INTERNSHIP REPORT

INTERNSHIP REPORT
SUMMER INTERNSHIP II
Submitted by

ASWIN JOSEPH
(2101050930)

Department of Automobile Engineering

MGM Polytechnic College, Pampakuda,
Ernakulam

MAY, 2023
 MGM
POLYTECHNIC COLLEGE
PAMPAKUDA P.O, ERNAKULAM, KERALA- 686667

CERTIFICATE
This is an INTERNSHIP REPORT done by ASWIN JOSEPH (2101050930)
of fifth semester Diploma in Automobile Engineering at MGM Polytechnic
college for the award of Diploma in AUTOMOBILE ENGINEERING under
the Board of Technical Education, KERALA, during the year 2023.

Mr. Dennis George Mr. Subin C

HEAD OF THE DEPARTMENT INTERNSHIP
Department of Automobile Department of Automobile
Engineering MGMPTC Pampakuda. Engineering MGMPTC Pampakuda.

INTERNAL EXAMINER EXTERNAL EXAMINER

CERTIFICATE
 CONTENTS
CHAPTER NO: TITLE: PAGE NO:

INTRODUTION
1 1-12

DALY WORKING
2 EXPERIENCE 13-15
1-30

COMPANY LAY OUT

3 16

4 CONCLUSION 17

ACKNOWLEDGMENT
I feels extremely lucky to have the help and support from our automobile
department At this moment i express my honest thanks to PROF. NK RAJAN
our principal, mgm polytechnic college pampakuda provides an opportunity to
all the members in our class to go for industrial training.

I also like to express a special thanks to MR. DENNNIS GEORGE our head of
department. (hod) in automobile for providing safety precautions and also some
valuable messages to our team

And also a special thanks to our lectures SUBIN.C, JAISON BABY,

for there valuable support and encouragements to this industrial training

program also express a heartfelt thanks to my parents who provide me a
encouragements and support

And also thanks to all staffs those who are directly or indirectly supported for
our training program and all my friends who provide me suggestions and
sharing their knowledge are also are

remembering now

And also, a never to be forgotten support and help from our training masters in
the company with their friendly mindset and patience

All valuable support are remembering at this moment........

INTRODUCTION
The Internship gives a real opportunity to have a outer sight of the automobile
sector. It helps to understand how the real world of service section and advisor
section. It gives the practical knowledge in terms of experience and is closely
related to academics wherein the latter provides the theoretical knowledge. It is
no wrong in stating that both are inter-related. Being a student of Diploma in
Automobile Engineering, internships provide a platform to enter in the
automobile field and apply various applications and shine. It also helps one to
furnish their skills and get huge exposure and understand the heat of being a
part of automotive world.

This report was about our internship details that was completed on the month
of May 2023, at Maruti Suzuki Indus Motors in Alappuzha. We completed one
month training at indus motors at various sections like Service Technician,
Service Advisor and also in Customer Care Service. The one month training
was very helped to acquire pratical knowledge. We are about five members
done those training section.

COMPANY HISTORY
MARUTHI SUZUKI

Maruti Suzuki India Limited (formerly Maruti Udyog Limited) is the

Indian subsidiary of Japanese automaker Suzuki Motor Corporation As of
September 2022, the company had a leading market share of 42 percent in the
Indian passenger car market. The company is known for making low-
maintenance cars for the Indian market. The Government of India established
Maruti Udyog Limited in February 1981 as a joint venture with Suzuki Motor
Corporation as a small partner. The Government of India partially departed
the business in 2003 and then sold all of its remaining shares to Suzuki Motor
Corporation in 2007. In 1982, Maruti opened its first production facility in
Gurugram, Haryana, India

INDUS MOTORS

Indus Motor Company Private Limited, (trade name, Indus Motors) is the top
ranking Maruti Dealer in India. The Company having its registered office at
Indus House, Chakorathukulam, Calicut and. Corporate Office at Thevara,
Kochi was incorporated on 11th July, 1984. The founders of the company were
prominent NRI's Dr. PA Ibrahim Haji &Mr TM Nair.Now Indus Motors
literally reigns as the most sought after Maruti dealer in India with significant
and competitive track records and achievements. It races through bagging The
No I dealer Award in India for 13 consecutive year. And obviously in the line of
tremendous progress with more than 75 workshops, 100 plus sales outlet with a
total number of 6000 employees. Indus Motors' contribution to the economic
growth of the state is also commendable, With 6000 employees under the wings,
it is a perfect model for efficiency and effective and result oriented service.
Indus Motors has more than 100 sales outlets in the state and more than 75
workshops in different parts of the state.

