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INDUSTRIAL TRAINING
A Report on Industrial Training
Submitted by
SAKARWALA MEET PIYUSHBHAI
BACHELOR OF ENGINEERING
Prepared in fulfillment of the industrial training
At
MARUTI SUZUKI KATARIA AUTOMOBILE,

PVT .LTD
GUJARAT TECHNOLOGICAL UNIVERSITY, AHMEDABAD
GIDC DEGREE ENGINEERING COLLEGE, NAVSARI
Guided by: - Mayur . J. Jalanapurkar
Head of Department: - Toral .V. Patel
27 July 2023 to 10 August 2023

GIDC DEGREE ENGINEERING COLLEGE
Block No.997, Tal. Jalalpore, Dist. Navsari, Abrama, Gujarat-
396445
CERTIFICATE
This is to certify that the Industrial report submitted long with entitled
Industrial training has been carried out by Sakarwala Meet Piyushbhai
under my guidance in partial fulfillment for the degree of bachelor of
engineering in Automobile 7th Semester of Gujarat Technological University,
Ahmedabad during the academic year 2023-2024.
Sign: __________________ Sign: __________________
Mayur J. Jalanapurkar Toral .V. patel
Internal Guide Head of the Department
External Examiner: ___________________
Page i
MARUTI SUZUKI KATARIA AUTOMOBILE PVT.LTD, SURAT
GIDC DGREE ENGINEERING COLLEGE, NAVSARI
Company
Certificate
Page ii
Permission
letter
Page iii
Page iv
ACKNOWLEDGEMENT
Guidance from the experienced employees and technician help us to deeply

