Report of Internship at

MARUTI SUZUKI COMET MOTORS

A PROJECT REPORT

Submitted by
DEV PRADEEP MORE
22076319017

In partial fulfillment for the award of the degree of

BACHELOR OF ENGINEERING
In

MECHANICAL ENGINEERING
Under the Mentorship of

Prof. MAYUR B. GOHIL

SHREE SWAMI ATMANANAD SARASWARTI INSTITUE OF

TECHNOLOGY, SURAT

GUJARAT TECHNOLOGICAL UNIVERSITY,

AHMEDABAD
APRIL,2025
 Shree Swami Atmanand Sarasawati Institute of Technology
Varachha Main Rd, Opp. Police Station, Kapodra Patiya, Surat, Gujarat

CERTIFICATE
This is to certify that the project report submitted along with the project

entitled MARUTI SUZUKI COMET MOTORS has been carried out

by DEV PRADEEP MORE under my guidance in partial fulfillment for

the degree of Bachelor of Engineering in Mechanical Engineering 8 th

Semester of Gujarat Technological University, Ahmedabad during the

academic year 2024- 25.

Signature of Internal Guide, Signature of HOD,

Prof. Vipu Dr. Jignesh Vaghasia
 SSASIT, SURAT

COMPLETION CERTIFICATE

GUJARAT TECHNOLOGICAL UNIVERSITY [4] SSASIT, SURAT

GUJARAT TECHNOLOGICAL UNIVERSITY [3]

Shree Swami Atmanand Sarasawati Institute of Technology

Varachha Main Rd, Opp. Police Station, Kapodra Patiya, Surat, Gujarat

DECLARATION

We hereby declare that the Internship report submitted along with the
Internship entitled Q-TECH CONSULTANTS submitted in partial
fulfillment for the degree of Bachelor of Engineering in Mechanical
Engineering to Gujarat Technological University, Ahmedabad, is a Bonafied
record of original project work carried out by us at Q-TECH
CONSULTANTS & that no part of report has been directly copied from any
student’s reports or taken from any other source, without providing due
reference.

Name of Student Signature

 RAJ.A.LAD

GUJARAT TECHNOLOGICAL UNIVERSITY [6] SSASIT, SURAT

 ACKNOWLEDGEMENT

I am heartily thankful to our Industrial Mentor and Guide Mr. C.K Purohit Sir for
his constant support and guidance throughout the internship. His supervision, teachings and
motivation has always been our driving force at work. Also, I am grateful to all other staff
members of Q-TECH CONSULTANTS for being and essential part of my journey by helping
me, providing knowledge and clearing our doubts.

I would like to thank my industry mentor PROF.VIPUL M. GOTI for helping me

throughout my internship by giving me the necessary suggestions and advices along with his
valuable co- ordination in completing this internship.

I am also grateful to DR. JIGNESH VAGHASIA Head of the department of

Mechanical engineering for providing the precious guidance, inspiring discussions and
constant supervision. I am also thankful to all the staff members of the department of
mechanical engineering and to all my well-wishers who helped me in successful completion
of this internship.

Thank You,

RAJ .A. LAD

GUJARAT TECHNOLOGICAL UNIVERSITY SSASIT, SURAT

 ABSTRACT

This report summarizes the learning and practical experience of my three

Months internship at Q-TECH CONSULTANTS located in Bhatpore G.I.D.C
near I.T.I Center Surat.

The purpose of internship is to provide engineering student with experience to

the world of engineering practice through a period of work place employment and to
get a practical aspect of the theoretical work studied and to understand the operations
in the business sector and to enable student to gain experience in different tasks.
Internship is an opportunity to relate what has been covered in class and what is
applicable in the field is an operational environment.
During my internship period a number of approaches and exposure method
were used. Internship in automobile industry provides me valuable hands on
experience for the students or young professionals. During this period I learn about
various aspect of the industry, such as workshop, body shop, painting, assembling,
testing, marketing and sales.
Also got opportunity to work with experienced professionals and gain insight
into how different collaborate to create a finished product, learn about the latest
technologies, trends in the industry and develop skills in area such as problem
solving, communication and teamwork.
Overall, the internship provided valuable insights had practical experience in
automobile industry and excellent way to gain practical knowledge and skills that can
help prepare individuals for successful career.

GUJARAT TECHNOLOGICAL UNIVERSITY [8] SSASIT, SURAT

 NOMENCLATURE

ASME: America Society of Mechanical Engineering

ASNT: American Society of Non Destructive Testing
IS0: International Organization for Standardization
ASTM: American Society for Testing and Material

GUJARAT TECHNOLOGICAL UNIVERSITY [7]

 List of Figures

Fig. No. Fig. Name Page No.

1.1 Front view of Maruti Suzuki Comet Motors 15

1.2 Work Shop Area 17
1.3 Industry Layout 18
2.1 Safety Suit 19
2.2 Safety Helmet 19
2.3 Safety gloves 20
2.4 Safety Goggles 20
2.5 Safety Shoes 21
2.6 Respirator 21
2.7 Welding Helmet 22
3.1.1 Open End Wrench 23
3.1.2 Combination Wrench 23
3.1.3 Flare Nut Wrench 24
3.1.4 Socket Wrench 24
3.1.5 T Spanner 25
3.1.6 Adjustable Wrench 25
3.1.7 Torque Wrench 26
3.1.8 Extension Bar & Universal Joint 26
3.1.9 Nose Plier & Lock Plier 27
3.1.10 Screwdriver 27

GUJARAT TECHNOLOGICAL UNIVERSITY [10] SSASIT, SURAT

 3.1.11 Allen Key or Allen Wrench 28
3.1.12. Ball Peen Hammer 28
1
3.1.12. Sledge Hammer 29
2
3.1.12. Soft Faced Hammer 29
3
3.1.13 Cup Wrench 30
3.1.14 Oil Drainer 30
3.2.1 Vernier Scale 31
3.2.2 Bore Gauge 31
3.2.3 Piston Ring Compressor 32
3.2.4 Gear Box Stand 32
3.3.1 Hydraulic Car Lift 33
3.3.2 Wheel Balancing 34
3.3.3 Wheel Alignment 36
4.1 Flow of Work 37
4.2 Auto Body Repair Process Map 37
7.3.2 Oil Filter 49
7.3.3 Break Fluid DOT 3 49
7.3.8 A.C Filter 50
8.2.1 Engine Parts 53
8.2.2 Swift Car Engine 53
8.3.1 Battery 54
8.3.2 Battery Tester 54

GUJARAT TECHNOLOGICAL UNIVERSITY [11] SSASIT, SURAT

 8.4.1 Clutch Assembly 55
8.4.2 Clutch Plate 55

8.5.1 Disc Brake 56

8.5.2 Drum Brake 57
8.6 Shock Absorber 58
8.7 Egr Valve 59
8.8 Spark Plug 60
8.9.1 Air Filter 61
8.9.2 Diesel Fuel Filter 62
8.9.3 Petrol Fuel Filter 62
8.10.1 Gear Box 63
8.10.2 Gear 63
8.10.3 Reverse Gear 63
8.11 Radiator 64
8.11.1(a) Coolant 65
8.11.1(b) Coolant Storage 65
8.11.2 Water Pump 66
8.12.1 Manual Gear Shifter 68
8.12.2 Automatic Controller 69
8.12.3 Automatic Shifter 69
8.13 Turbo Charger 70
8.14 Oil Pump 71

GUJARAT TECHNOLOGICAL UNIVERSITY [12] SSASIT, SURAT

 10.1 Egr Valve 74
10.2 Clutch Plate 74
10.3 Steering Power Rack & amp, Pinion 75
10.4 Stabilizing Road 75
10.5 Starting Motor 76
10.6 Break Pad 76
10.7 Back Suspension 77
10.8 Front Suspension 77

GUJARAT TECHNOLOGICAL UNIVERSITY [13] SSASIT, SURAT

 List of Table

TABLE TABLE NAME PAGE

NO. NO.
3.3.1 HYDRAULIC CAR LIFT 33

GUJARAT TECHNOLOGICAL UNIVERSITY [14] SSASIT, SURAT

 Table of Contents
Title Page……………………………………………………………………….1
Certificate………………………………………………………………………2
Company Certificate…………………………………………………………3
Declaration……………………………………………………………………4
Acknowledgement……………………………………………………………5
Abstract………………………………………………………………………...6
Nomenclature…………………………………………………………………..7 List of
Figures………………………………………………………………….8
List of Tables…………………………………………………………………12
Table of Contents……………………………………………………………13

Chapter 01: Overview of the company………………………………………..13-16

1.1 Vision and Mission…………………………………………………………..
1.2 Scope of Work……………………………………………………………
1.3 Car Handling Capacity……………………………………………………..
1.4 Workshop Facilities………………………………………………………….. 1.5
Industry Layout……………………………………………………………….

