Eno-190240102002

Internship Project Report

ON

“PEGASAUS MARUTI SUZUKI ”

Prepared by

PANCHAL AAKASH

Enrollment No.: 190240102002

B.E AUTOMOBILE ENGINEERING

Under the guidance of

Prof. Sujal Thakkar

ACADEMIC YEAR

2022-23

Hasmukh Goswami College of Engineering, Ahmedabad.

Gujarat Technological University, Ahmedabad

May, 2023

HASMUKH GOSWAMI COLLEGE OF ENGINEERING

Automobile Engineering

2022-23
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CERTIFICATE

Date:

This is to certify that a study on entitled “Internship training in Pegasus

Maruti ’’ has been carried out by PANCHAL AAKASH (190240102002)
under my guidance in fulfillment of the degree of Bachelor of Engineering in
Automobile Engineering (8th Semester) of Gujarat Technological University,
Ahmadabad during the academic year 2022-23.

Internal Guide: Prof. Sujal Thakkar Head of Dept.: Prof. Sujal Thakkar

Asst. Professor, AE Dept. Head, ME Dept.

HGCE, Vahelal HGCE, Vahelal

Sign of External Examiner:

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Student’s Declaration

I undersigned __________________ a student of HGCE B.E Automobile

Engineering 8th semester, declare that summer internship project titled
“_________________________” is a result of my/our own work and my/our
indebtedness to other work publications, references, if any, have been duly
acknowledged. If I/we are found guilty of copying any other report or published
information and showing as my/our original work, I understand that I/we shall be
liable and punishable by Institute or University, which may include ‘Fail’ in
examination, ‘Repeat study & re-submission of the report’ or any other
punishment that Institute or University may decide.

Name of Student:

Enrollment Number:

Signature :
Eno-190240102002

ACKNOWLEDGEMENT

I wish to express my heartfelt appreciation to all those who have contributed to this project, both
explicitly and implicitly, without the cooperation of whom, it would not have been possible to
complete this project.

This final year project has been carried out at the Department of Automobile , Gujarat
Technological University. I would like to express my sincere thanks to my internal guide Mr .
Sujal Thakkar whose guidance and encouragement is invaluable. It has been an honor and
memorable experience working with him.

I would also like to thank my internal guide Prof. Sujal Thakkar , Head of AE Department,
Prof. Sujal Thakkar and the faculty members of HGCE who had helped me directly or
indirectly in my project work.

I thank my parents for standing behind me all the time and I thank my friends for their advice,
guidance and help. I thank God for all his blessings.

PANCHAL AAKASH (190240102002)

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ABSTRACT
Industrial Internship plays an important role in a student’s life. A well planned, properly
executed and evaluated industrial training helps a lot in developing a professional attitude. It
develops an awareness of industrial approach to problem solving based on a broad understanding
of process and mode of operation of organization. Aim of industrial internship is to receive
practical and communication skills and technical knowledge which will help me, as an
Automobile Engineering student.

The period of 12 weeks at Maruti Suzuki Arena(Visual Auto link pvt ltd ) I was authorized in
service department . In service centre , I was exposed to all the modern services processes of
Swift desire, alto800 and so on. All the modern instruments such as oil filler machine, wheel
balancer, wheel alignment machine were all required to service the vehicles in service
department.

In service department, service all required part with check list mark it out. Than start repairing or
service as per given servicing steps and need to provide the daily reports about serviced vehicles
and replaced parts. After completion of servicing and replacing, run-off or testing of vehicles
takes place for a pre-determined time to examine any issues and trouble shoot them.
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 PREFACE

Maruti Suzuki Motor company is committed to becoming leading global enterprise under
The rapidly changing auto industry by creating new value's base on continue challenge
and Innovation.

Additionally , the company contributes to enhancing the sustainability of corporate and

society through various active and active ESG improvement activity as a respected global
enterprise .

This characted aims at providing a comprehensive and transparent disclosure of the

company's governance under the supervision of a professional independent board of
directors.

Our goal is to become a company that ensure a sustainable future through the balanced
promotion of the rights of our stakeholders including but not limited to,
Shareholders ,customers , employees ,and partners .
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 TABLE OF CONTENT

Chapter No Particular Page No

1 Introduction of Maruti
1.1 History of Maruti 1
1.2 Manufacturing Facilities
1.3 Models of Maruti
2 Visual Auto link PVT.LTD 5
2.1 Introduction of Pegasus
Maruti Suzuki
2.2The Layout of Workshop
2.3 Information of the
workshop
2.4 Types of Vehicle services
2.5 Job card Details
2.6 Types of Services
3 Types of Tools and Major
Equipment’s 15
3.1 Introduction of tools and
Equipment Shops
4 Information of Major and 28
Minor work
4.1 Minor work
4.1.1 General check up
4.1.2 Cleaning of Component
4.1.3 Finding the Fault
4.1.4 Read the job card
Details
4.2 Major work
4.2.1 Full vehicle service
4.2.2 Find out there Estimate
of vehicle service
4.2.3 Replace the Damage
Parts
4.2.4 Cleaning The parts
4.2.5 Customer Demand
4.2.6 Final Inspection
4.2.7 fill the Job card Details
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 List of Table

Chapter No Particular Page No

1 Introduction of Maruti
Suzuki
1.1 Founder and Owner of the
Maruti Suzuki
2 Gallops Hyundai PVT.LTD
2.1 Sales and Marketing Area
2.2 Service Area
2.3 Washing Area
2.4Workshop Layout
2.5Job card Details
3 Types of Tools and
Equipment
3.1 ALLEN KEYS
3.2 T- HAND TOOLS
3.3 OIL FILTER WRENCH
3.4 RING WRENCH
3.5 OPEN END WRENCH
3.6 RACHAT& BOX
WRENCH
3.7 SCREW DRIVERS
3.8 COMBINATION
WRENCH
3.9 ADJUSTABLE
WRENCH
3.10 AIR GUN
3.11 JUMPER PULLER
3.12 SPECIAL TOOLS
4 Information of Major and
Minor Work
4.1 General Check up
4.2 Find out The fault
4.3 Ask The Advisor
4.4 Find out The Estimate
4.5 Cleaning The parts
4.6 Replace The parts
4.7 Full Service
4.8 Check the oil level
4.9 Air filling
4.10 Car Washing
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Chapter 1 Introduction of Maruti Suzuki

Chapter 1.1 Founder and CEO of Maruti Suzuki

• Founder and CEO of Maruti Suzuki : Hisashi Takeuchi

Maruti Suzuki’s Board of Directors today appointed Hisashi

Takeuchi as new Managing Director and Chief Executive Officer
for three years with effect from 1st April 2022, consequent to the
completion of the term of Kenichi Ayukawa on 31st March 2022.

