MARUTI SUZUKI

SIX WEEKS INDUSTRIAL TRAINING REPORT

SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE
AWARD OF THE DEGREE OF

BACHELOR OF TECHNOLOGY
(MECHANICAL ENGINEERING)

SUBMITTED TO
MAHARAJA RANJIT SINGH PUNJAB TECHNICAL UNIVERSITY,
BATHINDA

SUBMITTED BY
JASMEET SINGH UNIVERSITY ROLL NO.
15111665
SUPERVISED BY

BABA BANDA SINGH BAHADUR OF ENGINEERING COLLEGE,

FATEHGARH SAHIB PINCODE -140407 PUNJAB

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 ACKNOWLEDGEMENT
I also wish to extend my thanks to my training supervisor. _____________ Audi Motors, Sri
Ganganagar, Rajasthan and other members of the team for their guidance and training they gave
to me and also their insightful comments and constructive suggestions to improve the quality of
this training work

I would like to place on record my deep sense of gratitude to Dr. _____________, HOD-Dept.
of Mechanical Engineering, BBSBEC, FGS, Punjab for his generous guidance, help and useful
suggestions.

I extend my deepest gratitude to all those persons who supported me all through my training. My
interaction with all these people has left a long lasting impression in my mind that will influence
my project and my behaviour for all times to come.

Jasmeet Singh

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 INDEX
Sr. Topics Page
No. No.
1 Introduction 4

2 Introduction to Workshop & Safety Guidelines 6

3 Parts of Automobile Engines 7-15

4 Key Specifications of Maruti Suzuki Dzire Engine 16

5 Transmission System 17-19

6 Cooling System 20,21

7 Fuel Supply System 22,23

8 Steering System 24

9 Braking System ( ABS ) 25,26

10 Electronic Components 27-29

11 Miscellaneous 30,31

12 Some Important Tools and Equipment/Machines Used 32,33

13 Car Maintenance 34,35

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 Introduction
Maruti Suzuki India Limited (MSIL, formerly known as Maruti Udyog Limited) is a subsidiary
of Suzuki Motor Corporation, Japan. Maruti Suzuki has been the leader of the Indian car market
for over two and a half decades. The company has two manufacturing facilities located at
Gurgaon and Manesar, south of New Delhi, India. Both the facilities have a combined capability
to produce over a 1.5 million (1,500,000) vehicles annually. The company plans to expand its
manufacturing capacity to 1.75 million by 2013.

The Company offers 15 brands and over 150 variants ranging from people’s car Maruti 800 to
the latest Life Utility Vehicle, Ertiga. The portfolio includes Maruti 800, Alto, Alto K10, A-star,
Estilo, WagonR, Ritz, Swift, Swift DZire, SX4, Omni, Eeco, Kizashi, Grand Vitara, Gypsy and
Ertiga. In an environment friendly initiative, in August 2010 Maruti Suzuki introduced factory
fitted CNG option on 5 models across vehicle segments. These include Eeco, Alto, Estilo, Wagon
R and Sx4. With this Maruti Suzuki became the first company in India to introduce factory fitted
CNG vehicles.

In terms of number of cars produced and sold, the Company is the largest subsidiary of Suzuki
Motor Corporation. Cumulatively, the Company has produced over 10 million vehicles since the
roll out of its first vehicle on 14th December, 1983.

Maruti Suzuki is the only Indian Company to have crossed the 10 million sales mark since its
inception. In 2011-12, the company sold over 1.13 million vehicles including 1, 27,379 units of
exports.

The Company employs over 9000 people (as on 31st March, 2012). Maruti Suzuki’s sales and
service network is the largest among car manufacturers in India. The Company has been rated
first in customer satisfaction in the JD Power survey for 12 consecutive years. Besides serving
the Indian market, Maruti Suzuki also exports cars to several countries in Europe, Asia, Latin
America, Africa and Oceania.

