Vandan Report

SEM-5 INDUSTRIAL TRAINING REPORT
NAME-: GOSWAMI VANDANGIRI K

ENROLLMENT-:206170302093
COMPNY NAME -: KATARIA AUTOMOBILES
ADRESS-:NR k.s Lokhandwala Compound Outside,Dariyapur Darwaja cir, Dariyapur,
Ahmedabad,gujrat380016
INDUSTRIAL TRAINING 3350201
Maruti Suzuki India limited type public traded as BSE:532500, NSE: MRUTI BSE
SENSEX Constituent Industry Automotive Predecess or Maruti Udyog
Founded 1981, Headquarters New Delhi, India. Limited
R.C Bhargava chairman of Maruti Udyog Limited.
Kenchi Ayukawa(M.D & C.E.O) of Maruti Udyog Limited
Product Automobile Revenue 43272 crore(US $ 7.0 billion) (2013-14) and net
income 2469 crore ( US $ 400 million) (2013-14)
Maruti Suzuki India Limited, commonly referred to as Maruti and formerly known as
Maruti Udyog Limited, is an Automobile manufacture in India. It is a subsidiary of
Japanese automobile and motorcycle manufacture in Suzuki. As of November 2012,
it had a market share of 37% of the Indian passenger car market. Maruti Suzuki
manufactures and sells a complete range of car from the entry level Alto, to the
hatch back Ritz, Celerio, Ciaz, A-Star, Swift , Wagon R, Zen and Sedans DZire,
Kizashi, and SX4, in the ‘c’ segment Eeco, Omni, Multi purpose vehicle Suzuki Ertiga
and Sports utility vehicle grand vitara.The company’s headquarters are at
no.1 ,Nelson Mandela Road, new Delhi. In February 2012, the company sold its 10
millionth vehicle in India.
GOVERNMENT POLYTECHNIC A’BAD 2

History Logo of Maruti udyog limited
Maruti Udyog Limited was established in February 1981. Though the actual
production commenced only in 1983. It started with Maruti 800, based on the Suzuki
Alto-k car which at the time was the only modern car available in India. Its only
competitors were Hindustan Ambassador and Premier Padmini Originally, 74% of the
company was owned by the Indian government and 26% by Suzuki of Japan. As of
may 2007, the government of India sold its complete share to Indian financial
institution and no longer has any stake in Maruti udyog.
Suzuki enters in 1982; a license & Joint venture Agreement (JVA) is signed between
Maruti udyog ltd. And Suzuki of Japan. At first, Maruti Suzuki was mainly an
importer of cars. In India’s closed market, Maruti received the right to import
40,000 fully built- up Suzuki in the first two years, and even after that the early goal
was to use only 33% indigenous parts. This upset the local manufactures
considerably.

Maruti Suzuki India limited commonly referred to as Maruti and formerly known
as Maruti udyog limited, is an automobile manufacturer in India.
It is a subsidiary of Japanese automobile and motorcycle manufacturer Suzuki

Maruti Suzuki Motor corporation (‘Suzuki’) a Japanese company, owned over 50% of
Maruti Suzuki India (‘Maruti’), an Indian company.
In 1982 Maruti Udyog signed a license and joint venture agreement with the
Suzuki Motor Corporation of Japan.
In 1983 the company launched the Maruti 800, rebadged version of the first
generation Suzuki Alto. The three cylinder car had a 796 cc petrol powered
engine and a top speed of about 120kmph.
By about 2003, with sales of 2.4 million, it was the top selling car in India
between 1990 and 1994 the company produced the maruti1000.
The Zen a 993 cc hatchback car was produced in 1993.
In 1995 an upgraded version of the maruti 1000, called the Esteem, was
introduced, originally with either 1.3 litre petrol or a 105 litre diesel engine.
The Three cylinder, 796 cc petrol powered, Alto model was introduced in 2000. It
had a top speed of 130kmph.
Certificates and awards: 1999- certified as per ISO 14001:1996 for maintaining EMS
(environment management system) certified for changing its EMS from ISO
14001:2004 Golden peacock award by world environment foundation in 2007. 1st
prize for excellence in energy conversation by Haryana government. 1st company in
world in automobile industry to get an ISO 9001:2000 certification.