Kenichi Ayukawa will be the Executive Vice Chairman till 30th

September 2022 to facilitate the transition process and provide
guidance to the MSIL. Ayukawa has been the Managing Director
of Maruti Suzuki India Limited since April 2013.

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Maruti Suzuki appoints Hisashi Takeuchi as MD and CEO

Maruti Suzuki’s Board of Directors today appointed Hisashi
Takeuchi as new Managing Director and Chief Executive Officer
for three years with effect from 1st April 2022, consequent to the
completion of the term of Kenichi Ayukawa on 31st March 2022.

Kenichi Ayukawa will be the Executive Vice Chairman till 30th

September 2022 to facilitate the transition process and provide
guidance to the MSIL. Ayukawa has been the Managing Director
of Maruti Suzuki India Limited since April 2013.

Maruti Suzuki said that in order to seek the approval of the

members for aforesaid appointments through postal ballot by
providing a facility to vote by electronic means pursuant to Section
108, Section 110 and other applicable provisions, if any, of the
Companies Act, 2013 read with Rule 20 and Rule 22 of the
Companies .

 History of the Maruti Suzuki

Maruti Suzuki India Limited (MSIL), formerly known as Maruti Udyog Limited, a
subsidiary of Suzuki Motor Corporation of Japan, is India’s largest passenger car
company, accounting for over 50 per cent of the domestic car market. Maruti Udyog
Limited was incorporated in 1981 under the provisions of Indian Companies Act 1956
and the government of India selected Suzuki Motor Corporation as the joint venture
partner for the company. In 1982 a JV was signed between Government of India and
Suzuki Motor Corporation.

It was in 1983 that the India’s first affordable car, Maruti 800, a 796 cc hatch back was
launched as the company went into production in a record time of 13 month.

More than half the number of cars sold in India wear a Maruti Suzuki badge. They are a
subsidiary of Suzuki Motor Corporation Japan. The company offer full range of cars–
from entry level Maruti 800 & Alto to stylish hatchback Ritz, A star, Swift, Wagon R,
Estillo and sedans DZire, SX4 and Sports Utility vehicle Grand Vitara .

Since inception, the company has produced and sold over 7.5 million vehicles in India
and exported over 500,000 units to Europe and other countries.

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 Manufacturing Facilities

Maruti Suzuki has two manufacturing facilities in Haryana (Gurugram and Manesar), and
one manufacturing complex in Gujarat wholly owned by parent company Suzuki which
supplies its entire production to Maruti Suzuki. All manufacturing facilities have a combined
production capacity of 2,250,000 vehicles annually (1.5 million from Maruti Suzuki’s two
plants and 750,000 from Suzuki Motor Gujarat).

The Guru gram manufacturing facility has three fully integrated manufacturing plants and is
spread over 300 acres (1.2 km2).[24] The Gurgaon facilities also manufacture 240,000 K-
Series engines annually. The Gurugram facility manufactures the Alto 800, WagonR, Ertiga ,
XL6, S-Cross, Vitara Brezza, Ignis, and Eeco . The Gurugram facility also assembles the
Jimny starting from January 2021 solely for export markets. It was reported the Indian-
assembled Jimny will be exported to African markets and countries in the Middle East.[25]

The Manesar manufacturing plant was inaugurated in February 2007 and is spread over 600
acres (2.4 km2).[24] Initially, it had a production capacity of 100,000 vehicles annually but
this was increased to 300,000 vehicles annually in October 2008. The production capacity
was further increased by 250,000 vehicles taking the total production capacity to 800,000
vehicles annually.[26] The Manesar plant produces the Alto, Swift, Ciaz , Baleno and
Celerio . On 25 June 2012, Haryana State Industries and Infrastructure Development
Corporation demanded Maruti Suzuki pay an additional ₹235 crore for enhanced land
acquisition for its Haryana plant expansion. The agency reminded Maruti that failure to pay
the amount would lead to further proceedings and vacating the enhanced land acquisition.
[27]

In 2012, the company decided to merge Suzuki Powertrain India Limited (SPIL) with itself.
[28] SPIL was started as a JV by Suzuki Motor Corp. along with Maruti Suzuki. It has the
facilities available for manufacturing diesel engines and transmissions. The demand for
transmissions for all Maruti Suzuki cars is met by the production from SPIL.

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 Models of the Maruti Suzuki

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Chapter 2 Visaul Auto Link PVT LTD

 Introduction of Pegasus Maruti

Pegasus Maruti is a chain of Maruti Suzuki Brand dealerships of Aggarwal GROUP, The
group runs under the leadership of Prachin Aggarwal and Other Partners . The Aggarwal
Group is now recognized as a major business group in Ahmedabad, Mumbai & Rajkot with
for the state art showrooms and workshops. Maruti currently has ten car models across
segments – ALTO 800 , EECO ,EECO STAR , SWIFT , SWIFT DZIRE , BALENO , CIAZ
,BREZZA , ERTIGA, XL6 & XL7 . We provide facilities like Finance, Exchange, Insurance,
Accessories and Car Detailing. We truly believe in Customer Satisfaction and we give all
customer a delightful experience and family like environment. We are a proud family of over
70,000 happy customers and counting .

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 Customer Facilities

1. 24 hours breakdown Service

2. 7 days working
3. First aid Kit
4. Great Working hours 9.30 am to 7 pm
5. Large Parking Area
6. Waiting room with AC
7. Faithful Staff
8. Good communication

 Employee Facilities

1. Engine & Dashboard Room

2. Accessories
3. GDS System
4. Chilled water cooler
5. Washing Area
6. Hydraulic lifts
7. Individual tool box
8. Store room for parts
9. Paint room
10. Oil filling pipe
11. Worker Rest room
12. Safety service
13. Large area
14. Air filling pipe
15. Good facility for equipment

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2.1 Sales & Marketing Area

In that area customer comes in a showroom for looking a new car .

