NO. CONTENTS PAGE NO.

1. INTRODUCTION 1

2. AUTOMOBILE INDUSTRY IN INDIA 2

2.1 INVESTMENT 2

2.2 GOVERNMENT INITIATIVES 3

3. MARUTI SUZUKI INDIA LTD 4

3.1 HISTORY 4

3.2 OUR VISION 5

3.3 OUR MISSION 5

3.4 OBJECTIVES 5-6

3.5 VALUES & BELIEFS 6

3.6 QUALITY POLICY 6

3.7 SERVICE AND REPAIR 6

4. ORGANIZATIONAL STRUCTURE 7

4.1 SERVICE STATION LAYOUT 8

5. QUALITY TOOLS IMPLEMENTED 9

6. MARUTHI VEHICLES 10

6.1 ALTO 10

6.2 ALTO K10 11-12

7. ACTIVITIES IN THE WORKSHOP 13-14

FOR SERVICING THE VEHICLE
8. SPECIAL TOOLS USED DURING 15
TRAINING
9. GENERAL VEHICLE 16
MAINTENANCE
9.1 AIR CLEANER 16

9.2 OIL 16

9.3 ALTERNATOR BELT TENSION 16

9.4 COOLING SYSTEM 16

9.5 TURBO CHARGER 16

9.6 EGR 17

9.7 PROCEDURE OF CAR REPAIR 17

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 9.7.1 AIR CLEANER CHANGING 17

9.7.2 OIL AND OIL FILTER CHANGING 18

9.7.3 FRONT DISC BRAKE PAD 18

CHANGING
9.7.4 ALTERNATOR AND AC BELT 18
REMOVAL AND REFITTING
9.7.5 TIMING CHAIN REPLACING 18-19

9.7.6 SUSPENSION LOUNGE REMOVING 19-20

9.7.7 CLUTCH DISC ASSEMBLY 20

REPLACING
9.7.8 TURBO CHARGER REMOVAL AND 21
REFITTING
9.7.9 FIP REMOVAL AND REFITTING 21

9.8 PROCEDURE FOR ALIGNING THE 21-22

WHEELS
9.9 PROCEDURE FOR WHEEL 22
BALANCING
10. MAJOR VEHICLE MAINTENANCE 23

10.1 CYLINDER HEAD REMOVAL 23

10.2 DISMANTLING AND 24

OVERHAULING OF THE ENGINE
10.2.1 REMOVING OF THE ENGINE FROM 24-25
THE VEHICLE
10.2.2 DISMANTLING THE ENGINE 25-26

10.2.3 INSPECTION 25-6

10.2.4 PISTON 26

11. CONCLUSION 27

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 1.INTRODUCTION

An Industrial Training is a period of work experience offered by an

organization for a limited period of time. Once confined to medical graduates,
internship is used practice for a wide range of placements in businesses, non-
profit organizations and government agencies. They are typically undertaken
by students and graduates looking to gain relevant skills and experience in a
particular field. Employers benefit from these placements because they often
recruit employees from their best interns, who have known capabilities, thus
saving time and money in the long run. Internships are usually arranged by
third-party organizations that recruit interns on behalf of industry groups.
Rules vary from country to country about when interns should be regarded as
employees. The "INPLANT TRANING" is in connection with the syllabus of 5th
semester diploma in automobile engineering. The training duration is two
weeks that is 14 days this training aim of making the students familiar with
automobile servicing in direct expense.

Indus Motors dealer of Maruthi Suzuki cars provided us this in-plant

training. They provided the training faculty. This is the report of that training to
understand the methods and features of a service centre.

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 2.AUTOMOBILE INDUSTRIES IN INDIA

2.1 INVESTMENTS

In order to keep up with the growing demand, several auto makers have started investing
heavily in various segments of the industry during the last few months. The industry has
attracted Foreign Direct Investment (FDI) worth USS 14.32 billion during the period April
2000 to December 2015, according to data released by Department of Industrial Policy and
Promotion (DIPP).

Some of the major investments and developments in the automobile sector in India
are as follows:

 Japanese two-wheeler manufacturer Honda Motorcycle and Scooter India (HMSI) has
opened its fourth and world's largest scooter plant in Gujarat, set up to initially produce
600,000 scooters per annum to be scaled up to 1.2 million scooters per annum by mid
2016.