Chapter 02: Safety equipment………………………………………………..17-20

Chapter 03: Tools & major equipment……………………………………..21-34

3.1 Basic Tools………………………………………………………………………
3.2 Special Purpose Tool…………………………………………………………….
3.3 Major Equipment………………………………………………………………..

Chapter 04: Flow of work……………………………………………………35-35

Chapter 05: Roles & responsibility of manpower………………………….36-42

5.1 General Manager…………………………..
5.2 Help Desk Coordinator…………………………..
5.3 Assistant Works Manager……………………….
5.4 Service Advisor………………………………………..
5.5 Floor Coordinator……………………………………

GUJARAT TECHNOLOGICAL UNIVERSITY [15] SSASIT, SURAT

 5.6 Dealer Technical Leader (DTL)……………..
5.7 Technical Advisor………………………..
5.8 Technicians…………………………………
5.9 Customer Care Executive…………………………….
5.10 Customer Care Support Executive…………………….

Chapter 06: Vehicle tracking for delivery at promised time…………….43-43

Chapter 07: Types of maintenance in vehicle………………………………44-44

Chapter 08: Main components of a car & their function……………...…47-66

8.1 The Basics…………………
8.2 Engine……………………….
8.3 Battery……………………………..
8.4 Clutch Plate Assembly……………………….. 8.5
Brakes……………………………….
8.6 Shock Absorber……………………..
8.7 Exhaust Gas Recirculation……………………… 8.8 Spark
Plug……………………………..
8.9 Air Filter and Fuel filter………………………..
8.10 Gear Box……………………………………………
8.11 Radiator…………………………………………….
8.12 Transmission……………………………….
8.13 Turbo Charger……………………………………. 8.14 Oil
Pump…………………………………………….

Chapter 09: Maruti on road service……………..…………………………..67-68

Chapter 10: Major Problem & Solution……………………………………………69

10.1 Egr Valve………………………………………………………………………..
10.2 Clutch Plate…………………………………………………………………….
10.3 Steering Power Rack & amp; Pinion………………………………………….
10.4 Stabilizing Road………………………………………………………………
10.5 Starting Motor………………………………………………………………..
10.6 Break Pad…………………………………………………………………….
10.7 Back Suspension………………………………………………………………
10.8 Front Suspension…………………………………………………………….

GUJARAT TECHNOLOGICAL UNIVERSITY [16] SSASIT, SURAT

 COMET MOTORS is authorized dealer of maruti suzuki india ltd in surat city south
gujarat region. COMET MOTORS commenced its operations in august 1996 as a
Maruti Suzuki authorized service station. The office of COMET MOTORS dealership
is located in pandesara area of surat city. It is a modern and state of the art facility with
3S (Sales, Service, Spares) infrastructure under one roof.

Fig 1.1 Front view of Maruti Suzuki Comet Motors

GUJARAT TECHNOLOGICAL UNIVERSITY [17] SSASIT, SURAT

 1.1 Vision and Mission

Vision

We will inspire and create an exceptional place to work and to do business. One
employee, one customer, one vehicle at a time. Through our transparent atmosphere,
premium auto inventory, and individualized customer care, we create the luxury
shopping experience that our customers truly deserve.

Mission

Comet motor co, holds a responsibility to foster an environment which empowers

employees, promotes innovation, relationships, and growth. We will continuously
strive to inspire consumer confidence by supplying a transparent atmosphere and
offering a premium automobile product with individualized customer care.

1.2 Scope of Work

Vehicle Maintenance and Repairs:

The spectrum of activities and jobs performed in an automobile workshop includes a

variety of tasks linked to the upkeep, repair, and servicing of cars. Workshops for
automobiles are essential for maintaining vehicles in top condition, assuring their
safety, and extending their lifespan. The following are some important components of
an auto shop's scope of work:

Vehicle Maintenance and Repairs:

Performing routine maintenance tasks such as oil changes, filter replacements, tire
rotations, and brake inspections.

Scheduled Servicing:
• Following manufacturer-recommended service schedules for different vehicle
models.

Body and Paintwork:

• Repairing and repainting vehicle body panels that have been damaged due to
accidents or wear and tear.

GUJARAT TECHNOLOGICAL UNIVERSITY [18] SSASIT, SURAT

 Electrical and Electronics:
• Repairing and replacing electrical components such as batteries, alternators, starters,
and wiring.

Wheel Alignment and Balancing:

3 Ensuring proper alignment of vehicle wheels to improve handling and tire wear. The
range of work done in an auto shop may change depending on the workshop's area of
expertise (general repairs, bodywork, particular car brands, etc.), technology
developments, and market trends. To guarantee that automobiles receive top-notch
care and maintenance, qualified specialists, mechanics, and support personnel are
necessary.
1.3 Car Handling Capacity

At MARUTI SUZUKI COMET MOTORS, Pandesara, there are 9 bays for

maintenance and repair of cars and one bay for electrical repair and ac repair. They
have 3 service advice and 8 technicians. They handle around 15 to 18 cars in one day.

1.4 Workshop Facilities

• Break Down Service is available

• Pick Up service
• Electric & Hydraulic lift Available
• Wheel Alignment & Balancing Machine
• All type latest machineries
• Customer waiting Room
• 24*7 helpline service
• 90 minutes quick, free & paid service

GUJARAT TECHNOLOGICAL UNIVERSITY [19] SSASIT, SURAT

 Fig 1.2 Work Shop Area
1.5 Industry Layout

GUJARAT TECHNOLOGICAL UNIVERSITY [20] SSASIT, SURAT

 Fig 1.3 Industry Layout
CHAPTER 02: SAFETY EQUEPMENT

1. SAFETY SUIT

Fig 2.1 SAFETY SUIT

GUJARAT TECHNOLOGICAL UNIVERSITY [21] SSASIT, SURAT

 Function: Safety suit enables you to better protect the lives of your workers while
maintaining compliance, enhancing productivity.

2. SAFETY HELMET

Fig 2.2 SAFETY HELMET Function: Protection against head

injuries.

3. SAFETY GLOVES

Fig 2.3 SAFETY GLOVES

Function: Safety gloves are the type of hand

protection equipment made up of
plastic, rubber, or synthetic material.

4. SAFETY GOGGLES

Fig 2.4 SAFETY GOGGLES Function: Protection against

eyes.

GUJARAT TECHNOLOGICAL UNIVERSITY [22] SSASIT, SURAT

 5. SAFETY SHOES

Fig 2.5 SAFETY SHOES

Function: It prevent from getting foot injuries due to slippery surface, heavy falling or
rolling and sharp objects.

6. RESPIRATOR

Fig 2.6 RESPIRATOR

Function: A respirator is a device designed to protect the wearer from inhaling
hazardous atmospheres, including fumes, vapors, gases and dust.

GUJARAT TECHNOLOGICAL UNIVERSITY [23] SSASIT, SURAT

 7. WELDING HELMET

Fig 2.7 WELDING HELMET

Function: A welding helmet is a type of headgear used when performing certain types
of welding to protect the eyes, face and neck from flash burn, ultraviolet light, sparks,
infrared light and heat.