Customer specially came in showroom with great joy for purchasing a
car .
Customer ask the sales manager about a car that manager started
telling features about car model and price then he communicate with
customer very nicely they have knowledge to give advice to customer
for purchasing our company product .

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2.2 Service Area

Automobiles need maintenance from time to time. Like humans are required to maintain
hygiene, similarly automobiles also need to be kept clean. Automobiles have to run on dirty
roads and in a polluted environment.

Vehicle maintenance and servicing is carried out when the vehicle completes certain kilometers
on its normal running or when the vehicle does not give proper performance.

It is suggested that the vehicle owners carry out regular and periodical checks on their vehicle
In that area employees have to check full car and make a report about checked vehicle and Find
out some fault and ask the advisor give a possible solution after talking with customer .

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2.3 Washing Area

This is the area after completing service or before starting service of vehicle car Enters in that
Area. Washing Area It’s also called cleaning Area .

Washing men start washing car and it’s remove dust contaminate mud dirt oil .

It’s Clean car from inner and outer side .

After this procedure a car looks like new car from recently purchased from Showroom .

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2.4 Workshop Layout

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2.5 Information of the Workshop Layout

Workshop layout is Shown in figure 2.4 . Customer carries their car at

the security office. Than customer visits the front office and then service
adviser make the job card for Workshop. The car comes into the Work
shop. When the car in service process then after the work done on car
the car is gone for the test run then if any problem is found then it should
solved on the sport then after the final inspection the car goes to wash
from service if the car is in body shop after the process done on the car
going to paint area from body shop than going to washing area. After
wash the car is delivered to the customer.

Types of Service

1. Free Service
2. Paid Service
3. Running Repair Service
4. Warranty Repair Service

In our Workshop basically there are Four types of Service . As above 1st
Service is free Service , 2nd is Paid Service , 3rd is Running Repair
Service and Last one is Warranty Repair Service .

In free Service Customer put his vehicle on workshop technician check

the full vehicle if there is fault as per Free service They solve the

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problem . If there is a low level of wiper wash or other part that need
lubrication then technician fill lubricant viya top up .

In paid Service As per Above but There is Minor difference between

Free and Paid Service . In paid Service As per Customer Demand we
communicate with that customer and then Make a job card .

In Paid Service all the free Service must be included As per job card .
Technician find some fault after checking a Car Then a job card Made
by a FI officer .

Technician must do work As per job Card Details . Technician Ask

about the Fault to Service Advisor . Service Advisor check the Full
Details of the Job card and tell the customer . Then customer Demand
Technician Must Solve the Problem .
Types of Vehicle Services

1. 1st Service
2. 2nd Service
3. 3rd Service
4. Paid Service
5. Running Repair-Customer Demand
6. Warranty Repair Service

As per Above in our Company There are Five types of Service .

1st ,2nd 3rd , Paid , Running Repair-Customer Demand Service and
Warranty Repair Service .

This Type of Service are in Details in 1,2,3 Service Customer put

his Car in Workshop . After putting his Car a Computer Operator
Make a job card of that Vehicle .

After completing that process a Job card that Job card send into FI
officer . FI officer Check the Vehicle Details and Send to
Technician For Solve the Problem in a Vehicle .

Technician First of all Check up the Vehicle means General check

up . That Check up Technician Find some fault maintain the level
of oil , lubricant etc.

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In that Service It has General check up is common In all Service .

But different types of Service have Different types of Method to
Perform a work on a Vehicle .

After Completing all the Services Car Send to Test Drive . On

Test Track if a Minor problem is Caught by Drive a Vehicle . So
that Problem have been Solved by Technician immediately .

Customer Demand Service Means Customer Came With There

Problem We Listen there Problem and Make a job according There
Problem and also make schedule Service Job- card and
We assure that to customer we tried to solve your problem in
Minimum time and we want to make our customers happy
When they leave from our showroom .
Warranty Repair Service is also a type of Free Repair but in that
Service Customer knock there car because of some incident and
they tow there vehicle and came into show room and tell us to
make a damage parts fault of Company When made this Model
Company had to replace that parts and no charged and Single
Rupee just because of Company’s mistake and also Showroom
apologize to customer .

In that service there a insurance is a part of vehicle a service they

make a car to old to new one but there is some conditions applied
in that service if there is a huge cost of vehicle repairing then
customer have to paid more money after take a estimate of
insurance if there is less money of repairing so that repair cover
insurance .

1 1st Service

 General check up
 Solve the Problem
 Make a Report
 Find some fault

2 2nd Service

 General check up
 Cleaning The parts

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 Maintain oil level

 Make a Report
 Find out some fault
3 3rd Service
 Service the Damage Parts
 Clean The Damage Parts
 Replace The Damage Parts
 General Check up
 Maintain oil level
 Fill The oil in Parts

4 Paid Service

 General Check up
 Customer Demand
 Compulsory Replace the Parts
 Service Parts
 Fill the oil
 Filter Replace
 Clutch Repair
 Gear Box Repair
 Wheel Balancing
 Alignment Balancing
 Suspension Repair
 Maintain oil level
 Break pad Replace
 Liner Replace
 Make a Report
 Air fill in the Car Wheel

5 Running Repair

 As per Above
 Wheel Balancing
 Wheel Alignment
 Send a car on test Track
 Air filling on Wheel
 Solve the Problem on Vehicle
 Solve problem if you’re Drive a Vehicle

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Chapter No 3 Types of Tools and Equipment

There are Many Types of Tools and Equipment used in Work shop while Performing a Work.
Some Equipment has More than One use to solve the problem like Ring Spanner , T- Spanner etc
.

