INDUSTRIAL TRAINING REPORT

INTERNSHIP AT PATEL MOTORS PVT. LTD.

Submitted in partial fulfillment of the

Requirements for the award of
Degree of Bachelor of Engineering in Automobile Engineering

NNN
Submitted to: Mr. vimal dixit Submitted By: - Durga Prasad Sharma
Roll No. : - 0802AU151014

Department of Mechanical & Automobile Engineering

Shri Vaishnav Institute of Technology and Science, Indore

 DECLARATION

I hereby declare that the Industrial Training Report entitled ("INTERNSHIP AT PATEL
MOTORS PVT. LTD.") is an authentic record of my own work as requirements of Industrial
Training during the period from 16.JUNE.2018 to 30.JUNE.2018 for the award of degree of
B.E. (Automobile Engineering), Shri Vaishnav Institute of Technology and Science, Indore
under the guidance of (Name of Project Guide).

(Durga Prasad Sharma)

(0802AU151014)
Date: 17/11/2018
 CERTIFICATE

This is to certify that the report entitled “INTERNSHIP AT PATEL MOTORS PVT. LTD.’’
submitted by Durga Prasad Sharma(0802AU151014) to Shri Vaishnav Institute of Technology
and Science, Indore during the year 2018-2019 is approved towards the partial fulfillment for
the award of the degree of Bachelor of engineering in Automobile Engineering.

Internal Examiner External Examiner

Date: Date:
 ACKNOWLEDGEMENT

This training report would have been impossible without the collective effort of the members
having training at this renowned automobile workshop.

A note of thanks to Mr. Harveer Sir for allowing us to have training at this authorized Maruti
Suzuki showroom cum workshop.

We would also like to thank all the operator and mechanics on the workshop floor for tetting us
roam freely and occasionally giving us valuable feedback to increase our practical knowledge to
a great extent.
 HISTORY OF MARUTI SUZUKI

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.
 PREFACE

Automotive world has always been a matter of concern for technical research and innovations
leading to advancements in vehicle design and power keeping in mind the passenger’s comfort,
safety and ergonomics.
This training report has been written in accordance to all the valuable enrichments met by us
during the training session at Patel Motors Ltd. (Indore) the authorized sales and service centre
of leading passenger car producer of India, MARUTI SUZUKI.
This training report aims to include all major details, mechanism and specifications of the
automotive subsystems like Power Train, Transmission, Suspension, Brakes, AC system etc. in
reference to Maruti Suzuki products in Indian Market.
All the details that have been mentioned inside are tried to be strictly as per industrial
specifications preferred by automotive makers. We believe this report would be extremely
beneficial to those who want to put a step ahead than others in automobile basics.
 CONTENTS

 CAR NAMES & SPECIFICATION OF MARUTI SUZUKI

 TOOLS, GAUGES & EQUIPMENT USED IN WORKSHOP
 DESCRIPTION OF FOUR STROKE IN PETROL AND DIESEL ENGINE

 ENGINE
1. DIESEL ENGINE AND PETROL ENGINE

 MAIN PARTS OF ENGINE

 TRANSMISSION SYSTEM
1. CLUTCH
2. GEAR BOX
3. PROPELLER SHAFT
4. DIFFERENTIAL

 COOLING SYSTEM
1. RADIATOR
2. THERMOSTAT
3. WATER PUMP
4. FAN

 FUEL SYSTEM IN DIESEL ENGINE

1. FUEL TANK
2. FUEL FEED PUMP
3. FUEL INJECTION PUMP
4. INJECTOR

 FUEL SYSTEM IN PETROL ENGINE

 1. FUEL TANK
2. FUEL FILTER
3. FUEL PUMP
4. CARBURETTOR
5. SPARK PLUG

 MISCHELLANEOUS
1. STEERING SYSTEM
2. BRAKE SYSTEM
3. CHASSIS

 PARTS NAME AND ITS FUNCTION

 CAR NAMES & MODEL CODES OF
MARUTI SUZUKI

SR. NO. CAR NAME CODE

1. A-STAR AMF
2. ALTO MRF
3. BALENO MY
4. MARUTI 800 MB
5.` DZIRE RN
6. DZIRE(DIESEL) RN
7. EECO MGA
8. ESTEEM MF
9. ESTEEM DIESEL MF
10. GRAND VITARA XL-7 JA
11. GYPSY MG
12. NEW WAGONR A1J
13. OMNI MT
14. RITZ ASE
15. SW7IFT RS
16. SWIFT DIESEL RS
17. SX4 RW
18. SX4 DIESEL RW
19. VERSA MGA
20. WAGONR MRD
21. ZEN MH
22. ZEN DIESEL MH
 SPECIFICATION