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 Company’s Vision
TERMS OF PRODUCTION VOLUME, COSTS AND PROFITS. WE MUST NOT ONLY
MAINTAIN LE
“TO BECOME AN INTERNATIONALLY COMPETETIVE COMPANY IN ADERSHIP IN
INDIA BUT SHOULD ASPIRE TO BE AMONGST THE GLOBAL PLAYERS. THE
CULTURE, THINKING AND ACTIONS HAVE ALL TO BE CONSISTENT WITH THIS
VISION “

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 Introduction to Workshop
Workshop is a place where various components are repaired and manufactured. In Audi Motors
workshop the various parts like engine, gear box, wheel system, differential, battery etc. are
repaired or tested, for the good and long running of the vehicle the testing of vehicle is also
necessary for safety of users. Therefore at several time intervals cars are serviced here. It is also
a place where the skills of the out coming engineers and mechanics can be developed. The
efficient use of fuel and given resources is also taken in to consideration.

Safety Guidelines
 Provide your attention at most to the job and work quietly.
 Keep tools to your reach.
 Never put sharp objects like screw driver in your pockets otherwise you will cut yourself.
 Always wear suitable clothes and shoes while entering the workshop.
 Clean oil on your hands.
 Compressed air should never be used to blow dust from clothes. Compressed hose should
never be pointed to any person.

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 Parts of an Automobile Engine

1. Cylinder Block :
Cylinder block or Cylinder are main part of an engine. It is a part in which combustion of
fuel takes place. All other parts like piston, connecting rod, crankshaft, water jacket etc. are
bolted on it.

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2. Piston :
Piston is placed in the cylinder and transmits thrust to the connecting rod. It is free to move.
It compresses the air fuel mixture and convert the fuel energy into mechanical energy. It
transmits the power to the crankshaft.

3. Cylinder Head :
Cylinder head is fitted on the top of cylinder block and the function of the cylinder head is to
seal the working end of cylinder and not to permit entry and exit of gases on cover head
valves of the engine. The valves, spark plug, camshaft etc. are fitted on it.

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4. Connecting Rod :
It connect piston to the crank shaft and transmit the motion and thrust of piston to crank shaft.
The lower end of connecting rod is connected to the piston and the bigger is connected to the
crank shaft.

5. Crankshaft :
It is located in the bottom end of cylinder block. It transmits the reciprocating motion of
piston into rotary motion. This rotary motion used to rotate wheels of the vehicle.

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6. Oil Sump :
It is located in the bottom end of cylinder block. It transmits the reciprocating motion of
piston into rotary motion. This rotary motion used to rotate wheels of the vehicle.

7. Camshaft :
It is fitted either in the cylinder head or at the bottom of the cylinder block. It is use to open
or close valves at proper timing in multi-cylinder engine.

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8. Valves :
It is fitted on the cylinder head. It regulates the flow of air fuel mixture inside the cylinder
and exhaust gas outside the cylinder block. When both inlet and exhaust valves are closed no
pressure can go inside or outside of cylinder block.

9. Spark Plug :
It is used in Petrol engine (Spark Ignition Engine). It is fitted on the cylinder head. It is used
to ignite the air fuel mixture inside the cylinder at the end of each compression stroke.

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10. Injectors :
It is used in Diesel engine (Compression Ignition Engine). It is fitted on the cylinder head. It
is used to inject fuel in spray form inside the cylinder at the end of compression stroke.

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11. Push Rod :
It is used when the camshaft is situated in the bottom of the cylinder head. It regulates the
timing of valves open and close through rocker arm and camshaft.

12. Manifold :
It is bolted on the cylinder head one each for intake and exhaust. Its function is to evenly
distribute air-fuel mixture for intake & collects the exhaust gases from all cylinders.

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13. Piston Rings :
It provides the good sealing fit and less friction resistance between piston and cylinder. It is
split at one point so it can be easily installed into the grooves cut in the piston.

14. Gasket :
It is used to seal the cylinder head and cylinder so no pressure is allowed to escape. It is
placed between the cylinder block and cylinder head.

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15. Gudgeon Pin (Piston Pin) :
It is the parallel spindles fitted through the piston boss and connecting rod small end. It
connects the piston to the connecting rod.

16. Engine Bearing :

Bearings are used to support the moving parts. The purpose of bearings is
to reduce friction. The crankshaft is supported by bearing. In engine two types
of bearing are used sliding bearing and rolling bearing.