Many Tools and Equipment in detail As follows :

1. Allen keys
2. T-Hand Wrench
3. Oil Filter Wrench
4. Open-end Wrench
5. Box-end Wrench
6. Combination Wrench
7. Flare-nut Wrench
8. ratcheting Box Wrench
9. flex-head socket Wrench
10. adjustable Wrench
11. Monkey Wrench
12. Pipe Wrench
13. Socket Wrench
14. Ratchet Wrench
15. Special Tools
16. Pneumatic Gun
17. Jumper Puller

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 Allen Key

A wrench used to turn screw or bolt heads designed with a hexagonal socket (recess) to receive the
wrench. The wrenches come in two common forms: L-shaped and T-handles. The L-shaped wrenches are
formed from hexagonal wire stock, while the T-handles are the same hex wire stock with a metal or
plastic handle attached to the end. There are also index able-driver-bits that can be used in indexable
screwdrivers .

 T – Handed Spanner

It has T-shape because of its shape it less slips and it can easily go in small holes where
our hands does not reach or to open the nut with more power. Because of its long bottom
area where it is fixed long head bolts also can be removed by it.

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 Oil Filter Wrench

A self-lightening wrench with either a chain or strap of Metal leather or rubber attached
to a handle, used to Grip and turn smooth cyndrical objects such as Automotive oil
filters). It relies entirely on friction between The strap on chain and the object to be
manipulated.

Similar to a pipe wrench, but uses a chain similar to a drive chain or strap, instead of an
adjustable jaw. The links of the chain have extended pegs which fit into grooves in the
front of the handle, with one end of the chain attached permanently to the handle. This is
used in situations where pipe wrenches cannot maintain a proper grip on an object such
as a wet or oily pipe. Larger versions of chain wrenches are sometimes known as “bull
tongs” and are used with large diameter pipe such as is used deep wells.

4 Box-end Wrench

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A one-piece wrench with an enclosed opening that grips the faces of the bolt or nut. The
recess is generally a six-point or twelve-point opening for use with nuts or bolt heads
with a hexagonal shape. The twelve-point fits onto the fastening at twice as many
angles . E square-shaped nuts and bolt heads. Ring the nut or bolt.

5 Open end Spanner

A one-piece wrench with a U-shaped opening that grips two opposite faces of the bolt
or nut. This wrench is often double-ended, with a different-sized opening at each end.
The ends are generally oriented at an angle of around 15 degrees to the longitudinal
axis of the handle. This allows a greater range of movement in enclosed spaces by
flipping the wrench over.
6 Combination Wrench

A double-ended tool with one end being like an open-end wrench or open-ended
spanner, and the other end being like a box-end wrench or ring spanner. Both ends
generally fit the same size of bolt.

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7 Flare-nut Wrench

A wrench that is used for gripping the nuts on the ends of tubes. It is similar to a box-
end wrench but, instead of encircling the nut completely, it has a narrow opening just
wide enough to allow the wrench to fit over the tube, and thick jaws to increase the
contact area with the nut. This allows for maximum contact on plumbing nuts, which
are typically softer metals and therefore more prone to damage from open-ended
wrenches.

8 Ratcheting- Box Wrench

A type of ring spanner, or box wrench, whose end section ratchets.

Ratcheting can be reversed by flipping over the wrench, or by activating a
reversing lever on the wrench. This type of wrench combines the compact
design of a box wrench, with the utility and quickness of use of a ratchet
wrench. A variety of ratcheting mechanisms are used, from simple pawls to
more complex captured rollers, with the latter being more compact,
smoother, but also more expensive to manufacture. The one pictured also
features a drift pin on the tail.

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9 Flex- head Socket Wrench

Similar in concept to a socket wrench. A Saltus wrench features a socket

permanently affixed to a handle. Sockets are not interchangeable as with a
socket wrench. The socket often rotates around the handle to allow the user
to access a fastener from a variety of angles. Commonly a Saltus wrench is
part of a double-ended wrench, with an open-end type head on the opposite
side from the socket head .
10 Adjustable Wrench

The most common type of adjustable wrench in use today. The

adjustable end wrench differs from the monkey wrench in that the
gripping faces of the jaws are displaced to a (typically) 15 degree angle
relative to the tool’s handle, a design feature that facilitates the wrench’s
use in close quarters. The modern adjustable end wrench was invented
by Johan Petter Johansson of Bahco . The common use of “Crescent
wrench” to describe this design is derived from the Crescent brand,
owned by Apex Brands, Inc. Apex Tool Group, LLC.

11 Monkey Wrench

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An old type of adjustable wrench with a straight handle and smooth jaws
whose gripping faces are perpendicular to the handle.

12 Pipe Wrench

A tool that is similar in design and appearance to a monkey wrench, but

with self-tightening properties and hardened, serrated jaws that securely
grip soft iron pipe and pipe fittings. Sometimes known by the original
patent holder’s brand name as a “Stillson wrench” or a “Stilly”.

13 Socket Wrench

A hollow cylinder that fits over one end of a nut or bolt head. It may include
a handle, if it does not then it is often just referred to as a socket and is
usually used with various drive tools to make it a wrench or spanner such as

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a ratchet handle, a tee bar (sliding tommy bar) bar or a knuckle bar (single
axis pivot). It generally has a six-point, eight-point or twelve-point recess,
may be shallow or deep, and may have a built-in universal joint.

14 Ratchet Wrench

It contains a one-way mechanism that allows the socket to be turned without

removing it from the nut or bolt simply by cycling the handle backward and
forward. (The photo shows both ratchet and sockets.)
15 Special Tools

Special Purpose Tools comprise of tools designed to do just one thing—but do it well. From Pipe
Cutters and Wrenches (for plumbers) to Punches and Scribers (for machinists) to Pliers and Files
(for mechanics) to Knives and Tweezers (for hobbyists), General offers more special-purpose
hand tools than any other supplier.

16 Pneumatic Air Gun

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A powered wrench that delivers quick, repeated impulses of torque. Typically

powered by air, but can also be electric. Like other wrenches which deliver a
large amount of torque that can easily open nut and bolt .

17 Jumper Puller Tools

Pneumatic and hydraulic shock absorbers are used in conjunction with

cushions and springs. An automobile shock absorber contains spring-
loaded check valves and orifices to control the flow of oil through an
internal piston .