CHAPTER 03: TOOLS & MAJOR EQUIPMENT

3.1 BASIC TOOLS

1. OPEN END WRENCHES:

GUJARAT TECHNOLOGICAL UNIVERSITY [24] SSASIT, SURAT

 Fig 3.1.1 OPEN END WRENCHES
Function: A wrench with an open end fits around a fastener instead of over it, so you
can slip it into an area where there isn’t space for socket. COST: 600-100 INR

2. COMBINATION WRENCH:

Fig 3.1.2 COMBINATION WRENCH

Function: A combination wrench, as the name suggest, is a combination of the both an

open ended as well as a box ended wrench. This can be used to unfasten nuts and bolt
with the box- end, and then separate them quickly using the open-end.
COST :500-1200INR

3. FLARE NUT WRENCH:

Fig 3.1.3 FLARE NUT

WRENCH

Function: Tubing wrench or flare nut wrench is a

box-end wrench with a small opening or split in
the jaw. The opening allows the wrench to
be slipped over fuel lines, brake lines, or power
lines and onto the fitting nut. COST: 550 -
1000INR

4. SOCKET
WRENCH:

GUJARAT TECHNOLOGICAL UNIVERSITY [25] SSASIT, SURAT

 Fig 3.1.4 SOCKET WRENCH
Function: A SOCKET wrench or ratchet allows you to turn bolt and nut with easier
than using a regular wrench. The ratcheting feature allows you to keep the wrench on
the bolt eliminating the need to refit the wrench every time you need to make a turn.
COST: 4000 – 9000 INR

5. “T” SPANNER
Fig 3.1.5 T SPANNER
Function: T shaped wrench that consist
of a handle or lever with a fixed or
removable socket to fit over a but or bolt
head.it is used where it is hardy to reach
fasteners and remove fasteners speedy.
COST: 700IN

6. ADJUSTABLE WRENCH

Fig 3.1.6 ADJUSTABLE WRENCH

Function: An adjustable wrench has jaws that can be adjusted to fit different size bolt
and nut heads of various sizes and can be tight and loosed. COST :300INR.

7. TORQUE WRENCH:

Fig 3.1.7 TORQUE

WRENCH

GUJARAT TECHNOLOGICAL UNIVERSITY [26] SSASIT, SURAT

 Function: A torque wrench is used where the tightness of screws and bolts is crucial. It
allows the operator to measure the torque applied to the fastener so it can be matched
to the specifications for a particular application. COST: 2700 – 3000INR

8. EXTENSION BAR & UNIVERSAL JOINT:

Fig 3.1.8 EXTENSION BAR & UNIVERSAL JOINT

Function: An extension bar is long, generally solid piece of metal piping that allow a
user to extend the reach of a socket wrench by as much 10 inches or more. They are
commonly employed to help reach bolt that recessed or otherwise unreachable with a
standard wrench. COST: 1500 -2000INR

9. NOSE PLIER & LOCK PLIER:

Fig 3.1.9 NOSE PLIER & LOCK

PLIER
Function:
Locking plier
are used where
more torque is
needed to pry
or remove objects or where added grip is needed for
holding objects in place.

Nose plier use to grip small objects, reach awkward places, holding wires, bend loop [,
and attach wires. COST: 900INR

10. SCREWDRIVER:

GUJARAT TECHNOLOGICAL UNIVERSITY [27] SSASIT, SURAT

 Fig 3.1.10 SCREWDRIVER
Function: screwdrivers are used to remove or install screws. COST: 200INR

11.ALLEN KEY OR ALLEN WRENCH:

Fig 3.1.11 ALLEN KEY OR ALLEN WRENCH

Function: An Allen key is also known as Hex key. This is a small handheld tool used
for turning bolts and screws which have hexagonal socket. COST: 400INR

12.HAMMERS:

A. BALL PEEN HAMMER

B. SLEDGE HAMMER
C. SOFT FACED HAMMER

A. BALL PEEN HAMMER:

GUJARAT TECHNOLOGICAL UNIVERSITY [28] SSASIT, SURAT

 Fig 3.1.12.1 BALL PEEN HAMMER

Function: The ball peen hammer is useful for many tasks, such as striking punches
and chisel. It also has a round end for shaping metal parts, such as sheet metal or rivet
heads. COST: 150 - 250INR
B. SLEDGE HAMMER:

Fig 3.1.12.2 SLEDGE HAMMER

Function: The sledge hammer is a heavy duty hammer. It has a very large head.
COST: 1500INR

C. SOFT FACED HAMMER:

Fig 3.1.12.3 SOFT FACED HAMMER

Function: A soft faced hammer is a designed to offer force without damaging surface.
They also reduce the force transmitted back to the arm or hand of the user. COST:
250INR

GUJARAT TECHNOLOGICAL UNIVERSITY [29] SSASIT, SURAT

 13.CUP WRENCH:

Fig 3.1.13 CUP WRENCH

Function: The Cup wrench oil filter remove &
tight easily. COST: 2500INR

14.OIL DRAINER:

Fig 3.1.14 OIL DRAINER

Function: It collect waste oil from car. COST:
42,000INR

3.2 SPECIAL PURPOSE

TOOL

1. VERNIER SCALE:

GUJARAT TECHNOLOGICAL UNIVERSITY [30] SSASIT, SURAT

 Fig 3.2.1 VERNIER SCALE
Function: A vernier caliper use for disk checking, brake pad size & use for tire thread
depth. COST: 400INR

2. BORE GAUGE:

Fig 3.2.2 BORE GAUGE Function: A bore gauge is tool used

to measure the inside

of a bore. COST: 5500INR

3. PISTON RING COMPRESSOR:

Fig 3.2.3 PISTON RING
COMPRESSOR

Function: A piston ring compressor is a tool used

to compress the piston ring onto a piston in
order to fit the piston inside of the cylinder wall.
Cost: 800 INR

4. GEARBOX STAND:

Fig 3.2.4 GEARBOX STAND

Function: To carry gearbox. Cost: 5000 – 9000 INR

GUJARAT TECHNOLOGICAL UNIVERSITY [31] SSASIT, SURAT

 3.3 MAJOR EQUIPMENT

1. HYDRAULIC CAR LIFT:

Fig 3.3.1 HYDRAULIC CAR LIFT

Lifting Capacity 2.0 Ton

Max. Lifting Height mm
Min. Lifting Height mm
Distance Between Column mm
Lifting Time s
Lowering Time s
Oil Pressure Mpa
Overall Width mm
Overall Height mm
Motor Power 2.2 kw
Motor Voltage 415v , 3PH
Weight Kg
LIFT INFORMATION:

GUJARAT TECHNOLOGICAL UNIVERSITY [32] SSASIT, SURAT

 TABLE 3.3.1 HYDRAULIC CAR LIFT
How to use:

Turn your machine OFF then ON, which resets the balancer. The machine wake up
using standard clip on wheel weight location.

Then swing arm at the lifting point so that the pad of the wing arm comes to the lifting
point. Then check once more again that the swing arm pad has arrived all side at the
lifting point.

After donning that, go to the place where the power switch is located and press the
button till the distance from the tyre to the ground is 6 inch. Lift swing arm
automatically come to a safety lock. Then we can work on car.

After that all work is done, to get the car down safety lock lever and pull down lever
at same time to pulled down. The car tyre touch the ground so pulled down lever and
safety lock lever can leave it.

Then remove swing arm under the car and you can drive the car.

COST: 2,00,000INR

2. WHEEL BALANCING:

GUJARAT TECHNOLOGICAL UNIVERSITY [33] SSASIT, SURAT

 Fig 3.3.2 WHEEL BALANCING
Function: Wheel Balancing is a tune up for your wheel tyre set. When all area of the
wheel tire unit are as equal in weight as possible, the tyre will roll smoothly.
This helps to tyre longest life. Balancing also contribute to bride comfort. Imbalanced
tyre will wobble or hold up and down, which cause vibration.

SPECIFIC USE:
Turn your machine OFF then ON, which resets the balancer. The machine wake up
using standard clip on wheel weight location.

Remove stones/ rock or other debris from tread and any weight already attached to the
wheel. During this process you also should remove any mud or dirt on the wheel and
make sure that the mounting surface of the wheel is completely clean.

Mount a wheel assembly on a balancing shaft then spin the wheels if you use dynamic
balancing, wait until the tires settle into a stationary position if you use static
balancing.

Lower the hood. The wheel will spin and unbalance are measured and displayed. The
corrective weight amount appear in the weight display window for inboard and
outboard weight location.

Raise the hood after the tyre stops rotating. Make sure that the wheel has stopped
before raising the hood.

Attach inboard corrective weight. Attach specified weight amount at the top dead
center on the inside flange of the wheel.

Press NEXT, causing bar will blink.

Attach outboard corrective weight. Attach specified weight amount at the top dead
center on the outside flange of the wheel.

Lower the hood to respin the wheel and check balance. The weight reading should

now be 0.00. Now wheel remove from balancing shaft.

