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Progress report of Arjun C P mechanical AWH ptc kuttikkattor in plant training attended. .

Indus motor co (p) ltd panikkar road Calicut for a period of 15 days wef 14 may 2012 to 28 may 2012 14/5/12 (8am -5pm) tyres, engine oil, radiators or coolant levels 15/5/12 (8am -5pm) engine oil, battery 16/5/12 (8am -5pm)steering & brake 17/5/12 (8am -5pm) headlight 18/5/12 (8am -5pm) engine trouble shooting 19/5/12 (8am -5pm) ac checking 20/5/12(8am-5pm) water servicing 21/5/12(8am-5pm) car body welding 22/5/12(8am-5pm) car body painting 23/5/12(8am-5pm) wheel balancing 24/5/12(8am-5pm) tools &equipments 25/5/12(8am-5pm) working 26/5/12(8am-5pm) working 27/5/12(8am-5pm) working 28/5/12(8am-5pm) working

INDUS MOTORS
Indus Motor Company Private Limited, (trade name, Indus Motors) is the top ranking Maruti Dealer in India. The business life of the company is started by starting their Ist Dealership in Calicut in the year 1986. The sale of Maruti vehicle is soundly boosted by marketing intelligence of the Indus Motors. Indus maintains the No. 1 dealer position continuously for the last five years. Based on the recent business reports, the company delivers one Maruti Car in every 13 minutes. I nd us m o to r s workshop has well trained manpower to meet the service requirements of the customers. The body shop has dust free paint booths and paint mixing racks of all leading Maruti colors. Anexclusive spare parts division with all necessary Maruti genuine parts and Maruti Genuineaccessories are available to meet the necessary needs of the customers at the workshop.

CAR SERVICING
Car servicing essentially means inspecting the car thoroughly for any damaged components and replacing some parts periodically that wear out over time. T h e p a r t s t h a t r e q u i r e inspection are the tire pressures, the brake fluid levels, air filters, oil filters, spark plugs, wheel balancing and alignment, battery fluid levels, etc. A typical car servicing will involve the following steps Hosting the car up to check the under body. This can be done on a ramp or using a jack. A quick inspection of the under body will let know if there is any damage. When this has done, now need to replace the engine oil. Always remember that the e n g i n e o i l s h o u l d n e v e r b e c h e c k e d o r r e p l a c e d w h i l e t h e e n g i n e i s r u n n i n g . T o proceed, you will need to unscrew a bolt that is just below the engine oil chamber and drain the oil in to a pan. When all the oil has been drained you will need to screw the nut back in tightly. It can also change the oil filter and it is usually just adjacent to the oil chamber. Use the correct type and size as specified for your car.

Then lower the car and fill the new engine oil. Be sure that, do not pour excess oil over the dipstick mark as this is going to be very difficult to drain off. Wait patiently for the oil levels to settle. The other things that will need to check include the spark plugs. Spark plugs need to be cleaned periodically. Unscrew the spark plugs from the engine and clean them with a soft cloth. Need to shine the plug contact points using sandpaper. Fit them back in,and now check out the air filter. Cleaning the air filter is easy and can use the vacuum cleaner to do the job. Also check out the suspension. Bump the car and observe how long it takes to settle. Ideally this will take no more than 3 bumps. Also check out for any spills, or leaks coming out of the shock absorbers Now check out levels of brake fluids and top them up if necessary. Also, inspect the brake shoe condition by removing the wheel and inspecting the braking unit. If worn out, change them. With this, the major servicing part of the car is completed. The r e maining things include oiling doors and the hin ges, checking if the l i g h t s a r e working, testing if the seat belts are working, and measuring the tire pressures (front and rear).

CHECKING OF THE CAR


10 easy steps for a quick check.
Step 1: Engine Checking the engine should happen at least once a month. While the engine is cool use a dry cloth and wipe down the engine as well as the leads. You should also make sure your engine is steam cleaned at least once or twice a year. Spray down the engine with a degreaser and then pressure wash and steam clean it, a professional detailer can do this job for you.

Step 2: Engine oil First, you need to warm up your engine. Make sure your car is on level ground, and then start the engine. Let the engine run for at least 1-2 minutes, then switch off the ignition. Take out the dipstick and wipe it clean with a lint-free cloth. Place the d i p s t i c k b a c k i n t o t h e compartment, and take it out to read the level of oil on the dipstick. If you are in doubt what t h e l e v e l o f o i l s h o u l d b e o r w h a t t yp e o f o i l y o u s h o u l d u s e , yo u c a n c h e c k t h e o w n e r s manual or contact your mechanic.

Step 3: Radiator and coolant levels Y o u m u s t a l w a ys k e e p i n m i n d t h a t t h e r a d i a t o r c a n b e h o t . S o yo u m u s t n e v e r t a k e t h e radiator cap off when the engine is warm. When taking off the radiator cap, prepare yourself by holding down the radiator cap with a piece of unwanted cloth, twist slowly making sure that nothing will burst out. The radiator should have a certain amount of coolant (antifreeze),c h e c k b y l o o k i n g a t t h e l e v e l o f c o o l a n t i n t h e p l a s t i c c o n t a i n e r . T h e c o o l a n t s h o u l d b e between the top and bottom marks on the container.

