VISVESVARAYA TECHNOLOGICAL UNIVERSITY

BELAGAVI, KARNATAKA-590014

INTERNSHIP REPORT
Submitted in partial fulfillment of the requirement for the award of the degree

Bachelor of Engineering
In
Automobile Engineering

SUBMITTED BY

Ravindra B 1AY15AU01

Guided by:
Dr. Chandrappa C.N
Head of the Department

Department of Automobile Engineering

ACHARYA INSTITUTE OF TECHNOLOGY
SOLDEVANAHALLI, BENGALURU-560107
2018-2019
 Department of Automobile Engineering

ACHARYA INSTITUTE OF TECHNOLOGY

CERTIFICATE

Certified that the internship carried out by Mr. Jitendra Reddy T S bearing the USN
1AY15AU017, student of Acharya Institute of Technology in partial fulfillment for the award
of Bachelor of Engineering / Bachelor of Technology in Automobile Engineering of the
Visvesvaraya Technological University, Belgaum during the year 2018-2019. It is certified
that all corrections/suggestions indicated for Internal Assessment have been incorporated in
the Report deposited in the departmental library.
The internship report has been approved as it satisfies the academic requirements in
respect of Internship work prescribed for the said Degree.

Name & Signature of the Internship Coordinator Name & Signature of the HOD

External Viva

Name and signature of the examiners with date

1.

2.
 ACKNOWLEDGEMENTS

I would like to take this opportunity to sincerely express my gratitude to my respected Head

of the Department and project guide Dr. Chandrappa C.N, who has supervised me and

mentored me at every stage.

I would also like to sincerely thank Mr. Sadheesh and Mr. Vasantha Kumar, my superiors

in this internship. I am indebted to all contributions received or obtained from them and also

for their guidance

Last but not least, I would like to thank my institution ‘Acharya Institute of Technology’ and

the Automobile Department for allowing me to pursue this subject and to carry out the tasks

required for it.

Jitendra Reddy T S
 TABLE OF CONTENTS

i. Cover Page
ii. Institute Certificate
iii. Company Certificate
iv. Acknowledgements
v. Table of Contents

1. INTRODUCTION…………………………………………....1
⮚ Foundation 1

⮚ Anant car Service 2

⮚ About the workshop 3

2. Cycle of operation…………………………………………....4
3. Services offered……………………………………………....6
⮚ Front Suspension Overhaul 6

⮚ Fuel Filter Replacement 7

⮚ Ball Joint Replacement 9

⮚ Engine Oil Removal 10

⮚ Oil Filter Replacement 11

⮚ Engine Oil Fill Up 12

⮚ Lower Chamber Replacement 14

⮚ Wheel Balancing 15

⮚ Brake Calliper Replacement 18

⮚ Replace the Wheel Cylinder 22

4. Conclusion…………………………………………………...26
5. Appendix A…………………………………………………..27
6. Appendix B…………………………………………………..29
Chapter 1
Introduction

I received the chance to work as an intern at an outstanding corporation that services

Mahindra cars and Trucks. The company where I worked as an intern for a duration of one
month was Anant cars auto pvt ltd.

Foundation
Mahindra group founded in 1945 as a steel trading company entered the automotive
manufacturing in 1947 to bring the iconic Willys Jeep on to Indian Roads. Over the years,
Mahindra Group has diversified into many businesses in order to meets the needs of
customers. Mahindra Group’s operations span 18 key industries that form the foundation of
every modern economy. From aerospace, agribusiness, automotive, construction equipment
to consulting services, real state, retail, two wheelers, Aftermarket Sector and even Defence
services.
Over the past few years, the company has taken interest in new industries and in foreign
markets. They entered the two-wheeler industry by taking over Kinetic Motors in India.
M&M also has a controlling stake in the Reva Electric Car Compony and acquired South
Korea’s SsangYong Motor Company in 2011. In 2010-11 M&M entered in micro drip
irrigation with the takeover of EPC Industries Ltd in Nashik.
In October 2014, Mahindra and Mahindra acquired a 51% controlling stake in Peugeot
Motorcycles.
In December 2015, Mahindra and Mahindra Ltd and affiliated Tech Mahindra Ltd, through a
special purpose vehicle (SPV), have agreed to buy a 76.06% stake in Italian car designer
Pininfarina SpA, for €25.3 million (around ₹186.7 crore).
In January, Mahindra and Mahindra Ltd acquired Erkunt Traktor Sanayii AS, a Turkish
tractor maker and its foundry business for ₹80 crore.
Mahindra has almost 1.5 lakh employees and its span is over 100 countries.
Anant Cars