DETAILS
Our internship at Maruti Suzuki Indus Motors, Alappuzha was starts at 02 nd
May 2023 and ends on 31st May 2023 with a group of our five members our
duty time was starting at 8:30 AM and ends at 5:30 PM. For these days mainly
our training was scheduled as divided into Periodic Service, Running Repairs,
Service Advisor and Customer Care. In the service center the higher level post
was Work Manager.

The employee post was classified as follows:

1. Work Manager

2. Customer Care Manager

3. Service Advisor

4. Public Relation Officer

5. Floor Supervisor

6. Technical Advisor

7. Technicians

PERIODIC SERVICE
PMS was the major work that we done in the centre. For every 10,000km the vehicle
must service and replace some parts and things as per the manual. We studied about
the items which was changed with several interval of km and Also trained about to
handle the service of vehicle.

Periodic maintenance services include a thorough check-up of all the critical

components of your car, such as the engine, transmission, suspension, brakes, and
more.

The Maruti Suzuki cars require periodic maintenance services to keep the vehicle in
good condition and ensure its smooth functioning. These services typically include:

A. Engine oil and oil filter change

B. Brake fluid replacement

C. Air filter replacement

D. Suspension and steering check

E. Coolant top-up

F. Spark plug replacement

G. Fuel filter replacement

H. Brake pad and rotor inspection.

(a) Engine Oil And Oil Filter Change

Tools Required: Socket, spanner, or sump plug kit. Torque wrench , service manual
for your vehicle, Oil filter removal tool, Oil Drain, pan Large funnel Trolley jack,
Jack stands

Procedure:

1) locate and loosen the sump plug

2) lift pan as you remove sump plug

3) drain the oil

4) replace and tighten sump plug remove the old oil filter

5) prepare new oil filter

6) check for any obstruction and wind on oil filter to vehicle specifications
7) pour in new oil and replace oil cap

8) check oil indicator, start engine and check under the car for oil leaks

9) lower car off jack stands and check oil levels

(b) Brake Fluid Replacement

Tools Required: Jack Jack/Axle Stands, Line Wrench Or Box End Wrench, Socket
Set, Rags, Rubber Gloves, Safety Glasses, Drain Pan.19

Procedure:

1) Drain the old fluid

2) Change brake fluid

3) Flush the calipers/wheel cylinders

4) Drain the old brake fluid.

5) Bleed the brakes

6) Repeat the process

(c) Spark Plug Replacement

Tools Required: Spark plug swivel socket with extension, Flexible handle ratchet,
Spark plug boot puller pliers Spark plug gap gauge ,Torque wrench

Procedure:

1) Gather the necessary tools

2) Make sure the engine is cold

3) Disconnect the battery

4) Remove spark-plug wires or coil-on-plug connectors

5) Remove spark plug with socket

6) Examine the spark plug

7) Install new spark plug

8) Reattach wires/coil-on-plug connectors / battery

(d) Fuel Filter Replacement

Tools Required: Wrench set (socket or open-ended, depending on your vehicle),
Flathead screwdriver, Needle-nose or hose clamp pliers, Rags or shop towels.

Procedure:

1. Depressurize the fuel system (optional).

2. Locate the fuel filter.

3. Remove the old fuel filter.

4. Install the new fuel filter.

5. Start the engine and check your work.

6. Clean up and hit the road.

For the periodic service the service was done by the vehicle at every 10,000 km or 1
year. For this service mainly we have to inspect the every thing and the chart show
above the details of items that was inspect or replace at every 10,000 km. By this
chart we done the service of the vehicle as per the manual.

We studied about the changing engine oil,air filter, spark plug, oil and fuel filter, belt
etc...