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Key Specifications of Maruti Suzuki Dzire Engine (Diesel)

 Engine type: 4-cylinder

 No. of valves : 16
 Engine displacement: 1298 cc
 Stroke and bore: 74 and 75.5 mm
 Maximum power: 65.3 kw at 6000 rpm
 Maximum torque: 113 Nm at 4500 rpm
 Configuration: SOHC
 Fuel supply and ignition system: MPFI, spark ignition.

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 Transmission System

1. Clutch :
It consists of only one clutch plate, mounted on the spines of the clutch shaft, the flywheel is
mounted on engine crankshaft and rotates with it the pressure plates bolted to the flywheel
through clutch springs and free to slide on clutch shift when the clutch pedal is operated.
When the clutch is engaged plates is gripped between the flywheel and pressure plate.

The friction linings are on both the sides of the clutch plate due to friction between the
flywheel. Clutch plate and pressure plate, the clutch plate revolves with the flywheel. As
clutch shaft is also connected to the transmission thus engine power is transmitted to the
crankshaft to the clutch shaft.

When the clutch pedal is pressed, the pressure plate move back against the force of the strings
and the clutch plate become free between the flywheel and the pressure plate thus the
flywheel remain rotating as long as the engine running and the clutch shaft speed reduce
slowly and finally it stop rotating as soon the clutch pedal is pressed, the clutch is said to be
disengaged, otherwise it remains engaged due to the spring faces.

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2. Gear Box :

Its function is to provide the high torque at the starting, hill climbing, accelerating and pulling
a load. When a vehicle is starting from rest, hill climbing, accelerating and meeting other
resistance, high torque is required, at the drive wheels. Hence, a device must be providing to
prevent the engine crankshaft to revolve a relatively high speed, while the wheels turn at
slower speed.

This obtained by set of gear called a transmission or gear set of enclose in metal box called a
gearbox. The vehicle speed is also change with the help of the transmission box keeping the
engine speed it with certain limit.

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3. Differential :
When the automobile round a corner or travel over uneven ground, its right and left wheel
covered differential distance. If the wheels are rotates at equal speeds. One of them would be
forced skid. To prevent skidding, there must be a mechanism is called differential.

The car use a differential pinions is free mounted on the journal of the slider. The slider with
pinions is secured in the differential case to rotate with the letter. The pinion is inconstant
mesh with the left and right side gear.

When an automobile moves straight on the even road, the right and left driving wheels meet
the same rolling resistance and the ring gear of the final drive rotate the differential case with
the sliders and pinions. Meshed with the right and left side gears the pinion rotates them at
equal speed but do not revolve themselves around their axes.

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 Cooling System

1. Radiator :
A radiator very efficiently cools the circulating water passing through it. It hard water jackets
and tubes, which acts as insulator and make the in efficient.

2. Thermostat :
Thermostat is a valve type components used in the cooling system, which regulates the engine
temperature by automatically controlling the quantity of cooling water flowing from the
water jackets to the radiator core.

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3. Water Pump :
The power is transmitted to the pump spindle for a pulley mounted on the end of the camshaft
or crankshaft. The water pump used in cooling system is either centrifugal pump is the one
which is used for this purpose.

4. Fan :
Fan is mounted behind the radiator on the same shaft on which the water pump is mounted.
It is driven by a v-belt from the crankshaft pulley.

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 Fuel Supply System

1. Fuel Tank :
The fuel tank acts as a reservoir in which fuel is stored. The fuel tank is provided with air-
want so that the pressure in the fuel tank always remain equal to the atmospheric pressure.

2. Fuel Filter :
To prevent possible blockage by dust particles, the fuel is filtered by installing a fuel filter or
strainer at the inlet to the float chamber. In a fuel supply system, there are three fuel filters.
One fuel filter is mounted at the inlet of the fuel storage tank. The second fuel filter is fitted
in the fuel pump and the third is placed in between the fuel pump and carburettor. The fuel
entering the glass bowl passes through a ceramic filter which separates the foreign particles
and the filtered fuel come out from it. The water and sediments are collected in the bowl
which can be removed for cleaning.

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3. Fuel Pump :
The function of the fuel pump is to deliver fuel from the fuel tank to the carburettor. Many
types of fuel pumps are used, out of which two are as follows:
A. Mechanical fuel pump
B. Electrical fuel pump

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 Steering System

This system is consists generally of many linkage. It is mostly attached to the front wheels. Its
main components are steering wheel, steering column, steering box, pitman arm, pull & push
rod, tie rod, tie rod arm and king pin.
The main function of steering system:-
1. It allowed gear wheel to turn to the right or left.
2. The steering gear swing on piston arm to the right or left when the wheel is turned.