Anant Cars is a part of Kalyani Bajaj founded by Mr A.Krishna Raju who is the leading
dealer for Bajaj Auto Ltd in Bengaluru with full fledged sales, service and spares network in
Mekri Circle, Yelahanka, Devanahalli and Chickballapura. Kalyani Bajaj are also the
Authorised distributor for Bajaj Genuine spare parts for Bangalore, Tumkur and Kolar
Districts.
Mr Krishna Raju has vast experience in Automobiles and Construction Business and has
been very successful in both the businesses due to the focus on Quality service and
Customer's Satisfaction.
Anant Cars is the Authorised Dealer for Mahindra & Mahindra for both personal and
commercial range of vehicles in Bangalore with state of the art Personal Car Dealership on
Bannerghatta Road, opp to IIMB and Commercial Vehicle Dealership in K R Puram on Old
Madras Road. The Company has got an exclusive State of the art service centre for XUV and
Scoprio and Body shop in Bannerghatta Road and second Service centre for the personal
range in Hulimavu on DLF Road, A state of the art service centre facility has been provided
for the commercial vehicles in Deepanjali Nagar on Mysore road.
About the workshop

The workshop has three divisions. The services department, the inventory department and the
washing department. The services department is divided into 2 shops namely workshop and
alignment shop. Further the workshop has 2 division. one is for Cars, SUVs and MUVs and
the other is for Auto and goods carriers. All the shops are equipped with different types of
machineries. The first division of workshop has 10 bays working properly. Each bay has
hydraulic or pneumatic motor on which vehicles are lifted, tool box and again a pneumatic
motor to clean the dust with the help of high pressure air or can be used as wrenches with the
help of gun. The workshop has 20 mechanics, 8 helpers and 7 service advisors. The service
advisors guides the mechanics.

BAY LIFT
Chapter 2
Cycle of operation
GATE
● Entry from the gate to workshop gallery.
● Issue of job card.
CHECK
● The mechanic asks the problem from the owner.
● Inspection by mechanic.
INVENTORY
● The mechanic makes a list of required accessories.
● The service advisor inspects the problems and suggest changes.
SERVICE
● Accessories and oils are collected from inventory.
● The service is started in guidance of service advisor.
WASHING
● The vehicle is washed in the washing shop with pressured water using paint friendly
reagents to give shine.
OUT
● All the bills are cleared and gate pass is given.

First the vehicle is entered through the gate and it is lined up in gallery. A job card is
prepared and a mechanic is allotted for the service. The mechanic whom it is allotted asks the
problem from the owner of the vehicles and then the mechanic himself inspects the vehicle
and note down the problems in job card.
The job card is forwarded to the service engineer and the service engineer himself inspects
the problems and gives an okay sign for the accessories and oils to be collected from the
inventory.
The service is started in presence of service advisor. All the problems are solved and oil is
changed in the bay.
After this the vehicle is sent to the washing there it is washed.
After clearing all the bills, the gate pass is issued and vehicle goes out. At the bills counter a
feedback is given to customer to give true ratings of mechanic.

Auxiliaries
Free services- are offered to new cars which have run 10000 km or age less than one year.
The first free service is done at 1000 km or 1 month, whichever comes first. The second free
service is done at 5000 km or 6 months and third free service is done at 10000 km or 12
months. The labor charges are not added in the free services. The other charges like Engine
oil, Gear oil are imposed on the customer. The average oil charges come around Rs.750 per
service. The average time taken for the free service is 1 hour.

Paid services- are offered to cars which have run more than 10000 km or age more than 1
year. The average labor charge for a paid service is Rs.700. The spare part charge for the paid
service varies with the km run. The Average spare part charges for the cars between 10000
km and 20000 km is Rs.1500 and for the cars greater than 20000 km is Rs.2500. The oil
charges are also included in the paid services. The average time taken for paid service is 1.5
hours.