Maruti Suzuki is largest Indian passenger vehicle manufacturer in local

market.
Maruti Suzuki manufactures and sells a complete range of cars from the entry level
Alto , to the Hatchback WagonR, A-star, Zen Estilo, Celerio, Rits, Swift and sedan
Swift desire,Kizashi, esteem, SX4 and in the Van segment Omni, Eeco and
multipurpose vehicle Maruti Suzuki Ertiga and Sports Utility Vehicle Gypsy and
Grand Vitara.

1.3.2 Company in manufacture car:
Model & Category Lunched Image

& Discontinued
Omni, Minivan 1984-2020
Gypsy, SUV 1985 – 2000
Wagon R,cng Hatch 2022

back

Swift, Hatch back 2020

Grand vitara 2022
Swift DZire, Sedan 2017
Ritz, Hatch back 2009-2017
Eeco, mini van 2010

AltoK-10, Hatch back 2010

Kizashi, Sedan 2011-2014
Ertiga, MUV 2022
Alto – 800, 2012

Hatch back
Stingry, Hatch back 2013-2017

Celerio , Hatch back 2014-2021

Ciaz , Sedan 2014
Zen , Hatch back 1993 – 2006
Esteem, Sedan 1994 – 2008
Baleno, 2022


Versa , mini van 2001 – 2010
Maruti – 800, Hatch 1983 – 2012

back
Alto , Hatch back 2000 – 2012
Zen – Estilo, Hatch 2006 – 2013

back

A – Star, 2008 – 2014

Hatch back
SX4, Sedan 2007 – 2014
1.3.3 List of Maruti Suzuki Authorized Dealership

1. KATARIA AUTOMOBILE
2. KIRAN MOTERS
3. UDAY AUTOLINK
4. MANAN AUTOLINK
5. AUTOWAY AUTOLINK

6. STARLINE AUTOMOBILE
7. POPULAR MOTERS
8. SPEED AUTOLINK
=> My Industrial training is completed by the KATARIA AUTOMOBILES of 5

month in our company for his 5th semester .

D Kataria automobiles Authorized dealership in

Gujarat
1. AHEMEDABAD
2. BARODA
3. SURAT
4. HIMMATNAGAR

CHAPTER-2
LAYOUT
2.1WORKSHOP LAYOUT:

CHAPTER-3
ORGANIZATION CHART
3.1 Organization Chart

CHAPTER – 4
FACILITIES & WORK PROCESS
4.1Facility:
In kiran motors, there are so many facilities like section,
department, equipments, machines, safety provided.
1. Car lift in my workshop
Work shop in very helpful car lifting. Car lifting is mostly use the major work in
car. My work shop is number of car lifting is 10. Working the car lifting it is a use
for hydraulic pressure. Hydraulic oil use for pressure reduce.

This is a car lifting use the accident car lifting the body shop because my workshop
in a body shop is a second flour. Car lifting is a use the only staff members. This
car lifting is a use the hydraulic oil and pressure. This car lifting maximum weight 5
tons.

3. Wheel alignment & wheel

balancing
Wheel alignment is a mostly use of the car. Wheel alignment is a work by rear two
wheel . rear two wheel is a mostly driving because the engine compartment mostly
weight is only rear wheel . it is a very important use for car in wheel alignment.
Wheel alignment is a only two sensor work of a wheel alignment. There are a
wheel vibration only use for the wheel alignment.

Wheel balancing
Balancing machine once the tire professional sees how the tire is out of
balancer , he needs to correct it. Normally , this is done through the use of
wheel weights. There are small weighted clips that snap on the rim of your
wheel. The mechanic adds weights off- balancing side of the wheel until the
balancing machine shows a perfectly balanced tire.

Another type of dynamic balancer operates on the wheels while they are still on the
car . the machine attaches to the wheel and spins it while taking readings
regarding the balancer.
5. Fuel injector testing

machine

The fuel injector testing machine use of auto fuel injectors is a sophisticated way
to provide the right fuel and air mix to an engine for a vehicle. The small cylinder
fuel injectors play a specific role in a larger fuel intake system, along with other
with other elements like the fuel pump and the fuel tank. Over time , fuel injector
may need to be maintained or checked for proper functioning. They are
vulnerable to specific kinds of wear and generally will not last forever. If you need
to check fuel injectors to make properly , hear are some of the most
common basic steps suggested by mechanics and auto pros who have extensive
knowledge of the fuel delivery system.
5. A.C gas recharge machine
A.C gas recharge machine is an air conditioner has three main parts. A condenser ,
a compressor and an evaporator . The condenser and evaporator are , more or less,
two radiators connected in a loop . the compressor is situated between them on
one side of the loop. The system is sealed from the outside , and filled with a
working fluid in this case r- 134a. the compressor take low pressure gaseous, r-
134a, compresses it ( which creates heats ) , them sends it to the condenser ,
where the heat is dissipated to the outside. After the condenser, liquid refrigerant
travels.
to the evaporator, located inside the passenger compartment where it is allowed

to expand , removing heat and cooling the evaporator.