 American car maker Ford has unveiled its iconic Ford Mustang in India and will make its
debut in second quarter of FY2016 within the price band of Rs 45 lakh (US$ 66,146) and
Rs 50 lakh (USS 73,496) in the Indian market.

 Nissan Motor Co. Ltd is in discussion with Government of India to bring electric and
hybrid technologies to India as the government plans to reduce air pollution caused by
vehicles.

 Global auto major Ford plans to manufacture in India two families of engines by 2017, a
22 liter diesel engine code named Panther, and a 1.2 liter petrol engine code named
Dragon, which are expected to power 270,000 Ford vehicles globally.

 The world's largest air bag suppliers Autolivinc, Takata Corp. TRW Automotive Inc and
Toyoda Gosei Co are setting up plants and increasing capacity in India.

 General Motors plans to invest US$ 1 billion in India by 2020, mainly to increase the
capacity at the Talegaon plant in Maharashtra from 130,000 units a year to 220.000 by
2025.

 US-based car maker Chrysler has planned to invest Rs 3,500 crore (US$ 513.5 million) in
Maharashtra, to, manufacture Jeep Grand Cherokee model.

 Mercedes Benz has decided to manufacture the GLA entry SUV in India. The company
has doubled its India assembly capacity to 20,000 units per annum

 Germany-based luxury car maker BayerischeMotoren Werke AG's (BMW) local unit has
announced to procure components from seven India-based auto parts maker

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 Mahindra Two Wheelers Limited (MTWL)acquired 51 percent shares in france-based
Peugeot Motorcycles (PMTC)

2.2 GOVERNMENT INITIATIVES

The Government of India encourages foreign investment in the automobile sector and
allows 100 per cent FDI under the automatic route.

Some of the major initiatives taken by the Government of India are:

 Mr. NitinGadkari, Minister of Road Transport, Highways & Shipping has announced
plans to set up a separate independent Department for Transport, comprising of experts
from the automobile sector to resolve issues such as those related to fuel technology.
motor body specifications and fuel emissions, apart from exports,

 Government of India aims to make automobiles manufacturing the main driver of 'Make
in India' initiative, as it expects passenger vehicles market to triple to 9.4 million units by
2026, as highlighted in the Auto Mission Plan (AMP) 2016-26. In the Union budget of
2015-16, the Government has announced to provide credit of Rs 850,000 crore (USS
124.71 billion) to farmers, which is expected to boost the tractors segment sales.

 The Government plans to promote eco-friendly cars in the country i.e. CNG based
vehicle, hybrid vehicle, and electric vehicle and also made mandatory of 5 per cent
ethanol blending in petrol.

 The government has formulated a Scheme for Faster Adoption and Manufacturing of
Electric and Hybrid Vehicles in India, under the National Electric Mobility Mission 2020
to encourage the progressive induction of reliable, affordable and efficient electric and
hybrid vehicles in the country.

 The Automobile Mission Plan (AMP) for the period 2006-2016, designed by the
government is aimed at accelerating and sustaining growth in this sector. Also, the well
established Regulatory Framework under the Ministry of Shipping, Road Transport and
Highways, plays a part in providing a boost to this sector.

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 3. MARUTI SUZUKI INDIA LTD
3.1 History

MarutiUdyog Limited was established in February 1981, though the actual

production commenced only in 1983 It started with the Maruti 800, based on the Suzuki
Altokei car which at the time was the only modern car available in India. Its only competitors
were the Hindustan Ambassador and Premier Padmini. Originally, 74% of the company was
owned by the Indian government, and 26% by Suzuki of Japan [14] As of May 2007, the
government of India sold it complete share to Indian financial institutions and no longer has
any stake in MarutiUdyog

3.1.1. Under the Maruti Name

In 1970, a private limited company named Maruti technical services private limited (MTSPL)
was launched on November 16, 1970. The stated purpose of this company was to provide
technical know-how for the design, manufacture and assembly of "a wholly indigenous
motor car". In June 1971, a company called Maruti limited was incorporated under the
Companies Act. Maruti Limited went into liquidation in 1977. MarutiUdyog Ltd was
incorporated through the efforts of Dr V. Krishnamurthy.