Maruti Suzuki Inspection Schedule:

First Free Service: 1000kms or 1 month (whichever comes first)

Second Free Service: 5000kms or 6 months (whichever comes first)

Third Free Service: 10000kms or 12 months (whichever comes first)

After third service, regular periodic service should be done every 10000kms

2. RUNNING REPAIR

The running repair includes the work that except all the periodic service. The
technicians where repair the vehicle as per the data in the job card. It was created by
the service advisor. Running repair have just work at only at any parts that the
customer was noted and complainted. We studied about the repair of severals parts
replace and how to prepare internal part receipt to the spare parts.

Time takes a toll on every vehicle. Every part of your vehicle would require repair or
replacement at certain times. Good Automobile offers a comprehensive range of Car
repair and replacement services to ensure that you face minimum inconveniences if
your vehicle starts causing problems.

In these unfortunate and unforeseen situations where your car breaks down and stops
functioning properly, experts at Good Automobile Services can provide the care your
car needs. Our trained technicians cater to more than numerable types of repairs and
services.

Things do in running repairs:

(a) Brakes

Staff will investigate the car and conduct a thorough evaluation. Following this, the
malfunctioning brake components will be replaced.

Procedure:

1. Safety first. Park the vehicle on a dry, flat surface and install wheel chocks.

2. Check the brake fluid level.

3. Raise the vehicle and remove the wheel.

4. Remove the bolts and the caliper.

5. Remove the old pads and rotor.

6. Clean the rotor mounting surface.

7. Clean the new rotor.

8. Install the new rotor

9. Install brake hardware

10.Get brake pads ready to install

11. Install new brake pads

12. Inspect brake caliper and piston, then compress

13. Install the caliper

14. Check brake fluid reservoir

15. Pump the brakes

16.Check the brake fluid reservoir again

17. Install the wheel and lower the vehicle

18. Repeat on the remaining wheels

19.Go for an easy drive

(b) Clutch

Is there a burning paper smell in the car. Is the transmission slipping gears Or is the
clutch sticking Such situations may arise when the clutch is worn out and in need of
repair or replacement, depending on the severity.

Procedure:

Step 1: park car in a secure position.

Step 2: get the transaxle ready to remove.

Step 3: unbolt the engine mount.

Step 4: replace the clutch.

Step 5: reattach the transaxle.

Step 6: release the car jack.

(c) Electrical
One of the most essential systems of a car is its electrical system; from the battery to
the wiring. This system is what provides power to other parts of the vehicle and
hence aptly named, 'the powerhouse' of the vehicle. If unable to turn on your car, or
don't hear the grinding of the ignition, electrical repair services you might need.

(d) Engine

The engine is arguable the most important, and intricate, aspect of your car. One of
the first signs your car gives you if your engine is in need of repair, is oil leaks. To
ensure smooth functioning of the vehicle's engine when suggested by the
manufacturer. If you do end up in a situation where our vehicle requires undue repair
or replacement of engine.

(e) Exhaust

The exhaust system is an intricate system playing a vital role in your car. It clears the
car from all the unwanted pollutants given away by the mechanical systems of the
vehicle. If the car has become too noisy, if smell gasoline, you aren't able to
accelerate smoothly, or if there's a downfall in fuel efficiency, there is a high
possibility that your exhaust system needs repair.

Procedure:

1. Purchase the Replacement Parts.

2. Park and Jack Up Your Car.

3. Remove the Car Muffler.

4. Remove the Catalytic Converter.

5. Remove and Replace the Old Rubber Hangers.

6. Replace the Exhaust Manifold.

7. Fasten the Flange and Tighten Each Bolt.

8. Finalise Your Work.

(f) Fuel System

Is thecar engine making an unusual sound. Your fuel pump may be damaged or your
fuel filter could be clogged.