Step 4: Battery The battery produces explosive gas and corrosive fluid so it is important that you are very careful when checking and handling the battery. You must not smoke anywhere near the battery or check the battery near flames or paint. Do not bring the battery fluid anywhere near your eyes, skin or clothes. The first step to battery checking is to tighten the battery leads if the leads are loose and make sure they are clean. Finally remove the battery cap to check the fluid level, there should be at least 5mm of fluid covering the metal plates. If the fluid level is low, you will need to refill it with distilled water.

Step 5: Headlights When you are always the one driving your car, it is very rare you would notice if the lights are working. So it is important to take some time to check the light this includes the low beam, high beam, indicators, stop and reverse. In order to achieve the check you will need to have a second person with you so they can sit in the car and switch on the lights while you look. If you're alone you can test it by parking the car close to a wall or next to a mirror in the garage and watch the lights flash.

Step 6: Windscreen washer You will need to find the windscreen washer bottle which is in the engine bay, if you are not sure you can check the owners manual. Fill the bottle up with clean water and windscreen washing liquid, which you can purchase from your local petrol station or automotive retailer .Some people have been opting for a cheaper alternative like using normal dishwashing liquid, but be careful it could potentially harm your vehicle's paint or wiper blades.

Step 7: Windscreen wipers Turn on the windscreen wipers and make note if its not w o r k i n g p r o p e r l y . I f y o u r windscreen wipers are cracked or arent working correctly you may need to replace it. You should also make sure the rubber is intact, if the rubber is falling off or scraping hard against the windscreen then its time you bought new rubber. The rubber can be easily removed and replaced. The windscreen rubber is fairly cheap and can be purchased at any automotive retailer.

Step 8: Steering and brake Sit in your car without turning on your engine and press the brake pedal, to check if its loose. While the engine is still off place your hands on the steering wheel and try to point the tyres from side to side. This is to check how much free movement there is, t h e s t e e r i n g w h e e l shouldnt move more than 50mm. If it does make sure you take it to the mechanic to have a look at it.

Step 9: Wiring and hosing

If you find any loose, disconnected or damaged wiring under your bonnet you should get this checked out immediately. Check that your radiator, heater hoses, fuel lines, pipes, brake line sand or power steering lines are not damaged. To do this just trace the pipe from one end to the other, and feel for any strains that may reveal a leak.

Step 10: Tyres It is important to check you r tyre pressure when your tyres are cold. Y o u c a n c h e c k t h e pressure at your local petrol station but it is better to purchase a tyre gauge rather than using the one at the service station, which may not always provide an accurate reading. If you are unsure of the correct pressure for your tyres you may be able to find a tyre chart inside th e drivers door, glove box or owners manual under car specification. Check that the tyre treads are not worn out. The tread should be at least 1.5mm where the tyre touches the road. Look at your tyres carefully and make sure there is no visible damage such as a bludge or a hole.

PROBLEMS AND ITS TROUBLESHOOTING


ENGINE TROUBLESHOOTING
Engine Start-up Problem
Ensure that you have enough gas in your car. When you try to start the car, check if there is a cranky noise. If there is no such noise, then you need to check the battery and insure that there is no wiring problem. Before removing battery terminals, observe positive and negative terminals of the battery And then try to tighten them; or unplug, clean and join the terminals again. A low Battery can be judged by dim lights, low horn, slow or no movement of windscreen wipers, etc. and needs to be recharged. If the battery is fine, you need to check the starter as it may have to be repaired or replaced. If the engine starts but stops; in the case of cars having carb engines, you need to check the choke. Start the engine, press the accelerator lightly, and rev up the engine till it is heated. But if you own a fuel-injected car, there can be many issues such as a vacuum hose leak, or at the air valve or fuel pressure regulator.

Engine Overheats Quickly


If the engine overheats after driving for sometime or a mile, then there may be a possibility of some smoke or steam coming out from the hood. Check and adjust the ignition timing as it can be wrongly set. Check if there are any mechanical problems in the engine; such as compression, And insure proper working of thermostat that regulates the temperature. The level of the engine coolant can be low, and if it is, it should be refilled to a proper level. Examine if there's a leak in the cooling system and repair it as soon as possible. The cylinder head gasket needs to be replaced as it may have conked out. The drive belts of the engine may be slipping or broken, tighten or replace them if needed.

Backfiring Engines
When you start the engine and accelerate, you hear a continuous noise like fire crackers from the silencer of your vehicle, that's how the engine backfires which can be harmful to the engine. You need to check for a broken or a burnt valve. A broken camshaft can also be a problem and should be repaired to avoid serious engine issues. The ignition timing may need to be adjusted. T h e t i m i n g c h a i n o r b e l t o f t h e c a m s h a f t m a y h a v e b e e n s l i p p e d , a n d n e e d s t o b e replaced at the earliest. The wiring of the spark plug may not be proper. Adjust the wiring in a proper way and check the firing noise.