understand the working of automobile workshop and its tools and equipment and
the way they work in systematic manner. Thanks to the staff that taking cares
our safety during working in severe condition and giving the correct knowledge of
each and every doubt that we have. We have learned a lot from the staff of the
company like how to attend the customer, how to work in team. We are thankful
to our Prof.Mayur .J. Jalanapurkar and whole automobile department.
My heartiest credit to our beloved head of department Prof. Toral .V. Patel who
was taking cares our studies. We sincerely thanks to our friends to provide
guidance and helping us inevery difficulty faced during the whole period of
internship.
We are thankful from our heart to our parents for supporting us in every step of
our lif e and to make us successful to achieve our dream.
Thanks to GTU for addingthe15 days internship to the semester.
Page v
ABSTRACT
An engineering student our aim should not be learn theoretical concept in the
classroom, but it becomes more important ask how we apply those concept in
practical. The training of industrial is to create awareness about industrial
environment amongst the student, such training plays vital role in automobile
engineering. The important of training and project preparation has been widely
accepted in the education institution, our college is providing off training. My
objectives are us training gain general information and knowledge about
automobile. I am learning in training period how communicate with customer.
The report provides an overview of training. In this report describe automobile
related question and solution. Also describe automobile system, Morden
technology, and general information about service centre, etc. Training has an
important role to play, and it is expected to inculcate positive changes are
knowledge, skills, and attitude.
Page vi
Table of Figure
Figure: - 1.1 Maruti Suzuki logo………………………………………………….............01
Figure: - 1.2 Kataria Logo………………………………………………………….............04
Figure: - 1.3 Workshop layout …………………………………………………...............06
Figure: - 1.4 Body Shop layout……………………………………………………............07
Figure: - 1.5 Organization Structure…………………………………………….............08
Figure: - 1.6 Gysy………………………………………………………….........................11
Figure: - 1.7 Omni…………………………………………………………........................12
Figure: - 1.8 Eeco………………………………………………………….........................13
Figure: - 1.9 Alto…………………………………………………………...........................14
Figure: - 1.10 Wagonr…………………………………………………………...................15
Figure: - 1.11 Celerio…………………………………………………………....................16
Figure: - 1.12 Swift………………………………………………………….......................17
Figure: - 1.13 S-cross…………………………………………………………...................18
Figure: - 1.14 Ignis………………………………………………………….......................19
Figure: - 1.15 Baleno…………………………………………………………....................20
Figure: - 1.16 Dzire………………………………………………………….......................21
Figure: - 1.17 Ciaz…………………………………………………………........................22
Figure: - 1.18 Ertiga………………………………………………………….....................23
Figure: - 1.19 Vitara Brezza……………………………………………………….............24
Figure: - 1.20 S-presso………………………………………………………….................25
Figure: - 1.21 XL6…………………………………………………………........................26
Page vii
Figure: -1.23 Grand Vitara………………………………………………………...............27
Figure: - 2.1 Allen Keys…………………………………………………….......................28
Figure: -2.2 Adjustable Wrench…………………………………………………..............29
Figure: - 2.3 T- Spanner……………………………………………………………............29
Figure: - 2.4 Nose Pliers………………………………………………………...................30
Figure: - 2.5 Screw Driver………………………………………………………….............31
Figure: - 2.6 Ring Spanner…………………………………………………………...........31
Figure: - 2.7 Fixed Spanner……………………………………………………….............32
Figure: - 2.8 Combination Spanner……………………………………………..............32
Figure: - 2.9 Hammers………………………………………………………....................33
Figure: - 2.10 Chisel…………………………………………………………....................33
Figure: - 2.11 Ratchet………………………………………………………….................34
Figure: - 2.12 Box Spanner………………………………………………………............34
Figure: - 2.13 Extension and Universal joint………………………………..............35
Figure: - 2.14 Oil Filter…………………………………………………………...............35
Figure: - 2.15 Wheel Wrench………………………………………………………..........36
Figure: - 2.16 Dolly………………………………………………………….....................36
Figure: - 2.17 Pnemetic Gun………………………………………………………...........37
Figure: - 2.18 Air Gun………………………………………………………….................37
Figure: - 2.19 Bench Grinder…………………………………………………….............38
Figure: - 2.20 Grinder……………………………………………………….....................38
Page viii
Figure: - 2.21 Heat Gun.........................................................…........................39
Figure: - 2.22 Press Machine……………………………………………………..............39
Figure: - 2.23 MIG Welding……………………………………………………….............40
Figure: - 2.24 Hydraulic Lift………………………………………………………...........40
Figure: - 2.25 Wheel Balancing………………………………………………….............41
Figure: - 2.26 Wheel Alignment………………………………………………................41
Figure: - 2.27 AC Filling And Removing Machine……………………………...........42
Figure: - 2.28 Gas Welding……………………………………………………….............42
Figure: - 2.29 Hydraulic Jack……………………………………………………............43
Figure: - 2.30 Jumper Puller………………………………………………………..........43
Figure: - 2.31 Torque Wrench……………………………………………………...........44
Figure: - 2.32 Car-O- Liner………………………………………………………............44
Figure: - 4.1 Oil Filter Replacement…………………………………………...............50
Figure: - 4.2 Replacement of Air Filter…………………………………………...........51
Figure: - 4.3 Replacing Ac Filter…………………………………………………...........52
Figure: - 4.4 Replacing Of Brake Pads………………………………………..............53
Figure: - 4.5 Engine Oil Change…………………………………………………...........54
Figure: - 4.6 Replacement of Coolant………………………………………….............55
Figure: - 4.7 Wheel Balancing……………………………………………………...........56
Figure: - 5.1 Synchronizer Ring Change……....................................................57
Figure: - 5.2 Shock Absorber Change…………………………………………............58
Page ix
Figure: - 5.3 Lower Arm changing………………………………………………...........60
Figure: - 6.1 Jobcard………………………………………………………………...........63
Figure: - 6.2 Customer Declaration…………………………………........................64
Figure: - 7.1 SHVS (Smart Hybrid Vehicle System)……………..........................65
Figure: - 7.2 S-CNG…………………………………………………………...................66
Page x
List of Table
Table: - 3.1Free Service Schedule…………………………………………………......45
Table: - 3.2 preventive Maintenance Schedule……………………………….........46
Table: - 3.3 Parts And Elements Changing Time Period.................................47
Page xi
Contents
CERTIFCATE……………………………………………………………………………..i
COMPANY CERTIFICATE……………………………………………………………..ii
PERMISSION LETTER..........................................................................….iii
ACKNOWLEDGEMENT………………………………………………………………..v
ABSTRACT...............................................................................................vi
TABLE OF FIGURE……………………………………………………………………vii
CHAPTER – 1 INTRODUCTION…………………………………………………….01
1.1 About of Maruti Suzuki………………………………………………………..01
1.2 History Of Maruti Suzuki……………………………………………………..02
1.3 Company Milestones…………………………………………………….........03
1.4 About Kataria Automobiles……………………………………..….............04
1.5 Workshop layout ………………………………………………………………06
1.6 Body Shop layout……………………………………………………………….07
1.7 Organization Structure………………………………………………………..08
1.8 Classification different section and their explanation………………….09
1.9 Specification Of Cars…………………………………………………............11
CHAPTER – 2 MAJOR AND MINOR TOOLS AND EQUIPMENTS…………28
2.1 Major Tools…………………………………………………………………….28
2.2 Minor Tools……………………………………………………………………28
2.3 Hand Tools…………………………………………………………………….29
2.4 Power Tools……...........................................................................37
2.5 Major Equipments…………………………………………………………..40
Page xii
CHAPTER – 3 PERIODIC AND PREVENTIVE MAINTENACE…………….45
3.1 Process of Service……………………………………………………….....45
3.2 Free Service………………………………………………………………….45
3.3 General service ……………………………………………………………..46
3.4 Breakdown Maintenance…………………………………………………47
3.5 Pre- Delivery Inspection…………………………………………………..48
3.6 Parts & Elements changing time period………………………………49
CHAPTER 4:- PERFORMED/OBSERVED WORK…………………….…...50
4.1 Oil Filter Replacing…………………………………………………………50
4.2 Replacing Air Filter…………………………………………………………51
4.3 Replacing Ac Filter…………………………………………………..........52
4.4 Replacing Filter……………………………………………………….........53
4.5 Engine Oil Change………………………………………………………….54
4.6 Replacing Engine Coolant………………………………………………...55
4.7 Wheel Balancing…………………………………………………………....56
CHAPTER 5:- CASE STUDIES…………………………………………………..57
5.1 Synchronizer Ring Change ………………………………………………....57
5.2 Suspension…………………………………………………………………..58
5.3 Lower Arm Changing……………………………………………………..60
CHAPTER: - 6 JOB CARD.………………………………………………………61
6.1 Importance of job card……………………………………………………61
Page xiii
6.2 Information that advisor fills in job card are………………………..61
6.3 Information filled by technician in job card………………………....61
CHAPTER 7:- MORDEN VEHICLE TECHNOLOGY………………………..65
7.1 SHVS (Smart Hybrid Vehicle System)…………………………………65
7.2 S-GNG………………………………………………………………………..66
CHAPTER 8:- CONCLUSION.......................................................….67
8.1 Conclusion……………………………………………………………………67
REFERENCES……………………………………………………………………….68
Website………………………………………………………...............................68
Page xiv
CHAPTER – 1 INTRODUCTION
1.1 About of Maruti Suzuki
Figure: - 1.1 Maruti Suzuki logo
Mauti Suzuki is the No. 1 Cars Selling Company in India. Slogan of This
Company is Way of Life! It is the Child Company of Suzuki Motors Corporation,
Japan. Suzuki is Most popular Company in Japan. It is Manufactures
Motorcycle, Bikes and Cars. Maruti Suzuki India limited is known as Maruti
Udyog Pvt. Ltd, India Maruti Suzuki is Established in 1981 in India But The
company Started Its Actual Production in 1983.At That Time, Compretitors of
Maruti is Hindustan Ambassador & Premier Padamani is Competitor.
Nowadays, Chairman of Maruti Suzuki is R.C. Bhargava & C.E.O is Kainichi