COST: 3,00,000INR

GUJARAT TECHNOLOGICAL UNIVERSITY [34] SSASIT, SURAT

 3. WHEEL ALIGNMENT:

Fig 3.3.3 WHEEL ALIGNMENT

Function: Wheel alignment consists of adjusting the angles of the wheels so that they
are perpendicular to the ground and parallel to each other. The purpose of these
adjustments is maximum tire life and a vehicle that tracks straight and true when
driving along a straight and level road.

COST: 3,50,000INR

GUJARAT TECHNOLOGICAL UNIVERSITY [35] SSASIT, SURAT

 CHAPTER 04: FLOW OF WORK

=-
Fig 4.1 FLOW OF WORK

GUJARAT TECHNOLOGICAL UNIVERSITY [36] SSASIT, SURAT

 Fig 4.2 AUTO BODY REPAIR PROCESS MAP

CHAPTER 05: ROLES & RESPONSIBILITY OF MANPOWER

5.1 GENERAL MANAGER

General Manager is the overall business head of dealership and responsible for
business growth, expansion, manpower planning, infrastructure development and
customer satisfaction.
Detailed activities are as given below:
• Plan, organize, lead and control total service management operations.
• Set and monitor service performance targets for workshop.
• Monitor customer satisfaction reports and trends.
• Share customer satisfaction information with service personnel for counter
measure planning and monitoring.
• Conduct weekly/monthly meetings for analysis of key performance indicators
(productivity, efficiency, labour earnings, parts consumed in workshop, etc.)
and expenses.

GUJARAT TECHNOLOGICAL UNIVERSITY [37] SSASIT, SURAT

 • Provide monthly performance results to the CEO.
• Monitor complaint resolution and analyzes complaints generation, counter
measure for improvement.
• Plan and recruit workshop manpower. Plan and implement good HR practices
like appraisal system, incentives, recognition schemes.
• Set marketing strategies to target new business and fleet companies. Plan and
execute special offers to enhance business.
• Ensure efficient service operations through providing adequate tools and
equipment, and smooth workflow procedures.
• Maintain service and parts coordination through regular meetings with Spare
Parts Manager.
• Conduct analysis of market competitors, market conditions and campaign
effectiveness.
• Promote customers satisfaction by planning effective appointment system,
service reminder systems, loyalty programs like AMCS, etc.
• Monitor service shop environmental and safety issues.
• Ensure Maruti Suzuki infrastructure standards are maintained.

5.2 HELP DESK COORDINATOR

Help desk coordinator is responsible for attending and guiding the customer visiting
the workshop for handover and delivery of their vehicle.
Detailed activities are as given below:
• Vehicle allocation to Service Advisors in the morning.
• Identify Customer requirement (Repeat job, Complaint/MVEW etc.) in
the morning & coordinate to expedite the process on priority.
• Guide the customer (new customer) regarding the service process
• Coordinate to provide transportation (Shuttle Service) facility to the
customer
• Coordinate with Service Advisors for smooth vehicle delivery.

GUJARAT TECHNOLOGICAL UNIVERSITY [38] SSASIT, SURAT

 5.3 ASSISTANT WORKS MANAGER
Assistant Works Manager is responsible for implementation of workshop process
including vehicles work control, reduction in waiting time in workshop, tools
equipment working condition and workshop staff productivity.
Detailed activities are as given below:
• Complete activities of floor - vehicles movement control.
• Daily reporting of delays in workshop, productivity, enhancement
• Accountable for delay delivery, carryover, productivity, allocation,
pending vehicle.
• Attending repeat jobs and complaint vehicles.
• Countermeasure implementation for reduction in repeat jobs.

Customer Care Manager:

CCM is responsible for customer care at workshop. CCM is responsible for
implementation of customer care activities such as Fast-Service follow-up, complaints
tracking and updating of complaints, etc.
Detailed activities are as given below:
• Ensure effective PSF is done by CCES as per script to achieve high
contact percentage.
• Front office upkeep, customer receiving area cleanliness.
• Ensure feedback from customers through cards and actions on
dissatisfied customers. Complaint’s resolution compliance as per system.
• Organizing customer meets.

5.4 SERVICE ADVISOR

Service Advisors are responsible for capturing customers demand and completion of
all demanded repairs up to the customer satisfaction.

GUJARAT TECHNOLOGICAL UNIVERSITY [39] SSASIT, SURAT

 Detailed activities are as given below:
• Ensure speedy maintenance and repair of vehicles through clear
identification of customer's needs and accurate demanded repair
understanding by using probing sheet.
• Ensure vehicle cleanliness through use of vehicle protection materials
(seat covers, floor mats etc.).
• Provide clear cost estimates and keep customers informed of work
progress
• Monitor the work progress and keep customers informed of changes in
cost and completion times.
• Ensure clear and precise service invoices that shows parts, labour and
lubricant charges.
• Take all necessary actions to resolve customer complaints as per
promised time.
• Ensure all customer vehicles are clean and ready according to the
promised delivery time.
• Conduct Post-Service Follow-up after 3 days of vehicles delivery to
check customer satisfaction.

5.5 FLOOR COORDINATOR

Floor coordinator work as supervisor coordination role for workshop service bays,
ensuring job completion of vehicles in time.
Detailed activities are as given below:
• Ensure that all items on the repair order are completed in a timely
manner
• Keep Works Manager and Service Advisors constantly informed of
delays and additional work load.

GUJARAT TECHNOLOGICAL UNIVERSITY [40] SSASIT, SURAT

 • Ensure all Technicians are appropriately dressed and ready for work on
time.
• Ensure availability of all technical bulletins and manuals.
• Ensure tools and equipment’s are in proper working condition with each
Mechanic.
• Maintain a clean and orderly workshop floor and safe working
condition.
• Ensure all required special service tools are arranged when required.
• Ensure delivery of spare parts in the bay by Spare Parts Runner
• Monitor, record and identify the causes of vehicle carryover.
• Ensure final inspection is done as per standards.
• Ensure that seat covers & fender covers are fitted in all vehicles.

5.6 DEALER TECHNICAL LEADER (DTL)

DTL is responsible for providing diagnostic support to the workshop in resolving critical
vehicle problems.
Detailed activities are as given below:
• To monitor the pending vehicles due for diagnosis.
• To escalate the diagnostic issues through technical help desk and close
the tickets within the timeline as specified.
• To ensure analysis of revisit due to poor diagnosis.
• To coordinate for recall activities and complete the same within the
stipulated time.

5.7 Technical Advisor

Technical Advisors are responsible for quality of work through diagnosis of customer
reported problems and verification of rectification of complaints. Technical Advisor
shall support Service Advisors and Floor Coordinators Detailed activities are as given
below:

GUJARAT TECHNOLOGICAL UNIVERSITY [41] SSASIT, SURAT

 • Road test for critical complaints along with the customer (e.g.,
Problems related to engine, transmission, suspension brakes etc. and
repeat problems).
• Proper diagnosis of problems reported by the customers and support
mechanic for resolution of complaints.
• Updating of road test register.
• Sharing of critical complaints diagnosis process with workshop staff.
• Refer Service Manual, Bulletins and Circulars for diagnosis of
problems.

5.8 TECHNICIANS
Technicians are responsible for completing all the demanded repairs requested by
customer right the first time within promised time.
Detailed activities are as given below:
• Use all protective equipment’s to maintain the cleanliness of the
customer vehicle (seat covers, floor mats, fender covers).
• Maintain an adequate inventory of hand tools to meet the service and
repair requirements.
• Ensure all customer requests on the job card are completed, first time
right.
• Complete all repair orders within the time allotted.
• Identify and inform the Floor Coordinator of any additional repair
• Treat customer vehicles and belongings with care.
• Note clear and accurate details of all work complete on job cards
• Maintain a clean and professional appearance at all times.
• Keep work area clean and tidy at all times.

GUJARAT TECHNOLOGICAL UNIVERSITY [42] SSASIT, SURAT

 5.9 CUSTOMER CARE EXECUTIVE
CCE is responsible for conducting Post-Service Follow-up with customers for taking
service feedback in polite structured manner.
Detailed activities are as given below:
• Follow-up with customers as per scripts and scheduled time.
• Coordinate with Service Advisors for technical queries of customers
• Maintaining the dissatisfied customers records and date of attending.
Control of appointments of dissatisfied customers.
• Daily report of PSF (summary).
• Calling customer for customer meets.
• Customer complaints reports/record keeping.

5.10 CUSTOMER CARE SUPPORT EXECUTIVE

CCSE shall assist CCM for data management, file management and report generation
for analysis.

