on 6 June
2016 until 26 August 2016 at Angahma Enterprise. I would like to thank all the parties
involved to make my industrial training a successful. Most appreciation I would like to
grant to my supervisor, Br Alief Almalik who guide and supervise me though out the
internship. Not forget to my colleges at workshop who also work besides me to share some
skills and knowledge. Last but not least I am grateful to my family who supporting me
financially and spiritually along the internship. I pray to Allah SWT to grand the best
reward to all the people involved in order to make my internship ended with flying colors.

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 TABLE OF CONTENTS

Company Verification Statement……………………………………………………….. i

Acknowledgement………………………………………………………………...…… ii
Table of Contents ……………………………………………………………….…...... iii
List of Tables …………………………………………………………………….……. iv
List of Figures …………………………………………………………………….....… v
1.0 Background of the Company ……………………………………………..…...…. 1
2.0 Summaries of Duty ………………………………………………………...….… 2
3.0 Working Experience ……………………………………………………..……..... 3
3.1 Projects carried out ……………………………………………..……...… 3
3.1.1 Overhauling Proton Perdana V6 engine …………………....... 3-5
3.1.2. Upgrading Mitsubishi Pajero engine to high capacity engine....6-8
3.1.3. Overhauling Proton Wira 1.6L engine ……………………..... 9-11
3.1.4. Upgrading Proton Gen 2 engine to high performance engine..12-14
3.2. Supervisory Work …………………………………………………..….... 15
3.2.1. Teaching and Demonstration …………………………….....…. 15
3.2.2. Supervising ……………………………………………..…...… 15
3.3.3. Inspection …………………………………………………...… 15
3.3. Problems Encountered ………………………………………..………… 16
3.4. Problem solving process, approach ……………………………..……… 17
4.0 Conclusion ………………………………………………………………..….….. 18
5.0 Reference …………………………………………………………………...…… 19
6.0 Appendices …………………………………………………………………... 20-24

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 LIST OF TABLES

Table 1 – Summary of Duty ………………………………………………………… 2

Table 2 – In and Out Car Flow Schedule (IOC) ……………………………...……. 24

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 LIST OF FIGURES

Figure 1 - Hydraulic Engine Crane ……………………………………………………… 4

Figure 2 - Removing the carbon deposited by using grinder ……………………………. 5
Figure 3 - Mitsubishi Pajero 2800 cc half cut …………………………………………… 6
Figure 4 - The engine compartment need to be empty ………………………………….. 7
Figure 5 - Removing the wiring …………………………………………………………. 7
Figure 6 - Engine Mount ………………………………………………………………… 8
Figure 7 - Example of broken valve …………………………………………………….. 9
Figure 8 - Personal Protective Equipment (PPE) ………………………………………. 10
Figure 9 - Head engine …………………………………………………………………. 10
Figure 10 - Pistons ……………………………………………………………………... 11
Figure 11 - Example of Mitsubishi CK half cut …………………………………….…. 13
Figure 12 - Original disc plate (small size) …………………………………………….. 13
Figure 13 - Mitsubishi CK disc plate (larger size) ……………………………………... 13
Figure 14 - Oxygen cutting …………………………………………………………….. 14
Figure 15 - Installation of new wiring system …………………………………………. 14
Appendices …………………………………………………………………………. 20-24

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 BACKGROUND OF THE COMPANY

Angahma Enterprise was founded by two brothers, Sir Alwijy Ayub and Br Alief
Almalik. The company was registered on 26 June 2012 and it operates more than four years
now. The company has two division of departments, which are Petrol Engine Department
and Diesel Engine Department. Sir Alwijy Ayub is the Head of Petrol Engine Department
and Br Alief Almalik is the Head of Diesel Engine Department and the company has 3
technicians.

The company provide various type of services to the customers like repairing,
modification and upgrading the engine performance. The company provide the service to
any kind of car brand, not like certain workshop who only provide the service to the certain
car brand. But, usually they deal with the car brand like Mitsubishi, Mercedes, BMW,
Honda, Naza, Proton and Perodua. Repairing service that they provide are like engine
overhaul, gearbox maintenance, wiring problem and others.

They also provide modification and upgrading engine performance like installing
turbocharger, change engine to higher capacity engine, installing cabin, adjusting the
chassis and others. They got a lot of tools and instrument like cutting machine, welding
machine (TIG & MIG), air compressor pump, hydraulic engine jack, hydraulic crocodile
jack, drill and spanner set. Their working experience which is more than 25 years before
establish Angahma Enterprise make the customers convince with their services.