Ayukawa. As of January 2016, Maruti Suzuki Had A 47% Market of Indian
Passenger Cars. Maruti Suzuki Manufactures and Sells Popular Cars Such as
The Alto, Swift, Zen, Celerio, Swift Dzire, Omni, Vitara Brezza, Ertiga, Ciaz,
Baleno, Sx4, Eeco, S-cross and Ritz.In February 2012, The Company Sold Its Ten
Millionth Vehicle in India
Page 1
1.2 History of Maruti Suzuki
Maruti’s history begins in 1970, when a private limed company named
“Maruti technical services private limited” (MTSPL) is lunched 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 and Sanjay Gandhi became its first managing director. After a
series of scandals, “Maruti limited” goes into liquidation in 1977. This is followed
by a commission of inquiry headed by justice A.C. Gupta, which submits its
report in 1978. On 23 June 1980 Sanjay Ghandhi dies when a private test plane
he was flying crashes. A year after his death, and at the behest of Indira Gandhi,
the Indian central government salvages Maruti limited and starts looking for an
active collaborator for a new company : Maruti udyog Itd being incorporated in
the same year.
In 1982, a license & joint venture agreement (JVA) is signed between Maruti
udyog limited and Maruti 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 Suzuki in the first two years, and even after that the early
goalwas 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 the petrol tax and lowering the excise duty
in order to boost sales. Finally, in 1983, the Maruti 800 is released. This 796cc
hatchback is based on the SS80 Suzuki alto and is India’s first affordable car.
Initial product plan is 40% saloons, and 60% Maruti van. Local production
commences in December 1983. In 1984 the Maruti van,with the same three-
cylinder engine as the 800, is released. Installed capacity of the plant in Gurgaon,
reaches 40,000 units.
In 1985 the Suzuki SJ410-based gypsy, a 970cc 4WD off-road vehicle, is

launched.In 1986 the original 800 is replaced by an all-new model of the 796cc
hatchback Maruti 800. This is also when the 100,000 vehicle is produced by the
company. In 1987 follows the company’s first export to certain neighboring
Page 2
countries already. By 1988, the capacity of the Gurgaon plant is increased
100,000 units per annum.
In 2000 Maruti becomes the first car company in India to launch a call
center for internal and customer services. The new alto released, somewhat laeger
and more morden than the 800.
1.3 Company Milestones

1970 : The Indian government launched a new car company called Maruti
Technical service limited which created competition for the existing Ambassador
car Company.
1971 : The government changed the name of the company to Maruti limited.
Indira Ghandhi’s son, Sanjay Ghandhi became the managing director of
company.
1977 : The Company was liquidated as a result of corruption.
1978 : Where the court issued a notice to Maruti. Sanjay Ghandhi passed away.
1981 : The Company was re-established when the founder’s mother, Indira
Ghandhi took charge. The company was called Maruti Udyog Limited.After
partnership with Japanese giant Suzuki Motor Corporation in a Joint Venture
Agreement,the company was called Maruti Suzuki.
1983 : Maruti produced its first car, the Maruti 800. It took the company
thirteen months to produce this car.This changed the landscap of the Indian car
market as Maruti 800 was the most cost-effective and fuel-efficient car in india.
1984 : Maruti produced a large mini-van called Omni that seated up to eight
people.
BETWEEN 1985 TO 1995 : Maruti launched the Gypsy, the Maruti 1000, the
Zen, the Esteem,and the Maruti on road service, A 24hours service which gives
customers 24hour access to technicians and vans who are ready to help with any
problem of the car round the clock. In 1987, the company made its first export
sales, 500 cars to Hungary.
Page 3
1996 : This was a prominent year for Maruti as five new models of its cars were
lunched including the Gypsy (E), Omni (E), and Gypsy king (E), the automatic
Zen and the Esteem in a 1.3 liter engne. Gypsy has the engine had the engine
had a horsepower of 65bhp.
2000 : Maruti lunched India’s first call center and Alturas, a luxury car.
2003 : Maruti lunched the grand vitara.
2006 : Maruti had produced up to six million cars.
1.4 About Kataria Automobiles

Kataria Automobile Pvt. Ltd. Near Gujarat gas station road, vesu, Surat.
Contect website:-Kataria.srt.edp3@marutidealers.com
 Workshop Manager
- Mr. Vipul Patel
 Assistant workshop manager
- Mr. Parth Patel
Figure: - 1.2 Kataria Logo

The KATARIA GROUP was founded by Mr. Shobhagmal Kataria in the year
1956 and has grown to become one of the biggest Transport Operators in India,
having 60 branches. The Kataria group has since expanded its wings, by way of
expansion and various sectors, the first being in 1984 with dealership of LML- 2
wheelers. It further expanded its wings to become one of the Most Trusted Brand
Page 4
for Maruti Car Dealership in 1996. Not stopping at its unflinched Automobile
Growth, it further acquired the dealership of TVS Two Wheelers in 2003.
Today Kataria Automobiles is one of the “most trusted brands” in the