GUJARAT TECHNOLOGICAL UNIVERSITY [43] SSASIT, SURAT

Detailed activities are as given below
• Consolidation of data.
• Report generation
• Assist CCM for monthly reviews.
• Consolidation of pending complaint.
GUJARAT TECHNOLOGICAL UNIVERSITY [46] SSASIT, SURAT
CHAPTER 06: VEHICAL TRACKING FOR DELIVERY AT
PROMISED TIME

Following are the steps for delivery tracking:

STEP 1: Transfer job card to workshop floor.

STEP 2: Allocate job to Technician in Vehicle Allocation Control Board (VACB).

STEP 3: Receive job from VACB.

STEP 4: Job start entry into Vehicle Tracking System (Service Start).

STEP 5: Inform Floor Coordinator/Service Advisor about job stoppage during

service/repairs.

STEP 6: Track vehicle repair status in the shop floor.

STEP 7: Track vehicle repair status in the shop floor.

STEP 8: Confirm completion of vehicle demanded repairs.

STEP 9: Enter job end into Vehicle Tracking System (after completion of repairs).

STEP 10: Vehicle road test.

STEP 11: Vehicle handover for final inspection.

STEP 12: Final inspection.

STEP 13: Final washing.

STEP 14: Close the job card and generate pre-invoice.

STEP 15: Delivery preparation.

 STEP 16: Vehicle delivery.

GUJARAT TECHNOLOGICAL UNIVERSITY [45] SSASIT, SURAT

CHAPTER 07: TYPES OF MAINTENANCE IN VEHICLE

7.1 PREVENTIVE MAINTENANCE:-

It is a daily maintenance (cleaning, inspection, oiling and re-tightening), design to

retain the healthy condition of equipment and prevent failure through the prevention of
deterioration, periodic inspection or equipment condition diagnosis, to measure
deterioration. It is further divided into periodic maintenance and predictive
maintenance. Just like human life is extended by preventive medicine, the equipment
service life can be prolonged by doing preventive maintenance.

➢ Types of preventive maintenance: - 1. Periodic maintenance

2. Predictive maintenance

1. PERIODIC MAINTENANCE:
Time based maintenance consists of periodically inspecting, servicing and cleaning
equipment and replacing parts to prevent sudden failure and process problems.

2. PREDECTIVE MAINTENANCE:
This is a method in which the service life of important part is predicted based on
inspection or diagnosis, in order to use the parts to the limit of their service life.
Compared to periodic based maintenance, predictive maintenance is condition-based
maintenance. It manages trend values, by measuring and analyzing data about
deterioration and employs a surveillance system, designed to monitor conditions
through an on-line system.

SSASIT, SURAT

GUJARAT TECHNOLOGICAL UNIVERSITY [48] SSASIT, SURAT

7.2 FREE SERVICE

Maruti Suzuki Comet Motors Provide 3 Free Service.

1. 1st FREE SERVICE :

1st free service provide at 1500KM.

• Check Air filter
• Check Ac filter
• Check oil level
• Check all light
• Check coolant condition
• Check battery condition
• Check brake pad condition & brake disc condition
• Check All Nut fitting

2. 2nd FREE SERVICE :

2nd free service provide at 5000KM.

• Change Air filter
• Change Ac filter
• Change oil & oil filter
• Check Coolant level
• Greasing
• Check all light
• Check battery condition
• Check all parts are proper fitting

2. 3rd FREE SERVICE :

3RD free service provide at 10,000 KM.

• Check Air filter condition
• Check Ac filter condition
• Check oil level
• Check all light
• Check battery condition
• Check Coolant level
• Check tyre condition
 • Check brake pad and brake disk condition
• Wheel alignment
• Wheel balancing

GUJARAT TECHNOLOGICAL UNIVERSITY [47]

7.3 PAID SERVICE

• CHANGE OIL & OIL FILTER

• Check Air filter
• Check Ac filter
• Check Tyre pressure & depth condition
• Check spark plug
• Check brake fluid
• Check steering link
• Check lower arm & bushing
• Check brake disk
• Check brake pad
• Check Ac cooling
• Check coolant condition
• Check dickey lifter
• Check power window switch
• Check wiper blade
• Check all light working properly
• Service throttle body
• Clean cowl panel
• Check fuel filter
• Check fuel tank cap

➢ Here’s an overview of what is typically involved in a car service:\

1. Oil change 2. Oil Filter Change 3. Coolant check and top ups 4. Brakes Fluid
Change 5. Caliper greasing 6. Tire Inspection and Rotation 7. Air Filter Change 8.
A.C filter replacement 9. Spark plug replacement 10. Battery water check 11.
Lighting and electronics check 12. Visual inspection 13. Test Drive

GUJARAT TECHNOLOGICAL UNIVERSITY [50] SSASIT, SURAT

 1. Oil Change
• Replacing the engine oil help keep the engine lubricated and functioning
smoothly.
• Regular Oil Change Increase Life Spane Of Engine.
• Normally Engine Oil Change At 10,000 KM Or One Year.

2. Oil Filter Change

• Oil Filter Change When Engine Oil Change.
• Oil Filter Collect all metal parts of engine and keep engine clean.

Fig 7.3.2 Oil Filter

3. Break fluid change
• After 30,000 to 40,000 km break its color change and turn into red.
• So old fluid is removed and new fluid has to be added, normally DOT3 or
DOT4 fluid are used.

GUJARAT TECHNOLOGICAL UNIVERSITY [51] SSASIT, SURAT

 Fig 7.3.3 Break Fluid DOT 3
4. Coolant check and top ups
• Checking and topping up essential fluids such as coolant and windshield washer
fluid.

5. Caliper greasing
• Proper caliper greasing helps ensure smooth and even brake operation,
prevents uneven pad wear, and maintains optimal braking performance.
• Caliper slide pins are the components that allow the caliper to move
smoothly and evenly when the brakes are applied.
• These pins need to be properly lubricated to prevent sticking, binding, or
uneven pressure on the brake pads. If the slide pins become corroded or dry, it can
lead to brake noise, uneven wear, and reduced braking efficiency.

6. Tire Inspection and Rotation

• inspecting tire tread depth and condition.
• Rotating tires to promote even wear and extend tire life.

7. Air Filter clean

• Air filter need to clean at 10,000 km or One year.

8. A.C filter replacement

• A.C filter need to clean at 10,000 km or One year.

GUJARAT TECHNOLOGICAL UNIVERSITY [52] SSASIT, SURAT

 Fig 7.3.8 A.C. Filter
9. Spark plug replacement
• Replacing spark plugs to maintain proper combustion and engine efficiency.
• It needs to be change at 40000km in patrol cars and at 20000 in CNG cars

10. Battery water check

• Battery water needs to check at every service and top-up.
11. Lighting and electronics check
• Checking the functionality of headlights, taillights, turn signals, and dashboard
warning lights.
• Ensuring proper electrical system operation.

12. Visual inspection

• Conducting a thorough visual inspection of the vehicle's exterior and interior for
any signs of wear, damage, or issues.

13. Test Drive

• Conducting a test drive to assess the vehicle's overall performance, handling, and
any unusual noises.

GUJARAT TECHNOLOGICAL UNIVERSITY [53] SSASIT, SURAT

 CHAPTER 08: MAIN COMPONENTS OF A CAR & THEIR
FUNCTION

8.1 THE BASICS

There are many parts that make up your vehicle, and each one plays a vital role in its
operation. It’s thanks to the performance of these components that you’re able to get
from place to place. While you may understand these parts are important, you might
not understand how they operate.
Knowing how things work under the hood can help make you an educated consumer,
which can come in handy when your vehicle needs repairs. Being able to have a
conversation with an automotive technician means you’ll know exactly what they’re
doing and why.
We’re not saying you have to have a master technician’s knowledge! But we are here
to help you identify basic car parts to assist with troubleshooting problems and to
help make you a more responsible car owner. Continue reading to find out more
about different car components.
There are a many things to cover when it comes to car parts and what they do, but
starting with the basics is key. Having a foundational knowledge of the major
components in your vehicle will serve you well in the long run.

8.2 ENGINE
It makes sense to start with the most important part under the hood of a vehicle,
which is the engine. Most modern vehicles run on internal combustion engines,
which generate energy by igniting a mixture of air and fuel that moves pistons, which
in turn move the car. There are also electric motors, which store energy in
rechargeable batteries. Vehicles with electric engines accelerate faster than those with
fuel-powered engines. Whether your car has a traditional or electric engine, it can’t
run without it.