EPAS/MDPS:
Electric power assisted steering (EPS/EPAS) or motor-driven power steering (MDPS) uses an
electric motor to assist the driver of a vehicle. Sensors detect the position and torque of the
steering column, and a computer module applies assistive torque via the motor, which connects
to either the steering gear or steering column. This allows varying amounts of assistance to be
applied depending on driving conditions. Engineers can therefore tailor steering-gear response
to variable-rate and variable-damping suspension systems, optimizing ride, handling, and
steering for each vehicle.[18] On Fiat group cars the amount of assistance can be regulated using
a button named "CITY" that switches between two different assist curves, while most other EPS
systems have variable assist. These give more assistance as the vehicle slows down, and less at
faster speeds.

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 Braking System

Stopping of the vehicle is as necessary as its starting. Once the vehicle is started, it must be
stopped somewhere. Brakes are applied on the wheels to stop the vehicle. Before applying the
brakes, the acceleration is released to stop the fuel supply thus the engine develops no more
power to run the vehicle, and then the brakes are applied which stop the rolling of the wheels on
the road and hence the vehicle is stopped.

ABS (Anti-Lock Braking System)

The theory behind anti-lock brakes is simple. A skidding wheel (where the tire contact patch is
sliding relative to the road) has less traction than a non-skidding wheel. If you have been stuck
on ice, you know that if your wheels are spinning you have no traction. This is because the contact
patch is sliding relative to the ice (see Brakes: How Friction Works for more). By keeping the
wheels from skidding while you slow down, anti-lock brakes benefit you in two ways: You'll
stop faster, and you'll be able to steer while you stop.

There are four main components to an ABS system:

 Speed sensors
 Pump
 Valves
 Controller

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 Electronics Components

1. ECU ( Engine Control Unit ) :

ECU is the brain of the engine that controls all the functioning of the engine. It serves several
functions which includes regulating and maintaining the amount of fuel and air in the fuel
injection part and helps in increasing horsepower of the engine.

The main function of ECU or Engine Control Unit is the controlling of series of function of
actuators on an internal combustion engine and ensuring the excellent engine performance.
The Engine Control Unit is also called Power train control unit.

Within the Engine Bay ECU takes the values from a multitude of sensors and then interpret
that data by using multidimensional Performance maps and in this way adjust the engine
actuators accordingly.

This is also responsible for the best Engine performance. Engine Control Module or ECM is
the same as Engine Control unit the difference is that if we named overall combined section
of control unit in engine then we called it as Engine Control Module or ECM.

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2. Battery :
An automotive battery is a rechargeable battery that supplies electrical energy to a motor
vehicle. It is also known as an SLI battery (starting-lighting-ignition) and its main purpose is
to start the engine. Once the engine is running, power for the car's electrical systems is
supplied by the alternator. Typically, starting discharges less than three per cent of the battery
capacity. SLI batteries are designed to release a high burst of current and then be quickly
recharged. They are not designed for deep discharge, and a full discharge can reduce the
battery's lifespan.

3. Fuse Box :
Fuses protect your car’s circuitry in the case of a overload in current and a relay is a device
that controls a highly amp or voltage rated device with a small amount of electricity. The
‘relay box’ is a place to store these neat little devices.

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4. Infotainment System :
In-car entertainment (ICE), or in-vehicle infotainment (IVI), is a collection of hardware and
software in automobiles that provides audio or video entertainment. In car entertainment
originated with car audio systems that consisted of radios and cassette or CD players, and
now includes automotive navigation systems, video players, USB and Bluetooth
connectivity, computers, in-car internet, and Wi-Fi. Once controlled by simple dashboards
knobs and dials, ICE systems can include steering wheel audio controls and hands free voice
control.