“Automobile Dealership of Maruti Suzuki” with Showrooms in Ahmedabad, Surat,
Navsari and Vapi Today the kataria Group is proud to have a family of 2000
dedicated and committed work force. The Group further has a “satisfied”
customer base of more than 2,00,000 happy families.
Page 5
1.5 Workshop layout
Figure: - 1.3: - Workshop layout
Page 6
1.6 Body Shop layout
Figure: - 1.4 Body Shop layout
Page 7
1.7 Organization Structure
Figure: - 1.5 Organization Structure
Page 8
1.8 Classification different section and their explanation
Engine room:-
Engine room is used during engine making or dismantling of it.
Warranty room:-
Vehicle parts which are in warranty are stored in this room and the in
charge of warranties provides necessary assistance in warranty process.
Tool room:-
All the special and costly equipment and tools are stored in this room and
technician can access it any time during servicing and the in charge of tool
room also keeps logs of tools and who used it during particular time.
Part store:-
Part store provides diﬀerent parts required for servicing of vehicle and
also place an order for any parts which is not available in store.
Job control room:-
In this room the workshop manager and workshop supervisor sits and
control the workshop for smooth operation of it.
Electric room:-
Used for storing electric items of cars which are servicing right now or
the electrical equipments of workshop.
Store room:-
Room is used to store the parts of vehicles and workshop.
Paint booth:-
It is used to paint the car or any parts of vehicles. It is used because
paint booth prevents the harmful paint particles from leaking in atmosphere.
Compressor room:-
This room stores the air compressor in it which is much needed
equipment of any workshop.
Body store room:-
Body store room is used to store the parts of vehicles body.
Page 9
Body tool room:-
It is used to store body cutting, grinding, surfacing etc
Scarp area:-
It used to put scrap of the vehicles like bumpers, break disks, tyres,
alloys etc.
Washing area:-
Vehicle is washed in this area by using high pressure water and
washing solution.
Service parking:-
This area used to park the vehicles whose service is finished or for the
vehicles whose service is paused due to unavailability of certain parts.
Staff parking:-
It is used by staff of workshop to park their vehicles.
Technician lunch room:-
This room is used by technicians during lunch break to sit and take
lunch and rest in it.
Page 10
1.9 SPECIFICATION OF CARS
GYPSY:
Figure: - 1.6 Gysy
 Gear Box: - 5 speed

 Mileage: - 11.96 Kmpl
 Transmission: - Manual
 Engine: - 1298CC
 Power: - 80.0Bhp
 Torque: - 103.0Nm
 Fuel Type: - Petrol
Page 11
OMNI:
Figure: - 1.7 Omni

 Mileage: - 14Kmpl
 Engine: - 799CC
 Torque: - 59Nm
 Fuel Type: - Petrol & CNG
Page 12
EECO:
Figure: - 1.8 Eeco

 Mileage: - 18 Kmpl
 Power: - 63Bhp
 Torque: - 83Nm
Page 13
ALTO:
Figure: - 1.9 Alto

 Transmission: - Manual & Automatic
 Engine: - 796CC
 Torque: - 69Nm
Page 14
WAGONR:
Figure: - 1.10 wagonr

 Engine: - 998CC
 Torque: - 113Nm
Page 15
CELERIO:
Figure: - 1.11 Celerio

 Gear Box: - 5speed
 Engine: - 998CC
 Torque: - 90Nm
Page 16
SWIFT:
Figure: -1.12 Swift

 Engine: - 1248Cc
 Power: - 74Bhp@4000Rpm
 Torque: - 190Nm@2000Rpm
 Fuel Type: - Petrol & Diesel
Page 17
S-CROSS:
Figure: - 1.13 S-cross

 Power: - 88.5Bhp@4000Rpm
 Fuel Type: - Diesel & Petrol
Page 18
IGNIS:
Figure: - 1.14 Ignis

 Fuel Type: - Petrol
Page 19
BALENO:
Figure: - 1.15 Baleno

 Gear Box: - CVT
Page 20
DZIRE:
Figure: - 1.16 Dzire

 Torque: - 190Nm
Page 21
CIAZ:
Figure: - 1.17 Ciaz

 Torque: - 229Nm@1500rpm
Page 22
ERTIGA:
Figure: - 1.18 Ertiga

Page 23
VITARA BREZZA:
Figure: - 1.19 Vitara brezza

Page 24
S-PRESSO:
Figure: - 1.20 S-presso

 Mileage: - 21kmpl
 Engine: - 998cc
 Power: - 67bhp@5500rpm
 Torque: - 90nm@3500rpm
 Fuel Type: - petrol
Page 25
XL6:
Figure: - 1.21 XL6

 Mileage: - 19 Kmpl
 Engine: - 1462 cc
 Power: - 103.2bhp@6000rpm
Page 26
GRAND VITARA:
Figure: -1.23 Grand Vitara

 Mileage: - 10.4 Kmpl
 Engine: - 2393 cc
 Power: - 163.5bhp@5000rpm
Page 27
CHAPTER – 2
MAJOR AND MINOR TOOLS AND EQUIPMENTS
2.1 MAJOR TOOLS
1. Wheel Alignment machine

2. Wheel Balancing machine
3. A.C gas filler machine
4. Hydraulic lift
2.2 MINOR TOOLS

1) Fix spanner
2) Ring spanner
3) Combination spanner
4) Screwdriver
5) Rachet
6) Chisel & center punch
7) Box tools
8) Allen key spanner
9) Oil filter wrench
10) Adjustable Wrench
11) Plastic Hammer
12) Pillars
13) Coil spring Compressor
14) Air Gun
15) Multimeter
16) T-spanner
Page 28
2.3 Hand Tools:-
 Allen key set
Figure: - 2.1 Allen Keys
 It is used for open allen key bolts.
 Adjustable wrench
Figure: -2.2 Adjustable Wrench
 An adjustable wrench has jaws that can be adjustable to fit different size
bolt and nut heads.
Page 29
 T-spanner
Figure: - 2.3 T- Spanner

 T-bar socket wrench is used where it is hardy to reach fasteners and remove
fasteners speedy.
 Nose pliers
Figure: - 2.4 Nose Plier