GUJARAT TECHNOLOGICAL UNIVERSITY [54] SSASIT, SURAT

 Fig 8.2.1 ENGINE PARTS

Fig 8.2.2 SWIFT CAR ENGINE

GUJARAT TECHNOLOGICAL UNIVERSITY [55] SSASIT, SURAT

 8.3 Battery
A car battery is rechargeable device that provides electrical energy to power the
various electrical components and systems in a vehicle. The battery plays a critical
role in starting the engine and providing power to the car electrical system when the
engine is not running. Most car batteries are lead acid batteries, which consists of
lead plates submerged in an electrolyte solution of sulfuric acid and water. When the
battery is charged, a chemical reaction occurs between the lead and sulfuric acid,
producing electrical energy. When the battery is discharged the chemical reaction is
reversed, and the battery needs to be recharged.
Car batteries can vary in size and capacity, depending on the vehicle’s electrical
needs and the manufacture’s specification. Generally car batteries are designed to last
for several years, but their lifespan can be affected by factors such as extreme
temperature, frequent shorts trips and leaving the light on when the engine is not
running.
The device which is used to test the battery is known as battery tester.

Fig 8.3.1 Battery Fig 8.3.2 Battery Tester

GUJARAT TECHNOLOGICAL UNIVERSITY [56] SSASIT, SURAT

 8.4 CLUTCH PLATE ASSEMBLY
The clutch plate is the driving member of the clutch and is gripped between the
flywheel and the pressure plate. It is mounted on the clutch shaft through the splines.
When it is gripped, rotates the clutch shaft and the power is transmitted from the
engine to the transmission through the clutch. No matter the application, the function
and purpose of a clutch is to transmit torque from a rotating driving motor to a
transmission. Clutches require a mode of actuation in order to break the transmission
of torque. Clutches can be categorized into two main classifications: friction clutches
and fluid flywheel. Friction clutches rely on the principle of friction.
The clutch plate assembly consist of several parts, including the clutch disc, pressure
plate, release bearing and flywheel. The clutch disc is as flat, circular plate that sits
between the engine and transmission and is sandwiched between the pressure plate
and flywheel. The pressure plate, which is bolted to the flywheel, applies pressure to
the clutch disc, allowing it to engage and disengage the engine power.
The clutch plate assembly can be wear over time due to normal use and can also be
damaged by aggressive driving, high horse power modification, or improper clutch
use and it will need to be replaced.

GUJARAT TECHNOLOGICAL UNIVERSITY [57] SSASIT, SURAT

 Fig 8.4.1 Clutch Plate Fig 8.4.2 Clutch Assembly

8.5 BRAKES
Brakes are vital components of car’s safety system. The brakes in car are used to
slow down and stop your vehicle, as well as keep it in place when parked. They work
by converting kinetic energy into heat energy. There are different types of brakes
used in cars including:
1. Disc Brakes: Disc brakes are a common type of brake used in cars. They
consist of a rotor attached to the wheel hub and a caliper that contains brake
pads. These brakes use a hydraulic system to press brake pads against a disc
attached to the wheel. This creates frictions that slows down or stop the car.
Disc brakes offer several advantages over drum brakes, including better heat
dissipation, less brake fade, and more consistent stopping power. They are also
easier to maintain and repair than drum brakes. However, disc brakes do have
some potential drawbacks.
They can be more expensive to manufacture and replace than drum brakes, and
they can be more prone to squeaking or squealing noises. Additionally, they
can be more vulnerable to rust and corrosion if the car is not driven frequently
or is operated in harsh environments. Overall, disc brakes are a reliable and
effective braking system for cars and are used in the majority of modern
vehicles on the road today.

Fig 8.5.1 Disc Brake

GUJARAT TECHNOLOGICAL UNIVERSITY [58] SSASIT, SURAT

 2. Drum Brakes: These car use brake shoes that press against the inside of a
drum attached to the inside of a drum attached to the wheel .this creates
friction that slows down or stop the car. Drum brakes are a type of braking
system commonly found on older cars and some newer models. They consist
of a drum-shaped housing, typically made of cast iron, which is attached to the
wheel hub and rotates with the wheel. Inside the drum, there are two brake
shoes that are lined with friction material, typically made of organic or semi-
metallic material, which are forced against the inner surface of the drum to
slow down or stop the vehicle.
When the brake pedal is pressed, hydraulic pressure is applied to the brake
shoes, causing them to expand and press against the drum. The resulting
friction generates heat, which causes the brake shoes and drum to wear over
time. One advantage of drum brakes is that they are generally less expensive
and easier to maintain than disc brakes. However, they tend to be less effective
at dissipating heat, which can cause them to fade and lose stopping power
under heavy use. In addition, they can be more prone to brake pull or uneven
wear, which can affect the vehicle's handling and require more frequent
maintenance.
Overall, drum brakes are still used in some applications, particularly on the rear
wheels of smaller cars and trucks.

Fig 8.5.2 Drum Brake

GUJARAT TECHNOLOGICAL UNIVERSITY [59] SSASIT, SURAT

 8.6 SHOCK ABSORBER
A shock absorber is a suspension component that is designed to absorb and dampen
the impact of bumps, potholes, and other irregularities on the road surface. The
suspension system in car helps to stabilize while you drive. This way, you get a
smooth ride and you’re not bouncing around every time you hit a bump or dip.
There are many parts that make up the suspension, and shock absorbers play an
important role in this system. The shock absorbers’ main function is to ensure your
tires are contacting the road at all times.
Proper maintenance of shock absorber is important to ensure that they continue to
function correctly over time, shock absorber can wear out or become damaged,
leading to reduced performance and increased wear on other suspension.
This allows you to drive the vehicle safely and efficiently. They also help the brakes
do their job by always keeping the tires in contact with the road surface. Worn shocks
can result in vibrations when you’re driving and uneven tire wear, among other
issues.

GUJARAT TECHNOLOGICAL UNIVERSITY [60] SSASIT, SURAT

 Fig 8.6 Shock Absorber
8.7 EXHAUST GAS RECIRCULATION

A vehicle emissions control concept used in both gasoline and diesel engines.
The EGR valve which works differently depending on how old the car is and
whether it uses gasoline or diesel fuel is a key component to a car's exhaust
system and engine health. EGR systems recycle a portion of the exhaust gas back
into the combustion chamber, where it combines with fresh intake air. This
lowers the amount of Oxygen and increases the water vapour content to the
combustion mixture which reduces the peak combustion temperature
It won't affect the health of your engine, but it will hurt the environment. The role
of your EGR valve is to reduce the number of toxic NOx gases in the air, so if it
isn't working quite right, more toxic gases will be released into the air. At higher
loads, increased rate of EGR reduces NOx to a great extent but deteriorates
performance and emissions.

GUJARAT TECHNOLOGICAL UNIVERSITY [61] SSASIT, SURAT

 Critical sensors are an exhaust manifold pressure sensor (P2), an intake manifold
pressure sensor (P2) and a speed density estimate of total mass flow. Exhaust and
intake manifold pressures are used to control the EGR valve.

Fig 8.7 Egr Valve

8.8 SPARK PLUG

Spark plugs are the spark of electricity that ignites the combustion needed to start
your vehicle. Spark plugs emit a bolt of electricity across a small gap igniting the fuel
and air mixture that puts the pistons in motion and gets your vehicle up and running.
Without properly working spark plugs, your car more than likely wouldn't be able to
run at all. In this blog, our auto repair experts will take a closer look at why your
spark plugs are so important, including what they do and how to know when it may
be time to replace them.
A spark plug is used as a source of ignition, as the "spark" in its name implies. It is a
key component of internal combustion engines and its primary function is to ignite a
fuel/air mixture within the combustion chamber of a car, or other system. Spark plugs
are used to get the engine into motion and the vehicle moving. These small
components deliver an arc of electric charge that ignites the fuel and air that is mixed

GUJARAT TECHNOLOGICAL UNIVERSITY [62] SSASIT, SURAT

 in the cylinder head. The resultant explosion sets the piston in motion within the
cylinder.

Fig 8.8 Spark Plug

8.9 AIR FILTER AND FUEL FILTER

1. AIR FILTER: The air filter prevents any insects, dust, particles, sand or debris
reaching the engine and ensures a good mixture of air and fuel to support
performance.