One design consideration, when designing or choosing a shock

absorber, is where that energy will go. In most shock absorbers,
energy is converted to heat inside the viscous fluid. In hydraulic
cylinders, the hydraulic fluid heats up, while in air cylinders, the hot
air is usually exhausted to the atmosphere. In other types of shock
absorbers, such as electromagnetic types, the dissipated energy can be
stored and used later. In general terms, shock absorbers help cushion
vehicles on uneven roads.
 Features
 Maximum thrust: 2 tons (10 bars) – 1.6 tons
(8 bars) – 1.2 tons (6 bars)
 Spring compression stroke: 335 mm
 Working position: working height on rear Fork raised up to 875
mm
 Supplied with 2 lower forks for diameters 78-205 mm
 Protective “Full Body” Grille: provides maximum safety and
working area coverage
 Control Lever operation: increased accuracy and sensitivity during
compression stage

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Equipment

1. Automatic Car Washer

It is an ingenious Equipment Which reduces manpower and amplifies efficiency .

This Automatic Car Wash Machine is equipped to deliver a spotless glossy car in
a little more than 5 minutes . It has corrosion resistant hot dipped galvanized
structure .

Features

 Corrosion dipped hot galvanized Structure

 Variable Frequency Drive with less maintenance
 Varied length brushes
 Shampoo Spray
 Under chassis wash
 Automatic drying

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2. Two post lift

Car Hydraulic lift is a 2 post lift or Column Lift . It Carry the Vehicle
by two Hydraulic rod . This rod is fitted at 90 degree by high pressure
oil . This lift can carry a Heavy vehicle easily

Features
 Cable type equalization
 Mechanical lock for primary safety
 Load holding valve on power track for auxiliary safety
 Base free design makes working under the vehicle easily

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3. 3D Wheel Alignment Machine

Wheel Alignment sometimes referred to as breaking is a part of

standard automobile maintenance that consists of adjusting the
angles of wheels to the car Manufacturer specifications .
Wheel Alignment Machine is to reduce tire wear and to ensure that
vehicle travel is straight without pulling to one side .

Features

 Variable High Quality Camera Support

 Vehicle Orientation Direction indicator
 Advanced Customer Database
 Advanced Alignment Measurements
 Custom Vehicle Specifications
 Front - Rear all zones readings
 Easy to Operate

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4. Digital wheel Balancing Machine

Wheel Balancing is the Process of Balancing the weight of a tire
and wheel assembly so that it travels evenly at high speeds . In wheel
Balancing Machine a Mounted Wheel put on a Balancer Which
Centers the Wheel and spins it to determine Where the weights
should go .

Features

 Optimization program for tire and rim unbalance

 Automatic minimization of static unbalance
 Easy setting
 Brief cycle time of 6 seconds
 Single spin low RPM Balancing technology

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5. AC Gas filling Machine

AC Gas filling Machine is a Single series of operations . This machine

permits recovering and recycling refrigerant with no risk of releasing the
fluids into environment . This Machine is provided a gas to Car AC
when a Car AC gas is empty .

Features

 Alarm : High Pressure , Full bottle , empty bottle

 On – board bottle filling : Automatic
 Alarm on leaking gas
 Simple and user friendly software

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6. Paint booth

Paint booth or Paint shop is a mandatory shop . They are used to ensure
dust free operating during paint is improved . It has paint back facility
for proper drying of painted area . This helps in getting factory finish
paint quality .

Features
 Dust free paint chamber
 High capacity burner for quick drying painted area
 Improve paint quality of job
 Reduce the safety of hazard of operator by reducing the fumes in the
chamber
 Batter velocity for exhaust of paint fumes

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Chapter No 4 Information of Major and Minor work

Basically in our Company technician do two types of Work in workshop . First

Major Work and Minor Work . Major Work means Technician Repair the Damage
Part of the Vehicle otherwise Replace the Damage part by new part . Major work
Technician have responsibility to Service the vehicle without any mistake . It
perform Work in time limit as per customer requirements .
Minor Work is also a type of Service . In that service technician follow as per
advisor Advice . He do his work as per job card details but . In that service
technician have some important duties also .
Means Technician check the full vehicle in general inspection .Like all the lights ,
Doors , Windows , tools box , Wheels , filters , Also check the Level of All types
of oils , means coolant , engine oil and they also checked the all the types Filters .
In that service technician Also check Wheels . Technician maintain the Oil level if
it’s low then technician fill the Level .
Major and Minor work in detail as follows as :

Minor Work
1. Read the job card details
2. General Check up
3. Finding the fault
4. Maintain the oil level
Major Work
1. Read the job card details
2. General check up
3. Find the fault
4. Find out the estimate
5. Ask the advisor about fault
6. Check the details about car service
7. Collect some new parts from store
8. Set a car into service lift
9. Replace the parts by old Parts
10. Maintenan oil level
11. Belt Drive changing

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12. All Filter Changing

13. Wheel Alignment & Balancing
14. Change the spark plug
15. Change Steering module
16. Change clutch
17. Change the Break pads
18. Change the break liner
19. Car Washing
20. Test drive

Minor Work

1 read the job card details

In this service first of all technician must read the details before service the
vehicle .

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2 General check up
In this General check up it’s routine service in our workshop after entering in
the workshop check the all lights and Parts of the vehicle body it’s working or
not in good condition .

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If there is any parts not working properly then customer note down into in a paper and ask
advisor about that parts condition .

3 Finding the Fault

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In this service after finishing a General check up Technician find out some
fault While Check up then Vehicle Technician saw Fault in vehicle then it
note down Fault in a paper .

4 Maintain the oil level

Most modern day cars come with an engine oil replacement interval of
10,000km or more. However, due to increasing traffic and lowering average
speeds, an engine tends to run for a longer duration which can increase oil
consumption, especially in older cars. Low engine oil level can be harmful to
the internal parts of the engine .

Major Work

1 Read the Job card Details

In this work technician must have read job card details before service the
vehicle . In job which Types of service is given in job card Technician must
follow through given details .

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2 General check up

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In this General check up it’s routine service in our workshop after entering in
the workshop check the all lights and Parts of the vehicle body it’s working or
not in good condition .
If there is any parts not working properly then customer note down into in a
paper and ask advisor about that parts condition .

3 Finding the Fault

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In this service after finishing a General check up Technician find out some
fault While Check up then Vehicle Technician saw Fault in vehicle then it
note down Fault in a paper .

