SEETHI SAHIB MEMORIAL POLYTECHNIC COLLEGE TIRUR-5

IN-PLANT TRAINING REPORT ON

MARINA MOTORSPVT.LTD.
Authorized dealers of Tata Motors & Fiat Pantheerankavu, Kozhikode

DEPARTMENT OF AUTOMOBILE ENGINEERING 2010-2013

SUBMITTED BY:

SYAM K. JAYAN ROLL NO.: 56 REG. NO.: 10050179 S.S.M.P.T.C.

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ACKNOWLEDGEMENT

First of all, I would like to praise the God for blessing me to complete this project successfully. I am deeply incepted to Mr. S.N.M. Basil (Head of dept. in Automobile engineering, S.S.M. Polytechnic College, Tirur) for providing me the opportunity to undergo In-plant training in such a prestigious institution. I extend my unexplainable gratitude towards all of the staff and technicians of MARINA MOTORS who gave me a lot of information and support. They consider me as a member among them. I give my heart full thanks to my friends & family whom offered me all kind of support for me.

SYAM K. JAYAN

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CONTENTS
INTRODUCTION ABOUT TATA MOTORS ABOUT MARINA MOTORS REPORT WORKSHOP PROCESS WORKSHOP LAYOUT ORGANIZATION STRUCTURE DETAILS OF VEHICLES MANUFACTURED BY TATA MOTORS DETAILS OF VEHICLES MANUFACTURED BY FIAT PROCEDURE FOR RECEIVING & DELIVERING THE VEHICLE JOB CARD (model) SPECIAL TOOLS USED COMMON WORKS DONE IN WORKSHOP FIRST FREE SERVICE SECOND FREE SERVICE THIRD FREE SERVICE CONCLUSION 4 5 6 7 8 9 12 13 32 36 38 39 40 43 44 46 48

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INTRODUCTION

This in-plant training is a connection with the syllabus of 5th semester Diploma in Automobile Engineering within duration of 2 weeks. It aims at making students familiar with automobile servicing in direct exposure. Marina Motors Pvt.Ltd., dealers of commercial vehicles like Nano, Indica, Sumo, Safari, Punto, Linea etc. of Pantheerankavu, Kozhikode proved to be the correct platform for such training.

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ABOUT TATA MOTORS

Tata Motors Limited is a multinational automotive corporation headquartered in Mumbai, India. Part of the Tata group, it was formerly known as TELCO (TATA Engineering & Locomotive Company). Tata Motors is Indias largest automobile company, with consolidated revenues of USD 20 billion in 2009-10. It is the leader in commercial vehicles and third dealer in passenger vehicles. Tata Motors has products in the compact, midsized cars and utility vehicle segments. The company is the worlds 4th largest truck manufacturer and employs 25000 workers. Since first rolled out in 1954, Tata Motors has produced and sold over 4 million vehicles in India. Established in 1945, when the company began manufacturing locomotives, the company manufactured its first commercial vehicle in 1954 in collaboration with Daimler-Benz AG, which ended in 1969. Tata Motors is a dual-listed company traded on both the Bombay Stock Exchange, as well as on the Newyork Stock Exchange. Tata Motors in 2005 was ranked among the top 10 corporations in India with an annual revenue exceeding INR 320 billion in 2010. Tata Motors surpassed Reliance to win the coveted title of Indias most valuable brand in an annual survey conducted by Brand Finance and The Economic Times. Tata Motors has automobile manufacturing & assembling plants in Jamshedpur, Patnagar, Lucknow, Ahmadabad, Sanand, Dharwad and Pune in India, as well as in Argentina, South Africa and Thailand.

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ABOUT MARINA MOTORS

(LOCATION : Bypass road, Pantheerankavu, Kozhikode)

Marina Motors (P) Ltd. was established in 2010 to operate the automobile dealership of Tata Motors and Fiat with a 3s facility at Kozhikode and now, it is one of the best authorized dealer & service centre in Kozhikode. They promote very good relationship with the customers; all of the company staff are very hard working, for that it become the no.1 dealer in Kerala. Tata Motors is a famous Indian brand & Fiat is an Italian company. The main models available in Marina Motors are: TATA: NANO INDICA DLS INDICA EV2 INDICA VISTA INDIGO E-CS INDIGO MANZA VENTURE SUMO GOLD SUMO GRANDE SAFARI DICOR ARIA FIAT: PUNTO LINEA

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REPORT
The two weeks in-plant training at Marina motors (P) Ltd. was one of the good experiences to me. It helped to improve my practical knowledge. The total dealership is split into Sales section, Spare parts and Service section. The main service section is under the service reception, body shop, service & maintenance. There I understood the main working of a dealership showroom and also about the procedure of vehicle servicing. The first 3-4 days, I studied about the company, their working procedure, about vehicles, their parts & accessories. Next we went to the service & maintenance section. That section mainly handles normal servicing such that free servicing and paid servicing. From there, we studied about the inspection of vehicle condition & parts change or adjustment of components. The main works done on this section are inspection of rear brake, front disc brake, brake pedal, fuel filter changing, oil filter changing & A/C system works.

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WORKSHOP PROCESS
The two important elements involved in workshop process are: i. ii. ITEM ACTION
INSPECTION JOB CARD REPAIR FINAL CONTROL

The following procedures are followed when a vehicle enters for service: 1. CUSTOMER RECEIVING Service advisor receives the customer. Collecting all details about the vehicle, a job card is prepared. 2. PROBLEM IDENTIFICATION Service advisor enquires about the complaints of the vehicle. The complaints are entered into the job card. 3. VEHICLE INVENTORY Vehicle body is checked for any scratch or dents. The extra accessories are noted and entered into the job card. Fuel level is also checked and entered into the job card. 4. PREORDER The information obtained from the above three are entered into the preorder sheets of the job card and signed by customer. 5. WORKSHOP ORDER Vehicle enters into the bay concerning complaints. Technicians check the vehicle and shares inference with the service advisor

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WORKSHOP LAYOUT
BASEMENT

1. Water Service 2. Staff Room 3. Tools Room 4. Lubricants 5. Lift 6. Warranty Room 7. Engine Room 8. Quick Service Area 9. Wheel Alignment & Balancing 10. Office (Service) 11. Car Interior Works 12. Parking Area

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GROUND FLOOR

1. 2. 3. 4. 5. 6.