 TECHNICAL SPECIFICATION OF GRAND VITARA XL-7

1. MECHANICAL

 Engine type: 6 Cylinder, V-type, Petrol

 Valve per cylinder: 4
 Torque to weight ratio: 14.09kgm/tone
 Bore: 88.0mm
 Stroke: 75.0 mm
 Engine displacement: 2736 cc
 Compression ratio: 9.5
 Transmission: 5 speed automatic
 Brakes: 4 wheel brake, ABS

2. SECURITY
 Air bags: All air bags are standard

3. CAPACITIES
 Seating capacity: 7 person
 Fuel tank capacity: 66 liter

4. FUEL ECONOMY
 Mileage Highway: 10.2 km/liter
 Mileage city: 7 km/liter
 Mileage overall: 7.6 km/liter

5. BREAKE
 Front: disc
 Rear: drum

6. FUEL SUPPLY
 Ignition and fuel system: Electronic MPFI

7. DIMENSION, CAPACITY & WEIGHT

 Length: 4760 mm
 Width: 1780 mm
 Height: 1740 mm
 Ground clearance: 183 mm
 Gross vehicle weight: 2300 kg
 No. of doors: 5
 Wheel base: 2800 mm
 
 TECHNICAL SEPCIFICATION OF SWIFT

1. MECHNICAL
 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

2. TRANSMISSION
 Transmission type: Manual
 Gear box: 5 speed

3. STEERING
 Steering type: Power
 Steering gear box type: Electrical associated rack & pinion.
 Minimum turning radius: 4.7 metres

4. BREAKE
 Front: Disc
 Rear: Drum

5. FUEL
 Millage city: 11.5 km/liter
 Millage highway: 16.2 km/liter
 Fuel type: Petrol
 Fuel tank capacity: 43 liters

6. DIMENSION
 Length: 3695 mm
 Width: 1690 mm
 Height: 1530 mm
 Wheelbase: 2390 mm
 Ground clearance: 170 mm

7. SPECIFICATION
 Seating capacity: 5 person
 No. of doors: 5

8. WEIGHT
 Gross weight: 1415 kg
 TOOLS, GUGES AND EQUIPEMENT USED IN
WORKSHOP
 TOOLS
 Micrometers
 Screw drivers
 Hammers
 Thickness gauge
 Wrenches
 Air pressure gauge
 Pliers

 EQUIPEMENTS
 Bench vice
 Hydraulic jacks
 Pullers
 Hydraulic hoist
 Surface table
 Pistol oiler
 Spanners & socket with handle
 Grease gun
 Hacksaws
 Vehicle washer
 Chisels
 Air compressor
 Files
 Working lamp
 Punches
 Bench grinder
 Tap & dies
 Tyre inflaters
 Piston ring expander
 Battery tester

 GAUGES
 Battery charger
 Steel rule
 Tyre changer
 Dial indicator
 Spark plug cleaner
 Spring caliper
 Injector tester
 Vernier caliper
 Speedometer
 DESCRIPTIONOF FOUR STROKE IN PETROL ENGINE

1. In starting the piston position at top, when the piston moves downward the inlet valve is open,
then the air/fuel is intake the cylinder. This is known as SUCTION
STROKE.

2. Then the piston moves upwards and compresses the air/fuel mixture. There is a spark plug is
provided which produce spark to brunt the fair/fuel mixture. This stroke known as
COMPRESSION STROKE.

3. When the spark plug produce spark there is blast in the cylinder and the piston moves down
wards strickly and power is produce. By this power, the vehicle is move forward /backward as
per desire. This stroke is known as POWER STROKE.

4. Now the piston is moves upwards, there are gasses are produce by the burning of the air/fuel
mixture are exit from the outlet valve. This stroke is known as EXHAUST.
 DESCRIPTIONOF FOUR STROKE IN DIESEL ENGINE

1. In starting the piston position at top, when the piston moves downward the inlet valve is open,
then the air is intake the cylinder. This is known as SUCTION STROKE.

2. Then the piston moves upwards and compresses the air. There is a injector is inject the fuel in
spray formation to brunt the air and fuel. This stroke known as COMPRESSION STROKE.

3. When the injector injects the fuel there is blast in the cylinder and the piston moves down wards
strickly and power is produce. By this power, the vehicle is move forward /backward as per
desire. This stroke is known as POWER STROKE.

4. Now the piston is moves upwards, there are gasses are produce by the burning of the air/fuel
mixture are exit from the outlet valve. This stroke is known as EXHAUST.
 ENGINE

Engine is convert chemical energy to heat energy and heat energy to mechanical energy is called
engine.

4 STROKE DIESEL ENGINE

MAIN PARTS OF ENGINE

CYLINDER BLOCK
Carbon 2.2%
Silicon 1.2%
Manganese 0.63%
Sulphur 0.12%
Phosphorus 0.85%
Top of the cylinder is covered by separate cast iron piece known as cylinder head. It is bolted on
the top of the block. It contain nozzles, valves, rocker arms, tappets etc. The bottom of cylinder
head and top of the cylinder block is machined very accurately. so that there are very less
changes of gas leakage for sound gas tight joint the holding studs must be distributed as possible
around the circumference of each cylinder the combustion chamber is made of cast iron.

CRANK CASE
Crankcase is attached to the bottom face of the cylinder. It acts as the base of the engines. It
supports the cranks shaft and camshaft in suitable bearings lower part of the cylinder block
together is called the crankcase.
CONNECTING ROD
The connecting rod is the connection between piston and crankshaft. Small end of the connecting
rod is connected to the piston pin and big end is connected to the crank pin. The function main
function of connecting rod is to convert the liner motion of the piston to rotary motion of
crankshaft.
Aluminum alloy is also used for connecting rod. The connecting rod carries the power thrust
from piston to crank pin and hence it must be very rigid and as light as possible.
Crankshaft is the first in power transmission. System the reciprocating motion of piston is
converting into rotary motion with the help of connecting rod. Crankshaft consists of crank pins,
webs balancing weights and main journals. Big end of connecting rod is connecting to crank pins
of crankshaft.
The part of crankshaft inside the main bearing is called the main journals. Balancing weights are
provide on the opposite side of crank arms for balancing crankshaft is made of casting of forging
of heat created.

FLYWHEEL
A flywheel is a heavy steel wheel attached to the near end of the crankshaft. The size of
flywheel is depends upon the number of cylinder and general construction of the engine. The
flow of power from the engine cylinder is not smooth although the power impulses in a multi
cylinder overlap or follow each other to provide a fair fly even flow of power, however
additional leveling off power impulses is required.
It also has teethes on its periphery to mesh with electric cranking motor drive pinion when
engine is being cranked to start it.

VALVES
Valve is a device to close and open a passage. In motor vehicle, engines valves used for each
cylinder and an exhaust valve. Exhaust valve is usually of austenitic stainless steel, which is
highly heat &corrosion resistant. Inlet valve is being subject to less heat usually of nickel
chromium alloy.
CAMSHAFT
A camshaft is simply a shaft on which cams are mounted. The camshaft is mounted on lower part
of the camshaft into linear motion of the follower or lifter. A camshaft is responding for opening.
A camshaft has a numbers of cams along the length, two cams for elfish cylinder one to operate
inlet valve and other to exhaust valve. In addition, camshaft has an eccentric to operate the fuel
pump and gear to drive the ignition distributers and oil pump.
The camshaft is drive by crankshaft by machine gears. The crankshaft gear have twice the as
many as on crankshaft gear.

OIL PAN OR SUMP

The bottom half of the crankshaft is called oil pan or sump. It is bolted or screwed to lower
flange of the main casting and usually made of pressed steel or aluminum. It serves as a reservoir
for the storage, cooling and ventilation of engine oil. The oil sump draws oil from the pan and
sends it in the engine. The oil drains off run down into pan. There is a constant circulation of oil
between pan and the working parts of the engine.

OIL PUMP
It is generally located inside the crankcase below the oil level. The function of oil pump is to
supply oil under pressure to the various engine parts are lubricated. We generally use gear type
oil pump. It consist two gear of equal size. One is called driven gear and other is called driving
gear.
The driving gear should be 0.5 mm and clearance between the bodies to gear should be 0.5mm-
1mm. The oil enters the pump from the inlet port. The wear and tear of teeth, which occurs
slowly, produces an adverse effect on the delivery.

GASKETS
A gasket is placed between the cylinder head and to ensure metallic tight fit joint. The gasket
should able to withstand not only high pressure but also extreme temperature.
Following important gaskets are used in automobile engine:
1. Copper—Asbestos Gasket
2. Steel-- Asbestos Gasket
3. Steel-- Asbestos –Copper Gasket
4. Single Steel rigid or Corrugate Gasket

PISTON
Piston is considered one of the most important parts in a reciprocating engine that is used to
convert the chemical energy obtained by the combustion of fuel into useful mechanical power.

The piston must possess the following qualities:-

1. Rigid to withstand high pressure.
2. Lightness to reduce the weight of reciprocating masses and so enable to
get higher engines speeds.
3. Good heat conductivity.
4. Material should have low co-efficient of expansion.

PISTON RING
Piston rings are fitted into the grooves to maintain good seal between the piston and the cylinder
wall.
TRANSMISSION SYSTEM

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.

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.
PROPELLER SHAFT
This shaft is used to transmit power from universal joint to differential in case of rear wheel
drive vehicles. This shaft doesn’t remain at fixed position. There are two reasons for this. One,
the rear axle moves up and down because of unevenness of the road. Secondly, while braking
and starting, it tends to move axially forward and backward. One is internally splined and one
externally.

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.

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 temp. By automatically controlling the quantity of cooling water flowing
from the water jackets to the radiator core.
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.
 FUEL SUPPLY SYSTEM IN PETROL ENGINE

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 remains 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 carburetor. 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.
3. Fuel pump: - The function of the fuel pump is to deliver fuel from the fuel tank to the
carburetor. Many types of fuel pumps are used, out of which two are as follows:
A. Mechanical fuel pump
B. Electrical fuel
pump
Mechanical fuel pump: This type of pump is used in petrol engine for supply of fuel to the
carburetor. Due to rotation of the crankshaft the
cam rotates , it operates the rocker arm which in turn pushes the diaphragm up and down . The
downward moment of the diaphragm against the compression of spring produces a vacuum in the
pump chamber. The causes the suction of fuel though the strainer from the fuel tank . The
upward moment of diaphragm pushes the fuel up causes the inlet valve to close the outlet valve
to open. The fuel goes to the MPFI system through the outlet valve.

MPFI System:-
M.P.F.I. means Multi Point Fuel Injection system. In this system each cylinder has number of
injectors to supply/spray fuel in the cylinders as compared to one injector located centrally to
supply/spray fuel in case of single point injection system.
Advantage of M. P. F. I.: -
(1) More uniform A/F mixture will be supplied to each cylinder, hence the difference in power
developed in each cylinder is minimum. Vibration from the engine equipped with this system is
less , due to this the life of engine components is improved.
(2) No need to crank the engine twice or thrice in case of cold starting as happens in the
carburetor system.
(3) Immediate response, in case of sudden acceleration / deceleration.
(4) Since the engine is controlled by ECM* (Engine Control Module), more accurate amount of
A/F mixture will be supplied and as a result complete combustion will take place. This leads to
effective utilization of fuel supplied and hence low emission level.
(5) The mileage of the vehicle will be improved.
 FUEL SUPPLY SYSTEM IN DIESEL ENGINE

The fuel is stored in the fuel tank from where it is lifted by means of a fuel feed pump if the fuel
tank is place at a lower level. The fed pump supplies the fuel to the injection pump through a
filler. The fuel injection pump forces the fuel under a very high pressure to the fuel injector .The
fuel under a very high pressure is injected into the engine cylinder in the form of a fine spray by
means of the fuel injector at proper instant .The fuel injection system consists of the following
components.
4. 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 remains equal to the atmospheric
pressure.
5. Fuel feed pump: - the pump which supplies fuel from the tank to the injection pump, is
known is fuel feed pump. The pressure developed by pump is 1 bar to 2 bar.
6. Fuel injection pump: - The pump which supplies a metered quantity of fuel to the injector
under a very high pressure at correct moment is known as fuel injection pump.
7. Fuel injector: - A nozzle mounted on the combustion chamber, which supplies the fuel to
the engine cylinder in the form of a fine spray, is known as fuel injector. It is also sometime
called fuel automizer fuel valve, nozzle Or spray.
 MISCHELLANEOUS

STEERING
This system is consists generally of many linkage. It is mostly attached to the front wheels. It’s
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.

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. Braking system used in MARUTI SUZUKI vehicles is
braking system

CHASSIS
The portion without body of vehicle is called chassis. The layout of chassis components:-
1. Frame
2. Power unit
3. Transmission system
4. Braking system
5. Steering system
6. Suspension system
 CONCLUSION
The 2 weeks industrial training at “PATEL MOTORS Pvt. Ltd., Indore (Maruti Suzuki)” was
indeed the most learning experience. It provided me an opportunity to learn practical application
of my technical knowledge. I learnt a lot about automobile basic training and worked on
transmission in cars. I learnt about different types of transmission used in Maruti cars and the
problems concerned with the latter. During the training, I learnt of their advantages and
disadvantages and the advance features that Maruti Suzuki is introducing for costumer
satisfaction in the Market. Maruti Suzuki’s Tagline “WAY OF LIFE” symbolizes the changes
within Suzuki. I had interest in understanding basic engineering work.