6. Shop press
Shop press is a mostly use in the work shop. shop press use is gear box in remove
the teeth and siencroniger bearing. And the shop press removing the wheel
bearing. Shop press is in the engine room. Shop press is very helpful equipment.

7.Automatic engine oil machine
This machine is a very important by workshop because it is a use of engine oil

inside to outside . this machine is use for the every mechanic. This machine in the
engine oil removing by the haydrolic pressure. This machine is engine oil remove
the oil gun.
This machine in the four oil-gun. Some types of engine oil .
 PW 40 Type 2. PW 30 type 3. PW 20 type 4. Extra oil-gun

8. Car washing
Car washing is a mostly there is a service in periodic and free service. My work shop
in car washing charge is 350 Rs. Car washing in the three steps. First step in the car
top washing. And second step is shampoo cleaning on car top body. And last third
step is a again the car top washing.
Car washing is and of step which is the car in a passenger & luggage
compartment in very clear the vacuum cleaner use for car. And car in the
dashboard and all the door on polish. And 4 tire on the tire polish. And last step is
very carefully and very clear the car surface body use of towel.

9. Spare pats room
Spare parts room is a very important room. It is the use of new spare parte parches
. spare parts parches of the company job card. Spare parts is a parches the
mechanic
. spare parts room is a handle the spare parts manager and spare parts is use the
car . spare parts is very important section of damage section.
Spare parts room in a some parts
1. Oil & oil filter

2. Air filter
3. Petrol filter
4. Coolant bottle
5. Brake fluid bottle
6. Caliper pouch
7. Upper and rear aelbow pipe
8. Balancing weight
9. Diesel filter ( only use for diesel engine)
10.Head light & tail light
11.Fog lamp and fog lamp cover
12. L.H.S axle & R.H.S axle

13.Brake pad & brake liner
14.Stabilizer link
15.Balancing road
16. Stearing assembly
17. Spark plug
18. Gear oil
19.Clutch plate & pressure plate and clutch
bearing
20.Synchronizer bearing
10. Tool
kit


Tool kit is very important section in work shop. tool kit is use of spare parts fitting
and spare parts removing. The tool kit is always the mechanic use for car repairing
. Tool kit in the many tools. Tools is a very helpful by mechanic.
Names of tools in toolkit
1. +, - screw driver
2. – long screw driver
3. + long screw driver
4. Small connecter
5. Small stabie
6. Long connection
7. Medium connection
8. Small connection

9. Box spanner ( 8 to 30 box spanner)

10. 10 & 12 power tools, long box
spanner
11.
12 & 14 long box spanner
12.
16 & 17 long box spanner
13.
Ratchet
14.
L- tomi
15.
Universal joint box spanner
16.
T – 8 spanner
17. T- 10 spanner
18. T- 12 spanner
19. T- 14 spanner
20. Hammer
21. Small filter range &

spanner
22. Long filter range &
spanner
23. Spark plug Spanner
24. Alan key box
25. Ring spanners & fix spanners ( 6 to
26. 32 ) Combination spanner ( 8 to 20 )
27. Slip joint pliers
28. Diagonal pliers
29. Lineman’s pliers
30. Needle – nose pliers
31. Crimping pliers
32. Heavy duty crimping pliers
33. Hand crimp pliers
34. Cutter pliers
35. Tongue- and- groove

pliers
36. Locking pliers
37. Circlip pliers
38. Round- nose pliers
39. Adjustable
40. Air gun
4.2 for safety purpose

The ensure safe working condition in a workshop, it is important to know of the

proper safety equipments. The drawing to the left shows some more important
equipment to have and be used when working on a street rod. These include
safety goggles, oxyacetylene welding goggles , working gloves, safety shoes
respirator hearing protection and arc welding shield and gloves additional safety
equipment includes fire extinguishers, air tight containers, gasoline containers
and first aid boxes. Here are some extra tips for using some of these safety
items.
1. Make sure the safety glasses have safety glass and some sort
of side protection.
2. Make sure the safety glasses are comfortable so you will be inclined to use
them more often.
On certain procedures it might be necessary to have a full faced shield, for use
in grinding and cleaning carbon from valves
3. Hearing protectors and respirators should be comfortable and approved

by OSHA.
4.3 Types of Service
1. Free Service or General service :- free service is a company free service.