An air filter might not seem an important component to regularly check and
change, but they are essential in maintaining your car's performance. The filter
prevents small particles from entering the engine and causing potentially
expensive damage.
It may also remove odors and gaseous pollutants. And it acts as a silencer for
the carburetion system. Air filter enhances fuel economy, increases engine life,

GUJARAT TECHNOLOGICAL UNIVERSITY [63] SSASIT, SURAT

 lowers emissions and boosts acceleration. Impressive for a component that is
frequently overlooked.

Fig 8.9.1 Air Filter

2. FUEL FILTER: The fuel filter helps remove contaminants from your car
engine's fuel that can accumulate over time. Clean fuel filter is important because
if the oil were left unfiltered for a period of time, it could become saturated with
tiny, hard particles that can wear surfaces in your engine.

The heating oil filter prevents dirt and moisture from seeping into the fuel
system. It keeps dirt, water and oil from getting into the fuel nozzle and pump
and gumming these parts up so they can't work properly.
A clogged fuel filter will starve the engine of the extra fuel needed when
quickly accelerating. Depending on the extent of the fuel restriction caused by
a dirty filter, an engine may also shake or stutter at different speeds.

GUJARAT TECHNOLOGICAL UNIVERSITY [64] SSASIT, SURAT

 The fuel filter screens dirt and rust particles from the fuel, keeping them from
entering the engine and causing damage. If debris enters the engine - even tiny
rust particles - it causes unnecessary wear and tear on the engine components
and wreaks havoc on the overall system.

Fig 8.9.2 Diesel Fuel Filter Fig 8.9.3 Petrol Fuel Filter

8.10 GEAR BOX

A Gear Box is often called a transmission. Gear boxes simply refer to a set of gears
and their casing, most commonly found in automobiles. Since most motor vehicle
engines have high operating and idling speeds, transmissions allow the machinery to
operate efficiently and even aid in slowing and shutting down machinery
The purpose of a gearbox is to increase or reduce speed. As a result, torque output
will be the inverse of the speed function.
If the enclosed drive is a speed reducer (speed output is less than speed input), the
torque output will increase; if the drive increases speed, the torque output will

GUJARAT TECHNOLOGICAL UNIVERSITY [65] SSASIT, SURAT

 decrease. A gearbox is a mechanical component used to change the speed (RPM) and
increase the motor's torque in layman's terms. Now regarding the location of the
gearbox in the car, it is connected to the motor from one end. The shaft of the motor
is associated with the gearbox via gears.

Fig 8.10.1 Gear Box Fig 8.10.2 Gear

Fig 8.10.3 Reverse Gear

GUJARAT TECHNOLOGICAL UNIVERSITY [66] SSASIT, SURAT

 8
.11 RADIATOR
A car radiator is an essential component of a car's cooling system, which helps to
regulate the engine's temperature. It is typically made of aluminum or copper and
consists of a network of small tubes and fins. The radiator is usually mounted at the
front of the car, behind the grille, where it can receive fresh air as the car moves
forward.
The radiator is typically connected to the engine by hoses, and it also has a cap that
allows for the addition or removal of coolant. A thermostat controls the flow of
coolant to ensure that the engine stays at the proper temperature range. A
malfunctioning radiator can lead to engine overheating, which can cause serious
damage to the engine. Therefore, it's essential to ensure that the radiator is
functioning correctly and is properly maintained.
The radiator ensures your engine doesn’t overheat, increasing performance and
longevity. You can help maintain your radiator by checking coolant levels at least
twice a year.

GUJARAT TECHNOLOGICAL UNIVERSITY [67] SSASIT, SURAT

 8
Fig 8.11 Radiator

.11.1 Coolant

Coolant, also known as antifreeze, is a liquid that circulates through a car's

engine to help regulate its temperature. It is a crucial component in any vehicle's
cooling system and helps prevent the engine from overheating and sustaining
damage. When a car's engine is running, it generates a lot of heat, and the
coolant absorbs some of that heat as it passes through the engine block and
heads. The coolant then flows to the radiator, where it is cooled by air passing
over the radiator's fins, before returning to the engine to repeat the cycle.
It's essential to use the right type of coolant in your car and to keep it at the
appropriate level. The coolant should be mixed with water according to the
manufacturer's instructions, typically in a 50/50 ratio. This mixture helps prevent
the coolant from freezing in cold weather and boiling in hot weather.
If the coolant level is low, it can cause the engine to overheat, leading to
potential damage. Over time, coolant can become contaminated or break down,
which can also lead to engine damage. Therefore, it's essential to have your
cooling system inspected regularly and to have the coolant flushed and replaced
according to the manufacturer's recommended schedule.

Fig 8.11.1 (b) Coolant Storage

GUJARAT TECHNOLOGICAL UNIVERSITY [68] SSASIT, SURAT

 8
Fig 8.11.1 (a) Coolant

.11.2 Water Pump

The water pump assembly is responsible for circulating coolant through the engine to
regulate its temperature. It typically includes the pump itself, a pulley, a drive belt,
and a thermostat. The pump assembly in a car generally refers to the various pumps
that are used to transfer fluids or gases throughout the vehicle. There are several types
of pump assemblies found in cars, including fuel pumps, water pumps, oil pumps,
and air pumps.
Each pump assembly has a specific function and is critical to the proper operation of
the car. Regular maintenance, such as changing fluids and replacing worn parts, is
necessary to ensure that the pump assemblies continue to function correctly and
reliably.
It's important to keep the water pump assembly in good working order to prevent
overheating and other engine damage. Regular maintenance, such as checking
coolant levels and changing the coolant according to the manufacturer's
recommended schedule, is crucial. Additionally, if the water pump assembly shows
signs of wear or damage, it should be replaced promptly to prevent engine damage.

GUJARAT TECHNOLOGICAL UNIVERSITY [69] SSASIT, SURAT

 8

Fig 8.11.2 Water Pump

GUJARAT TECHNOLOGICAL UNIVERSITY [70] SSASIT, SURAT

 8.12 TRANSMISSION

The transmission, otherwise known as the car’s gearbox, is what takes the engine’s
power and transfers it to the wheels through various components. Manual
transmissions are controlled by the driver using a gear lever or shifter inside the
vehicle, while automatics do not require any driver input to change gears. Whether
it’s a manual or an automatic, there’s a lot going on inside a transmission.
Changing the transmission fluid at the manufacturer’s recommended intervals will
help you maintain this important component and prevent it from wearing out. A car
transmission is one of the most important components of a vehicle. It’s what moves
the power from the engine to the wheels.
Transmission in a car is a mechanical component that helps to transfer power from
the engine to the wheels. The transmission system includes various gears and other
components that work together to change the speed and torque of the wheels
according to the driving conditions.
The transmission system plays a crucial role in the overall performance and
efficiency of a car. Proper maintenance, including regular fluid changes, can help to
extend the life of the transmission and prevent costly repairs. There are two main
types of transmission systems in cars:
1. Manual: A manual transmission, also known as a "stick shift" or "standard"
transmission, is a type of transmission system used in some cars. In a manual
transmission, the driver uses a clutch pedal and a shift lever to manually change
gears. The clutch pedal is used to disengage the engine from the transmission,
allowing the driver to shift gears. In an automatic transmission, the gears are
changed automatically based on the vehicle's speed and load.

Manual transmissions typically have five or six gears, although some sports cars
and high-performance vehicles may have more. The gears are arranged in a

GUJARAT TECHNOLOGICAL UNIVERSITY [71] SSASIT, SURAT

 specific sequence, with first gear providing the most torque and the lowest
speed, and each subsequent gear providing higher speeds but less torque.

Driving a car with a manual transmission requires more skill and coordination
than driving an automatic transmission. However, some drivers prefer manual
transmissions because they provide greater control over the vehicle and can be
more engaging to drive. Additionally, manual transmissions often offer better
fuel efficiency and lower maintenance costs compared to automatic
transmissions.
Manual transmissions typically have five or six gears, although some sports cars
and high-performance vehicles may have more. The gears are arranged in a
specific sequence, with first gear providing the most torque and the lowest
speed, and each subsequent gear providing higher speeds but less torque.