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 SUMMARY OF DUTIES

Week Date Activity

1 6/6/2016-
9/6/2016 Overhauling Proton Perdana V6 engine
2 11/6/2016-
16/6/2016
3 18/6/2016-
23/6/2016
4 25/6/2016-
30/6/2016 Upgrading Mitsubishi Pajero engine to high capacity
5 2/7/2016- engine
7/7/2016
6 9/7/2016-
14/7/2016
7 16/7/2016-
21/7/2016 Overhauling Proton Wira 1.6L engine
8 23/7/2016-
28/7/2016
9 30/7/2016-
4/8/2016
10 6/8/2016-
11/8/2016 Upgrading Proton Gen 2 engine to high performance
11 13/8/2016- engine
18/8/2016
12 20/8/2016-
26/8/2016

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 WORKING EXPERIENCES

3.1 Project carried out

Along the internship, basically I was assigned with 4 projects, 2 are medium level
project and another two are high level project. Overhauling is categorized as the medium
level project while upgrading the engine is categorized as high level project. All these
project involve the repairing parts and modification of the vehicles.

3.1.1 Overhauling Proton Perdana V6 engine

 Identification of problems
- The white smoke was discharged from the car exhaust
- The engine lost the acceleration power

 Analysis of problem
The present of smoke is due to the improper combustion. The chemical
equation for the ideal combustion of SI engine should be as followed;

C8H18 + 12.5 O2 = 8CO2 + 9H2O

The present of cylinder oil during the combustion make the system failed
to follow the correct chemical equation as above. The present of oil in the
combustion chamber is due the failure of the oil seal ring at the piston. It
failed to wipe out all the oil splash on the wall of the combustion chamber.

The loss of the acceleration power also due to failure of compression rings
at the piston. Usually the ring is wear which make the pressure during the
compression become low.

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 Problem solving procedure
To solve this kind of problem, we need to overhaul the engine. The
overhauling process begin with taken out all of the related parts like intake
manifold, radiator, water pipe and any related wiring socket. The head
engine was lifted separately with the engine block to ease the work and
also to check the condition of the piston in the combustion chamber. The
engine block was lifted by using the hydraulic engine crane.

Figure 1; Hydraulic Engine Crane

Then the pistons were taken out one by one. All the old compression rings
and oil rings were taken out. The valves, springs and other components at
the head engine were also taken out. Then the head engine together with
the other components like piston were washed with the engine bleach to
wipe out all the burning effect. After that the head engine need to undergo
the valve grinding process. This process is very crucial, the failure in this
process will cause the engine to have the same problem again.

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During the process, we need to make sure the valve surface is smoothly
touch with the valve hole at the engine block. This is to ensure there is no
leakage between the two surfaces which can result the pressure loss during
the compression stage. The carbon deposited also wipe out using the grinder
machine.

Figure 2; Remove the carbon deposited by using grinder

After the grinding process done, the head engine and the other components
were rinsed again with the engine bleach. Then all the related components
were installed back at the head engine. The engine was installed back into
the engine compartment after the head engine was installed to the engine
block. After the installation was done, the car undergoes the testing process.
The exhaust emission was checked to make sure there is no smoke
discharged. The car was hand over to the customer after passed the test.

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3.1.2 Upgrading Mitsubishi Pajero engine to high capacity engine

 Identification of the problem

The car engine was brake down

 Analysis of problem
The cost to repair the engine is quite high, it is recommended to install
another engine with high capacity. Instead of repairing 2500 cc diesel
engine, it is better to install 2800 cc diesel engine, it will worth with the
cost.

 Problem solving procedure

The 2800 cc diesel engine was taken from the 2800 cc Mitsubishi Pajero
half cut. It is easier to take the engine from the half cut because the wiring
system can be taken from there since 2500 cc wiring system does not
support the 2800 cc diesel engine. The project started from taking out all
the parts and components in the engine compartment. Everything need to
be taken out because they will replaced with the parts and components from
the half cut.

Figure 3; Mitsubishi Pajero 2800 cc half cut

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 Figure 4; The engine compartment need to be empty

The original wiring system also need to be taken out, it will be replaced
with the 2800 cc wiring system. The dashboard need to be taken out first
before removing all the wiring system.