Free service is offer of company. Generally free service is four times per
month by companies offer. Free service in work by no nothing money.
4.3..1 Generally work of Free

service
1. Check the Engine oil

2. Check the brake fluid & oil

leakage

3. Check the windshield washer

fluid
4. Check the
coolant

5.check the battery in water level :- Non maintenance free battery check
water level and top up if with only use distilled water.
6. Check the tyres pressure

7. Check the tyre wear: - tread depth should be at least over about 5mm.
wear should be uniform across width. Wear should be uniform all tyres.
8. Check the
lighting

2. Periodic service: - Periodic service is work of any workshop. Periodic

service is short name is paid service. Periodic service is work by money for any
work shop . Periodic service a generally monthly service work by any workshop
and normal garage. Paid service in a customer complain for car the free charges
on your solve complain.
4.2.2 Periodic service schedule
1 ST SERVICE - 1000 Kms OR 1 Month [Whichever is earlier]
2ND SERVICE - 5000 Kms OR 6 Months [Whichever is earlier]
3RD SERVICE- 10000 Kms OR 12 Months [Whichever is earlier]
SUBSEQUENT SERVICE EVERY 10000 Kms
At every 5000 Kms in ‘SEMI DESERT REGION’

Periodic service is a very sensitive and very mostly service. Paid service in the
any type working is very harmfully.

4.1.3 Replacement of some consumables
Engine oil & oil filter 10000 KMS recommended at

5000KMS in semi desert region
4000KMS
Gear oil 4000KMS
Brake oil 20000KMS
Spark plug 20000KMS
Engine coolant 20000KMS
Air filter 40000KMS
Diesel filter 20000KMS
Cleaning EGR 40000KMS
4.1.4 Generally work in Periodic

service
1. change the engine oil & oil filter
2.Tyres alignment and balancing
3. change the Gear oil
4.change the brake oil and brake blieading
5. change the spark plug
6. change the air filter
7.change the diesel filter ( diesel engine )
8.change the coolant
9. Disc brake in caliper greasing
10. Throttle body cleaning ( Petrol engine )
11. EGR cleaning ( diesel engine )
12 change the clutch plate & pressure plate and the clutch
bearing
13. Injecter cleaning & testing ( petrol engine )
14. Cooling coil cleaning
15. Blower fan cleaning
16. change the A.C filter
17.change the axle seal
18.change the rear & upper albow
19. change the stabiliegar link
20.change the brake pad & liner
21.change the wheel bearing
22. change the lower arm & upper & rear cross

INDUSTRIAL TRAINING
3350201
CHAPTER- 5
WORK DONE & WORK AREA
Workshop in the many areas by work. Work done in the car service and car solve
the problem. workshop in the car service area is called the work area. The work
area specialty automobile repair shops are shops specializing in certain parts
such as brakes mufflers and exhaust systems, transmission, body parts , tires,
automobile electrification, automotive air conditioner repairs, automotive glass
repair and installation, and wheel alignment or those who only work on certain
brands of vehicle or vehicle from certain containers of the world. There are also
automotive repair shops that specialize in vehicle modification and customization.
Oftentimes, various specialized auto repair shops will have varied infrastructure
and facilities.
1. What we done
1. Working method of Wheel

Alignment
A car alignment is actually an elaborate process that brings the car ‘s suspension
into its proper configuration, positioning and adjusting component so that wheels
are alignment with one another and the road surface. The alignment should be
performed by an experienced mechanic, who use an alignment machine. Newer
alignment machines feature clamplike device that are attached to the wheels of the
car(which is raised up in the air) and that link to a computer that help makes
precise measurements. The mechanic will also take this opportunity to make sure
that no suspension components are excessively worn or broken . An alignment
essentially requires squaring a car ‘s wheels and axles with each other so that they
‘ re moving in same direction. The mechanic adjusts the various suspension angles-
know as toe. Thrust camber and caster that influence tire movement and position.
The technician will also ensure that the steering wheel is centered.