3.1.2. Affiliation with Suzuki

In 1982, a license & Joint Venture Agreement (JVA) was signed between MarutiUdyog Ind.
and Suzuki of Japan At first, Maruti Suzuki was mainly an importer of cars In India's closed
market, Maruti received the right to import 40,000 fully built-up Suzukis in the first two
years and even after that the early goal was to use only 33% indigenous parts. This upset the
local manufacturers considerably. There were also some concerns that the Indian market
was too small to absorb the comparatively large production planned by Maruti Suzuki with
the government even considering adjusting the petrol tax and lowering the excise duty in
uses boost sales Finally, in 1983, the Maruti 800 was released. This 796 cc hatchback was
based on the SS40 Suzuki Alto and was India’s first affordable car total product plan was
40% and 60% Maruti Van. E171 Local production time commented in December is 1984 the
Maruti Van with the same three-cylinder engine as the 800 was released and the installed
capacity of the plant in Gurgaon reached 40,000 units.

In 1985, the Suzuki SJ410-based Gypsy, a 970 cc 4WD off-road vehicle, was launched
In 1986, the original 800 was replaced by an all-new model of the 796 cc hatchback Suzuki
Alto and the 100,000th vehicle was produced by the company. In 1987, the company started
exporting to the West, when a lot of 500 cars were sent to Hungary. By 1988, the capacity of
the Gurgaon plant was increased to 100,000 units per annum.

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3.1.4. Manufacturing Facilities

Maruti Suzuki has two manufacturing facilities in India. Both manufacturing facilities
have a combined production capacity of 14,50,000 vehicles annually. The Gurgaon
manufacturing facility has three fully integrated manufacturing plants and is spread over
300 acres (1.2 km2). The Gurgaon facilities also manufacture 240,000 K-Series engines
annually. The Gurgaon Facilities manufactures the 800, Alto, WagonR, Estilo, Omni, Gypsy,
Ertiga, Ritz and Ecco.

The Manesar manufacturing plant was inaugurated in February 2007 and is spread over 600
acres (2.4 km2). Initially it had a production capacity of 100,000 vehicles annually but this
was increased to 300,000 vehicles annually in October 2008. The production capacity was
further increased by 250,000 vehicles taking total production capacity to 800,000 vehicles
annually. The Manesar Plant produces the A-star, Swift, Swift DZire, SX4. Vitara Brezza .Rite
and Celerio. On 25 June 2012, Haryana State Industries and Infrastructure Development
demanded Maruti Suzuki to pay an additional Rs 235 crore for enhanced land acquisition for
its Haryana plant expansion. The agency reminded Maruti that failure to pay the amount
would lead to further proceedings and vacating the enhanced land acquisition. It plans to
set up a plant in Gujarat and has acquired 600 acres of land.

3.2 OUR VISSION

Our Vision is to be the most valued and unbeaten endeavor, enchanting our
customers with an extensive range of products and solutions in the automobile
industry, with the best manpower and the latest technology available across the
country.

3.3 OUR MISSION

We will pursue the development of our financial and human resources through
diversified business activities, in an ethical and socially responsible manner and in pace with
the advancements of the day.

We will uphold a professional code of conduct in the pursuit of our goals and are
committed’ to taking up social responsibilities as a corporate citizen by dedicating a
significant share o four productive surpluses for espousing social causes that would benefit
our employees, their families and the society at large.

3.4 OBJECTIVES

 To establish dominant role in automobile industry and to attain maximum market share.
 To provide best quality products and services to our valuable customers.

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 To accomplish Complete Customer Care, Outstanding Customer Service and Total
Quality Management.

3.5 VALUES & BELIEFS

The enduring belief that their corporate destiny is inextricably entwined

with those of the employees and customers carries them towards a profitable
and ethical business model.

3.6 QUALITY POLICY

Customer satisfaction through quality services that achieved by through

constant adherence and continual improvement in quality services and
systems following P.D.C.A (Plan, Do, Check and Act) technique in all their
functions and actions complying with the requirements.