(1) Nose pliers are excellent for handling extremely small parts or reaching into
highly restricted areas.
(2) Locking pliers, or vise grips, clamp onto and hold a part; this frees both
hands to do other tasks.
Page 30
 Screw driver
Figure: - 2.5 Screw Driver
 Screwdrivers are used to remove or install screws. Types of Screwdrivers

are described below.
1.1.Flat blade screwdriver: Flat blade screwdriver fit neatly into the blade
the same width.
2.2.Phillips screwdriver: It has a cross on the end of the Shaft that fits the
star-shaped slot of the screw.
 Spanners
1) Ring spanners
 Box-end wrenches are completely closed on both ends .A box-end wrench
will not round off bolt heads as easily as an open-end wrench.
Figure: - 2.6 Ring Spanner
Page 31
2. Fixed Spanners
Figure: - 2.7 Fixed Spanner

 An open-end wrench has an open, or split, jaw on both ends. This angle
allows the open-end wrench to turn bolts and nuts with little wrench swing
space.
3. Combination spanners set
Figure: -2.8 Combination Spanner

 A combination wrench has a box-end jaw on one one and an open-end jaw
on the other, Combination wrench provides the advavtage of two type of
wrenches for the price of one.
Page 32
4. Hammer
Figure: - 2.9 Hammers

 Various type of hammers are used for operatons that involve striking a tool
or part.
5. Chisel
Figure: - 2.10 Chisel
 Generally it used in body shop for cutting.
Page 33
6. Ratchet
Figure: - 2.11 Ratchet

 A Ratchet is the most commonly used and multipurpose socket handle. A
Ratchet is the most commonly used and versatile socket handle. It has a
small lever that can be moved for either loosening bolts.
7. Box spanners
Figure: - 2.12 Box Spanner

 A socket is a cylinder-shaped. Box-end tool for removing or installing bolts
and nuts. One end Fits over the fastener. A socket’s drive size is the size of
the square opening for the ratchet or tool handle.
Page 34
8. Extension & universal joint
Figure: - 2.13 Extension and Universal joint

 Extensions are used between a socket and its handle. A Universal joint is
a swivel that lets the socket wrench reach around obstructions.
9. Oil filter wrench
Figure: - 2.14 Oil Filter

 Oil Filter Wrench is the most commonly use to easily open the oil filter &
easily to fit it.
Page 35
10. Wheel Wrenches
Figure: - 2.15 Wheel Wrench

 Wheel wrenches are one end open and one end closed that have six points
opening.
 Approximate cost :- 350rs.

 Specific use :- To tight or loose bolt and nut of wheel.
11. Dolly
Figure: - 2.16 Dolly

 A dolly is used with a hammer for panel forming.
Page 36
2.4 Power Tools:-
1. Pneumatic gun
Figure: - 2.17 Pnemetic Gun

 It is use for loose and tight wheel nut.
2. Air gun
Figure: - 2.18 Air Gun

 Air gun used clean dirty area. (Engine, air filter, ac filter, drum brake etc.)
Page 37
3. Bench Grinder
Figure: - 2.19 Bench Grinder

 That wire brush wheel is used in order to clean or polish the work piece and
on other side to perform rough grinding.
4. Grinder
Figure: - 2.20 Grinder

 It is used for cutting, grinding, polishing of metal.
Page 38
5. Heat gun
Figure: - 2.21 Heat Gun

 It is used for applied heat on fiber parts for required desire shape.
6. Press Machine
Figure: - 2.22 Press Machine
 It is used press wheel hub baring.
Page 39
2.5 Major equipment
1. MIG Welding
Figure: - 2.23 MIG Welding

 It is used for joint two sheet metal parts.
2. Hydraulic lift
Figure: - 2.24 Hydraulic Lift

 It used to easy car up and down as necessary.
Page 40
3. Wheel balancing
Figure: -2.25 Wheel Balancing

 It use for balance wheel of the car.
 When the wheel rotates of car sometime steering wheel get wobbling and
vibration is increases with it can harm and unbalance force can damage
the suspension parts. The ride disturbance due to unbalance and vibration
of car body.
 When we are working on balancing of wheels, we have to remove weight
which is on wheels
4. Wheel alignment
Figure: - 2.26 Wheel Alignment

 It’s used to set toe in, toe out, caster and camber.
Page 41
5. AC gas filling and removing machine
Figure: - 2.27 AC Filling And Removing Machine

 It is use to fill ac gas in the cars for cooling.
6. Gas Welding
Figure: - 2.28 Gas Welding

 It’s used to cutting a metal and welding a metal.
Page 42
7. Hydraulic jack
Figure: - 2.29 Hydraulic Jack

 It’s used to support a vehicle Operates a hydraulic.
8. Jumper puller
Figure: - 2.30 Jumper Puller

 It is use to compress the coil spring for disassemble the suspension.
Page 43
9. Torque wrench
Figure: - 2.31 Torque Wrench

 A torque wrench is used where the tightness of screws and bolts is
crucial. It allows the operator to measure the torque applied to the
fastener so it can be matched to the specifications for a particular
application.
10. Car-O-Liner bench
Figure: - 2.32 Car-O- Liner

 For body aligning, to gain initial position of frame and chassis.
 Capacity :- 2800 kg
Page 44
CHAPTER: – 3 PERIODIC AND PREVENTIVE
MAINTENACE
3.1 PROCESS OF SERVICE
As per the kilometre of vehicle different services are provided to the customer and
also as per the problems detected by the customer in their vehicle. Maruti Suzuki
Kataria provides mainly four free services to their entire customer and customer
can also extend their service by paying extra charges as per the company norms.
3.2 Free Service
 Engine oil.
 Check coolant.
 Check/Replace air filter.
 Check battery level.
 Check washer tank and fill.
 Replace oil filter as a PMS chart.
 Check horn.
 Check all lights.
 Check interior accessories.
 Check door noise.
 Washinng
Free Service Schedule
Service On Km On Time
1st Service 1000 KM AFTER 1 MONTH
2nd Service 5000 KM AFTER 6 MONTH
3rd Service 10000 KM AFER 1 YEAR