Each car ‘s manufacture designates standard angles for the alignment, specified in
degrees. If you ‘re a driver of a high- performance car or sports car , your
mechanic may be able to align your suspension to improve handling and tire
performance, but such an alignment still may lead to uneven tire wear.

2. Working method of Wheel

balancing
Balancing machine once the tire professional sees how the tire is out of balance, he
needs to correct it. Normally, this is done through the use of wheel weights. There
are small weighted clips that snap on the rim of your wheel. The mechanic adds
weights off- balancing side of the wheel until the balancing machine shows a
perfectly balanced tire.
Another type of dynamic balancer operates on the wheels while they are still on the
car . the machine attaches to the wheel and spins it while taking readings
regarding the balancer. These mechanics often spin at higher speeds than off- car
balancer. This more closely replicates actual road conditions and sometimes
detects balancer issue that other types of machine miss.

3. Working method of engine oil and oil filter

changing
The engine oil is to change the oil and oil filter regularly. Oil is the
lifeblood of your engine. Lessens wear provides lubricants, forms a seal
between the pistons, rings and cylinder walls while helping to cool engine
parts.
Without the clearing action of new oil, carbon and varnish build-up would be toxic
to the engine. and engine oil even dampens the shock and noise of moving parts.

Engine oil most cars on the road today use multi-grade oil-one that
can work efficiency in cold and hot weather. A multi- grade oil is rated by
two numbers, such as 5w-30. About the oil classification system each
engine oil comes with a classification indicating its viscosity , which is its
friction or resistance to flow. In a multi-grade oil, the first number
indicates how the oil will flow when it is cold.
The lower the number the lighter the oil and better it will perform
at lower temperatures. The second number indicates the thickness of
that same oil at high temperatures. For example , a 5W-30 oil will flow
as a5- weight oil zero degrees Fahrenheit and as a 30- weight oil at 210
degrees Fahrenheit .to lessen the friction when upper engine parts ,
such as the valve train, piston, overhead cam and cam bearings, scrub
against each other, a lower viscosity allows the oil to reach the oil
components more quickly.
4. Working method of oil filter changing

The oil filter is very important changing method . the oil changing
and next important step in changing your oil is replacing the oil filter .
remember , the oil filter hold all the excess sludge and grime that the oil
catches while lubricating the engine. Changing the filter is vital to car
maintenance because without a new oil filter in place , new engine oil will be
passing through the old filter , making it dirty and less effective. You can
check your car’s manual to find out which size filter you ‘ll need . they
can be purchased at any auto maintenance shop for 500 Rs or up to about
2000Rs for performance filters.

They can provided higher viscosity stability over a wider temperature range
reduced oil thickening reduced wear and increased load carrying ability.
Which oil is right for your car? The simplest and safest way to find out is to
check your As certified mechanic. Oil filter are designed to trap foreign
particles suspension in oil and prevent them from getting to the engine
bearings and other parts.

6. Working method of Throttle body

cleaning
You slip behind the wheel for the morning commute. The engine starts
easily, runs fine while fast- idling down the driveway and down the street for a few
miles , but then stall. You know instantly when the stall occurs because the air
horn in the tractor- trailer rig immediately behind you curdles the fluid in your inner
ear’s semicircular canals when forward motion fails to proceed at an orderly
pace. You restart, your car accelerates with a slight stumble, and when you coast to
a stop at a traffic light, it stalls again.

the stumbles and possible stall problem doesn’t go away when the engine is warm ,
so the common cold – engine poor – running possibilities are scratched from your
priority checklist. This is more than annoying and as soon as the weekend arrives,
the hood goes up.