Procedure:

1. Disconnect the battery.

2. Drain fuel from the tank.

3. Remove fuel lines and electrical connectors.

4. Loosen or remove the fuel tank filler neck.

5. Support tank with jack or wood.

6. Remove straps to remove the fuel tank.

7. Undo fuel pump retainer ring.

8. Remove the fuel pump and sender module.

(g) Suspension System

Is the front of your car dipping downwards when hit the brake? Is there a noise while
driving on rough roads? The car swayed by sideward winds? Is there something
wrong with the handling? If any of this is true, you probably have something wrong
in car's suspension. If not repaired on time, issues with the suspension system may
reduce the stability of the vehicle and the driver could lose control.

Procedure:

Replacing the front suspension on a car is a fairly straightforward process. First,

you'll need to jack up the vehicle and remove the wheels. Next, disconnect the tie
rods and ball joints from the steering knuckle. Finally, remove the shocks and
springs, and then install your new suspension components in reverse order. Be sure
to use all necessary safety precautions when working on your car

(h) Steering

Along with the suspension system, the steering is the device responsible for the
amount of control a driver has over the vehicle. If your steering feels heavy, or
makes noises, or vibrates, make sure you take the vehicle for evaluation.

Procedure:

1) Before you start the power steering replacement process disconnect the vehicle
battery to avoid any shock while working.
2) Remove engine covers or air filter hose from the power steering fluid reservoir.

3) Locate and identify the power steering pump.

4) Now, remove the power steering belt from the pump.

5) Place the liquid containment drain pan under the power steering pump to drain the
fluid from it by disconnecting the lines.

67 Detach the mounting bolts from the bracket.

7) Once you remove the mounting bolts, it's time to remove the power steering
pump.

8) Install a new power steering pump and carefully lock it with a mounting bracket.

9) Reconnect the feed and return lines to the pump.

10) Connect the power steering belt and make sure it is tight.

11) Refill the new power steering pump with the power steering fluid.

12) Reconnect the engine and let it run for a few minutes before you take a drive on
it. This process will allow the steering fluid to properly circulate to the new pump.

13) Check the level of the steering fluid by using a dipstick and make sure

that the level of fluid is enough. 14) Lastly, turn the steering wheel to all the sides to
check if it is moving properly or not.

(i) Transmission

Issues in transmission lead to unusual sounds, gear slipping, hard shifting and
various other serious intrusions while driving.

Procedure:

1) Remove the battery ground cable.

2) Disconnect the under-hood electrical connectors to the transmission.

3) Remove front wheels.

4) Move (or remove) drive axles.

5) Remove dipstick tube.

6) Disconnect cooler lines.

7) Disconnect electrical connections to solenoids and sensors.

8) Disconnect gear selector and throttle linkages

9) Remove starter motor

10) Remove exhaust pipes and catalytic converter

11) Support transmission with a transmission jack

12) Remove crossmember supports 13) Disconnect from chassis mounts

14) Remove flexplate to torque converter bolts

15) Remove bell housing to engine bolts

16) Remove transmission

(j) Wheels

Wheels keep your car tires intact with an airtight seal to maintain the grip between
the two.

Procedure:

1) Prepare the car. Apply the handbrake and remove all passengers from the car.

2) Position the wheel chocks. Chocks prevent the car from rolling while jacked up.

3) Loosen the wheel nuts.

4) Jack the car up.

5) Remove the flat tyre.

6) Mount the spare wheel.

7) Lower the car and tighten the bolts.

8) Fully lower the car.

9) Check the spare tyre pressure

10) Take your punctured tyre for repair

(k) AC

Procedure:

1) Remove the compressor belt. Locate the compressor belt on the front of the
compressor and remove it.

2) Disconnect the electrical connector.

3) Disconnect the refrigerant lines.

4) Remove the compressor.

5) Install the new compressor.

DAYS-1,7,8

FUEL CATEGORY :DIESEL

WORKING NOTED

Thermostat changing :First remove the battery connection and then remove the
battery. Remove the coolant and the pipe. Then remove the thermostat and place the
new thermostat and fix the coolant pipe back to its position.