3.7 SERVICE AND REPAIR

 ALTO
 OMNI
 ECCO
 GRAND VITARA
 SX4
 SWIFT
 RITZ
 GYPSY
 WAGONR

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 4.ORGANIZATIONAL STRUCTURE

JERY CHAKOCHAN
HR EXECUTIVE

JOHNEY AYYAPPAN ASHOK

EMPLOYEE EMPLOYEE EMPLOYEE
(SERVICE AND (SERVICE AND (SERVICE AND
REPAIR) REAPAIR) REPAIR)

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5S
SEIRI Proper Selection

SEITON Arrangement

SIESO Cleaning

SEIKETSU Cleanliness

SHITSUKE Discipline

3K

KIMERARETA What Has Been Decided

KHONDDRI Exactly be Followed

3G

GENBA GO to the Spot

GENBUTSU Look at the Actual Thing

GENSITSU Grasp the Fact & Take Realistic Action

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 6.MARUTHI VEHICLES
6.1. ALTO

BODY

 Two Box 4 door Hatchback

BRAKES

 Type - Powerful 8-inch booster assisted front disc brakes halt instantly on braking.

DIMENSION & WEIGHTS

• Front Track 1295 (mm)

• Fuel Tank capacity 35 (Litre)
• Gross Vehicle Weight 1140 (kg)
• Ground Clearance 160 (mm)
• Kerb weight 690 kg/ 705 kg (Lx/Lxi)
• Overall Height 1460 (mm)
• Overall Length 3495 (mm)
• Overall Width 1475 (mm)
• Rear track 1290 (mm)
• Wheelbase 2360 (mm)

ENGINE

• Displacement 796 (cc)

• No. cylinders/arrangement/Valves-3 cylinder, in-line, 4 valves per cylinder

• Type FC Engine, MPFI

• Fuel Type Petrol

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PERFORMANCE

• Max. Power 47 bhp @ 6200 rpm

• Max. Torque 62 Nm @ 3000 rpm

6.2. ALTO K10

BODY

•Two Box 4 door Hatchback

BRAKES

• Front - Ventilated Dise

• Rear - Drum

DIMENSION & WEIGHTS

• Front Track 1295 (mm)

• Fuel Tank Capacity 35 (Litre)
• Gross Vehicle Weight 1185 (kg)
• Ground Clearance 160 (mm)
• Kerb Weight 760 kg(Lxi)/ 765 (Vxi)
• Overall Height 1460 (mm)
• Overall Length 3620 (mm)
• Overall Width 1475 (mm)
• Rear Track 1290 (mm)
• Wheelbase 2360 (mm)

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ENGINE

• Displacement - 998 (cc)

• No. cylinders / arrangement/ Valves 3 cylinder, in-line, 4 valves per cylinder

• Type All Aluminium Light Weight KI OB

• Fuel Type Petrol

PERFORMANCE

• Max. Power -68 PS 6200 rpm

• Max. Torque -90 Nm @ 3500 rpm

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 7. ACTIVITIES IN THE WORKSHOP FOR SERVICING THE
VEHICLE
1. Receiving the Customer

First the customer is received by the service advisor. Then the problems from the
customer is reported and gives possible causes and explain about the problem, net amount
excepting.

II. Initial Test Drive

The service advisor calls the worker and together they go for a test in different road
conditions, Checks the customer's problems and other problems. Gives reason or possible
reasons for the trouble.

III. Inspection

The vehicle is brought into the work shop and placed on the lift and lets it cool. After the
vehicle is cooled it is inspected for the possible causes and trouble shoots it as per Fait
service procedure. Also other activities like servicing is done as per the explained below.

IV. Second Inspection

The second inspection is done by the co-tech in the static conditions. He gives other
suggestions to the worker for good performance of the vehicle. The technician works as per
suggestions and terminate the problems.

V. Final Test Drive & Washing

Test drive is again conducted as explained above and brought the car to the washing. The
vehicle is washed thoroughly with water, diesel and car shampoo. After the vehicle is
washed it is cleaned at the inside and outside with cloth and a vacuum unit. Then the entire
vehicle is polished.

VI. Final Inspection

Final inspection is done by a finales inspector. In this stage the finalist checks the vehicle for
the following features,

 Level of engine coolant in the reservoir and radiator

 Level of battery electrolyte and battery water

 Level of engine oil

 Level of gear oil

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 Play of all pedals

 Door pads and weather strips loose

 Door lock from inside and outside

 Fuel lead

 Functioning of all indicator lights.

 Level of water in windshield washer

 Function of all lamps

 Function of accessories

 Torque of wheel nuts

 Tyre pressure etc.

 Dashboard warning

VII. Billing

The service advisor and the technician prepare the bill of works and parts. It is checked
by the service manager and transferred to the customer.

VIII. Delivering

The Vehicle The vehicle is delivered to the customer to his house or at the office as per
is requirement. A rating card is given to the customer for knowing his satisfaction & for
suggestion and complaints.

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 8. SPECIAL TOOLS USED DURING TRAINING

 1/4" BOX SOCKET WRENCHES: It's a small size socket wrench helps to loosen and
fasten the nut and bolts where less space to work.

 PNEUMATIC WRENCH: It is used to tighten and loosen nuts and bolts by using
compressed air.

 PNEUMATIC RACHET: It is used to tighten and loosen nuts and bolts from 90° with help
of compressed air.

 ANGLE TORQUE WRENCH: It is used to fasten the bolts and nut with have specific angle
torque measurements

 SLIDING HAMMER: It is used to remove parts such as bearings wheel drums etc. It has a
hook and a sliding ram with a channel

 FILTER CUP: It is used to remove fuel filter of engine by easily fitting on a ratchet handle
or other

 Diagnostic Tool: Diagnostic is used Diagnostic tool for premium Cars.Since Suzuki
Diagnostic secured the contacts to supply OEM approved Maruthi Suzuki and Suzuki
Japan. It helps to delete the ECU memory and add new service details.

 PULLEY REMOVER: It is used to remove the key and pulley from the engine

 CLUTCH CENTER: Used to center the clutch disc

 OIL EXTRACTOR: It is a vacuum pump used to extract oils from vehicle with drain plug

 CAM LOCKER: It is used to lock the cam timing at the time of timing chain change

 BRAKE BLEEDER CAP: It is used to tighten the brake fluid reservoir tank to get vacuum
inside the brake line.

 AXLE BOOT HOSE CLIP LOCK PILER: It is used to lock the new axle boot locks.

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 9. GENERAL VEHICLE MAINTENANCE
The performance of the engine is depended on ensure that the following maintenance
carried out as per the scheduled without fail.

9.1 AIR CLEANER

The air cleaner element should be replaced by every 20.000kms as when the element
paper is turn dark when the light bulb. For the detailed procedure refer to the air intake
system

9.2 OIL

The oil filter and the oil should be changed 10,000kms. They should confirm cg4 grade
and wit a viscosity index of 15 W 40 for diesel and 5 W 20 for petrol. It should be kept in
mind
that the turbo charged engine the oil has to take an additional load of lubricating and
cooling the
turbo chargers shaft. If any oil of lower specification is used then it will break down under
the
high thermal load end of the turbine and the shaft especially during the host shut down.

9.3 ALTERNATOR BELT TENSION

To be checked and replace if required at 30,000kms

9.4 COOLING SYSTEM

Ensure that no leakages are present. Also check the wear of water hoses and coolant
quality

9.5 TURBO CHARGER

The engine is having an exhaust gas driven turbocharger. The shat speed varies from
4000 When engine id riding about 1700 when the engine is having full rated pen VCT
turbo is also using in some model its works from the starting of engine. That is very critical
that
y shifting down, the engine is allowed to run idle for at least me mute Similarly the engine
should be run at idle for one minute at starting before accelerating.

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9.6 EGR

On vehicle fitted with EGR system the following additional paints check have to done during
scheduled maintenance

 Check the vacuum hoses for any damage.

 Fasten all nuts and bolts as per the recommended torque.

9.7 PROCEDURE OF CAR REPAIR

The car repairs which can be carried out are,

1. Air cleaner changing

2. Oil and Oil filter changing

3. Front Disc Brake Pad Changing

4. Alternator and AC belt removal and refitting

5. Timing chain replacing

6. Clutch Disc assembly replacing

7. Suspension Lounge removing

8. Turbo charger removal

9. FIP removal and refitting and

10. Cylinder head removal

9.7.1 Air cleaner changing

 Disconnect the battery terminals

 Remove the air cleaner box from the car

 Remove the air cleaner cover and replace the air cleaner with new one.

16
9.7.2 Oil and Oil filter changing

 Lift the vehicle

 Drain the oil

 Remove oil filter cap first for diesel vehicles else for petrol remove the oil filter using the
special tool (oil filter wrench)

 While fixing the oil filter put oil on the seal and tighten cap still its last thread.

9.7.3 Front Disc Brake Pad Changing

 Lift the vehicle

 Remove both front wheels

 Loosen the calliper bolts

 Remove the lock from the calliper

 Remove the calliper also check the disc wear if it need a skimming or replace

 Remove the old brake pad and replace with new pair

9.7.4 Alternator and AC belt removal and refitting

 Remove the under shield.

 Remove the AC belt through slipping the belt from groove by rotation the crank

 Pull the alternator belt tensioner clock wise then remove the belt

 Replace both belt by new ones

9.7.5 Timing Chain Replacing

 Disconnect the battery

 Remove the air filter

 Drain oil and coolant

 Remove both belt from pulleys

 Remove the following

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 Belt tensioner

 Crank shaft pulley

 Water pump

 Power steering pulley

 Remove oil Sump

 Lock the Crank Flywheel timing

 Remove the main crank pulley

 Put the engine on stand

 Move the coolant and power steering tanks.

 Lock the cam timing with the special cam locking tool

 Remove

 Engine mounding holder from the engine

 Pipes from the timing chain cover and pull out the timing chain cover.

 Chain tensioner, pads and chain.

 Replace the parts that have to replace and do this list vice versa.

9.7.6 Suspension Lounge removing

 Lift the vehicle

 Remove following items

 Protective Shield

 Both wheel

 Lower arms from the hub

 Steering box from the lounge

 C gear box mound

 Silencer joint from the hub

18
  Link rod

 Loosen the lounge bolts and jack a stand on lounge

 Up the life and pick the lounge with a help of one another and place on floor

 Check all the suspension bushes

 Replace if any needed.

9.7.7 Clutch disc assembly replacing

 Disconnect the battery terminals.

 Remove the following items

 Air filter assy

 Battery and battery tray.

 Clutch sleeve cylinder from the gear box.

 Gear selecting cables

 Speedo gear

 Loose the B (Gear box mound) mound.

 Remove the suspension lounge and C gear box mound.

 Loose and remove all gear box bolts

 Jack the engine with a stand.

 Shake the gear box and remove the box from the engine.

 Grease the shafts.

 Replace the clutch assembly

 When fasten the pressure plate use the special tool "clutch centre" for centring the
clutch dise.

 Do this step vice versa for finishing the job.

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9.7.8 Turbo charger removal and refitting

 Disconnect the battery terminals

 Remove

 Air cleaner to turbocharger hose.

 Parts that make the work tough

 Turbocharger oil supply pipes and vacuum pipes from manifold

 Disconnect the exhaust pipe from the turbocharger

 Remove the exhaust manifold along with turbocharger

9.7.9 FIP Removal and refitting

 Disconnect the battery terminals

 Remove the battery from its tray.

 Disconnect the wiring from FIP

 Remove the high pressure pipe from the injector and FIP

 Remove the three bolt that fix the FIP in engine.

 Rotate the FIP and slowly push the out FIP with care.

9.8 PROCEDURE FOR ALIGNING THE WHEELS

 The wheel must have proper camber, caster angles and toe. It will change due to the
use. So the alignment must be checked properly. Check the tyre pressure and bring it to
correct as per specification.

 Bring the vehicle to the ramp

 Make sure that the front wheels are on the disc provided.

 Attach the sensors on all the wheels

 By operating the computer which has pre recorded data's of vehicles, select the
vehicle

 Jack up the front wheels and press the run out of each wheel and check it

20
  After that jack up rear wheels and set the run out.

 Rotate the steering wheel to left, right and centre

 Set the steering wheel correctness if not adjust it properly.

 Go under the vehicle and loosen the nuts of steering tie rod.

 Turn it and check the toe.

 Bring it to proper specification and tighten nuts.

9.9 PROCEDURE FOR WHEEL BALANCING

The wheels of the vehicle may not be perfectly balanced weight form the
axle to the outer part is not same at all points. It is balanced with the help of a machine
called wheel balancer. It determinates the position and weight to be added to balance the
wheel. Sticker weights are added in alloy wheels and clip in weights are added in normal
steel wheel.

 Make sure that the disc is proper and not bended

 Check the tyre pressure and make it as per manufacturer

 Remove the weights from the wheel.

 Place it on the axle and tighten it.

 Set the dimensions of wheel and rim tyre.

 After setting press the rotation key

 After the process stop the wheel from rotation by pressing the brakes

 Determine the position to ass the weight and amount with the machine

 Stick or clip the weight

 Repeat it until the machine indicates OK

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 10. MAJOR VEHICLE MAINTENANCE

10.1 CYLINDER HEAD REMOVAL

 Disconnect the battery terminals

 Remove the battery from its tray.

 Disconnect all wiring connections in head

 Drain the oil

 Remove

 All belts

 Water hoses from the head and thermostat

 Hose turbocharger to inlet manifolds

 Egr pipe to exhaust manifold

 Oil supply line to turbocharger

 High pressure pipe from the injector and fip

 Injector from head

 Timing chain.

 Top cover that have rocker arm

 Injectors

 Exhaust manifold from the head

 Cylinder head bolts

 While fitting the cylinder head gasket. Ensure that the blockhead and gasket are dry

 If the cylinder head gasket was skimmed, the please cross check the injector protrusion

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10.2 DISMANTLING AND OVERHAULING OF THE ENGINE

If comprises of 5 steps

1. Removal of the engine

2. Dismantling

3. Inspection

4. Assembling

5. Testing

10.2.1 Removing of the engine from the vehicle

 Disconnect the battery terminals

 Check the wheels

 Drain the oil andcoolant

 Remove

 Air cleaner

 The hose air cleaner to turbochargers

 Starting motor

 The electrical connection to starter, alternator, FIP injectors and all sensors.

 The fuel lines to FIP as well as the return line going to tank

 Disconnect the exhaust pipe from the turbocharger

 Disconnect the hose from the radiator end

 Remove the front grill along with the radiator

 Disconnect the clutch slave cylinder

 Support the transmission system security

 Support the engine using the lifting hook

 Check once more if any connections to be disconnected or removed.

23
 Remove transmission mounting bolt in the engine block

 Using a crane, pull the engine out of vehicle

10.2.2 Dismantling The Engine

 Remove

 Turbocharger hose to inlet manifold

 Egr pipe to exhaust manifold

 Oil supply line to turbocharger

 Dipstick guide

 High pressure pipe at the injector end and flip

 Loosen the alternator brace at the top

 Loosen the alternator mounting bolt at bottom. Move the alternator towards inner

 Take off the belt

 Remove the alternator

 Rocker arm cover.

 Injector and fip.

 Water pump.

 Damper mounting bolt and damper.

 Rocker aim cover.

 Loosening the camshaft mounting bolts

 Remove
 Flywheel mounting bolts.

 Oil sump.

 Timing cover and chain.

 Camshaft along with the thrust plate.

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  Camshaft mounting bolts.

 Connecting rod nuts.

 Rear-end oil seal along with the carrier.

 Crankshaft.

 Piston along with connecting rod.

10.2.3 Inspection

All the components should be inspected for wear. Any components, which are
beyond the wear limits, have to be replaced. Over and above the near limits, the following
paints also need to be ensured.

10.2.4 Piston

Check for stifling scaring on a head think larger of carbon acquire on top land is
acceptable.

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 10.CONCLUSION

This report is based on industrial training at STAR MARUTI GARAGE Pvt,Ltd,. The
Mustang Motors is the leading service and repair of premium cars in Kerala. During 10 days
of training through exposure was created in management function of various department of
the company. There was also opportunity to go through real hand maintenance activities.
The meaning of Training is to learn a skill. Training is the act of increasing the knowledge
and skill of a person for doing a particular job. Training enables to acquire latest skills, thus
increase versatility for qualification for busting carrier. It provides better safety,
remuneration and security. It also enables to drive greater satisfaction and utilize the full
skills and capacity. Proper training teaches proper operation and changes the wrong
attitude and also tells the safe points. In-plant training for diploma automobile engineering
students is important because it is the time to obtain as much knowledge about their field.
As a diploma student, training helps me to implement the concepts I learned at my classes.
Actual challenges only appear when I work in real-world of automobile. All the automobile
subjects based on the theories already I learned during my diploma course, but there are lot
more things involved in developing a live application and those things can be learned only
from a good service centre environment and that never taught me at classes. Training
increases the confidence in my field that I learned. After completing training I feel much
confident about me field. If my Concepts not clear or I have any confusion with them, then
at the time of interview, exams or in professional life I may face many problems. All
experienced people always like to hear accurate to the point solution to every problem, my
carrier depends on my sharpness, intelligence and of course in my confidence. So as much
as possible, I cleared my confusion and got the new ideas from the fields with the help of In-
plant training and become confident and sincere in this field.

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