All sensor wire are connected. There‘s no check engine light and there are no
trouble codes. What do you look for now? A disconnected or damaged vacuum
hose/ sure , that ‘s a good bet , because many vacuum hoses can be pinched and
damaged where it’s really difficult to see. But take the time to check them all,
making sure they ‘re not only on tight , but not cracked or burned through due to
contact with an exhaust gas recirculation tube. Don’t be surprised if the last hose
you check is the one that ‘s damaged. If all the hose are intact and on tight , there
‘s another possibility that ‘s just as likely : dirt and gum accumulation in the
throttle body.
Remove any hose or wires on the air duct connecting the throttle body to the
air cleaner housing. Make which hose or wire goes where to avoid confusion
later.
7. Working method of brake

bleeding
The brake bleeding conjures up images of a clean , contented person

stepping on a brake pedal while another grumpy, dirty, frustrated person yells “
push down” from under the car your image would be correct . brake bleeding is
general repair job that many people would not enjoy , but it is something that must
be done throughout the lifespan of an automobile. Most brakes should be bled
every two or three years to keep your brake system at optimum performance
(source: Allen ) small amounts of air can become trapped in the brake line creating
a spongy felling.

When you step on the pedal. If large amounts of air enter the brake line ,
your vehicle can suffer a complete braking failure so how does air get in there ?
air can sneak into your brake system during certain types of servicing or if there is
a leak. Air can also enter the line for less obvious reasons like worn pads (or an
impatient driver who constantly slams on the brakes). When you bleed brakes you
are removing the air from the line. This helps ensure that your brakes are in top
condition, and that you won ‘t drive off the edge of a cliff like some tragic
characters do in the moves. There are three methods of bleeding brakes. 1.
Vacuum pumping 2. Pressure pumping pump and hold if you find that your
master cylinder is low on fluid, you should investigate the problem. the entire
braking system is a closed system, meaning no fluid should ever escape. If you
are low , finding and fixing the leak should be your first order of business.
8. Working method of brake pad

changing

Nearly all cars these days have front disc brakes. Front brakes usually wear out
more quickly than the rear brakes (which could either be disc or drum brakes), so
they
INDUSTRIAL TRAINING
3350201
need to be changed more often. You need to change brake pads when they get too
thin especially if they begin to make a persistent metallic squeaking or grinding
noise when you press the brake pedal . but noise alone isn’t always the best
indicator , so it ‘s best to anticipate when this will happen by periodically inspecting
the thickness of the brake pads.

The brake pads are now exposed and the retaining clips hold them loosely in
place. Simply slide the old brake pads out , as shown in the photo. In the above
photo
, you can see a comparison of the new , thicker brake pad , next to the old
worn- down brake pad ( bottom). The photo above shows the pad’s new retaining
clips. New pads almost always come with new clips, which allow the pads to slide
back and forth easily. Use the new ones there are not retaining screws for the clips
. they just snap in place. There are usually left- handed and right – handed clips, so
change one at a time , making sure they match up exactly as you go. Often , a
small packet of graphite- based grease will come with the brake pads. Apply this to
the clips of the new brake pads to keep them from squeaking, as shown in the
photo above. the new brake pad has a riveted- on shim, which is the thin metal
plate. Some brake pads might have unattached shims that have to be temporarily
held in positionPOLYTECHNIC
GOVERNMENT until you A’BAD 57
lock the pads in

place.

9. Working method of Petrol fuel filter

changing
The fuel filter on a fuel injected vehicle can be tricky. On fuel- injected
vehicles , you need to disable the fuel pump to relieve the pressure on the fuel
lines which may be secured to the filter with clamps , threaded fittings, or special
quick- connect fittings. Lines with threaded fittings require a special flare – nut line
wrench
. lines with special quick- connect fittings may require special tools to disconnect
them. Ask the clerk at an auto parts store or the service department at your
dealership which type of filter your vehicles.

INDUSTRIAL TRAINING
3350201
Relive the pressure in the fuel line before disconnecting it. To do so, you
have to disable the electric fuel pump before you start the engine. To disable
the fuel pump, do the following 1. With the engine off, remove the fuel pump fuse
from the fuse box(your owner ‘s manual should show you where it is) 2. Make
sure that the parking brake is on and that the vehicle is in park or neutral , and
then start the engine. It won ‘t run very long after you start it up, but the pressure
in the fuel lines will be reduced 3. Turn off the engine with the fuel pump
disabled , you ‘re ready to disconnect the fuel lines from the filter.
10. working method of diesel fuel filter

changing
The diesel filter in

diesel car. Both fuel
filters are usually easy to
change, and your owner
‘s manual should show
you how to do this job.
On some diesels, the job
is much like changing
the oil filter or a
conventional vehicle :
you unscrew the old
one , moisten the
gasket of the new one
with fuel, and screw it
into place. Other have
filters with replaceable
cartridge ; you just
remove the old one and
one. pop in the new