Chapter 3
 SERVICES OFFERED

FRONT SUSPENSION OVERHAUL:

Procedure-
● Remove front tyres using pneumatic gun.
● Remove jumper mounting bolts at top side of bonnet.
● Leave the bolts from the shock tower as they are for now.
● Turn the wheel to the right for easy access. Unclip the brake sensor from the
mounting point.
● Undo the bolt at the rear that holds the shock and mounting plate for brake sensor and
ABS sensor.
● Undo the 2 bolts at the rear of the brake caliper. Remove the caliper and just put it on
your suspension links.
● Remove coil springs using spring puller tool and disassembly all parts.
● Now take a new shock absorber and same coil spring of old suspension.
● Shift coil spring over the shock absorber using tool.
● Similarly assemble all the parts over the car.

Suspension Mounting Suspension Removal (Side View)

Spring Puller Tool

FUEL FILTER REPLACEMENT:

Procedure-
● Locate fuel filter
● Refer to the vehicle service manual to identify the location and type of fuel filter, and
the correct procedure for removing and replacing it.
● Remove static pressure from fuel system.
● If the engine is fitted with an electric fuel pump, locate the fuel pump fuse using the
service manual, and remove it. Start the engine and wait for it to stop as it runs out of
fuel. Switch the ignition off.
● Obtain correct replacement.
● Obtain the correct replacement filter and components. If the vehicle has a carbureted
fuel system, new intake and outlet hoses may have been supplied with the filter. If so,
then attach them to the new filter before you disconnect the old one.
● Using correct equipment, remove fuel filter.
● Loosen the clamps on the fuel line on the engine side of the filter at the outer end of
the hose and disconnect it. If necessary, drain any excess fuel into the fuel proof
container.

Fuel Filter
● Install carburetted system filter.
● Connect the new filter hose and tighten the clamp. Make sure that you have the filter
facing in the right direction, with the flow indicator arrow pointing towards the
engine. Then remove the old filter and reconnect the new one to the fuel intake. If you
do this quickly, very little of the residual fuel in the line should leak from the system.
● Remove old EFI system filter.
 ● In a fuel injected system, the fuel is under greater pressure, so the fuel lines are
normally made of metal, which are not replaced at the same time as the filter. Using
the correct tool, loosen the metal line connectors and remove the filter, catching any
leaking fuel in a fuel-proof container.
● Install EFI system filter.
● Connect the new filter and tighten the line connectors. Make sure that you have the
filter facing in the right direction, with the flow indicator arrow pointing towards the
engine. Finally, remember to replace the fuel pump fuse.

BALL JOINT REPLACEMENT:

Procedure-
● Remove the wheel and access the ball joint.
 ● Soak all the bolts withWD-40 or PB Blaster or TBC Spray.
● Pull the cotter pin and loosen the large castellated nut.

● Pop loose the ball joint.

● Remove the allen bolts and slide the control arm free.

● Guide the new joint through the knuckle hole.

● Bolt the joint into place using the hardware included.

ENGINE OIL REMOVAL:

Procedure-
● Lift your car.
 ● Remove the oil cap or bolt from the lower chamber.

● Loosen the plug counter-clockwise using the proper sized socket or cresc wrench if
you’ve got room to maneuver.
● It will take several minutes for all the oil to drain out of the car.

● Finally tighten the chamber bolt.

OIL FILTER REPLACEMENT:

Procedure-
● Locate the filter assembly
 ● Unscrew the oil filter. Get a twit low and steadily, counter-clockwise.

● Prepare the new filter.

● Dip the tip of your finger in the new replacement oil and smear it on the gasket ring
of the new filter. This will lubricate the gasket and create a good seal for the new
filter, and ensure that you’ll be able to get it off the next time.

● Carefully screw the new lubricated filter, being careful to not cross the threads.

ENGINE OIL FILL UP:

Procedure-
● Add new oil to the car at the fill hole. The amount you need is in the owner’s manual,
listed under “capacities”.
 ● If you hold the bottle with the spout on the top, it will pour more smoothly without
bubbling.
● Make sure you’re adding the correct oil. Typically, you can safely add 10W-30 to
most cars in a pinch, but you should consult your owner’s manual or the experts at an
auto shop before adding oil.

Types of oil used in different vehicles:

Mahindra Scorpio XUV 300

XUV 500 Bolero

LOWER CHAMBER REPLACEMENT:
Procedure-
● Remove engine oil by loosening the bolt of lower chamber.
● Remove the oil sump.
● Replace the new sump by applying glue to it.
● Fix it and let it remain there for at least 3 hours to stick and harden up.
● Finally pour engine oil from the top.

Oil Sump

WHEEL BALANCING:
Procedure-
● Turn your machine OFF then ON, which resets the balancer. The machine wakes up
using standard clip-on wheel weight locations.
● Remove stones/rocks or other debris from tread and any weights already attached to
the wheel. During this process you also should remove any mud, dirt or snow on the
inside of the wheel and make sure that the mounting surface of the wheel is
completely.
● Mount a tire/wheel assembly on a balancer that will use standard clip-on wheel
weights. Use the most appropriate mounting meth - od. Technicians should be careful
to avoid back injury and should seek assistance when lifting a heavy tire/wheel
assembly onto a balancing shaft.
● There are two main mounting methods. They include:
⮚ Back Cone- Most original equipment and steel wheels can be mounted
properly using this method. The wheel is centered on a cone from the inner
side of the wheel.

⮚ Front Cone- A wheel should be centered by the outer side of the hub only
when the inner surface will not provide an accurate surface.

● For automatic measurement, pull the offset arm out to the wheel, hold it still at clip-
on weight position against the wheel flange and wait for a “beep.” Return the arm to
home position.
 Wheel balancing Machine
● Lower the hood. The wheel will spin and unbalances are measured and displayed.
The corrective weight amount appears in the weight display window for inboard and
outboard weight locations.
● Raise the hood after the tire stops rotating. Make sure that the wheel has stopped
before raising the hood.
● Inboard center bar blinks. If an inboard corrective weight is not required, the wheel
will stop at the outboard corrective weight location and you can go to further Step.
● Attach inboard corrective weight. Attach specified weight amount at top-dead-center
on the inside flange of the wheel.
 ● Press NEXT, causing the wheel to rotate.
● The outboard center bar will blink.
● Attach outboard corrective weights. Attach specified weight amount at the top-dead-
center on the outside flange of the wheel.
● Lower the hood to respin the tire/wheel and check balance. The weight readings
should now be 0.00.

Weights

Wheel Alignment of Scorpio

FRONT BRAKE CALLIPERS REPLACEMENT:

Procedure-
● Lift up the car up to required height.
● Remove the lug nuts or bolts completely from studs and remove the front tires.
● Compress the caliper piston completely into the bore with a C-clamp or piston
retracting tool.

● Remove the retaining bolts that hold the caliper's brake hose in place to allow
movement with a wrench.

● Loosen and remove the caliper fitting with a wrench. The fitting shown is also known
as a "banjo" fitting.
● Remove the caliper mounting bolts with a wrench, be sure to save these bolts as you
may need to reuse them.
● Lift the caliper up until it clears the rotor and then slide it off. Carefully remove the
brake pads from the caliper. Try to avoid dropping brake pads as it can cause serious
damage.

● Inspect the caliper supports for rusting or corrosion that would interfere with the new
caliper. If there is any corrosion or interference be sure to remove before new caliper
installation.
● If provided or recommended by the manufacturer, lubricate the BACK of the brake
pads, mounting bushings and sleeves with the recommended grease. Place the brake
pads into the new caliper if they are not preloaded. DO NOT APPLY GREASE TO
THE SIDE OF BRAKE PAD THAT IS IN CONTACT WITH THE ROTOR.
● Carefully slide the brake pad and caliper assembly over the rotor. Install new
mounting bolts (if supplied) if not reuse the bolts you removed and tighten to your
vehicle's specifications. You might need a torque wrench to do this. BE SURE NOT
TO OVER TOURQUE.

● Reconnect the caliper hose with the caliper (banjo) fitting and new washers.
● Remove the plug from the hose and use a wrench or torque wrench to replace the
retaining bolts or clips.
● Bleed your brakes until they are firm. Refill with proper DOT specification for your
vehicle, any brake fluid that was lost.

● Put the wheels back onto your car.

● Test the feel of your car’s brakes before you travel. If brakes don’t feel like they are
working properly, contact a certified technician immediately.
REPLACE THE WHEEL CYLINDER:
Procedure-
● After the brake shoes have been removed from the backing plate, the wheel cylinder
is ready to be replaced.
● When replacing the wheel cylinder, use a line wrench to avoid damage to the fitting
while removing the brake line.

● Once the brake line has been removed, brake fluid will drip out of the line until the
brake master cylinder is empty, a vacuum cap should be used to prevent the loss of
fluid from the master.

● Next, use a wrench or socket to remove the wheel cylinder mounting bolts.

● After removing the wheel cylinder mounting bolts, grasp the unit and separate it from
the backing plate.
● Once the old wheel cylinder has been matched up to the new unit, insert it into the
backing plate and secure the mounting bolts.
● Then, using a wrench or ratchet tighten the wheel cylinder mounting bolts.

● Using a sealed container of brake fluid, top off the brake master cylinder with fluid.
● Once the fluid level has been added to, reinstall and tighten the reservoir cap.
● Have a helper press the brake pedal down and hold.
● Apply brake and adjust it accordingly.
Some other things that are checked while vehicle is in service bay:
● Engine oil leakage.
● Air bags.
● Music system.
● Tyre pressure.
● Head lights.
● Windshield wiper.
● Operation of horn.
● Gear shifting condition.
● Parking brake liver operation.
● Rear view mirrors.
● Central lock functioning.
● Wiper water spray.
● Condition of wiper blades.
● Head lamp focusing.
● Road test.

Chapter 4
 CONCLUSION

The entire internship experience was a positive and rewarding stimulus. Learning about the
minute details of the vehicle and the ability to solve the problem that may arise in a vehicle is
really helpful apart from the theoretical knowledge that I got to learn from the college. The
principles involved shine a light on how precise an individual must be while working in the
said organization.
Comparing the theoretical and practical experience, practical always has an added advantage.
Theory practice merely enables you to learn the fundamentals and mechanics of a subject but
practical approach teaches you on how to apply them. It is a more holistic approach
compared to plain theory. But practical approach cannot be understood without
understanding the theory first. Both go hand in hand when it comes to work. Even then,
practical experience is a better tool than only theory.
I am really grateful for receiving this opportunity to work for a prestigious organization. I
learnt and gathered information of immense value over the period which will help me
tremendously in my career. The support that I received, both from my superiors at the
company and my institute, enabled me to complete this internship successfully.

APPENDIX A
 INTERN DAILY LOG

Intern: Jitendra Reddy T S Period: 12/01/2019 to 09/02/2019

Position: Trainee Employer: Anant Cars Auto pvt. ltd
Internship Supervisor’s Name: Mr. Sadheesh Phone: +919611128662
Internship Coordinator: Mr. Prashant KP

Date Attendance

12/01/19 Present
14/01/19 Present
15/01/19 Present
16/01/19 Present
17/01/19 Present
18/01/19 Present
19/01/19 Present
21/01/19 Present
22/01/19 Present
23/01/19 Present
24/01/19 Present
25/01/19 Present
28/01/19 Present
29/01/19 Present
30/01/19 Present
31/01/19 Present
01/02/19 Present
02/02/19 Present
04/02/19 Present
05/02/19 Present
06/02/19 Present
07/02/19 Present
08/02/19 Present
09/02/19 Present

_____________
Supervisor Sign

APPENDIX B
WEEKLY REPORTS
 1. Activities, tasks, duties, responsibilities: (12/01/19-19/01/19)

Description of Observed Assisted Performed Performed Trained or

activity, task, Others with alone supervised
duty, or supervision others
responsibility
Inventory Check Yes Yes Yes No No

Servicing Yes Yes Yes No No

Monitoring

Supervisor Sign

2. Activities, tasks, duties, responsibilities: (21/01/19-25/01/19)

Description of Observed Performed Performed Trained or

activity, task, duty, Assisted with alone supervised
Others
or responsibility supervision others
Inventory Check Yes Yes Yes No No
Servicing Yes Yes Yes No No
Monitoring
Optimization Yes Yes Yes No No
Process & General
Servicing

Supervisor Sign

3. Activities, Tasks, Duties, Responsibilities: (28/01/19-02/02/19)

 Description of Observed Assisted Performed Performed Trained or
activity, task, duty, Others with alone supervised
or responsibility supervision others
Inventory Check Yes Yes - Yes No
Servicing Yes Yes Yes Yes No
Monitoring
Optimization Yes Yes Yes Yes No
Process & General
Servicing

Supervisor Sign

4. Activities, Tasks, Duties, Responsibilities: (04/02/19-09/02/19)

Description of Observed Assisted Performed Performed Trained or

activity, task, duty, Others with alone supervised
or responsibility supervision others
Inventory Check Yes Yes - Yes Yes
Servicing Yes Yes - Yes Yes
Monitoring
General Servicing - Yes Yes Yes -

Supervisor Sign