Table: - 3.1Free Service Schedule
Page 45
3.3 General Service
 Check under body parts damage.
 Check wheel bearing.
 Check suspension system.
 Check bolt joint.
 Check engine oil, coolant, all filters, gear oils, wiper blades, all lighting
system.
 Check leakages.
 Customer’s approval and replace.
 Check battery electrolyte.
 Check washer tank water level.
 Check brake fluid level.
 Check wheel pressure.
 Check interior accessories.
 All door oil and greasing.
 Washing and cleaning
Preventive Maintenance Schedule
PMS type Petrol Diesel
Pms20 Oil filter + coolant + brake Service kit + coolant + brake

fluid fluid +engine oil
+ engine oil
Pms30 Oil filter + engine oil Oil filter + engine oil
Pms40 Service kit + coolant + brake Service kit + brake fluid +

fluid + engine oil coolant + engine oil
Pms50 Oil filter + engine oil + engine Oil filter + engine oil
oil
fluid fluid + engine oil
+ engine oil
Page 46
Pms80 Service kit + coolant + brake Service kit + coolant + brake
fluid + water pump belt + fluid + engine oil
engine oil

fluid fluid + engine oil
+ engine oil
Table: - 3.2 preventive Maintenance Schedule
3.4 Breakdown Maintenance

 What is vehicle breakdown maintenance?
A vehicle breakdown is the mechanical failure of a vehicle in such a way
that the underlying problem prevents the vehicle from being operated at all,
or impedes the vehicle’s operation so much, to prevent breakdown is very
difficult, nearly impossible. Vehicle can occur for a large number of reason.
 Causes a vehicle breakdown

 Alternator
 Battery
 Brakes
 Broken belts
 Broken tie rods
 Engine overheating
 Fuel pump
 High pressure pump
 Ignition modules
 Starter
 Timing belts
 Tyre
 Transmission
 Water pump
Page 47
 Injectors
 Wiring cutting
3.5 Pre- Delivery Inspection

 Pre-delivery inspection is a type of service which is carried out before
delivering the vehicle to the customer.
 Checking coolant level.
 Checking all window & door switches.
 Checking all fuses.
 Checking all electric connections & lights.
 Checking other damages if any.
 Checking spear wheel lock is tight.
 Checking wiper water tank.
 Checking battery terminal check& battery water check.
 Checking all gear is working.
 Checking seat.
 Checking Engine oil.
 Checking Ac.
 Checking replace parts.
Page 48
3.6 Parts & Elements changing time period
Parts changing time Parts changing time
Part name (Kilometer) (Year)
Air Filter 40000 4 Year

Ac Filter 10000 1 Year
Diesel Filter 40000 4 Year
Petrol Filter 40000 4 Year
Oil 10000 1 Year
Oil Filter 10000 1 Year

(Diesel)
Oil Filter 10000 1 Year

(Petrol)
Brake Oil 20000 2 Year
Coolant 20000 2Year
Gearbox Oil -
V Belt 60000 -
Spark Plug 40000 -
Table: - 3.3 Parts And Elements Changing Time Period
Page 49
CHAPTER 4:-PERFORMED/OBSERVED WORK
In this chapter we will learn about different practical work which I have worked
and perform during my 15 Days internship training in company. In this chapter
there are Practical work which I have done are replacing engine oil, oil filter,
replacing AC filter and air filter, brake bleeding, replacing brake pads, calliper
greasing, wheel balancing, wheel alignment, replacing lower arm, tie rod and many
other practical works Has been shown in this chapter.
4.1 OIL FILTER REPLACING
Figure: - 4.1 Oil Filter Replacement
 It is use to filter the oil and give to the engine. It removes dirt from oil.
Procedure: -
 Put a car on a lift and lift the car to its correct position.
 Then open the oil filter with the oil filter spanner.
 Replace the oil filter tight them properly and clean that with clean cotton.
 Before fitting new oil filter apply oil on the oil filter o-ring so it is easy to
remove oil filter, in some oil filter the grease is already applied by company.
Page 50
4.2 REPLACING AIR FILTER
Figure: - 4.2 Replacement Of Air Filter
 It is used to give clean air to engine.

Procedure: -
 Open car bonnet.
 Open air filter box with the use of 12 no T-spanner.
 Remove air filter and check filter.
 If no need to change then just clean it with the help of air gun.
 If air filter is damaged then place it with new filter.
 Clean the air box with air gun then fit new filter and fit air filter box.
 Tighten all the bolts.
 Clean box with clean cotton cloth
Page 51
4.3 REPLACING AC FILTER
Figure: - 4.3 Replacing Ac Filter
 It is used to supply clean air to AC.
Procedure: -
 Open glow box.
 Open AC filter box cap.
 Remove AC out of the AC filter box.
 Clean AC filter with air and if needed then replace.
 Replace new AC filter with old filter and fix it at proper place.
 Fit the AC filter cap.
 Fix the glow box again and close the glow box.
Page 52
4.4. REPLACING BRAKE PADS
Figure: - 4.4 Replacing Of Brake Pads
Procedure: -
 Lift the car on the lift at proper height.
 Take a 19 no box spanner, attach it with air gun and open both front
wheels.
 Open the calliper bolts with 12 no ring spanner.
 Carefully remove calliper and then remove the brake pads.
 Check the brake pads. If no need to change then just clean it with sand
paper.
 Remove calliper pin and grease it properly and fit it again at the proper
position.
 If the brake pads are damaged then replace it with new brake pads.
 Fit calliper carefully and tight the bolts again.
 Check the process again and then fit the wheel.
Page 53
4.5 Engine oil change
Figure: - 4.5 Engine Oil Change
It is used for lubrication, absorb heat, reduce friction etc.