There ‘s one catch to changing the fuel filter however : when you change
the fuel filter or run out of fuel in a diesel vehicle , you must bleed the air
bubbles out of the system and then prime it to get a new supply of fuel
circulating. Cranking the engine does the job but also wears down the battery , so
most diesels include a manual primer pump and an air – bleed screw for the
purpose of bleeding the system and priming it. On many vehicles , you simply
pump the primer ‘s handle to get the fuel moving , and then you turn the air
bleed screw until a hissing noise tells you that the air is escaping. Just keep
pumping until all the air leaves and the noise ceases ; then tighten the air – bleed
screw and replace the pump handle.

11. Working method of Spark plug changing

INDUSTRIAL TRAINING
3350201
First all , the upper part of engine is removed such is engine cover ,
air filter with harness and etc.

Igniter is dissembling from engine and then after with the help 16 no. box.
Spanner , medium connection and ratchet spark plug is
opened.
The terminal of spark plug rubbing with ruff paper with help of
and thickness gauge air gap is set and ten after its refitted.
To change the spark plug. We need follow steps given

below:
1. Locate tine spark plug in your car.
2. Let the engine cool before removing your spark plugs.
3. Remove the first spark plug.
4. Measure the gap of the spark plug.
5. Check the exiting plugs for wear.

INDUSTRIAL TRAINING
3350201
6. Get the correct replacement plug.
7. Consider cleaning around the threads before reinserting the new

spark plug .
Insert the new plug and tighten with your ratchet.

12. Tapped & timing belt

setting
Tapped setting is use to open and close valve at perfect time. Which result
in proper combustion of fuel and exhaustion and this lead to better performance
of engine and decrease emission.
In tapped setting gap between exhaust valve and cam 0.25mm and gap
between inlet valve and cam 0.15mm. to measured gap by thickness gauge in
tapped setting.

13. Horn Change
1. Check the fuses for the horn. If this is not an elective replacement,
checking the fuses.
2. Disconnect the ground wire from the battery. The ground wire is the black
wire extending from the battery to the frame of the vehicle.
3. Locate the car’s horn. The horn is found under the hood in one of three
place usually: near the car’s battery, above the left or right wheel-well or
near the from grille.
4. Disconnect the power supply wire from the rear of the horn. The place in
into the replacement horn.
5. Mount the horn to the vehicle. Again , if you need to find another location,
you will be need to only attach the horn, you will need to remove and
replace the entire mounting bracket. The removal of the bracket will require a
screwdriver. You may also need to prepare receiving holes for the
remounting.
6. Reconnect the battery grounding w
2. Work service area
1. Paid service

Paid service are almost same for all Maruti cars but calliper greasing is the not
done in SX4 under paid service.
Brake service greasing & oiling , top up coolant water , wiper water ,brake fluid
& battery distil water and door , spark plug , horn setting are normally included in
paid service.
If required minor repairing is done after examining vehicle.

5.2.1Brake service
Maruti car have two types of brake. Once of them is used in front
wheel as disc brake and second one is used in rear wheels as drum
brakes.
Disc brake service include calliper pin’s greasing. In which grade of grease
is universal (silicone) and brake pad is rubbing by using ruff paper.
Caliper pin and brake pad are substituted if necessary.
Drum brake service included the rubbing of brake shop and adjustment of
brake cylinder. Drum set is replaced required.

5.2.2Coolant water top

up

Whenever the leval of coolant is water is decrease then coolant water

couldn’t absorb sufficient heat from water passage in engine this result
in overheating of engine which cause the possibility of thus to maintain
the leval of coolant water it is top up.
5.2.3Oiling and greasing
To reduce the wear & tear and noise between moveable parts by oiling and
greasing. Which provide lubricant to moveable parts. Oiling is normally used in door

and trunk hinges and bonnet locker mechanism and wiper blade
joint.
Greasing is generally used in bonnet locker mechanism. Fuel cap door

stopper is used for greasing universal grease used.
5.2.4Door setting

INDUSTRIAL TRAINING
3350201
When the problem occurs in opening and closing of door then door setting is
done to out the problem. Mallet is used in door setting to adjust the door striker if
required door mechanism is replaced or repair.
5.2.4Change oil & Oil

filter
Due to wear & tear in engine the metal part mix with oil thus oil couldn’t
function properly as lubricant. For smoothly function of engine and remove
impurities oil and oil filter must be changed.
According to P M S engine oil should be change after 10000kms
The engine oil grade

is :-
Petrol cars: 20w40
Diesel cars:- 5w40

K- series cars:- 5w30
Its volume is approximately 3.2 liters. Oil filter changed when the engine oil
is change.
5.2.5Throttle body cleaning
Throttle body cleaning done to increase engine performance, average and

decrease emission. Thinner is normally body cleaning it is uses remove carbon
from throttle body. All maruti car have size of throttle body.
5.2.5Change synchronizer ring

Synchronizer ring is used for easily gear shifting synchronizer ring is

replaced when gear shifting becomes hard.
To replaced synchronizer ring. the gear box is to be disassemble and damage

synchronizer ring replace by new one.
Replace clutch assembly

The main function of clutch is to gradually engine and disengage the power to
the wheel . when the clutch plate is out wear hence is no friction between clutch
plates thus cannot transfer power efficiently. Generally, clutch plate , diaphragm
spring , clutch bearing and clutch wire replaced in clutch assembly.

Stabilizer rod , lower arm, balancing bused & rod

replaced
The vibration occurs in steering and passenger compartment due to

irregularity of unmetalled road. To prevent this vibration stabilizer rod ,
lower arm , balancing bused & rod are changed. This leads to comfort of
driver.
Electrical accessory &

auxiliary

Electrical accessory includes (comprise) light, wire harness, fuse, rely,

etc.

noticed then use of sanding machine it is

leveled.
1. Paint change room
To paint the painting are with car color, color is prepared

in color matching room.

INDUSTRIAL TRAINING
3350201
To color is filled spray gun and painted areas are painted in paint room.
2. Drying paint film


All diploma students are required to undergo industrial training for 16

weeks as part of their curriculum to complate their 3 year course for the
automobile engineering. The attachment will be during the 5th semester of their
syudy. During the 16 week period of training, students have to go in automobile
company for their industrial, I did at KATARIA AUTOMOBOLE situated at Dariyapur.
It is a Maruti

Suzuki service station.
For the first month. I leran about the basic operation in servicing. That
includes the use of different types of tool used in servicing. Then for the second
and third month I was assignned to servicing department there I learn about
overhual engine,gear box overhaul, wheel balancing machine, wheel alignment & etc.

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SEM-5 INDUSTRIAL TRAINING REPORT

NAME-: GOSWAMI VANDANGIRI K

R.C Bhargava chairman of Maruti Udyog Limited.

Kenchi Ayukawa(M.D & C.E.O) of Maruti Udyog Limited

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History Logo of Maruti udyog limited

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It is a subsidiary of Japanese automobile and motorcycle manufacturer Suzuki

The Zen a 993 cc hatchback car was produced in 1993.

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Maruti Suzuki is largest Indian passenger vehicle manufacturer in local

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1.3.2 Company in manufacture car:

Model & Category Lunched Image

Omni, Minivan 1984-2020

Gypsy, SUV 1985 – 2000

Wagon R,cng Hatch 2022

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Swift, Hatch back 2020

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Grand vitara 2022

Swift DZire, Sedan 2017

Ritz, Hatch back 2009-2017

Eeco, mini van 2010

GOVERNMENT POLYTECHNIC A’BAD 8

AltoK-10, Hatch back 2010

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Kizashi, Sedan 2011-2014

Ertiga, MUV 2022

Alto – 800, 2012

Stingry, Hatch back 2013-2017

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Celerio , Hatch back 2014-2021

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Ciaz , Sedan 2014

Zen , Hatch back 1993 – 2006

Esteem, Sedan 1994 – 2008

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Versa , mini van 2001 – 2010

Maruti – 800, Hatch 1983 – 2012

Alto , Hatch back 2000 – 2012

Zen – Estilo, Hatch 2006 – 2013

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A – Star, 2008 – 2014

SX4, Sedan 2007 – 2014

1.3.3 List of Maruti Suzuki Authorized Dealership

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=> My Industrial training is completed by the KATARIA AUTOMOBILES of 5

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D Kataria automobiles Authorized dealership in

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3.1 Organization Chart

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1. Car lift in my workshop

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