TRIBHUWAN UNIVERSITY

INSTITUTE OF ENGINEERING
THAPATHALI CAMPUS

TITLE: A Progress Report on

OJT at LI Service Centre , Dhapasi
Submitted by :
Sujan Khadka (069/BIE/144)
Submitted to:
Department of Industrial Engineering

1.Introduction
Laxmi Intercontinental Pvt. Ltd started importing and selling Hyundai brands of vehicle in
Nepal after the acquisition of distributorship in February 2009. The companys aim was not only
the sales of Hyundai vehicles but also to provide quality after sales service Hyundai Customers.
In order to achieve this aim it is currently operating with two showrooms in the heart of
Kathmandu (Thapathali and New Baneshwor ) and two well equipped after sales service and
spare parts , one in New Baneshwor and another in Basundhara , northern part of Kathmandu. In
addition to this the company has opened its new service centre at Kupondole , Lalitpur.
Company showrooms have been opened with the intention of providing customers an improved
service in terms of quality, space and ambience. In these showrooms, customers would feel
different kinds of buying experiences.
Companys After Sales Service and Parts facilities follows the Hyundais Global Auto Servicing
offering the full range of after sales service facilities through its hig tech equipments and well
trained technicians.
In order to capitalize the growing automobile market outside the Kathmandu valley, it has
already established thirteen sub dealers in various places outside Kathmandu like Dhangadi,
Dang, Narayangarh , Pokhara , Butwal , Bhairahawa, Birgunj ,Damak and is planning to extend
its service centres all over Nepal in coming future.
LI Service Centre Pvt. Ltd is located in Dhapasi and spreads over 45000 sq. feet of area and
offers full range of services through high-tech equipments and well trained technicians. It has 4
work bays and dedicated for only quick service and another 6 work bays dedicated for repair and
maintenance jobs. Work bays are equipped with 2 post and 4 post lifts where technician can carry
out required repair jobs. It has got body shop with paint booth to carry out the body painting
activities.

Generator

Rest
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Hyundai Parking Zone

Spare Parts Department

Account
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Departm
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Traini
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Compressor
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Fig: Layout of LI Service Centre Pvt. Ltd

Main specifications of seven models of Hyundai:
1)Santro
Transmission: 5 forward speeds and reverse, manual. Gear ratios: 3.833,
2.105, 1.31, 0.919 and 0.784;Reverse 4.00 Final drive:4.221.1
Suspension
Front: Mac Pherson strut with stabilizer bar,
Rear: Torsion beam axle, 3 link offset coil springs and hydraulic dampers
3

Main Entrance

Guard room

Changing room

Engin
e
Roo
Room
m Centre Pvt. Ltd
Fig: Plant layout of LI Service
Wheel alignment

Tools

Union room

Scrap room

Service Room

alignmenralignmenr

Dent/Paint Department

Speciall Painting Chamber

Water
storag
e tank

Steering
Rack and pinion type, power assisted optional with DX. Collapsable steering column
Turning radius: 4.4m
Turns lock to lock: 2.97 (power-assisted) , 3.87 (manual)
Wheels and tyres
Wheels : 4.0J 13 Presses steel disc
Tyres : 155/70 R 13 Radial
Brakes
Power assisted, hydraulic , diagonally split. Discs at front , self adjusting drums at rear. Vacuumassisted booster. Pad wear warning clips
Dimensions
Wheel base:230mm, Ground clearance :172 mm
Front track : 1315mm , Rear track: 1300 mm
1)ACCENT TORNADO
Transmission:
5 speed manual with overdrive, Gear ratios: 3.615, 2.503, 1.370,0.971 and 0.825
Final drive ratio3.650:1
Suspension
Front: Mac Pherson strut with coil spring and stabilizer bar, Hydraulic shock absorbers
Rear: Dual link with coil spring and anti-roll bar, Hydraulic dampers
Steering
Rack and pinion type, Power steering (GLS), optional on GLE
Turns from lock to lock: 4.06 (manual), 2.93 (power)
Turning circle radius: 5.0m
Wheels and tyres
Wheels : 5.0J 14
Tyres : 185/60 R 14
Brakes
Ventillated discs (240 mm dia) at front, se lf adjusting drums (180 mm dia) at rear. Tandem
master cylinder and booster . Pad wear warning clips.
Dimensions
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Wheel base: 2400mm,