Procedure: -
 Lift the car on the lift at proper height.
 The put the oil reservoir in which you will drain the used oil below the drain
plug
 Now Diesel car Drain Plug are 17mm bolt & Petrol car Drain Plug are 14mm
bolt now remove the drain plug.
 Then you will see the used oil draining in the reservoir or big drum.
 Fit the drain plug when reservoir is empty.
 Now open engine oil filling cap which is situated on engine head.
 Put the conical flask on the oil filler hole so it is easy to fill oil.
 When the oil filled tight the filler cap.
 Check the oil level by removing the dip stick clean it with the cloth and dip
it to the hole and again remove it. You will the oil till the mark given on the
stick.
 Used company specified oil like (SAE 5- W-30) Diesel Car & Petrol car use
the oil [SAE 10-W-40].
Page 54
4.6 REPLACING ENGINE COOLANT
Figure: - 4.6 Replacement of Coolant
Procedure: -
 Put a car on a lift and take it on the high that person can work under a car
 Open the radiator drain valve half located just down on the radiator.
 Let old coolant drain inside the coolant container.
 Then take nose plier and disengage a coolant pipe and clip again to its
position.
 Let coolant drain inside the coolant containe.
 Close the radiator drain valve and fix the coolant pipe and clip again to its
position.
 Take a car down and open the coolant box and radiator cap.
 Pour new coolant inside the radiator and coolant box with distil water.
Page 55
4. 7 WHEEL BALANCING
Figure: - 4.7 Wheel Balancing
Procedure: -
 First of all fit the tyre to the machine.

 Remove the old weight.
 Check the proper tyre pressure.
 Set the machine according to the tyre dimensions.
 Now rotate the tyre by putting the cover on it.
 Now put the new weight as displayed in machine.
 Then again rotate the tyre.
 When the zero number is displayed in machine then the weight are correct.
Page 56
CHAPTER 5: - CASE STUDIES
5.1 Synchronizer Ring Change
Problem: - 1st & 2nd gear not working properly.
Reason: - Worn synchronizer ring.
Solution: - Change it.
Figure: - 5.1 Synchronizer Ring Change
Procedure:
 Remove battery.
 Remove battery holder.
 Remove coolant tank.
 Disconnect gear shift and gear select control cables.
 Remove gear box mounting.
 Remove lower arm.
 Remove exhaust pipe.
 Drain gear oil.
 Remove transaxle.
Page 57
 Disassemble gear box.
 Remove side cover bolts.
 Remove 5th gear.
 Open counter shaft nut related bolts.
 Remove counter shaft, main shaft and change.
 Then go to lathe and change synchronizer ring.
 Reassemble whole assembly and fit gear box.
5.2 Shock Absorber Change

Problem: - Noise From Front
Reason: - Any part of loose & any part of vibration
Solution: - Replace of new part
Figure: - 5.2 Shock Absorber Change
Page 58
Procedure:
 First lift up Car.
 Remove the Wheel.
 Remove Shock Absober.
 Remove Linkage.
 Remove brake oil pipe Bolt.
 Remove Mounties.
 And then new shock absober fitting.
 Fitting Shock Absober Mounting.
 Fitting Linkage bolt.
 Fitting Suspension bolt.
 Fitting wheel
Page 59
5.3 Lower Arm Changing
Figure: - 5.3 Lower Arm changing

Procedure
 First of all, remove the wheel.
 Then separate the lower from the axle by opening the bolt of 14.
 Then separate the shock absorber by opening the two bolts of 17.
 Separate the lower arm from the cross member by opening the bolt of 17
and 19.
 Before fitting the new lower arm apply the grease to the bolts.
 Fit the lower arm by hitting it with the hammer.
 Fit the lower arm with the axle.
Page 60
CHAPTER: - 6 JOB CARD
6.1 Importance of job card

It is important document for workshop as it contains the information
regarding customer, vehicle, last service details etc.
6.2 Information that advisor fills in job card are: -

1. Customer details
2. Vehicle km driven
3. Previous service details of vehicle
4. Damage on the vehicle parts
5. Fuel level
6. Equipment and tools that is present in car
7. Vehicle registration number and chassis number, engine number
8. Complaints from customer regarding the vehicle
9. New service information
10. Type of service
11. Time of vehicle arrival
6.3 Information filled by technician in job card: -

1. Vehicle registration number
2. R.O Number
3. Date
4. Model of vehicle
5. Battery specific gravity
6. Battery make and number
7. Brake pad thickness
8. Brake disc thickness
Page 61
9. Brake liner thickness
10. Disc run out
11. Torque given to the fasteners
12. Tyre rotation type (4 or 5 wheel tyre rotation)
13. Drive of vehicle front or rear wheel drive
14. All tyre tread depth with tyre number and company name
15. Condition of all tyre good or not good
16. Tyre pressure
17. Tyre defect like Bubble in tyre, uneven wear, cracks, multiple puncture,
valve condition
18. Remarks of vehicle
19. Work performed details
20. Time in and time out with total hours
21. Technician name
22. Road test information filled by driver’s signature and Guard signature.
Page 62
Figure: - 6.1 Job Card
Page 63
Figure: - 6.2 Customer Declaration
Page 64
CHAPTER 7: -MORDEN VEHICLE TECHNOLOGY
7.1 SHVS (SMART HYBRID VEHICLE SYSTEM)
Figure: - 7.1 SHVS ( Smart Hybrid Vehicle System)

 Smart Hybrid is an advanced technology that helps increase fuel
efficiency and enhances driving performance.
 The engine automatically stops when idle and silently starts when the
optimal conditions are met in manual and automatic transmissions.
 It comes with a dual battery setup including a Lithium Ion Battery. These
high capacity batteries store the energy generated during braking to
assist the engine's idle start-stop and the torque assist functions.
 The energy stored in the Lithium-ion battery assists during acceleration
which helps engine in providing optimal acceleration and performance.
 The Smart Hybrid Technology helps reduce emissions by saving fuel
consumption and improving efficiency thereby helping keep environment
clean and green.
Page 65
7.2 S-CNG
Figure: - 7.2 S-CNG
 Maruti Suzuki S-CNG vehicles are equipped with dual interdependent