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4 Find out the Estimate

In this procedure after checking the vehicle status technician Find out the
estimate with ask parts manager and take what’s price includes labor charge . If
parts available in store than take from store and fit new one by old Parts .

5 Ask the Advisor about Fault

It means When Technician check the Full vehicle after checking vehicle in
that vehicle there is big problem or if Part is not available in Then a
technician Ask about that Fault to Advisor to give him a possible solution .

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6 Check the Details about Car Service

In this work customer give his car to service advisor and then advisor make a
detailed about car as per customer demand he makes a job card for service the
vehicle . As per job card details Technician Start servicing Vehicle as per job card
details . If a Free service needed than Technician service in that vehicle .

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7 Collect the new Parts from Store

After finishing the General check up and fault finding procedure and than go to
parts shop for Collect some parts as per Job card Service . Than start serving the
vehicle after collecting some parts .

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8 Set a car into Service lift

In this work after taking Parts from store set a car into service lift and start a
service after set a lift .

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9 Replace a new parts by old Parts

In this work after checking job card details if there is paid service write down in
job card than Technician must have to change a new one to old parts .

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10 Maintain oil level

Most modern day cars come with an engine oil replacement interval of
10,000km or more. However, due to increasing traffic and lowering average
speeds, an engine tends to run for a longer duration which can increase oil
consumption, especially in older cars. Low engine oil level can be harmful to

the internal parts of the engine

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11 Changing belt Drive

When the belt Drive is damaged it cause to loose Power steering . Mainly
other parts of car body also effect like alternator , power steering also . Belt
Drive can be replaced when 1,00,000 km or 2 years it’s a time limit .

There are many steps to change the belt Drive as follows

 Pull the hood inside the Vehicle cabin

 Disconnect the battery
 Locate the drive belt
 Look for sign of damage or wear inside the belt
 Find the diagram of belt Drive

 Release tension on a belt Drive

 Use a Rachat spanner To release tension
 Check belt Drive condition
 Set a new belt Drive to as per diagram
 Tight a pulley check belt Drive

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12 Air Filter Changing

Dirty or damaged air filters reduce the air flow to the engine, changing your
car's air-fuel balance. Because of that reason can pollute spark plugs,
causing the engine to miss or rough idle; increase engine depositions . When
a technician replaced air filter it increases fuel efficiency , reduce emission ,
increase the life of air filter .

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13 wheel Alignment and Balancing

Wheel Alignment

Wheel alignment is a adjustment of wheels . When a wheel causes some

problem like vehicle pull one side , rapid tire wear , steering wheel is
crooked on driving sight than it’s need to alignment . Technician set a car
into a wheel Alignment Machine a hydraulic lift carry a vehicle and
Technician set some. Equipment and Start calculate the wheel Alignment
after some Time Technician Report of alignment and vehicle Alignment is
completed .

Wheel Balancing
It is process when driving vehicle customer feel disbalance car wheel wobbling
and it continues jumping . Than Technician tell to customer it’s need to balance
your car wheel . There are some reason like wheel is overflow of air , Tyre
widths gap is less than ideal width , wheel wobbling . Technician take all
wheel check air level and than put a wheel on wheel Balancing Machine than
start Balancing wheel while Balancing wheel technician stick some weights for
Balancing and set a two sides of wheels if it’s in zero possion it’s balanced .

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14 Change the Spark Plugs

When you drive a vehicle but you feel fuel economy is decrease day by day . So
you need to replace Spark plugs . Damage spark plugs cause your fuel economy
20-30 % decrease. There are few reason to replace spark plugs by damage spark
plugs .

 Car engine light is on

 Cause trouble to start Car
 Car Engine runs rough
 Car can’t accelerate quickly

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15 Change steering Module

When improper fluid comes from fuel tank than steering module need to
replace . There are some reason for replacing a power steering as follows

 Hard to steer
 Steering-wheel play
 Feeling the road
 Pulling
 Wandering
 Shimmy wheels
 Oscillating wheels
 Sticky steering wheel

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16 Clutch Overhauling

Clutch is main parts vehicle transmission system . It’s uses for Changing gears . Means it’s
engaged or disengage gear while driving a vehicle . There are few reason that can identify clutch
need to replace or not .
• A Soft or Spongy Clutch Pedal.
• Trouble Staying in Gear pedal
• You Smell Burning When Driving
• A Grinding Sound When Changing Gears
• Your Clutch Pedal Gets Stuck.
There are some steps to Replace clutch .

• Park a car into service lift

• Get a transaxle ready to remove
• Unbolt the engine mounting
• Replace the clutch
• Reattach the transaxle
Release the car from service lift Break

17 Engine Overhauling

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Engine Overhaul means a complete overhaul (hot section or cold section refurbishment and
life limited part replacement) of an Engine. There are some symptoms is Responsible for
Engine Overhauling As Shown Below .
There are two types Of Symptoms for two different Types of Engine Overhauling Process
1 Petrol Engine
2 Diesel Engine
Reasons ( Petrol Engine )
• A drop in engine performance;
• Cracked, leaking, or broken engine components;
• A reduction in engine oil levels even when no leaks are detected .
• Frequent overheating of the engine .
Reasons ( Diesel Engine )
 Oil Sludge .
 Metal Shavings .
 Increased Oil or Coolant Consumption .
 Excessive Exhaust .
 Knocking Sounds .
 Compression Loss .
 Hitting Milestones .
 Spun Rod Bearing

There are some basic Parts Which are Connected with Engine . Like the engine block (cylinder block), the
combustion chamber, the cylinder head, pistons, the crankshaft, the camshaft, the timing chain, the valve train,
valves, rocker arms, pushrods/lifters, fuel injectors, and spark plugs. It’s Shown in detail below .

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There are some basic parts which are connected with engine . let’s know about each and every
parts in detail . As shown Below
1 Cylinder Block
Cylinder Block is the main part of the IC (Internal Combustion) engine .
 Function
 The function of the cylinder Block in IC engines is to hold the fuel and guide the piston.