Front track : 1435mm,
Rear track: 1425 mm
Ground clearance: 172mm
3. ACCENT VIVA CRD
Transmission
Type: 5 speed manual,synchromesh
Gear ratios:3.615,2.503,1.370,1.031,0.825
Final drive: 3.650:1
Suspension
Front:Independent,Mac Pherson strut with coil spring, gas shock absorbers
Rear:Independent,dual link axle with coil spring,gas shock absorbers.
Steering
Type: Power assisted rack and pinion
Turns lock to lock: N.A
Turning circle diameter: 10m
Wheels and Tyres
Wheels: 4.5 J13 inch/5J13 inch, made of steel /aluminium alloy
Tyres: 175/70 R 13 radial with tube
Brakes
Front: Ventillated discs
Rear:Drums
Dimensions
Wheel base:2440mm
Front wheel track:1435mm
Rear wheel track: 1425mm
Ground clearance: 172mm
Kerb weight: 1150 kg

4. GETZ
Body
Type: Two-box, five door hatchback
Transmission
Type: 5 speed , manual,
Gear ratios:3.61,1.95,1.37,1.06,0.82
Final drive: 4.056:1
Suspension
Front: Independent with Mac Pherson struts torsion beam axle
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Rear: Gas filled dumpers

Steering
Type: Power assisted rack and pinion
Turns lock to lock: 3.0
Turning circle diameter: 10m
Wheels and Tyres
Wheels: 5 J13 inch/5J13 inch, made of steel / alloy
Tyres: 175/70 R 13
Brakes
Front: Ventillated discs
Rear: Drums
Dimensions
Wheel base:2455mm
Front wheel track:1450mm
Rear wheel track: 1440mm
Ground clearance: 160mm
Kerb weight: 1025-1050 kg
5.SONATA
Body
Type: Three-box, four door
Transmission
Type: 4 speed , shiftronic
Gear ratios:2.84,1.52,1.0,0.71
Final drive: 4.056:1
Suspension
Front: Independent , double wishbones with coil springs ,anti-roll bar and twin-tube gas dampers
Rear: 262 mm solid discs
Steering
Type: Power assisted rack and pinion
Turns lock to lock: 3.28
Turning circle diameter: 10.9m
Wheels and Tyres
Wheels: 166.5 inch , made alloy
Tyres: P 215/60 R 16
Brakes
Front: 280mm ventillated discs
Rear:262 mm solid discs
Dimensions
Wheel base:2728mm
Front wheel track:1575mm
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Rear wheel track: 1560mm

Ground clearance: 160mm
Kerb weight: 1481 kg
6.ELANTRA CRDi
Body
Three-box, four door,sedan
Transmission
Type: 5 speed manual
Gear ratios:3.455,1.952,1.295,0.698
Final drive: 3.47
Suspension
Front: Independent ,MacPherson strut with gas filled dampers
Rear: Dual link ,coil spring with anti-roll and gas-filled dampers
Steering
Type: Power assisted rack and pinion
Turning diameter: 10.12m
Turning circle diameter: 10.9m
Wheels and Tyres
Wheels: 5.5J5 inch , made of steel/ alloy
Tyres: 195/60 R 15 radial
Brakes
Front- ventillated discs , Rear discs ,ABS Standard with EBD,TCS and BA
Dimensions
Wheel base:2610mm
Front wheel track:1485mm
Rear wheel track: 1475mm
Ground clearance: 185mm
Kerb weight: 1365 kg
7. TUCSON 2.0 CRDi
Body
Two-box, five door wagon
Transmission
Type: Manual,5 forward speeds
Gear ratios:3.636,2.056,1.296,0.943,0.698
Final drive: 4.042:1
Suspension
Front: MacPherson struts with coil springs with double-acting pneumatics-assisted hydraulic
dampers
Rear: Independent dual-link with double-acting pneumatics-assisted hydraulic dampers
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Dual link ,coil spring with anti-roll and gas-filled dampers

Steering
Type: Power assisted rack and pinion
Turns lock to lock: N.A
Wheels and Tyres
Wheels: 6.5J16 inch , made of alloy
Tyres: 215/65 R l6
Brakes
Front- Ventillated discs
Rear:Solid discs
Dimensions
Wheel base:2630mm
Front wheel track:1540mm
Rear wheel track: 1540mm
Ground clearance: 195mm
Kerb weight: 1670 kg

DEPARTMENTS OF THE COMPANY

2. Repair /Maintenance
LI Service Centre Pvt. Ltd has well equipped repair section. It is responsible for all kinds of
maintenance and repair jobs that are to be carried out in the workshop. Various jobs are to be
carried from the opening of the job card to the delivery of vehicles. There are separate washing
and repair section.

Chart 1: Work flow of vehicle servicing

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Firstly booking is made via phone.The servicing priority is first given to

booked vehicles on the basis of time of the call. If there are less number of
booked vehicles in a day, the centre takes non-booked vehicles for servicing
and repairs. When a vehicle enters the service centre , it is recorded in the
entry book of guard house. After that a service advisor opens a job card as
per the description of customer.
The job card is handed over to the floor supervisor, where he checks the
problems and customer complaints. Then he assigns the technicians
according to the job that needs to be carried out. A senior technician
performs a test drive if it is required, then informs supervisor about the
additional problems in vehicles. In case of additional jobs, the floor
supervisor contacts the customer to make decision regarding the additional
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jobs. If the vehicle is from an accidental case, it is then transferred to dent

and paint sections.
Customer care
LI Service centre has benn putting customers satisfaction on the topmost list
of their priorities. Customers are in constant contacts with the officials of
customer Care department from the time of booking till the time of dispatch
and even after several durations of the delivery of vehicle. The customer are
dealt first by the officials of customer care department while booking. After
that the officials keep on informing the customers about the progress in the
repair/maintenance tasks. The customer care officials are also responsible for
making the booking list of next day and submit the list to the service
advisors and engineers. It is noteworthy that LI Service Centre has fully
facilitated and comforting customer lounge.
Spare parts section

3. Works accomplished
Observation of general workflow::
First few days of OJT were spent in observations as recommended by the
admin of the service centre. In order to work as a service engineer/advisor,
one needs to know the overall workflow of the service centre.
Preparing job card:
A job card is hand prepared.Job card contains all the information about
customers as well as the vehicle. It plays important role in maintenance of
any vehicle.Moreover it supplies all the general and specific informations of
the vehicles to the technicians while preparing.
Servicing and repair:
There are various types of repair and maintenance works to be carried in the
service stations. Some of them are free servicing , schedule servicing , paid
repair etc. A number of things needs to be checked in each type of repair
works.

General check up
The general check up includes a through checking of all the parts and
equipments. The major things that needs to be checked are battery
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conditions, radiator conditions , all oil levels including engine oil, gear
oil, differential oil, fuel filter , oil filter , brakes, clutches , etc
Regular servicing
There is a scheduled servicing of each vehicle as prescribed by
Hyundai. Generally it is required to change air filter, engine oil etc in
10000 km according to the road condition .However they can be
changed as soon as 5000km or whenever the filters are useless or the
oil becomes dirty.
Clutch plate inspection
Generally it is required to change the clutch plate within 1 lakh
kilometers but it is checked in every servicing and is replaced as soon
as it is damaged .Usually the vehicles that run in off road or the drivers
vehicles in half clutch tends to damage their clutch plate more often
than other vehicles.
Brake inspection
Brake is checked whenever a customer request for the servicing. While
checking the brakes, the roughness of brake pads is checked in case of
disc brake and roughness of lining as well as brake drum is checked in
case of drum brake. Brake fluid is also replaced whenever necessary.
Gear box check
A four post lift is required to make the job easy. First gear box is taken
out with the help of pneumatic lift attached to four post lift. Then the
gear box is dissembled and washed in kerosene or with the help of
throttle spray .The defected gears are replaced on customer approval.
Suspension inspection
The leaf spring and coil spring suspensions are also regularly checked.
Usually when leaf springs get slacked it is hammered and repaired but
in case it is broken then the specific layer of the leaf spring has to be
replaced. While in case of coil spring there is no any means of repairing
and it has to be replaced if damaged. Usually coil springs get damaged
in coil spring system and it is replaced.
Propeller shaft inspection
Propeller shafts are also inspected time to time. Generally the u/j cross
of propeller shaft gets damaged and it is replaced. U/j cross of vehicles
in off road tends to get damaged more often.
Electrical systems check up
Separate technicians are allocated to do electrical jobs. For any
electrical problems, first of all the battery is checked. If the battery is
ok the negative terminal is removed and continuity in the wire is
checked. The electrical equipments like head lights, parking lights,
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instrument cluster, radio, Window switches, fuse are checked. The

problem is then identified and defected parts are replaced.
Starter
motor
and
alternator
The device like starter motor and alternator are also diagnosed by the
electrical technicians. If there is defect in alternator it is detached from
the vehicle and taken to to the electrical room , where it is dissembled
and diagnosed for the problems. The common problem in starter motor
is the failure of carbon brush holder and the gear while the common
problem in alternator is the failure of windings.
AC System inspection: Generally the AC system and wiring systems
tend to be one of the hectic jobs. The main problem is less
effectiveness of AC cooling which is resolved by either cleaning the AC
filter or refilling the AC gas (R134a is used as the cooling agent) If
there is any other problems like leakage, the whole dashboard has to
be opened and the AC system is taken for diagnosis. The leaked parts
are either glued if possible or replaced.

Computer Diagnosis
In more recent models of Hyundai, many electrical problems can be sort out
with the help of computer diagnosis as it is well equipped with sensors. Only
those models that are equipped with ECU can be diagnosed for error.
Generally diagnosis is done to address three problems.

Engine check-lamp
Whenever there is any fault in any of the sensors, the engine check
lamp glows in the instrument cluster. Then the computer is connected
to the vehicle and synchronized through Python . It shows which of the
sensor is causing problems and why. Then the specific problem is
addressed using necessary procedure. Usually there are sensors in airbag, air mass, fuel-level, CRD, pre-tensioner belt etc. and whenever
there is anything wrong , check lamp glows.
Key programming
Whenever the vehicle owner lose his keys, the new set of keys needs
to be is reprogrammed. For this procedure, the new set of key is
installed in the vehice, python is connected and diagnostic software is
run. Then the TPK1 and TPK2 is generated and submitted to floor
manager, the floor manager sends it to parent company through internet
for approval. After it is approved the engine is started and the key programming
procedure is complete.
ECU Flashing
It is similar to formatting of computer. It generally means the brain of electrical system
12

which guides all electrical processes. Sometimes when new ECU is installed or the
current version of ECU software is outdated, ECU flashing is performed. For ECU
Flashing the python is connected to the vehicle and the respective software of flashing
tool is opened and the flashing is done as per instruction.
Training session
The service centre also provides technical training for the technicians for them to get familiarized
with the modern technologies of the company and to increase the efficiency in the service.
Generally technicians are sent to Hyundai Training Centre located in Patan Industrial Estate.
Along with the technicians and other fellow interns, I also got chance to attend various technical
trainings. During the 3 months training of vehicle immobilizer, CRD engine, and Tyres were
attended.

Vehicle immobilizer
Vehicle immobilizer is the anti-theft security system adapted by Hyundai in its recent
models. The main objective of the immobilizer system is to prevent unauthorized key
entry which prevents vehicle from theft and other tasks. There are three types of
immobilizer used in Hyundai vehicles. Starter immobilizer (RKE based) ,Starter and
engine immobilizer (RKE based), engine Immobilizer (TBI based). The starter
immobilizer reads the key encryption whenever a key is entered, if the data matches with
that of starter motor which prevents from cranking hence stopping the vehicle. Starter and
engine immobilizer works in the same concept except it locks down both starter and fuel
injection system so that vehicle wont start. The latest technology is engine immobilizer
which is TBI based. In this system a small chip is fixed in the key itself by the
manufacturer which is equipped with transmitter and responder. So,when a key is inserted
the radio signal is first read by the vehicle and the data is sent to to ECU. If the data
matches the engine starts otherwise the engine is locked as the fuel injection is cut off.
When a vehicle enters to immobilize condition it can be unlocked with the genuine key,
but if the wrong key is tried again it immobilizes permanently and the owner has to
contact authorized dealer for its diagnosis.
CRD engine
CRD engine stands for Common Rail Diesel Engine which is one of the latest
technologies in automobile sector. A CRD system is composed of various equipments like
ECU, sensors, actuators, turbo, EGR etc. A common rail system simply means the
utilization of a common rail for fuel injection before it directly reaches the engine.
Comparing with older types of engine it has improved pressure pump and a common rail.
The older DI engine can create pressure upto 800 bars whereas in common rail it can be
increased as much as 2200 bar. The engines electronic timing regulates injection
pressure according to engine on pressure precisely and as needed , based on data
obtained from sensors on the cam and crankshaft . This technique allows fuel to be
injected as needed, saving fuel and lowering emissions. The history of improving
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emission control starts from EGR valve then turbo was introduced which also helped to
control emission. Finally CRD system was introduced which remarkably improved the
emission control. The major advantages of a CRD system are:
Controls the emission of harmful gases like NOx.
Controls the engine temperature
Improved combustion of fuel
Improved overall efficiency
FINDINGS
After a 3 months long internship at LI Service Centre, Dhapasi , I came to know a lot of
things about the automobile technology as well as the company itself. I also analyzed various
data and informations I found and formulated the following findings:

LI Service Centre is on of the busiest service centre in Nepal owing to increased sales
of Hyundai vehicles in the country.
LI Service centre has impressive technical aspects.
The prime objective of LI Service is customer satisfaction
It is proving good learning ground for industrial as well as mechanical
engineers.
The avg. vehicle income is 30 vehicles per day with 75% delivery on
same day.
Washing section has average of 25 vehicles per day and can thus be
called as good business.
It has reliable technical manpower for performing high quality jobs.

4. Daily working report

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Date
22nd
May
23rd May
24th May
25th May
26th May
27th May
29th May
30th May
31th May
1st June
2nd June
3rd June
5th June
6th June
7th June
8th June
9th June
10th June
12th June
13th June
14th June
15th June
16th June
17th June
19th June
20th June
21st June
22nd
June
23rd June
24th June
26th June
27th June
28th June
29th June
30th June
1st july
3rd July
4th July

Jobs done
Visiting all departments and Introduction with staffs
engine oil change of 6 cars
Engine oil , gear oil, air filter, oil filter changes of cars
body bush change
Headlight check and change, parking light change
power window check and change
coolant change, engine oil change, oil filter change
Engine oil , gear oil, air filter, oil filter changes of cars
all brake check ups ,oil changes
clutch plate changes ,oil changes ,brake check-ups
pulley belt change, bearing change ,oil changes
silencer check-ups ,replacements, brake check-ups, general check-up
coolant change, engine oil change, oil filter change
power window maintenance ,door lock handle replacement
general check-up, gear box removal ,clutch adjustment
headlight check and change, spring bush change
Engine oil , gear oil, air filter ,oil filter changes of cars
filling the AC changes, oil changes, all brake check-ups
fuel tank cleaning ,oil changes, filling AC gas
engine opening and inspection and dispatch to external service for lathe
body bush change, all brake check ups
wheel alignment adjustment, tyre rotation, steering adjustment
brake check up and adjustment, general check-ups, test drives
pulley belt change, bearing change ,oil changes
power window maintenance ,door lock handle replacement
leaf spring suspension change, test drives, coolant change
all brake check ups ,oil changes
headlight check and change, spring bush change
pulley belt change, compressor bearing change
wiper blade change, coolant change, brake oil change
Shock absorber replacement ,bush change ,oil changes
clutch plate changes ,oil changes, brake check-ups
wheel alignment adjustment, tyre rotation, steering adjustment
brake check up and adjustment, general check-ups, test drives
pulley belt change, bearing change ,oil changes
power window maintenance, door lock handle replacement
leaf spring suspension change ,test drives, coolant change
all brake check-ups ,oil changes
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5th July
6th July
7th July
8th July
10th July
11th July
12th July
13th July
14th July
15th July

headlight check and change, spring bush change

pulley belt change, compressor bearing change
wiper blade change ,coolant change ,brake oil change
power window maintenance ,door lock handle replacement
leaf spring suspension change ,test drives, coolant change
all brake check- ups ,oil changes
data entry jobs as given by supervisor
data entry jobs as given by supervisor
data entry jobs as given by supervisor
data entry jobs as given by supervisor

Note:The above information has been checked and approved by supervisors

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