Figure 5; Removing the wiring

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All the parts and components from the half cut also taken out. Everything
from there will be installed at the car. But, the original engine mount does
not support the 2800 cc engine. This is due to the different dimension of the
engine and the engine mount. So after some measurement, calculation and
analysis being done, the engine mount need to undergo some modification.

The original engine mount foundation need to be removed by using oxygen

cutting. Then the engine mount foundation from the half cut was installed
at the car and being welded using MIG welding machine. Some
modification also need to be done on some parts brackets since the original
engine compartment does not have
this kind of brackets or it is not
compatible. For examples are the
radiator bracket, fuel pump bracket,
power steering oil tank bracket and
others.

Then, before installing the 2800cc

Figure 6 ; Engine Mount
engine, the wiring system need to be
installed first to ease the work. The engine wiring, lightning wiring and the
other wiring, all are taken from the half cut. After the wiring system done,
then the engine was installed followed by installing the other parts and
components. After all the parts and components were installed, the car
undergo the testing process to test the performance of the engine in term of
acceleration, fuel efficiency and handling. The car was sent to the other
workshop for alignment process. After all the process were done, the car
was hand over to the customer.

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3.1.3 Overhauling Proton Wira 1.6L engine

 Identification of problems
The car engine experience abnormal vibration and the engine operation
during idling was not stable

 Analysis of problem
The abnormal vibration is due to the imbalance combustion cycle. One of
the combustion chambers was not burn which also effecting the unstable
idling state. It might be malfunction of the spark plug. We try to replace the
old spark plug with the new one in order to test either the spark plug is the
true cause. But, after sometimes, the engine turn back to the same problem.

Then we take out the head engine for further analysis. Then we find the
main cause, which is one of the valve was
broken. This make the cylinder oil to
splash on the sparkplug which cause the
failure of the sparkplug to ignite. Since
the engine is very old, instead of only
replacing the broken valve with the new
one, we suggest the customer to overhaul
the engine so that they can experience
better engine performance. Figure 7; Example of broken valve

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 Problem solving procedure
The overhauling procedures are quite the same with the overhauling Proton
Perdana V6 engine. The engine block was lifted and washed with the engine
bleach. The crank case was taken apart from the engine block and also
washed with the engine bleach together with the engine head, piston and the
other parts and components. Since the engine bleach is very corrosive, we
have to wear PPE like gloves, eye protection and shoes.

Figure 8; Personal Protective Equipment (PPE)

After all the parts and components washed, they were rinsed with water to
remove out the remaining engine bleach and got dried using the high
compression air blow.

Figure 9; Head engine

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Then we continued with the valve grinding process to make the valve
smotthly touch with the intake channel or exhaust channel at the engine
block. The broken valve was replaced with the new one. All the parts and
components of the head engine like camshaft, rocker arm and others were
assembled to its place.

The crankcase,
crankshaft and
pistons also
installed back to
the engine block
before engine
block and head
engine were
attached
together. Then the engine Figure 10; Pistons

was lifted to the engine

compartment using the hydraulic engine crane. After tighten the engine
mount, the other parts like radiator, engine wiring socket, timing belt and
some other parts were installed. After setting the timing belt to the correct
standard, I tested the engine and let it on for half an hour in order to justify
either there is any cylinder oil splash on the sparkplug or not. After tested it
for several times and my supervisor satisfied, the car was hand over to the
customer.

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3.1.4 Upgrading Proton Gen 2 engine to high performance engine

 Identification of problem
The car engine was broke down due to the heavy flood. Everything was
ruined out and none of the parts can be used including the wiring system.

 Analysis of problem
Since none of the parts can be used, it’s clearly that we need to install
another engine. But, instead of installing the same engine which is 1.6 L
Campro DOHC engine, we suggest to the customer to install the engine with
higher performance. So after some analysis and discussion, we suggest the
customer to install 4G93 DOHC 16 Valve MPI engine which it can take
from Mitsubishi CK half cut. We suggest this engine because it is the most
compatible engine with the Proton Gen 2 in term of engine mount location,
dimension and space of the engine compartment and also the wiring system.

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 Problem solving
The project was started with taking out the original engine in Proton Gen 2.
The engine
compartment need to
be empty. All the
original wiring
system was removed
and all the
suspension system
parts like cross
camber, springs and
absorbers. The
braking system parts Figure 11; Example of Mitsubishi CK half
like front disc brake cut
also need to be taken out since the original disc plate size does not suitable
for high performance engine.

Figure 12; Original disc plate Figure 13; Mitsubishi CK disc

(small size) plate (larger size)

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After all of the parts were taken
out, I started to install the
suspension system first to ease
the work. Mitsubishi CK engine
is quite heavier compared to
Proton Gen 2 original engine,
that’s why we can’t use the
original suspension system.
Then I installed the wiring
system, but before
that, some modification need to be Figure 14; Oxygen cutting

the in the passenger compartment. The original dashboard brackets do not

support the Mitsubishi CK dashboard due to different dimension and
location. Thus, the
brackets need to
be cut out from the
half cut by using
the oxygen
cutting. Then the
holding brackets
were welded to the
dashboard
Figure 15; Installation of new wiring system bracket
foundation. After that all the parts like air conditioner blower, coil and
others were installed. Then all the wiring system were installed followed by
the installing of the engine. After that I connected all the wiring socket and
installed the remaining parts like radiator, water pipe, power steering pipe
and others. After all the parts were installed in order, the engine was started
for inspection. The fuel and intake air need to be adjusted a little for better
efficiency. The car was sent to the other workshop for alignment process
and hand over to the customer once it done.
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3.2 Supervisory Work
The supervisory work will cover 3 aspects as follows;
i. Teaching and demonstration
ii. Supervising
iii. Inspection

3.2.1 Teaching and demonstration

It involve when I want to use the tools or equipment. For example when I want to
use MIG welding, my supervisor will teach me one by one about the SOP of using
it including all the precautions that need to be paid attention to. Then he will
demonstrate to me on how to deal with the machine and some tips of using it for
excellent work and more efficient.

3.2.2 Supervising
While I was doing my work, he will supervise me and he will correct me if I did
any mistakes. I am so glad because I got excellent supervision from him. This will
avoid me from doing any serious mistake that can cause heavy damage to the
engine.

3.2.3 Inspection
After I done my job, he will inspect the car I have repaired. He will check
everything related to my work so that the engine will run smoothly and nothing is
left behind. Once he ensured everything is good and he is satisfied with my work,
only then the car will be returned to the customer. Anything that he does not
satisfied, he will inform me and guide me to fix it.

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3.3 Problems encountered

 Not enough skill to deal with certain machine

To use certain machine like welding machine, the user has to have skill in
dealing with it. But I don’t have enough skill to use it and make me quite
difficult to do the work.

 Some engine parts were run out of stock

Some of the engine parts were not in ready stock at the spare parts shop.
This will cause the delay time in the schedule and effect the flow of in and
out of the car at the workshop.

 Not enough space

This problem occur due to the previous problem. Since we have to wait for
the spare parts, then we need to extend the holding time for the car. This
will cause the workshop to have not enough space.

 Lacking in knowledge to do modification

I have to do a lot of modification at the car since it involves the upgrading
of the engine performance. The modification has to take a lot of things into
consideration, if not it might be oppose the safety guidelines.

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3.4 Problems solving approach

 See the demonstration

I strengthen my skill by looking my supervisor demonstrate on how to use
the machine. After he demonstrated, he asked me to try it under his
supervision. Days by days, I got really used with the machine and can use
it without his supervision anymore.

 Order the spare parts

Since the spare part are not available in ready stock, we have to order the
spare part from the main spare parts distributor. Usually it takes between
two to seven days to receive the items. But if we order the items from the
oversea, it may take around one month or more.

 Park the car outside

While waiting to receive the spare parts, we have to move the car outside
the workshop for a while so that we utilize the space in the workshop for
another car.Then, once we have received the spare parts, we move back the
car into the workshop for repairing.

 Consultation
I always consult with my supervisor to ask for his guidance about the certain
task that I don’t know. With his guidance, I can learn a lot of new things
and enhance my soft skill regarding modification.

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 CONCLUSION

Engineering Industrial Training is very crucial to the engineering

students. Through this training, I gain a lots of new knowledge and multiple
of skills which I can use in the workplace once I have graduated soon. I was
also exposed to the real working life that has a lots of challenges that need
to encounter.

Not to mention about the soft skill, I was able to enhance it.
Communication is the most vital soft skill that we need to have. In industry,
we have to deal with a lots of people and if we failed in the communication,
it will ruin the industry. Praise to God, in this internship, I have achieve all
the objectives as required from the university.

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 REFERENCES

 EIT4004 course outline, Kulliyyah Of Engineering, IIUM.

 Engineering Industrial Training Log Book
 http://eitunit.blogspot.com/
 http://italeem.iium.edu.my/

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APPENDICES

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