Fig 8.12.1 Manual Gear Shifter

GUJARAT TECHNOLOGICAL UNIVERSITY [72] SSASIT, SURAT

 2. Automatic transmission: An automatic transmission is a type of transmission
used in automobiles that automatically changes gear ratios as the vehicle moves,
without requiring the driver to manually shift gears. The transmission consists
of several components, including a torque converter, planetary gears, clutches,
and bands. The torque converter is a fluid coupling that transmits power from
the engine to the transmission, while the planetary gears and clutches work
together to change the gear ratios.
When the driver selects a gear, the transmission's electronic control unit (ECU)
determines the best gear ratio based on factors such as vehicle speed, engine
speed, and throttle position. The ECU then engages the appropriate clutches and
bands to shift the gears automatically.
One advantage of an automatic transmission is that it is easier to drive than a
manual transmission, as the driver does not have to worry about shifting gears.
Additionally, some automatic transmissions have a "sport" mode that allows the
driver to manually select gears for more responsive driving.
However, automatic transmissions can be less fuel-efficient than manual
Transmissions, and they can be more expensive to repair if something goes
wrong.

Fig 8.12.2 Automatic Controller Fig 8.12.3 Automatic Shifter

GUJARAT TECHNOLOGICAL UNIVERSITY [73] SSASIT, SURAT

 8.13 TURBO CHARGER
A turbocharger is a device that increases the power output of an internal combustion
engine by forcing more air into the engine than would normally be possible through
natural aspiration. The turbocharger achieves this by compressing the air intake using
a turbine driven by the exhaust gases.
The turbocharger consists of two main components: a compressor and a turbine, both
of which are connected by a shaft. The turbine is driven by the exhaust gases, which
exit the engine and flow through the turbine blades, causing the turbine to spin. The
spinning turbine then drives the compressor, which compresses the air intake and
delivers it to the engine's combustion chambers. The compressed air allows more fuel
to be burned in the engine, increasing its power output.
Turbo charging is commonly used in high-performance engines, such as those found
in sports cars, as well as in diesel engines, where it helps to increase efficiency. One
of the advantages of a turbocharger is that it can significantly increase an engine's
power output without requiring any additional displacement or major engine
modifications. However, turbocharged engines can be more complex and expensive
to maintain, and they can also generate more heat, which can lead to reliability issues
if not managed properly.

GUJARAT TECHNOLOGICAL UNIVERSITY [74] SSASIT, SURAT

 Fig 8.13 Turbo Charger
8.14 OIL PUMP
An oil pump is a vital component in an internal combustion engine, responsible for
circulating engine oil throughout the engine to lubricate its moving parts and prevent
excessive wear and tear. The oil pump is usually driven by the engine's crankshaft or
timing belt, and is typically located in the oil pan at the bottom of the engine. The
pump consists of a rotor and a housing, with the rotor spinning inside the housing to
create a vacuum that draws oil in from the oil pan and then pressurizes it, forcing it
through the engine's oil passages and bearings.
The oil pump is designed to maintain a consistent and sufficient flow of oil
throughout the engine, regardless of the engine's speed or operating conditions. A
properly functioning oil pump is essential to prevent engine damage due to
inadequate lubrication. Over time, oil pumps can become worn or damaged, leading
to reduced oil pressure and insufficient lubrication.
Symptoms of a failing oil pump can include low oil pressure warning lights, unusual
engine noises, and increased engine wear. If a failing oil pump is not replaced, it can
lead to catastrophic engine failure. Regular oil changes and proper maintenance can
help prolong the life of an oil pump, but eventually, all pumps will need to be
replaced. When replacing an oil pump, it is important to use a high-quality
replacement part and to ensure that it is installed correctly to prevent further engine
damage.

GUJARAT TECHNOLOGICAL UNIVERSITY [75] SSASIT, SURAT

 Fig 8.14 Oil Pump
CHAPTER 09: MARUTI ON ROAD SERVICE

Objective:
To provide the required assistance to Customer for breakdown vehicle through Maruti
On-road Service (MOS).

STEP -1: Provide emergency breakdown assistance to our customers In case of

vehicle breakdown, workshop must provide on-road service for repair of vehicles
through Maruti On-road Service (MOS).
• MOS vehicle should be available in the workshops. MOS team should
carry the following items on a visit to attend a breakdown vehicle
• All necessary tools and equipment’s as per Circular, apart from vehicle
and manpower.
• Required stationary like MOS log book/job slip/feedback card, etc.

• Install GPS/GPRS based vehicle tracking system in MOS vehicle, for

better Monitoring of MOS operations and reduce the cost of operation.
Responsibility: - General Manager/ Works Manager

STEP -2: Methodology

GUJARAT TECHNOLOGICAL UNIVERSITY [76] SSASIT, SURAT

 • In case of breakdown, customer calls MSIL's toll free number 1800 102
1800
• Call center transfer customer location details, vehicle details and
breakdown to the workshop. Reach the breakdown location and attend the
vehicle.

STEP- 3: Communication
• Provide proper response to the customer

• Interact courteously with the customer.

• Respond immediately on receiving the breakdown call.
• Put best efforts to help the customer to get out of the emergency situation
by coordinating with the workshop & local towing facilities.
Responsibility: - MOS Technician

STEP 4: Maintain records of vehicles attended through MOS

Responsibility: - MOS Technician

GUJARAT TECHNOLOGICAL UNIVERSITY [77] SSASIT, SURAT

 CHAPTER 10: MAJOR PROBLEM & SOLUTION

In MARUTI SUZUKI COMET MOTORS most of car Repair done by

replacing the faulty parts. First advice take test drive and then tell the
machine which part has to be replaced.

10.1 Clean the EGR valve

Problem: - Pick up is low.
Reason: - EGR valve chock up only carbon.
Solution: - EGR valve & Intake manifold clean.

Fig 10.1 EGR Valve

10.2 Change the clutch plate.
Problem: During gear change driver feel jerk.
Reason: frication plate line got erase.
Solution: change the frication plate and pressure plate.

GUJARAT TECHNOLOGICAL UNIVERSITY [78] SSASIT, SURAT

 Fig 10.2 Clutch Plate

10.3 Change Gear the Steering Power Rack & Pinion.

Problem: during the take the turn or drive on bed road or speed breaker unwanted
noise generates.
Reason: Steering Power Rack & Pinion is damage.
Solution: change the Steering Power Rack &

Fig 10.3 Steering Power Rack & amp: Pinion

10.4 Change the Stabilizing Road.

Problem: during the take the turn unwanted noise generates.
Reasons: Stabilizing Road`s rubber cut.
Solution: Change the Stabilizing Road.

GUJARAT TECHNOLOGICAL UNIVERSITY [79] SSASIT, SURAT

 Fig 10.4 Stabilizing Road

10.5 Starting motor Repair.

Problem: car did not start by self.
Reason: short circuit in starting motor
Solution: Repair or rewind the starting motor

Fig 10.5 Starting Motor

10.6 Change the brake pad
Problem: while applying the brake unwanted noise generate.
Reason: brake pad frication material is removed.
Solution: change the brake pad.

GUJARAT TECHNOLOGICAL UNIVERSITY [80] SSASIT, SURAT

 Fig 10.6 Break Pad
10.7 Change back suspension
Problem: On bed road or speed breaker back part of car touch the road
Reason: Back suspension is damage
Solution: change the back suspension

Fig 10.7 Back Suspension

10.8 Front Suspension change

Problem: front part of car touch the road during driving on bead road or speed
breaker.
Reasons: Front suspension is damage.

GUJARAT TECHNOLOGICAL UNIVERSITY [81] SSASIT, SURAT

 Solution: change the front suspension.

Fig 10.8 Front Suspension

CONCLUSION

The completion of this internship proved to be essential in my training, both

personally and professionally. I managed to connect most of the theoretical
knowledge that I acquired as a student of this course and were of tremendous help
throughout these week internship.
I realized that teamwork is fundamental for everything to work well, as well as
coordination and know how to manage the work in general and of each. Able to
manage small internal conflicts makes the company to be functional in its entire
entirety. Internship in this company gave me the experience of how an industry
works and how things work in a big organization.
I also learnt that in company, you will not be told to do everything. You have to take
the responsibility yourself, ask the senior members of the company if you want to
excel in your role. In my view, vehicle servicing sector is going to be of outmost
importance as the number of vehicles on the roads are only going to increase.

GUJARAT TECHNOLOGICAL UNIVERSITY [82] SSASIT, SURAT