As the trainees marched out of the trenches and into the debriefing room, one person was missing, we were assured he was not coming back by the survivors. The enemy (brake return spring ) had put a hole through the trainees arm and while in treatment asked to be exempt from further service.

The same trainees had his toes mashed by a slipped jack because he forgot to cover his flank – did not wedge the vehicle tires properly before jacking. It was also reported that this trainee was also hit on the head by a hammer as he was trying to see what another trainee was hitting on.

After the memorial service of the victim, the whole issue of safety was finally etched into the survivor’s brains. However, the morale of the rest of the trainees wobbled through out the rest of the debriefing period.

It is important to remember that the whole idea of this training is to produce competent graduate mechanics that can act as workshop technical managers and manage not huge workshops but small independent specialist shops employing three to four mechanics.

At least a twenty of such outfits will be needed in each state to alleviate the high cost of maintenance as well as the overall incompetence of the roadside mechanic and we believe that such outfits can match the earnings of a similarly employed graduate while at the same time paving the way for business ownership for the trainee.

As the trainees returned, unilateral response was that we should start looking for a workshop and investors for them where they will start work. We assured them that the training had not really started as we assumed that they should have known all that we have taught them so far.
The training continued with an explanation of the working principles of the several fuel injection systems available in the industry. We also explained to them that unlike the roadside mechanic, they were being trained to repair any vehicle and because of this a theoretical understanding of each vehicle subsystem must be thoroughly understood as well as the ability to read and correlate technical information and schematics.

After another four days of presentation, explanations, confusion and stress we finally concluded the section on mechanical fuel injection system. On screen, the trainees were able to identify the various components and sensors used in the mechanical fuel injection system, understand the electrical wiring and operating characteristics as well as the various adjustment points in the system.

We also demonstrated the use of the various meters and gauges for making tests. Due to the unfamiliarity of these systems to the trainees, the lecture period had to be extended daily till very late into the evening. The trainees asked for access to our computer systems over the weekend so that they could digest all that had been taught.

 Having experienced the variance between the trainees’ confidence during lectures and their poor performance when confronted with the real thing, We decided to engage them with two instances of a mechanical fuel injection system.

Their task was to identify the major parts of the system in a working VW K-Lambda- Jetronic and a Mercedes KE Jetronic injection. Next, they were to perform a fuel pressure test, nozzle performance test, Sensor to ECU wiring validation test and Component testing.

Basically, they were supposed to perform a complete fuel system service on both vehicles. Naturally, this proved a bit too much for the trainees so We had to carry out the procedures on the Mercedes while the trainees watched and asked a torrent of questions on every conceivable aspect of the operation.

We had the trainees duplicate our procedure on the VW after providing them with the correct technical data on Lift pump pressure, System pressure, Residual Pressure, Control Pressure, Rest Position of the Air Flow ,Sensor unit, Spray pattern, lambda control valve dwell, Idle switch and ECU wiring diagram.

To complete this task we had to return to the training room several times in order to delete some wrong ideas on the working principles of the fuel system that somehow got into the trainees brains.

Although we expected this part of the training to be relatively short, we ended up doing it for over ten hours a day for eleven days. During this period, the VW injection system needed some spare parts to be replaced so we decided to expand the trainees’ horizon by sending them to the spare parts market in town over the weekend.

They were to purchase new or used, a thermo-time switch, a coolant temperature sensor, two injector nozzles rated at 5.5bar and a Fuel system pressure regulator for the Mercedes. They were to test it in the market to confirm the usability of the components and return with it so that it can be fitted.

We also gave the trainees an idea of the prices to expect as well as a brief on the assortment of tricks that obtain in the market place. To ensure a diversity of experience we sent two of the trainees to Onitsha (Mgbuka Obosi) and the other one to Enugu ( Coal Camp)

21.0 Behind the enemy lines - Visit to Mgbuka (Obosi )

Its really a jungle out there! the embarrassment encountered by the two trainees bothered on shame as the illiterate traders mocked them when they said they were looking for a coolant temperature sensor.

The trainees insisted on the rating etched on the sensor, the traders replied that it did not matter so long as it fitted into the hole meant for it. One of the trainees came back with fairly used parts of the wrong specification. When retested, the components were not working.

The trainees insisted that the traders assured them that those components never goes bad as no one ever demanded for them and they believed them ( so much for education) .
His colleague excused himself on the return journey for an important appointment and was never heard from again.

22.0 And then they were two

 The trainee that went to Coal Camp spare part market for the pressure regulator just showed the traders the component that he wanted and immediately, over one hundred pieces of the pressure regulator appeared from various sources.

Armed with a hand vacuum pump, the trainee tested all and found only one working unit but by that time he was on the verge of being lynched by the traders.