SHRI VAISHNAV INSTITUTE OF TECHNOLOGY

AND SCIENCE

INDUSTRIAL TRAINING REPORT

AT PATEL MOTORS, INDORE

SUBMITTED TO: SUBMITTED BY:

MR. VIMAL DIXIT
 ACKNOWLEDGEMET
I express to my sincere to all officers at “PATEL MOTORS INDORE” who
have assisted me during my training period. I should be particularly thanks to
MR. PRATIK who helped in joining and completing the training.
I extended mu special thanks to him for their guidance & co-operation
throughout my training for completion of this project report. Their guidance has
helped me a lot understanding other process of service in workshop.

I also thank to all instructors for their kind that they have paid to me. That
project is result of co-operation of all the members and staff of “PATEL
MOTORS INDORE”.

CONTENTS
HISTORY OF MARUTI SUZUKI
LOGO OF MARUTI SUZUKI
CAR NAMES & SPECIFICATIONS OF MARUTI SUZUKI
TOOLS, GAUGES & EQUIPMENT USED IN WORKSHOP
DESCRIPTION OF FOUR STROKE IN PETROL AND DIESEL ENGINE

ENGINE
DIESEL ENGINE AND PETROL ENGINE

MAIN PARTS OF ENGINE

TRANSMISSION SYSTEM
CLUTCH
GEAR BOX
PROPELLER SHAFT
DIFFERENTIAL

COOLING SYSTEM
RADIATOR
THERMOSTAT
WATER PUMP
FAN

FUEL SYSTEM IN DIESEL ENGINE

FUEL TANK
FUEL FEED PUMP
FUEL INJECTION PUMP
INJECTOR

FUEL SYSTEM IN PETROL ENGINE

FUEL TANK
FUEL FILTER
FUEL PUMP
CARBURETTOR
SPARK PLUG

MISCHELLANEOUS
STEERING SYSTEM
BRAKE SYSTEM
CHASSIS

PARTS NAME AND ITS FUNCTION

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 .

CAR NAMES & MODEL CODES

 OF
MARUTI SUZUKI
Sr. NAMES CODES

No.

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 A5E

15. SWIFT 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

23. ZEN ESTILO RK

GRAND VITARA XL-7

 TECHNICAL SPECIFICATION OF
GRAND VITARA XL-7

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

SECURITY
Air bags: All air bags are standard

CAPACITIES
Seating capacity: 7 person
Fuel tank capacity: 66 liter

Fuel economy
Mileage Highway: 10.2 km/liter
Mileage city: 7 km/liter
Mileage overall: 7.6 km/liter

BREAKE
Front: disc
Rear: drum

FUEL SUPPLY
Ignition and fuel system: Electronic MPFI

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
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

TRANSMISSION

Transmission type: Manual

Gear box: 5 speed

STEERING

Steering type: Power

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

BREAKE

Front: Disc
Rear: Drum

FUEL

Millage city: 11.5 km/liter

Millage highway: 16.2 km/liter
Fuel type: Petrol
Fuel tank capacity: 43 liters

Dimension
Length: 3695 mm
Width: 1690 mm
Height: 1530 mm
Wheelbase: 2390 mm
Ground clearance: 170 mm

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

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 inject 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
remain equal to the atmospheric pressure.
2. Fuel filter:- To prevent possible blockage by dust particles, the fuel is
filtered by installing a fuel filter or strainer at the inlet to the float chamber. In a
fuel supply system, there are three fuel filters. One fuel filter is mounted at the
inlet of the fuel storage tank. The second fuel filter is fitted in the fuel pump and
the third is placed in between the fuel pump and 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 eachcylinder, 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 fuelsupplied
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
remain 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