ECUs (Engine Control Unit) and intelligent injection system.
 Vehicles are tuned and calibrated to deliver optimum performance and
enhanced drivability across all kinds of terrains.
 The S-CNG technology has managed to set a new benchmark in green
fuel mobility. CNG is integrated directly within the vehicle on the factory
floor by highly certified engineers.
 S-CNG vehicles are designed to deliver optimum performance,
 safety, engine durability, convenience and mileage.
Page 66
CHAPTER 8: -CONCLUSION
 It was a great internship in Maruti Suzuki With full of knowledge I really

enjoyed the training period. I have learned about different services and the
major minor defects generally seen in the car and how to solve them.
 most of time I used to the paid service and some repair also like i have
change the brake pads, types, replacing the engine oil, coolant and many
other things, and how to check all the sensor are working or not if not so,
then I have made a note for that in repair order.
 I also seen that how an organization work under extreme pressure and
how to handle it like when so many cars have to repair in the limited time
it is really a very big task.
Page 67
REFERENCES
 About of Maruti Suzuki
https://www.marutisuzuki.com/channels/arena/all-
cars?form=testdrive&utm_source=google&utm_medium=cpc&ut
m_campaign=13799391098&utm_term=maruti%20suzuki&utm_
content=c&gclid=CjwKCAjwp8OpBhAFEiwAG7NaEmmYqsoMOd
NGKAuLH9FYCkw5qpICgNnQ8KUgUFSCePx42Ty9w8Rt4xoChc8
QAvD_BwE
 History of Maruti Suzuki
https://en.wikipedia.org/wiki/Maruti_Suzuki
 About Kataria Automobiles
http://maruti.kataria.co.in/about-us.html
 About Kataria Automobiles Vesu Surat
http://maruti.kataria.co.in/outlet/workshop-kataria-vesu-
surat.html
Page 68

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INDUSTRIAL TRAINING

A Report on Industrial Training

SAKARWALA MEET PIYUSHBHAI

Prepared in fulfillment of the industrial training

MARUTI SUZUKI KATARIA AUTOMOBILE,

GUJARAT TECHNOLOGICAL UNIVERSITY, AHMEDABAD

GIDC DEGREE ENGINEERING COLLEGE, NAVSARI

Guided by: - Mayur . J. Jalanapurkar

Head of Department: - Toral .V. Patel

27 July 2023 to 10 August 2023

Sign: __________________ Sign: __________________

Mayur J. Jalanapurkar Toral .V. patel

Internal Guide Head of the Department

External Examiner: ___________________

Guidance from the experienced employees and technician help us to deeply

Thanks to GTU for addingthe15 days internship to the semester.

Figure: - 1.1 Maruti Suzuki logo………………………………………………….............01

Figure: - 1.2 Kataria Logo………………………………………………………….............04

Figure: - 1.3 Workshop layout …………………………………………………...............06

Figure: - 1.4 Body Shop layout……………………………………………………............07

Figure: - 1.5 Organization Structure…………………………………………….............08

Figure: - 1.6 Gysy………………………………………………………….........................11

Figure: - 1.7 Omni…………………………………………………………........................12

Figure: - 1.8 Eeco………………………………………………………….........................13

Figure: - 1.9 Alto…………………………………………………………...........................14

Figure: - 1.10 Wagonr…………………………………………………………...................15

Figure: - 1.11 Celerio…………………………………………………………....................16

Figure: - 1.12 Swift………………………………………………………….......................17

Figure: - 1.13 S-cross…………………………………………………………...................18

Figure: - 1.14 Ignis………………………………………………………….......................19

Figure: - 1.15 Baleno…………………………………………………………....................20

Figure: - 1.16 Dzire………………………………………………………….......................21

Figure: - 1.17 Ciaz…………………………………………………………........................22

Figure: - 1.18 Ertiga………………………………………………………….....................23

Figure: - 1.19 Vitara Brezza……………………………………………………….............24

Figure: - 1.20 S-presso………………………………………………………….................25

Figure: - 1.21 XL6…………………………………………………………........................26

Figure: - 2.1 Allen Keys…………………………………………………….......................28

Figure: -2.2 Adjustable Wrench…………………………………………………..............29

Figure: - 2.3 T- Spanner……………………………………………………………............29

Figure: - 2.4 Nose Pliers………………………………………………………...................30

Figure: - 2.5 Screw Driver………………………………………………………….............31

Figure: - 2.6 Ring Spanner…………………………………………………………...........31

Figure: - 2.7 Fixed Spanner……………………………………………………….............32

Figure: - 2.8 Combination Spanner……………………………………………..............32

Figure: - 2.9 Hammers………………………………………………………....................33

Figure: - 2.10 Chisel…………………………………………………………....................33

Figure: - 2.11 Ratchet………………………………………………………….................34

Figure: - 2.12 Box Spanner………………………………………………………............34

Figure: - 2.13 Extension and Universal joint………………………………..............35

Figure: - 2.14 Oil Filter…………………………………………………………...............35

Figure: - 2.15 Wheel Wrench………………………………………………………..........36

Figure: - 2.16 Dolly………………………………………………………….....................36

Figure: - 2.17 Pnemetic Gun………………………………………………………...........37

Figure: - 2.18 Air Gun………………………………………………………….................37

Figure: - 2.19 Bench Grinder…………………………………………………….............38

Figure: - 2.20 Grinder……………………………………………………….....................38

Figure: - 2.22 Press Machine……………………………………………………..............39

Figure: - 2.23 MIG Welding……………………………………………………….............40

Figure: - 2.24 Hydraulic Lift………………………………………………………...........40

Figure: - 2.25 Wheel Balancing………………………………………………….............41

Figure: - 2.26 Wheel Alignment………………………………………………................41

Figure: - 2.27 AC Filling And Removing Machine……………………………...........42

Sign: Sign: