INDUS MOTORS

INTERNSHIP REPORT

Submitted to

STATE BOARD OF TECHNICAL EDUCATION KERALA

In partial fulfilment of the requirements
For the award of the diploma in

AUTOMOBILE ENGINEERING
Submitted by
MUHAMMED ASLAM N S
(2201050379)

DEPARTMENT OF AUTOMOBILE ENGINEERING

JAI BHARATH COLLEGE OF MANAGEMENT AND ENGINEERING TECHNOLOGY

PERUMBAVOOR, KERALA 683556

JUNE 2024
 DEPARTMENT OF AUTOMOBILE ENGINEERING

JAI BHARATH COLLAGE OF MANAGEMENT AND

ENGINEERING TECHNOLOGY, PERUMBAVOOR

CERTIFICATE

This is to certify that this Internship Report entitled “INDUS MOTOR” is a bonafide record of
industrial program conducted by MUHAMMED ASLAM N S (2201050379) during the year 2024.
This report is submitted to The Directorate of Technical education in partial fulfillment of the
requirements for the award of the diploma in Automobile Engineering

Internship Guide Head of the Department

Mrs.Abhiramy L Mr. Shywin Thomas
Lecturer Assistant Professor
Department of Automobile Engineering Head of the Department
Jai Bharath College of Management Department of Automobile
Engineering And Engineering Technology Jai Bharath College of Management
And Engineering Technology

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 ACKNOWLEDGMENT

The satisfaction that accompanies that the successful completion of any task would be
incomplete without the mention of people whose ceaseless cooperation made it possible,
whose constant guidance and encouragement crown all efforts with success. We would like to
express our deep-felt gratitude to GOD Alrnighty for showing his grace upon us, without
which our dissertation AI Chat Bot would not have materialized.

We are gratefull to the Chairman, Mr. A M Kharim , and Management of JAI

BHARATH COLLEGE OF ENGINEERTING TECHNOLOGY for providing the facilities
for the completion of my task.
My heartfelt gratitude to Mr. Shywin Thomas, Lecture and Head of Automobile
Engineering for his apt guidance.
A special thanks to Mrs. Abhiramy L, Lecture of Automobile Engineering Department
our Internship coordinator.
Finally, I offer my sincere thanks to my family and friends for being there by our side on
all times , for their motivation , moral support and cooperation of this internship.

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iii
 `ABSTRACT

Industrial training is one of the requirements for the award of Automobile engineering. This
report illustrates the experience that I acquired during a one- month industrial training
program in Indus Motors. This training aimed to provide hands-on training/experience in
various aspects of vehicle maintenance and repair. Wide range of topics has been included in
this report which includes vehicle diagnosis as well as repair procedures, and role of an
engineers in service centers. Key findings include the significance of learning and acquiring
technical as well as practical skills and need for the continuous learning in the automobile
industry. Overall, this training program provided a close insight into the operation of
automobile service centre and skills required to excel in the field.

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 TABLE OF CONTENTS

CHAPTER TITLE ` PAGE NO

NO

1 ABSTRACT 5
TABLE OF CONTENTS 6
LIST OF FIGURES 7

2 INTRODUCTION 8
1.1 HISTORY
1.2 EXECUTIVE SUMMARY 9

3 MOTOR VEHICLE TECHNOLOGY 11

4 ` HANDS ON ACTIVITIES CARRIED OUT 20

3.1 LEARNING METHODOLOGY AND TASK ASSIGNMENT
3.2 INTRODUCTION TO VARIOUS ROLES

5 WORK FLOW AND SOFTWARE OVERVIEW 40

4.1 WORK FLOW
4.2 OVERVIEW OF SOFT WARE 42

6 CONCLUSION `45

7 REFERANCES 46

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 LIST OF FIGURES

S.NO FIGURES PAGE.NO

1 ENGINE OVERHAULING KIT 2

2 MAIN COMPONENTS OF ENGINE 14

3 COMPONENTS OF ENGINE 15

4 FUEL SYSTEM 18

5 ENGINE LUBRICATING SYSTEM 19

6 ENGINE WARNING LIGHTS 21

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 CHAPTER-1
INTRODUCTION

1.1 HISTORY
Maruti Suzuki India which was Maruti Udhyog Limited (MUL) was a JV between the
Government of India and Suzuki Motors Japan. It was signed in 1981 and first roll was rolled
out in 1983.
Before this car entry, India had just two models of cars – Hindustan Motor’s Ambassador and
Fiat design- Premier Padmini (see pictures). They were considered to be outdated and not at
all economical but considered to be solid in quality because of more iron content in sheets.
The world was moving in feature led cars and fuel economical cars and India’s political
environment was allowing foreigner manufactures to enter the Indian market. The then
government took this bold decision and signed the JV to allow Suzuki motors to enter with
new company name as Maruti Udhyog limited and set up the factory in south of Delhi
Gurgaon being the first plant. Ambassa

People of India welcomed this car which was cheaper than the above two old and
traditional car. The first car was names Maruti 700 and which in a year got upgraded to 800
CC and started ruling the Indian road (see picture). It was a hatch back car or two box car. It
was an unairconditioned car. There was not even an AC car in India. Maruti becomes the first
one to bring in AC car, MarutiZen car to India which became the craze in India and parallel
launched Maruti 1000 cc – the first 3 box car which later became Maruti Esteem 1300cc- The
firstluxury car of India.
In year 1996 after seeing the success of Maruti in passenger car segment government allowed
others international players also to enter India and Hyundai motors of south Korea launched
Santro 1000 cc car and there on India saw many many international manufacturers entering
India. But the excellent marketing and R&D efforts of Maruti Suzuki kept them at top.
Competitors did their best by launching cars with better features but strategies across product
mix, pricing, promotion, place, people, process, physical evidence has been keeping MUL at
top for the last 40 years. India has become the second largest market for Suzuki in the world
and till now have sold 17 millions cars in India and seeing the cheaper labour cost in India
they setup 3 more plants in India and have been exporting to rest of the world as well. Last
year they exported

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1,28,000 cars to Europe, Africa continents & south America. (Suzuki, 2019)
India being highly populated with 1.3 billion people has world largest segmentof middle
ages segment and middle income group as well. The cars pricing strategy is well fit for
MUL. After giving the first luxury car Maruti Esteem1300 cc which become me too car in
comparison of others luxury cars like Cielofrom Daewoo and Opel from General Motors,
they could not launch another competitive luxury car in India. The perception which
started from hatch back & affordable car segment for MUL got etched in people mind. They
kept rejecting expensive luxury cars launches from MUL and till today they don’t have any
car competing with likes of MERCEDES, AUDI or SUV likes of FORD or TOYOTA.
Hyundai motors which also launched hatch back with ZENof MUL also has been fighting
with its own image of affordable cars and could not win market share in SUV or premium
luxury segment of the cars.
The above picture shows the 2018 ending data trend which is visibly depicts the leadership
stature of Maruti Udyog even after 40 years
Currently they have about 75000 employees in India alone and 1,820 sales outlets across
1,471 cities in India. MUL has 3,145 service stations across 1,506 cities throughout India.
Maruti's dealership network is larger than that of Hyundai, Mahindra, Honda, Tata, Toyota
and Ford combined.
Service is a major revenue generator of the company. They have more than 15. Models of the
cars in many variants in both petrol and diesel version and soon will be launching its first
full electric car in India too. They also have threetypes of distribution network as NEXA
and ARENA own by them and Maruti Suzuki networks as private distributors.

1.2 EXECUTIVE SUMMARY

It’s very interesting to know how a schematic and planned marketing management can create
a right perception about the product the company produces or manufactures. The marketing
strategies embracing the product mix with right blend of pricing, promotion and right place
can create a spell of affinity about the products. Here in this assignment I have detailed out
how a Japanese car manufacturer can change the automobile market in India by truly
motorizing the country with efficient, modern and contemporary product which in-turn put
the demand to have better infrastructure in term of roads in India. Inspiring other auto
manufacturers to find India a lucrative market for their

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products too. While going through the assignment we will see the implemented and
performing 7Ps of marketing to its full glory. Also with an intention to see Maruti Suzuki
making India a hub to export cars further to other countries even developed ones like Europe
and USA. The SWOT analysis for the same andvery relevant PESTEL analysis which is to
be practiced when launching any car in any country. It covers the evolving scenario of
political, economic, social, technological, environmental and legal issues or opportunities of
that particular country. Maruti Suzuki is progressing on its export numbers and facing the
challenge of not meeting the embedded need of serviceability of the cars by having tie-up
with other major car manufacturer having an excellent service stations solving the problem.
The very valid product life cycle analysis too will give you how the marketing along
with sales phase out the product beforemarket fails them.

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 CHAPTER 2
MOTOR VEHICLE TECHNOLOGY
2.1 Introduction
A motor vehicle is a self-propelled road vehicle and movement is carried with the help
of no. of wheels installed on itself. Vehicle propulsion is done by engine power or
electric motor or sometimes both (hybrid vehicle). There are several systems that
combines to function an automobile. Each system is primarily independent but is
influenced by the other system interacting with it. Some of the systems are described
below.

2.1.1 The transmission system

Transmission systems enable automobiles to transfer mechanical energy from an engine
to the wheels. It comprises of gearbox, flywheel, clutch, propeller shaft,
differential/transaxle and other various electrical units which serves as a bridge to transfer
power and energy from engine to the wheels. Cruising speed is maintained with the
help of transmission system without disturbing the performance of vehicle.

Figure 3: Transmission System [2]

2.1.2 The electrical system

The electrical system comprises of battery, starter, and alternator. When we need to
start the engine, the battery provides the required power to starter initially. After the
engine is started, the alternator gives that batter energy to power the car. The alternator
is rotated by using rotational energy from crankshaft of an engine and is inter-connected by
fan belt.

Initially, batteries provide all the required electrical current to the ignitions and fuel
system which are necessary for creating combustion necessary for the engine to
function. A starter motor serves as a bridge between battery and engine cranking
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process. When the starter motor gets the power, a solenoid switch pushes the ring gear
which then mates
with the ring gear of the flywheel, which provides cranking power to the crankshaft of

12
the vehicle. When combustion starts alternator provides energy to the battery which needs
for the proper functioning of the vehicle until an engine is turned off. If the alternator is
not functioning properly, electrical systems of automobile will perform inconsistently,
eventually battery gets discharged and engine power will be lost.

Figure 4:Electrical System [3]

2.1.3 The fuel system

Three things are required for all internal combustion engines to operate: air, fuel, and
spark. The storage and delivery of gasoline or diesel engines needs to run depend
heavily on the fuel system. The gasoline pump, fuel lines, and filter are all parts of the fuel
system. The consequences of any of these fuel system failures are catastrophic for the
vehicle.

Fuel tank

This is essentially a gasoline storage tank. The gas flows down the filler tube and into
the tank when you fill up at a gas station. A transmitting unit in the tank notifies the gas
gauge how much gas is in the tank. The gas tank has gotten a little more complex in
recent years since it now frequently houses the fuel pump and has more pollution
controls to prevent vapors from seeping into the air.

Fuel pump

The fuel pump can often be found in the fuel tank of modern vehicles. In older vehicles,
the fuel pump was either linked to the engine or mounted on the frame rail between the
tank and the engine. If the pump is in the tank or on the frame rail, it is electric and is

13
powered by the vehicle's battery. fuel pumps attached to engines use the engine's
motion to pump gasoline, most often the camshaft, but sometimes the crankshaft.

Fuel filter

Clean gasoline is essential for engine durability and performance. Fuel injectors and
carburetors have tiny holes that clog easily; therefore, fuel filtration is required. Filters
can be installed before or after the fuel pump, or both. They are often composed of
paper but can also be made of stainless steel or synthetic material and are intended to be
disposable in most circumstances. Some performance fuel filters have washable mesh,
eliminating the need for replacement.

Fuel injectors

The fuel injector is a small electronic valve that opens and shuts in response to an
electric signal. By injecting fuel near to the cylinder head, the fuel remains atomized (in
tiny particles), allowing it to burn more efficiently when ignited by the spark plug.

Figure 5: Fuel Injector of Tucson

Carburetors

In a carburetor, air is mixed with incoming fuel. It is simple in operation but needs
frequent tuning and rebuilding. So, in modern cars, fuel injection is widely used.

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 Figure 6: Fuel system [4]

2.1.4 The braking system

The car's braking system is intended solely to do one thing: safely stop the vehicle. To
do this, three main elements are required: a vehicle operator, hydraulic pressure, and
friction. When the driver depresses the brake pedal, the pedal levers and rods activate
the power brake booster. The booster multiplies the force from the operator's foot to the
master cylinder using engine vacuum or a pump. Hydraulic lines attached to the master
cylinder travel to a proportioning valve or the ABS (Antilock Brake System) module,
then to each brake caliper if the vehicle has disc brakes, or to the wheel cylinder if the
vehicle has drum brakes. The braking fluid in the lines runs into the calipers or wheel
cylinders, and hydraulic pressure pushes the brake pads against the rotors of the brake
shoes against the
``

Disc brakes

A disk brake system is made up of three parts: a rotating disk, a brake caliper, and
brake pads. When the brake pedal is depressed, pressurized hydraulic brake fluid
squeezes the brake pad friction material against the revolving brake disc's surface. As a
result of this contact, friction is created, allowing the vehicle to slow or stop.

Drum brakes

A drum brake system includes hydraulic wheel cylinders, brake shoes, and a drum.

15
When the brake pedal is depressed, hydraulic wheel cylinders drive two curved brake shoes
with

16
a friction material lining against the inner surface of a rotating brake drum. As a result
of this contact, friction is created, allowing the vehicle to slow or stop.

Figure 7: Braking system and types of brakes used in passenger car [5]

2.1.5 The suspension system

Suspension is the system of tires, tire air, coil springs, shock absorbers, and link rod that
connects a vehicle to its wheels and allows them to move relative to one another.
Suspension systems provide two functions: they contribute to the vehicle's
roadholding/handling and braking for good active safety and driving enjoyment, and
they keep vehicle passengers comfortable and relatively well isolated from road noise,
bumps, and vibrations. The suspension also protects the vehicle from damage and wear,
as well as any cargo or luggage. A car's front and rear suspension may be designed
differently. The suspension system of a vehicle is separated into two parts: front
suspension and rear suspension.

The front suspension system

The front suspension's role is to withstand the vehicle's weight. Automobiles usually
use independent front suspension, which means that if one of the tires travels over a
bump, the other is unaffected. Ball joints, control arms, lower arm bushings, coil
springs, stabilizers, shock absorbers, steering knuckle, and spindle are the essential
components of the front suspension.

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The rear suspension system

The rear suspension system is intended to keep the back axle and wheels in their
appropriate location beneath the vehicle. To maintain alignment and effective vehicle
control, the rear suspension allows each of the back wheels to travel up and down
independently of the frame. The rear suspension is a dependent suspension system
which is connected to the torsion bar of cars.

Figure 8: Suspension system of a vehicle

2.1.6 The steering system

The steering mechanism combines steering-wheel rotation into twisting movement of
the road wheels in such a way that the steering-wheel rim turns a long distance to move
the road wheels a little distance. The rack and pinion and the steering box are the two
most popular types of steering systems. On larger vehicles, either system may be power
assisted to lessen the amount of work required to move it, especially when the vehicle is
moving slowly.

The rack-and-pinion system

A tiny pinion (gear wheel) is housed inside a housing at the base of the steering
column. Its teeth interlock with a straight row of teeth on a rack, which is a long
transverse bar.

18
The rack moves from side to side when the pinion is turned. Tie rods connect the rack's
ends to the road wheels.

Its operation is accurate, and the mechanism is simple. A universal joint in the steering
column connects it to the rack without unnecessarily tilting the steering wheel side to
side.

The steering-box system

A worm gear within a box is located at the base of the steering column. A worm is a
threaded cylinder, like a small bolt. Spinning the worm moves everything that fits
inside its thread.

Figure 9: Layout of steering system [5]

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 2.1.7 The intake and exhaust
systems Intake system

The intake system's function is to manage the supply of clean, filtered air to the engine
at the proper temperature while also providing vacuum to run other components.
Crankcase vapors are likewise drawn into the intake stream by the intake system and
burned by the engine. Modern automobiles have a lot more intake plumbing to
accommodate smaller engine bays that have a lot more electronics packed into them

Figure 10: Intake manifold of Santro (old)

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The exhaust system

The exhaust system is a component in a vehicle's engine that handles the burned gas
produced by the engine. It is made up of exhaust pipes that carry exhaust gas from one
chamber to another, a header that collects the same gas from different cylinders and
directs it to the pipes, a catalytic converter that converts pollutant gases produced
during combustion into less harmful substances, a muffler that reduces engine noise,
and a turbocharger that increases engine power. The exhaust system is critical to every
vehicle since it determines the life and performance of the engine. Back pressure in an
engine prevents it from working properly. Exhaust gas clogs an engine and prevents it
from performing useful work. As a result, the car cannot operate smoothly and quietly,
and in worst-case scenarios, it will not run at all.

Figure 11: Exhaust manifold of I20 Active

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 CHAPTER 3
HANDS-ON ACTIVITIES CARRIED OUT

3.1 Learning methodology and task assigned

First, the intern date was fixed. Then, I was introduced to different departments of the
companies where engineers played a vital role in the company. At first, technicians taught
me about different components and parts of vehicles, their maintenance procedures that
we must follow, and tools used during maintenance of vehicles. The teaching was
mutual as I taught some technicians about the working mechanism of various systems
of automobile such as working process of vacuum brake boosters. Later, I was taught
about the process of looking for parts in the inventory, inventory management, job card
opening, delivery, etc. Basically, I followed the following techniques to get trained
during my internship.

 Observation
 Questionnaires/Interviews
 Photography
 Directly involved in process with the supervision of experts

3.2 Introduction to various roles

During my training at L.I service center, I participated in different activities where I
was able to interconnect theoretical knowledge with practical and skills acquired in the
class into real world problem-solving situations. Various tasks were assigned to me
during my training period, which are listed below.

 Technician
 Spare parts
 Service advisor

3.2.1 Technician
During my time as a technician, I found that an individual job card was assigned to
individual vehicles by a service advisor which included general check-up task, periodic
maintenance task, problems that are being faced by customers while using vehicle and a
check-sheet to check different vehicle systems/components. Based on those job cards, I
was taught to perform the task slowly and gradually. During this period, I learned
various maintenance and repair practices, amount of time required to perform those

22
jobs, and use

23
of various tools for those practices. I am directly involved in many cases which are
detailed below.

Tools
One toolbox was assigned per two technicians. Some frequently used tools during training
are given below.
Table 2: Tools and its description

Ring Spanner
It has a closed opening that wraps bolts/nuts. There are ridge
inside the ring which are effective for hexagonal bolt heads.

Open end wrench

The two opposite ends of wrenched grip the nut or bolt.

Combine wrench
It contains both open end and closed ring with ridge inside

Rachet and extensions

Rachet provides more leverage in both directions while
tightening and loosening bolt, extension is used to extend the
distance up to which rachet can rotate easily.

Universal Joint
It is used to change the direction of force applied without
changing its magnitude.

Allen Key
It is used to turn bolt heads with a recessed hexagonal pattern.

Sockets
It has a hollow cylinder which grabs the hexagonal bolt or the
nut.

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 Oil filter wrench
It is used for opening and tightening engine oil filter.

L-shaped extension bar

It is used for multiplying torque while using socket and mostly
used along with oil filter wrench.

General servicing
This service includes the general check-up of the vehicle like under hood check-up
which include air filter / A.C filter conditions, belt noise/alignment, brake oil, coolant,
water inside wiper tank, engine oil condition and scale and battery wiring. After that the
vehicle is lifted and inspected for brake pad thickness, axle booth, any kind of leakage from
under the body, checking if wobbliness presents in the vehicle due to some bush failure,
insulator failure, ball joint failure or tie rod failure. After that the front and rear light is
checked to see if it is lit or not. Then the vehicle is driven and checked for its wheel
movement/alignment, steering noise, and clutch hardness.

Full servicing
It is a servicing which are done periodically. When a vehicle runs a specified distance,
full servicing is required for its longevity and smooth performance. It is done by the
following procedures.

Under hood visual inspection

 Brake oil check/ refill

 Coolant check/refill
 Water level check/refill
General checkup
Tools: 17mm & 19mm spanner ring

Procedure
 Using 17mm and 19mm spanner ring, bolt of axle and mount was checked for
its looseness.

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Air Filter/ AC filter (if available) check/change

 High velocity of air from pneumatic pump was blown onto filters to remove
dust otherwise replaced with new one.

Figure 12: Air filter and AC filter

Engine oil change

Tools: 17mm spanner ring, filter cap, L-handle

Procedure

 17mm spanner ring used to remove drain nut, oil is removed from the oil pan
and later, the bolt was fastened.
 To remove a filter cap, L-handle was inserted into filter cap which then used for
removing oil filter and new oil filter was reinstalled.
 Engine oil filler cap was removed and engine oil of 3.6 liters was poured into
the engine (10W-40 thickness of oil was used). First engine oil dip stick was
removed, cleaned, and plugged again and remove. Visual inspection was done if
oil was presented above F, oil amount is good otherwise repoured and engine oil
cap was tightened.
Note: Sometimes washer of drain nut remains attached to oil pan. In this case, we must
use screwdriver to remove it.

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 Figure 13: Oil drainer, oil filter and engine oil

All brake check

First, the tire was removed from the wheel hub.

Tools: pneumatic gun, 21mm socket

Procedure
 A 21mm socket was installed into the slot of pneumatic gun to loosen the bolts
of the tire. The procedure was done according to requirement.

Disc brake

Tools: 14mm spanner ring, dry sandpaper

Procedure

 Using a 14mm spanner ring, bolt was unfastened. The brake pad was removed
from the caliper. The brake pad surface was scrubbed with dry sandpaper. If the
frictional surface is thin, the brake pad was replaced with new one. The brake
pad was positioned into the caliper and tire was reattached into the wheel hub
by tightening bolts.

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 Figure 14: Brake pad and disc brake assembly

Drum brake

Tools: Impact, Hammer

Procedure
 After removing wheel, screw of drum was removed using impact. Impact was
hit with hammer to unscrew from the drum. After unscrewing, the drum was hit
with hammer with slight force to make easy to remove.
 Afterwards the braking surface was cleaned with dry sandpaper and air was blown
to clean the brake parts. If parking brake travel was too high or parking brake
was too tight brake exhauster was rotated using screwdriver
clockwise/anticlockwise (according to requirement) and all the parts was
reinstalled as it was before.

Figure 15: Drum brake and drum

Light check
• Headlights, side indicators, fog light, rear brake light, parking light were checked.
Wiper check
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Cutch system
A clutch set is used to transmit power from the engine to the gearbox. The clutch disk is
pressed against the surface of the flywheel with the help of a pressure plate when clutch
is in engage state. In this time power is transmitted from engine to gearbox. When
clutch pedal is pressed due to the mechanism of diaphragm spring, clutch gets
disengaged, and no power is transmitted to the gearbox and hence wheel. This condition
is useful while shifting gear. There are various problems which arise due to faulty
clutch system. Some of the signs of faulty clutch system that I came to know are.
• Reduce in pick-up though engine rpm is increasing due to clutch slippage.
• Sometimes when clutch pedal is released, vehicle move late, or some time vehicle
doesn’t move at all due to damaged friction disk.
• Trouble with shifting gears
Remedy: To remove these problems, we need to change the clutch set. We also must look
for the conditions of clutch fork and replace if there are deep cuts in the forks.

The procedure is given below.

Tools: 10mm &12mm T-handle, 14mm socket, 17mm, 14mm, 21mm & 12mm socket,
14mm combine wrench, 32mm socket, Rachet, Tire lever, Support, Extension (small &
medium) Pneumatic gun, Pliers

Procedure

 Air filter case, battery, battery clamp, batter holder plate and ECU module were
removed by using 10mm and 12mm T-handle.
 Wire clamps were untied by using screw drivers.
 The gear shifter wire holder was disassembled by untying three bolts by using
12mm T-handle.
 Slave cylinder was disconnected from clutch fork using 12mm socket and rachet.
 Front tires were removed using 21mm socket and pneumatic gun, then brake
line bracket and abs sensors bolts were removed using 10mm T-handle and
brake calipers were removed using 14mm ring spanner.
 Knuckles were disconnected from suspension using 17mm socket, pneumatic
gun and 17mm combine/ring spanner.
 The axle was removed from wheel hub using 32mm socket and pneumatic gun.
 Gear oil was removed from gear box by untying bolts from gear box using
17mm combine wrench/ ring spanner and was collected in gallon and one lower
bolt was tightened and one upper bolt was just hand tied.

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 The axle was removed from the transmission case using tire lever.
 The engine torque strut mount was disassembled from the frame using a
pneumatic gun, medium extension and 12mm and 17mm socket.
 Brackets were removed from the gear box using 14mm combine/ 14mm socket
and wrench.
 Then all the bolts were removed from the transmission assembly including the
starter motor. If bolts were too tight, pneumatic gun and 14mm sockets were
used otherwise rachet & 14mm sockets & 14mm combine were used though one
of the bolts was loosen but was kept in that transmission case to hold the gear
box and prevent it from being dropped.
 After that transmission assembly was held by long rod support and gear box
mount was removed by using pneumatic gun and 17mm long socket.
 After removing the bolt from mount, gear box was supported with hand,
remaining one bolt was also removed and gear box was pulled out. In some
cases, a tire lever was used to push gearbox.
 Clutch assembly was unattached from flywheel by untying bolt using 12mm
socket and pneumatic gun.
 Later the fly wheel was cleaned by blowing air pressure and transmission case
was cleaned by using antirust and clothes.
 Clutch fork, Throw out (T/O) bearing and spring were removed by untying
14mm bolt using ring spanner and replaced with new one.
 Grease was applied to the internal part of the T/O bearing and clutch fork before
installation.
 A new clutch set was installed, and bolts were tightened with 12mm ring by
using hand.
 All the parts were assembled by following the reverse process.

Figure 16: Friction disc and pressure plate-diaphragm assembly

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 Figure 17: T/O bearing and release fork

Sometimes flywheel surface also gets damaged. At that time, we needed to unscrew six
bolts using a 17mm socket and torque wrench and turned the flywheel surface. Later,
flywheel was installed setting torque up to 90Nm.

Figure 18: Surface damaged flywheel

Slave cylinder
This is used for applying force in clutch fork during disengagement process of clutch.
In the case of hydraulic system, clutch pedal might get spongy or might stick to the
floor. At that time, we needed to replace the slave cylinder with a new one. The technical
procedure is given below.

Tool: 12mm socket, medium rachet, 12mm & 10mm T-handle,

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Procedure

 The air intake line was disconnected from throttle body and air filter box was
removed using 12mm T-handle.
 Bolt of 12mm diameter was loosen using rachet and 12mm socket and new
slave cylinder was installed.
 Brake oil was added, and the bleed valve was left open until brake oil started
leaking by pumping clutch pedal. All the air was removed, and the bleed valve
was closed.

Figure 19: Slave Cylinder (for hydraulic clutch system)

Wheel wobbling
There is not one case that wheel wobbles but most of the time, it is failure in the
component which are related to suspension failure. The reasons for wheel wobbling are
given below.

 If wobbling is in vertical direction, it is failure of insulator. Insulator must be

replaced in this case.
 If wobbling is inwards and outwards according to horizontal axle, it is because
of bush failure or inner ball joint failure. Either ball joint and lower arm
bush or inner ball joint must be replaced.

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The technical procedure to replace the shock insulator are:

Tools: 21mm, 17mm and 14mm socket, extension, pneumatic gun

Procedure

• Front tires were removed using 21mm socket and pneumatic gun, then brake
line bracket and abs sensors bolts were removed using 10mm T-handle and
brake calipers were removed using 14mm ring spanner.
• Knuckles were disconnected from suspension using 17mm socket, pneumatic gun
and 17mm combine/ring spanner.
• From the upward, using a 17mm socket and pneumatic gun, nut was loosened,
and suspension was disassembled. Two clamps were used to clamp the coil spring
and were tightened using medium extension. A nut tightening a insulator was
removed using socket and gun and insulator was replaced with new one.
• Using the reverse process assembly was done.
Shock Insulator

Figure 20: MacPherson suspension assembly

The technical procedure to replace the ball joints and lower arm bush is given below.

Tools: 17mm and 19mm combine spanner, 17mm and19mm socket, pneumatic gun

Procedure

 After removing the wheel, the ball joint bolt was disconnected using 17mm
combine spanner.
 Then two bolt screwing lower arm to the cross link was unscrewed using
17mm and 19 mm socket with pneumatic gun.

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  Thus, the disassembled lower arm was sent to lathe to press-fit the bushes and ball
joint and later reassembled to the vehicle.

Lower arm bush

Figure 21: Ball joint and lower arm

Power window
A power window is a car window that is lowered and raised by using an electric motor
which is controlled by switch. This has become a fundamental component of modern
vehicles replacing the older hand cranked style.

A power window switch not working is another common problem that I found out
during my training period. Most of the time carbon is collected in between the switch
which prevents the switch from completing circuit and sometimes electric motor get
jammed and doesn’t rotate.

Figure 22: Power-window switch

The solutions for carbon were to remove switch from the door panel, disassembled all
the metal part then cleaned with sandpaper. Then it started working. In case of motor
jammed, all the four screws were loosened first, then hit using mallet with small impact

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and screws

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were tightened using screwdrivers. Antirust was sprayed at the side of glass panel to
remove all the carbon.

Shock absorber replacement

Sometimes there is an oil leakage from the shock absorber. Due to this, when piston rod
travels downward due to the shock it takes more time to return to its initial position or it
doesn’t return at all. At that time, the shock absorber was replaced with a new one.

Shock absorber

Figure 23: Suspension assembly

Gear box overhaul and oil seal change

Problem: Gear oil leaking as one of the technicians from the local repair shop forgot to
cap the gap with gear oil seal.

Tools: 10mm T-handle and socket, 12mm T-handle and socket, 28mm socket, magnet,
tire lever

Procedure

 After dismantling the gearbox from the engine, it was taken for
further disassembly.
 The first seven number of 10mm bolts were removed and three 12mm bolts
were removed.
 Spring and balls were pulled out by using magnet.
 All the 12mm bolts of gear housing were removed.
 The gear lock pin was removed by hammering that pin with a valve.

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  After that 5th gear along with gear shifter was dismantled using tire lever.
 Gear box housing was removed.
 By removing the 12mm bolt from shifter, we took out shifter from the assembly.
 Finally, the main shaft and layout shaft were removed along with differential
by hammering with small amount of force.
 Thus, the oil seal was replaced with a new one.
 All the components of gearbox were cleaned with petrol and re-assembled.

Figure 24: Overhauled Gearbox and it's components

Task performed: Eon era

Steering noise
Power steering comprises of an electric motor which assists the driver while steering
the vehicle. A driver can turn the vehicle by steering with less force with the help of
power steering. The additional rotation is provided by an electric motor. The power
assistance varies according to the speed of vehicle. To control the speed of electric
motor, Motor- Driven Power Steering (MDPS) is used. The force required to steer a
vehicle is inversely proportional to the speed of vehicle [6]. Therefore, when a vehicle is
moving at low speed, MDPS is designed to provide a higher amount of electric current
to electric motor and vice-versa.

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 Figure 25: Power Steering assembly

Being a mechanical part, the power steering system also faced a lot of problems and
there is not a single remedy to remove the problem. Generally, the power steering
problem was characterized by whining noise when we turned the wheel. The problem
was solved in a iterative manner. At first, the problem was tried solving by replacing
worm gear, secondly, electric motor and thirdly by replacing all the reduction part.
Sometimes, loosening the 12mm bolt of both universal joints and shaking vertically
with some force and tightening the bolt can also fix the problem. The tools required and
technical procedures that were followed for solving the power steering noise problem is
given below.

Tools: screwdriver, 14mm and 19mm combine spanner, 12mm T-handle, 12mm socket,
medium extension, rachet

Procedure

• First, the negative terminal of the battery was disconnected.

• Steering was locked by aligning front wheel in a straight line with reference
to side view of the vehicle. Different trims and column cover was removed.
• The column was disconnected from the rack by removing a 12mm bolt. This
bolt contains a spline at the end of the bolt.
• Various sensors and switches jacks were disconnected, and steering assembly was
taken out from the vehicle.
• MDPS and electric motor were removed by loosening a 12 mm bolt.
• If worm gear shaft rotates easily by rotating input shaft, then there is

38
a confirmation that there is failure in worm gear.

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 • A special tool is required to remove the plug nut as well as lock nut and later a
bush. Similarly, 19mm nuts were removed, after that 12mm bolt were removed
and soft hammering was done to dismantle the reduction gear assembly. The
new worm gear was greased properly. There was a special white grease
available for worm gear.
• All the components were then assembled back to their original position.

Figure 26: Steering motor, reduction gear and MDPS

Similarly, another cause for steering nose can be cause of overly compressed yoke plug
against the rack of steering and due to friction, it produces some noise. The yoke plugs
assembly was removed and assembled with new one. We used a special torque wrench
and a 22mm socket. It consists of yoke plug, spring, and tie nut. It required some
special tools and torque of 1.4 Nm was given while tightening the plug.

Figure 27: Yoke plug

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Faulty steering rack
A faulty steering rack also contributes to very tight steering wheel, leaking power steering
fluid (in hydraulic system), grinding noises when steering. The rack was replaced with a
new one. The tools required and technical procedures are given below,

Tools: 12mm, 17mm and 19mm socket, 14mm and 17mm combine spanner, long
extension, rachet, pneumatic gun

Procedure

• A lower universal joint was disconnected from the steering rack assembly.
• A link rod, tie rod and ball joint were detached from suspension and
knuckles respectively.
• A cross link was detached from the chassis by removing two 19mm bolts and two
17mm bolts.
• Later, the rack was dismantled and replaced with a new one.
• After the rack was installed, all the parts were reassembled.

Figure 28: Steering rack

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3.2.2 Spare parts
During my training period, I got a chance to engage with spare parts division. It lasted
for two weeks. At first, I was introduced to the inventory that this company holds. I was
also introduced to different spare parts along with their location in the inventory. I was
familiarized with different codes of parts like air filter, A/C filter, oil filter, brake pad,
etc. I learned how I can look for part number of different items, its availability using
Inventory Master Data, no. of stocks and committed items, and their price. I learned to
make entry of different items in the sales order which are used during repair process.

Figure 29: Entry of different parts into sales order

After continuous observing, analyzing, questionnaires and exploring through different

modules of software, following are the roles of engineers in spare parts division of
automobile service center.

 Inventory Management: It is the foremost responsibility of an engineer to

organize and manage parts in the inventory and ensure that there are adequate
quantities of parts available to meet the needs of customers. This involves
forecasting demand, placing orders, and tracking levels. For example, whenever
the number of Air filters of Creta gasoline (old) reach minimum level i.e., 6,
order of Air filter was placed immediately.
 Quality assurance: Engineers need to ensure that the spare parts meet the
required quality standards. This includes inspections and tests on existing part
by comparing and verifying that the component matched the previous task and
perform function without any hindrance. Beside these, identifying defective
parts and ensuring that genuine parts are used in repair process.
 Cost management: Another responsibility was to manage the spare parts,
ensuring that they are obtained at the best possible price and that there is no

42
 wastage or misuse of parts in the service center. The price must be set according
to the company viewpoint and customer viewpoint i.e., the company can be able
to make target profit while customers can be able to buy the parts and think this
value is the best value. In this service center, there are already declared margins
that spare parts engineers need to set the retail price of parts.
 Customer service: Engineers were responsible for providing excellent customer
service by ensuring that that the right parts are available for repairs, providing
accurate information about parts, and resolving related issues to spare parts
promptly. In the case of parts unavailability, spare parts division request for
information about parts availability first at its central distributor and again if
parts were not available, then put inquiries in other Hyundai branch and
ultimately to other dealers throughout the country according to the type of order.
Some types of orders are daily order, urgent order, etc.

3.2.3 Role as a service advisor

During my role as a service advisor, I was able to acquire some focus and communication
skills. I acted as a liaison between customers and a company’s service department,
providing information and assistance regarding repairs and maintenance to technicians.
Working as technicians at first helped me a lot during this role. I was able to describe
problems to the customers, it’s probable cause and its remedy in an understandable way
to customers.

Figure 30: Example of Job card

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I learned to prepare a manual according to the problem faced by customers in their
vehicle, create a job card of that problem, scheduling a repair and maintenance
program. Many times, I went to the floor to verify as well as learn the maintenance
procedure. When vehicles are repaired, I make delivery of some vehicle.

3.2.4 Global Diagnosis System

The Global Diagnosis System (GDS) Smart is a sophisticated diagnostic tool which is
being used by Hyundai service centers to diagnosis and repair Hyundai vehicles. It is a
hardware and software platform that uses a laptop computer or tablet and a VCI connector
to communicate with various electronic modules (ECMS) in vehicles. It allows
technicians to access and analyze data from the vehicle’s sensors, actuators, and other
components, helping them to diagnose and repair faults in the vehicle’s various system.

During my training period I was taught and had used GDS to diagnosis the problems
like reason of engine check light on, ABS, or airbag system, cleaning of throttle,
checking data related to EVs. I detected the failure of ultrasonic sensors, misfiring of
engine, etc.

Figure 31: GDS interface and fault detection

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 CHAPTER 4
WORKFLOW AND SOFTWARE OVERVIEW

4.1 Workflow
Laxmi Intercontinental Service Pvt. Ltd is a 2S based company i.e., this company
focuses on service and spare parts selling while many of the Laxmi Hyundai are 3S
companies i.e., service, sales, and spare parts. Services include the maintenance and
repair of faulty vehicles while spare parts refer to the sales of parts which are needed to
replace the faulty/damaged part to obtain the optimal performance of vehicles.

Servicing includes the maintenance bay and dent/paint. Maintenance is handled by

service supervisor, dent/paint supervisor, service advisor, and technicians. First
customer enters the service center who have complaint/queries/scheduled maintenance
program/parts required. Parts required are sent directly to the spare parts department,
while others remaining are considered by service advisor. The service advisor then
opens a new job card according to the requirements of customers. A sales quotation is
opened mainly for dent/paint purposes while for maintenance and repair purposes sales
order is opened. Then the vehicle is sent to maintenance bay where technicians carry
out the required and specified tasks to solve the customer problems. When a spare part is
required to repair the vehicle, in the absence of customers a phone call is made to get
permission as well to let them know about the problem with the vehicle. If parts need to
be replaced, a requisition was created to keep the record of all the parts that are sold to
individual vehicles. After replacement and repair of vehicle, a test drive is done to
check the condition of vehicle after carrying out the operation process. After solving all
thespecified problems, a delivery is made in the customer’s name and an AR invoice is
created. Those AR invoices are then handled by the account section.

45
 Figure 32: Check sheet

When a customer comes directly for part, they are sent directly to spare parts and
counter sell is done for them i.e., a direct delivery is made for them by spare parts and
thus generated AR invoices are handled by account sections. The overall workflow is
demonstrated in the given flowchart.

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 Flowchart

Figure 33: Flowchart of workflow inside the company

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4.2 Overview of software
A popular software called SAP Business One has been used since a few years ago. SAP
Business One is robust and flexible business management software for small and
medium-sized organizations. It offers a broad variety of tools for managing different
aspects of a business, including financial administration, sales and customer management,
inventory, and warehouse management, purchasing, and reporting [7].

Figure 34: SAP Home screen

4.2.1 Benefits of SAP Business One for service centers:

SAP Business One can assist service centers manage their operations and optimize their
workflows, resulting in enhanced productivity and profitability. The following are some
of the advantages of utilizing SAP Business One for service centers:

Improved Inventory Management: SAP Business One provides powerful tools for
managing inventory levels, tracking stock movements, and monitoring stock levels to
ensure that service centers always have the necessary parts and supplies on hand. This
can help prevent stockouts and minimize waste [7].

Customer Relationship Management: SAP Business One enables service centers to

maintain detailed customer records and track customer interactions. This information
can be used to provide better service, anticipate customer needs, and tailor marketing
efforts to specific customer segments [7].

Financial Management: SAP Business One offers robust financial management tools,
including accounts payable and receivable, cash management, and financial reporting.

48
This helps service centers track their financial performance, make informed decisions,
and plan [7].

Streamlined Workflows: SAP Business One provides a centralized platform for

managing all aspects of a service center's operations. This can help service centers
streamline workflows and eliminate redundancies, leading to increased efficiency and
productivity [7].

4.2.2 How SAP Business One works for service centers:

SAP Business One is a modular software solution that may be adjusted to a service
center's individual requirements. It is often made up of numerous modules, including:

This module includes tools for managing sales operations, making bids and orders,
recording client interactions, and evaluating customer data.

Inventory and Warehouse Management: Using this module, service centers may
control inventory levels, track product movements, and optimize warehouse operations
[7].

Financial Management: This module includes tools for managing financial transactions,
keeping track of spending, and creating financial reports [7].

Purchasing: This module allows service centers to manage their purchasing activities,
make purchase orders, and track the performance of their suppliers [7].

Reporting and Analytics: With this module's extensive reporting and analytics
capabilities, service centers may produce thorough reports and obtain insights into their
operations [7].

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 CHAPTER 5
CONCLUSION

In conclusion, the industrial training at Indus Motors. provided me with valuable hands-
on experience in the field of automotive engineering. My internship lasted for 30 days.
During my internship, I had a lot of opportunities to work on various tasks, Through this
experience, I was able to apply theoretical knowledge gained in my academic into real
world situations.
Additionally, the internship provided me with the opportunity to develop important
technical skills and soft skills such as problem-solving, teamwork and communication.
These skills will undoubtedly benefit me in my future academic pursuits and career
aspirations.
Overall, my internship was a positive and rewarding experience. I am grateful for the
opportunity to have worked with skilled professionals in the company and for the
knowledge gained during internship. I believe that this experience has prepared me and
given me some extra confidence for future challenges in the field of Automobile
engineering.

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 CHAPTER-6
REFERENCE

1. Online. Available: https://repairpal.com/electrical-lights.

2. I. Y. M. AUTOMOTRIZ, "INGENIERÍA Y MECHANIC AUTOMOTRIZ,"
01April2019.Online.Available:https://www.ingenieriaymecanicaautomotriz.com/
fuelsystem-components-working-principles-symptoms-and-emission-controls/.
3. S. Throat, "Learn Mech," Online. Available: https://learnmech.com/types-of-
brakes different-types-of-braking-system/.
4. H. M. co, "Motor-driven power steering system". USA Patent US7374015B2, 2004.
5. Online.Available:
https://www.ngkntk.co.jp/english/product/sensors_plugs/knock.html.
6.27October2021.Online.Available:
https://www.utmel.com/blog/categories/sensors/what-is-a-knock-sensor.
7. Online. Available:
https://www.hella.com/techworld/uk/Technical/Sensors-and actuators/Car-
knock-sensor-troubleshooting-401

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