DAYS-2,25;30
FUEL CATEGORY:PETROL,DIESEL

WORKING NOTED

Battery Replace: Battery replacement is done as per periodic service for Maruthi
suzuki cars at 36 months. First remove the negative terminal of battery and remove
the positive terminal after remove lock. The replate the battery by new. After that
connect the positive terminal first and then the negative terminal

DAYS-3,10,12,22

FUEL CATEGORY :PETROL,DIESEL

WORKING NOTED

Clutch disk change: This work is done on Brezza(diesel) swift (petrol). Remove the
front wheel and axle. Then leak off the gear oil from gearbox and then remove the
gear box from clutch casing. Replace the disk and fix the casing to flywheel, then
gear box at last the axle and wheels.

DAYS-4,18,27

FUEL CATEGORY:PETROL,DIESEL

WORKING NOTED

Engine head gasket change: Remove the engine head using ratchet and then
remove the damaged gasket from it. Replace it with new gasket and place the engine
head over it and tighten the nuts with the torque wrench. A head gasket provides the
seal between the engine block and cylinder head. Its purpose is to seal the
combustion gases within the cylinders and to avoid coolant or engine oil leaking into
the cylinders. Leaks in the head gasket can cause poor engine running and/or
overheating.
DAYS-5,14,21

FUEL CATEGORY:PETROL,DIESEL

WORKS NOTED

Brake shimming: This process done on disc brake caliper to reduce noise this is
done
by using thin copper plate rolling the bolt of caliper

DAYS-6,16,29

FUEL CATEGORY:PETROL,DIESEL

WORKS NOTED

WHEEL ALIGNMENT

• Inspect steering and suspension system, including tire condition and air pressure

• Place vehicle on alignment settings.

• Check initial alignment settings

• Adjusting camber, caster & too angles

DAYS-9,29

FUEL CATEGORY: PETROL,DIESEL

WORKS NOTED

Radiator fan change: This is done on Marathi Ciaz. And alto First cut off the
battery connection then remove the radiator coupler. Remove the screw of fan from
body and replace it then fix it

DAYS-11,15,19

FUEL CATEGORY: PETROL,DISESL

WORKS NOTED

Alternator Change: This work is done on Maruti Wagon R, swift. Remove the
battery
terminals and loose the belt. Then by unbolting the alternator and remove
connections from it. Replace it with new one

DAY-13

FUEL CATEGORY :PETROL

WORKS NOTED

Fuel tank hose leakage: The hose leakage is solved by replacing the hose connected
to fuel filter because it cause small pores that's why its leaked.

DAYS-17,20

FUEL CATEGORY:PETROL,DIESEL

WORKS NOTED

Timing belt adjusting: This is done for avoiding noise from engine crank belt. This
work is done by losing the lock nut and adjusting the adjuster nut tightly.

DAYS-23,24

FUEL CATEGORY:PETROL,DIESEL

WORKS NOTRD

Bleeding brakes :This is a crucial maintenance task to ensure optimal brake

performance. Use a brake bleeder kit, attach it to the brake bleeder valve, and open
the valve. Have someone pump the brake pedal while you monitor fluid flow,
ensuring no air bubbles. Close the valve when only fluid, no air, comes out. Repeat
for each wheel, starting with the farthest from the master cylinder. Check and top up
brake fluid as needed. Always consult your vehicle's manual for specific instructions.

DAY-26

FUEL CATEGORY :PETROL,DIESEL

WORKS NOTED

Synchronizer changing : This is done for avoiding noise from gear box and proper
gear selection
DAY-28

FUEL CATEGORY:PETROL,DIESEL

WORKS NOTED

Wheel balancing:It is integral to smooth driving, safety, tyre wear, and stability, and
allows the tyres to spin without causing vibrations. Distinct from wheel alignment,
tyre balancing refers to compensation for any weight imbalances in the tyre/wheel
combination.
 CONCLUSION

This internship was a useful experience. I have gained new knowledge, skills and
met many new people. I achieved several of my learning goals. The internship was
also good to find out what my strengths and weaknesses are. This helped me to
define what skills and knowledge I have to improve in the coming time. It would
also be better ifI can present and express myself more confidently. At last, this
internship has given me new insights and motivation to pursue a career in
automobile engineering. I can conclude that this industry is through I received a lot
of exposure in the automobile world.

I would like to thank also the MGM Polytechnic College Pampakuda and also a
special thanks to our tutors and guides giving students to find their own experience
with having industrial training like this.