BRAKE SYSTEM TROUBLESHOOTING


Brake Pedal Goes Too Far Down to Stop.
If you step on the brake pedal and it feels like it's going too far down before you start to slow, you might have the following problems: Low Brake Fluid Level: Check your brake fluid. If it's low, top it off to the mark on the side of the reservoir. Contaminated Brake Fluid: Even though your brakes operate in a closed system, c o n t a m i n a n t s c a n s t i l l w o r k t h e r e w a y i n t o t h e w o r k s . A i r c a n e n t e r t h e s ys t e m t h r o u g h t h e smallest hole, and you can end up with water i n the system from condensation and other means. There's not really any way to check for t h i s , b u t bleeding your brakes will remove the bad stuff and replace it with new fluid. Worn Brake Pads: Your brakes should never wear low enough to cause your brake pedal to feel low, they'll scream at you before then. But if they do get very low, you might have this problem. Replace your brake pads as soon as possible. Of course, this can be avoided with regular brake inspection. Bad Brake Power Boost Unit Finally, if your brake booster goes bad you'll have low brake pedal issues. Most brake boosters are vacuum controlled, so a special vacuum measurement device that connects to the brake booster is needed to check it. If it's bad, you'll have to replace the boost unit.

Brake Pedal Too Firm.


If you step on the brake pedal and all of a sudden it feels like you're doing leg presses at the gym with a new personal trainer, your brake pedal may be too firm. This symptom points to a few potential problems, all of which need to be fixed as soon as possible. Vacuum Problems: Your brakes are easier to press because of a brake booster that gives your foot the strength of 10 men. This booster uses vacuum to help you activate the brakes. If there is a vacuum leak somewhere in the system, it won't have enough negative pressure to do its job. Check the vacuum system for leaks. If you find none, your brake booster is probably bad and will need to be replaced. This can be tested by a shop if you want to be sure. Brake Line Obstruction: I t ' s p o s s i b l e f o r s o m e t h i n g t o b l o c k b r a k e f l u i d f r o m reaching a portion of the system. This could be something in the line like a chunk of rust, or it could be a pinched brake line. Visually inspect the brake lines and replace damaged brake lines as needed.

STEERING & SUSPENSION SYSTEM TROUBLESHOOTING


Car's suspension system is an intricate network of cooperating (usually, anyway) components designed to give you a smooth, even, stable ride. Since the suspension is ground zero when it comes to road abuse, the parts wear out, and even break. If your car doesn't seem to ride like it used to, you may have a problem down below. It may seem daunting to try to diagnose steering or suspension problems, but if you attack it systematically, you have a fighting chance. Just find the symptom that sounds like you and see what the probable causes are.

Money Saver:
Before you start replacing parts, it's a good idea to check all of the mounting nuts and bolts to be sure the problem isn't being caused by simple looseness! Symptom: Pulling to One Side While Driving. Low or uneven tire pressure -check tire inflation. Uneven tire wear - check front tires for even wear and replace both front tires. Alignment bad - check and adjust wheel alignment. Steering components bad - inspect tie rods and steering rack. Sticking brake caliper - inspect brakes for uneven wear or excessive heat. Repair as needed.

Symptom: Flip-flop wheel shimmy. Wheels seem to wander and wiggle rapidly back and forth. Low or uneven tire pressure -check tire inflation. One or more wheels out of balance - have wheels balanced. Uneven or excessive tire wear - inspect tires and replace in pairs. Vehicle out of alignment - check and adjust wheel alignment. Worn steering components - inspect tie rods and steering rack for excessive play andrepair if needed. Symptom: Porpoising over bumps or uneven roads. Porpoising, aka bouncing, dipping,diving. Car keeps going up and down after you go over a bump. Worn shocks or struts - replace shocks and/or struts. Broken or slipped leaf spring - inspect leaf springs and repair or replace as needed. Symptom: Steering seems to be slipping . A s y o u t u r n t h e w h e e l o r h o l d i t i n a t u r n e d position, it feels like its slipping slightly back and forth. Low power steering fluid -add fluid as needed. Loose or worn power steering belt - tighten or replace belt. Bad power steering pump - have checked for pressure and replace if needed. L e a k i n g p o w e r s t e e r i n g r a c k - i n s p e c t s t e e r i n g r a c k f o r l e a k s a n d r e p l a c e r a c k i f needed. Broken steering rack mounts - inspect mounts for excessive play and repair as needed Symptom: Hard to steer. Wheel is hard to turn, especially while moving at slow speed. Low power steering fluid -add fluid as needed. Loose or worn power steering belt - tighten or replace belt. Bad power steering pump - have checked for pressure and replace if needed. L e a k i n g p o w e r s t e e r i n g r a c k - i n s p e c t s t e e r i n g r a c k f o r l e a k s a n d r e p l a c e r a c k i f needed.