2 Cylinder head
cylinder head is the top cover of the engine cylinder which covers the cylinder from the topside
to seal the cylinder and does not give a permit to air and gas to enter and exit from the system.
The cylinder head consists above the cylinder block and contains various components such as a
spark plug in a petrol engine, inlet valve, exhaust valve, and injector for fuel supply in case of a
diesel engine.

 Function
 controlling air flow in and out of the cylinders and fuel deployment

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3 Piston
A Piston slides inside the cylinder in reciprocating motion and transfers mechanical energy to the
crankshaft with the help of connecting rod.
The piston is designed in such a way that it is strong, light, and sufficient to handle the pressure
and temperature which is generated after the combustion of fuel.
 Function
 To convert the energy released during the combustion process into mechanical work .

4 Piston Rings
The piston rings are used to provide the sealing effect between the cylinder and the piston. It
helps to do not leak the engine’s combustion gas and bypass the piston and also helps to
overcome the friction around the piston.
Piston rings are made up of cast iron and alloy cast iron. It is of two types:
Compressor Ring (Pressure Ring)
Oil Controller Ring
Compressor Ring transfers heat from the piston to the cylinder liner and it is inserted into the
top grooves of the piston. Compressor rings are also used to overcome the side thrust over the
piston which causes fluctuations .
The oil controller ring maintains the proper lubrication between the cylinder and the piston and
is placed under the pressure ring. It also maintains access to lubrication .

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 Function
The piston rings act to A connecting rod is used to connect the piston to the crankshaft with the
help of a piston pin and crank pin

5 Connecting Rod
A connecting rod is used to connect the piston to the crankshaft with the help of a piston pin and
crank pin .
Connecting rod transmits the reciprocating motion of the piston to into rotary motion of the
crankshaft so this is works as a lever arm that transfers the motion from one end to another end.
One end is called the big end which is connected to the crankshaft and another end is called the
small end which is connected to the piston.
 Function
 Connecting rod transmits the reciprocating motion of the piston to into rotary motion of the
crankshaft so this is works as a lever arm that transfers the motion from one end to another
end.

6 Crank
Crank means simply rotating or turning the engine’s crankshaft. The crank works as a
rotating member that receives power from the connecting rod and transmits to the crankshaft,
so the crank works as a lever between the connecting and crankshaft .
 Function
 Converting linear to rotary motion, and vice versa .

7 Crank Shaft

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In an engine, the crankshaft receives the power or efforts or thrust by the piston through the
connecting rod and transmits this power of reciprocating motion of the piston into rotary
motion of the crankshaft which is further connected to the flywheel and transmission shaft
which is used to move the vehicle.
 Function
 The crankshaft converts the force generated by the combustion in the engine into rotary
motion .

8 Combustion Chamber
The combustion chamber is enclosed with a cylinder head, cylinder walls, piston head where
the combustion of fuel has occurred.
 Function
 It’s area where the air / fuel mixture are ignited .
9 Manifold
There are two manifolds in the engine Intake and Exhaust Manifold
Intake manifold: The intake manifold is connected to inlet valves, It is the pipe that
helps to provide air-fuel mixture into the engine for proper combustion.
Whereas in diesel engine intake manifold is used for bringing only air to the combustion
chamber.

Exhaust Manifold: Exhaust manifold is responsible for taking out the exhaust gases
from the combustion chamber after combustion which is further connected to the exhaust
valves and its design and construction are the same as the inlet manifold.

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10 Intake and Exhaust Valve

Intake and Exhaust valves both are responsible for regulating and controlling the charge of
air and fuel mixture for coming and burning in the combustion chamber and thereafter to go
out the charge of the air from the engine cylinder.
Both valves are situated either on the cylinder head or on cylinder walls in various shapes
generally mushroom shapes existed.

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11 Gudgeon Pin
Gudgeon pins connect the piston to the connecting rod at the small end. It is also called a
Piston pin, a piston pin made hollow for lightweight.

12 Spark Plug
The spark plug is a device that is used to generate the spark between the two electrodes and
ignited the combustible mixture within the combustion chamber. It should be able to
withstand fluctuating pressure and temperature.
So its main function is to conduct the high potential from the ignition system into the
combustion chamber.
The spark plug provides the proper gap across which spark is produced by applying high
voltage to ignite the fuel in the CC.
 Function
 To conduct the high potential from the ignition system into the combustion chamber.

13 Fuel injector

Fuel is injected by means of an injector at the end of the compression stroke and proper
atomize of fuel into fine droplets.

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In a Diesel engine or CI engine, Air is alone drawn into the cylinder during suction stroke
and compressed to very high pressure .

14 Flywheel
Flywheel means fluctuation of energy, it reserves the energy and uses this energy when
requires it. A Flywheel is an inertial (force) energy storage device.
The flywheel absorbs mechanical energy and serves as a reservoir during the period when the
supply of energy is more than the requirement and releases it during the period when energy
is less than required .

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15 Gearbox
A Gear Box is often called a transmission. Gear boxes simply refer to a set of gears and their
casing, most commonly found in automobiles. Since most motor vehicle engines have high
operating and idling speeds, transmissions allow the machinery to operate efficiently and
even aid in slowing and shutting down machinery.

16 Rocker Arm
The rocker arm of an internal combustion engine is an oscillating lever that changes radial
movement into linear movement; this kind of device is properly known as a reciprocating
lever .
With the help of the spinning motion of the overhead camshaft that opens and closes the
valves and turns it into the up-and-down movement.

17 Timing Chain
Timing belts or chain is used to connect the crankshaft to the camshaft in an internal
combustion engine, which helps control the closing and opening of the engine’s valves.

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It helps to perform in vehicle’s engine to operate smoothly. It connects the engine’s

crankshaft to the camshaft and plays a crucial role in controlling the valves and pistons in our
automobile vehicles.
In design, the timing belt is made up of a reinforced rubber band with high tensile fibers with
notches or teeth on the inner side that helps very precisely synchronize the opening and
closing of the engine’s valves.
In an Internal combustion engine when the crankshaft turns, the crankshaft sets the timing
belt in motion.
Then timing belt turns the camshaft and helps to closes or open each valve and it gave
permission to the pistons to move up and down.

18 Turbocharger
Turbocharger is driven by a gas turbine which uses the energy of exhaust gases. The turbine
is connected to the compressor by a turboshaft .
The air sucked by the turbine into the compressor is thrown outward by centrifugal force.

19 Supercharger

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Supplying air at an increased density to the engine so that more amount of fuel can be burned
in the same cylinder space.
So supercharging is achieved by raising the pressure of the inlet by means of a pressure
boosting device called a Supercharger .

20 Water Pump
The purpose of the water pump is to provide continuously circulate the engine coolant all
over the cooling system. For the engine’s cooling system the water pump is taken as the
heart.
The water pump is also called the coolant pump because The water pump is used to
constantly circulate coolant throughout the engine and regulate the coolant flow rate of the
cooling system .

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21 Carburettor
The process of preparing a combustible fuel-air mixture outside the Spark Ignition engine
cylinder is called Carburation.
A carburetor is a device that atomizes the fuel and mixes it with air. A carburetor is used in a
petrol engine, it is a mixing device to supply the engine with an air-fuel mixture .
The carburetor is connected with the intake manifold of the engine .

Engine Overhauling Process :-

 Parts Removing Process
 set take the car to the lift.
 lift the car on the lift
 remove all wheels

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 remove the engine oil from the oil chamber

 remove the oil chamber and the oil strain
 remove the coolant from the radiator
 remove the negative and positive terminal from the battery
 remove the battery from the battery stand
 remove the air filter body
 remove the inter cooler and turbo from exhaust manifold
 remove the exhaust pipe from the exhaust manifold
 remove the injectors
 remove the tappet cover from the cam shaft
 remove the intake manifold
 remove the nuts from the main axel
 remove the lover arm from the suspension system
 remove the axel from the differential
 remove the starter motor
 remove the gear shifting cable
 remove the gear box mounting
 remove the water pump belt and alternator belt
 remove the timing chain cover and the water pump belt
 remove the gear box
 remove the fly wheel and the clutch plate
 remove the engine by using the engine lifting jack
 remove the engine head
 remove the oil pump
 remove the exhaust manifold from the engine head Remove the piston, connecting rod, and
the crank shaft
 Technician sent them for boring and sent the head for valve replacement

 Parts Installation Process

 fix the connecting rod, small end on the piston
 fix the connecting rod,s bigger end to crank shaft
 fix the water pump
 fix the oil pump

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 fix the alternator

 place the engine on the frame by using the lift
 fix the engine mounting on the framshaft
 fix the fly wheel and the clutch plate on the crank shaft
 fix the exhaust manifold on the engine head
 fix the head on the engine bloc
 take the valve timing
 fix the timing chain on the engine pulley and the camshaft pulley
 fix the gear box
 fix the gear box mounting
 fix the shifting cable on it
 fix the timing chain cover on the gear box
 fix the turbo and intercooler on the exhaust manifold
 fix the injection system
 fix the tappet cover on the cam shaft
 fix the intake manifold
 fix the compressor on the engine block
 fix the radiator system on the frame
 fix the main axel on the differential
 fix the nut on the main axel
 fix all wheels on it
 fix the battery on the battery cover
 fix the negative and positive terminal from the battery
 Get down the car from the lift
 Run the car and take the car for the test drive

17 Change the Break Pads

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Brake pads are a component of disc brakes used in automotive and other applications. Brake
pads are composed of steel backing plates with friction material bound to the surface that
faces the disc brake rotors.

Brake pads convert the kinetic energy of a vehicle to thermal energy through friction.

Specifications

• Break pads length : 47.4 mm

• Break Pads widths : 3-11 mm
• Break pads weight: 1 .5 kg
• Damage break pads widths : 1.5 – 2 mm

18 Change the Break liner

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Brake linings are the consumable surfaces in break systems, such as drum breaks and disk breaks used
in transport vehicles .

Specifications

 Break lining length : 65 mm

 Break lining height : 6 mm
 Break lining roll : 15 meter

There are few steps to replace break lining

 Set a car into service lift

 Remove wheel from drum brake
 Open drum brake bolt
 Set a liner spring
 Remove damage brake liner
 Install new brake liner
 Set a lining spring

19 Car Washing

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A car wash, is a facility used to clean the exterior, in some cases the interior of . Car washes can be
Self – Service , full-service or Fully auto-mated . After Service the Vehicle Car enter in washing area .
Car washer set a car into washing machine . Washing Area has electronically operated switch mechanism
. This machine wash the car from inner side and outer side . After washing car it looks like new one buy
from Showroom .

20 Test Drive

A test drive is the driving of a motor vehicle to assess its drivability or roadworthiness, and general
operating state. A person who tests vehicles for a living, either for an automobile company, automotive
media for review purposes, or a motorsports team, is called test driver.

When a full vehicle serviced by Technician in Time limit . Than it send into Test Drive basically two
types of test drive ( 1 )test drive (2 ) test drive . 1st test drive means when a customer come for
purchasing a car than he want to show a feature of vehicle it’s available or not in that vehicle . 2 nd Test
Drive means after service the vehicle Send for test drive . Technician and advisor take that car and check
while driving a vehicle there some fault after service the vehicle than it Repair the fault on test track .

 Review of Literature

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DR.MURLIDHAR A.LOKHANDE; MR.VISHAL.S.RANA (2013)in this study the research

objective was To focus on historical growth of Hyundai Motors India Limited To evaluate
the performance of Maruti Motors India Limited with respect to Export, Sales, Production.
Profit after tax. With a prime objective to fulfill the needs of diversified customers, the
company has been continuously offering variety of its brand with innovative features to
Indian customers. Since inception, Maruti Motors India Limited has dominated the
automobile market with the reputation of being the fastest growing automobile
manufacturing to apply for real life situation in India. Presently, Hyundai Motor is
considered as the largest exporter automobiles to European countries.

Arvind Malik D.M and Aqib Javeed Khan,( 2018) Maruti , Brand
Positioning. Consumer Behavior, Automobile, Promotional Activities
To sustain in this competitive environment, we need to differentiate
our products from the competitors for doing that we have to
understand the customer very well. This project is based on the
survey, which will be done in the Simona city. We will take almost
all aspects & suggestions from customers, which are related to
branding and brand positioning. The market survey report will help
the entire organization by making them to realize the importance .

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