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 Miscellaneous

1. EGR ( Exhaust Gas Recirculation ) :

In internal combustion engines, exhaust gas recirculation (EGR) is a nitrogen oxide (NOx)
emissions reduction technique used in petrol/gasoline and diesel engines. EGR works by
recirculating a portion of an engine's exhaust gas back to the engine cylinders. This dilutes
the O2 in the incoming air stream and provides gases inert to combustion to act as absorbents
of combustion heat to reduce peak in-cylinder temperatures. NOx is produced in a narrow
band of high cylinder temperatures and pressures.
In a gasoline engine, this inert exhaust displaces the amount of combustible matter in the
cylinder. In a diesel engine, the exhaust gas replaces some of the excess oxygen in the pre-
combustion mixture. Because NOx forms primarily when a mixture of nitrogen and oxygen
is subjected to high temperature, the lower combustion chamber temperatures caused by EGR
reduces the amount of NOx the combustion generates (though at some loss of engine
efficiency).Gases re-introduced from EGR systems will also contain near equilibrium
concentrations of NOx and CO; the small fraction initially within the combustion chamber
inhibits the total net production of these and other pollutants when sampled on a time average.
Most modern engines now require exhaust gas recirculation to meet emissions standards.
Chemical properties of different fuels limit how much EGR may be used. For example
methanol is more tolerant to EGR than gasoline.

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2. Turbocharger :
A turbocharger is a form of supercharger. It increases the amount of air entering the engine
to create more power. A turbocharger has the compressor powered by a turbine. The turbine
is driven by the exhaust gas from the engine. It does not use a direct mechanical drive.

3. Intercooler :
An intercooler is an intake air cooling device commonly used on turbocharged and
supercharged engines. An intercooler cools the air compressed by the turbo/supercharger,
reducing its temperature and thereby increasing the density of the air supplied to the engine.

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 Some Important Tools and Equipment/Machines Used

1. Automatic Pneumatic Air Gun :

Screw gun and torque meter are two different tools used for tightening screws and to measure
the torque by which the screws are tightened. There are some places where the screw has to
be tightened at a particular torque beyond that it may wear the screw or even shear stress may
damage the equipment. So regulators in pneumatic air gun system torque can be adjusted and
screw can be tightened accordingly.

2. Hydraulic Lift :
These are used to lift up or down car in service area to work under the car. Through simple
lever or push button mechanism the lift moves up or down.

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3. Wheel Balancing Machine :
Electronic tire balancing is done on machine that spins tyre at 60-100 MPH and feels the
wobble of tyre to determine how the mass is distributed, where the high and low spots are in
the mass of parts. To balance this out we add weights to the wheel. These weights are
hammered on where the machine suggest and the wheels is retested for balancing.

4. A.C. Gas Changer Machine :

It is used to refilling A.C. gas in vehicles.

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 Car Maintenance
Cars at Audi Motors workshop are serviced at fixed interval. There are two types of services:

 Minor Service: Minor Service is done after the vehicle completes 10,000 Km of run.
 Major Service: Major Service is done after the vehicles completes 20,000 Km of run.

Minor car maintenance should include following things:

 Checking of oil levels

 Engine coolant levels and life.
 Windscreen washer refilling.
 Tyre pressure and damages checking.
 Indicators, rear and headlight checking.
 Brake Testing.

Major car maintenance should include following things:

 Refilling of engine oils.
 Refilling of coolants.
 Wheel balancing.
 Wheel alignment.
 Refilling of gear oil.
 Cleaning of brake pads.
 Cleaning of brake drums.
 Refilling of brake oil.
 Replacing air filter of engine.
 Replacing engine oil filter.
 Replacing Fuel filter.
 Replacing A.C. Filter.
 Changing of spark plugs.

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Car Service Tools Checklist:
In order to service the car a checklist needed to be compiled
 Oil filter wrench or removal tool
 Spark plug removal tool
 Socket set or spanner for removing the sump plug for oil drainage
 Screwdriver for unscrewing air filter case if clips applicable may be the alternative case.
 Car jacks and axel stand
 Antifreeze tester
 Oil catch pan.

Car Service Parts Checklist:

Parts checklist consist of:
 Engine oil ( On consult of car manufacturer)
 Oil Filter ( Use car specific)
 Sump plug washer
 Spark plugs
 Air filter
 Antifreeze if applicable

The methods to remove replace any part or oil is according to the service manual of cars. Each
nut has its specific torque for tightening which is also according to the service manual.

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