Electrical Equipments Rest Room Spare Parts Lift Parking Area Sales Section

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FIRST FLOOR (BODY SHOP)

1. 2. 3. 4. 5. 6.

Paint Booth Tools & Equipments Rest Room Body Spare Parts Lift Parking Area

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ORGANISATION STRUCTURE

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DETAILS OF VEHICLES MANUFACTURED BY TATA MOTORS

TATA NANO

ENGINE
Engine Type/Model Power (PS@rpm) Torque (Nm@rpm) No of Cylinders (cylinder) 624 cc, 2 cylinder, MPFI 38PS @5500rpm 51Nm @4000rpm 2

TRANSMISSION
Transmission Type Gears/Speeds Manual 4 Gears

SUSPENSIONS
Front Suspension Rear Suspension Independent, Lower Wishbone, McPherson Strut with gas filled dampers and anti-roll bar Independent, Semi Trailing arm with coil spring & gas filled shock absorbers Standard 4

STEERING
Power Assisted Minimum Turning Radius (meter)

BRAKES
Front brake Rear brake 180 mm drum brake 180 mm drum brake

OTHERS
Mileage City (km/liter) Seating Capacity (person) Fuel Tank Capacity (liter) Maximum Speed 20.3 4 15 105 km/hr

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COMFORT
Air Conditioning with Heater Front Power Windows Gear Shift Console (with Provision for 12V socket) Head lamp leveling (Integral feature through innovative suspension design) Rear Seat Folding

SAFETY
Central Locking Center High Mount Stop Lamp Laminated Windshield Booster assisted brakes Intrusion beam (Integral feature through innovative door system design) Radial Tubeless tyres Front & Rear Seat Belts

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INDICA EV2

ENGINE
Engine Type/Model Displacement cc Power (PS@rpm) Torque (Nm@rpm) No of Cylinders Common Rail CR4 1396 70PS @4000rpm 140Nm @1800rpm 4

TRANSMISSION
Transmission Type Gears/Speeds Manual 5Gears

SUSPENSIONS
Front Suspension Rear Suspension Independent, Wish Bone type, with McPherson strut, Antiroll Bar Independent, Semi trailing arm with coil spring mounted on hydraulic shock absorbers Power assisted rack and pinion-hydraulic Standard

STEERING
Steering Type Power Assisted

BRAKES
Front brakes Rear brakes Disc brakes Drum brakes

OTHERS
Mileage City (km/liter) Seating Capacity (person) Fuel Tank Capacity (liter) 25 5 37

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COMFORT
2 way adjustable front seat headrests 60:40 flip-flop rear seat Air Conditioning System Central Locking Power Steering & Power Windows (Front & Rear) Remote Release of Fuel Lid Latch & Tailgate Latch

SAFETY
3 point ELR seat belts for front seats and rear side passengers Child Safety locks on Rear Doors Collapsible Steering Column Front Fog Lamps High Mounted Stop Lamp Provision for Rear Fog Lamps

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INDICA VISTA

ENGINE
Engine Type/Model Displacement cc Power (PS@rpm) Torque (Nm@rpm) Cylinder Configuration 4 Cylinder, Common Rail SDE 1248 75PS @4000rpm 190Nm @1750rpm In-line

TRANSMISSION
Transmission Type Gears/Speeds Manual 5 Gears

SUSPENSIONS
Front Suspension Rear Suspension Independent, Lower Wishbone, Mcpherson Strut with coil spring Semi Independent, Twist Beam with coil Spring and Shock Absorber Power Assisted Rack & Pinion- Hydraulic Standard

STEERING
Steering Type Power Assisted

BRAKES
Front Brakes Rear Brakes Disc Brakes Drum Brakes

OTHERS
Seating Capacity (person) Fuel Tank Capacity (liter) Wheel Type 5 37 Alloy Wheels

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COMFORT
Hydraulic Power Steering HVAC Tilt-Adjustable Steering Height-Adjustable Driver's Seat 60:40 Flip & Fold on Rear Seat Light Intensity Adjustment for Instrument Cluster Power Outlet Front and Rear Remote release levers for fuel lid, tail gated and front bonnet Power Windows (Front & Rear) Lumbar Support on Co-driver Seat (Fixed) Lumbar Support on Co-driver Seat (2-way adjustable) Intelligent Rear Wiper

SAFETY
Central locking & Child Safety Lock on Rear Doors Engine Immobilizer ABS with EBD Dual front SRS airbags Front ELR seat belts with pre-tensioner and load limiter Remote controlled key less entry Warning for driver door open Warning for seat-belt not fastened Collapsible Steering

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INDIGO E-CS

ENGINE
Engine Type/Model Displacement cc Power (PS@rpm) Torque (Nm@rpm) Cylinder Configuration No of Cylinders Valves per Cylinder (value) Common Rail CR4, 16-valve, DOHC 1396 70PS @4000rpm 140Nm @1800rpm In-line 4 4

TRANSMISSION
Transmission Type Gears/Speeds Manual 5 gears

SUSPENSIONS
Steering Type Power Assisted Minimum Turning Radius (meter) Rack and Pinion Type with Collapsible Steering Column Standard 5

BRAKES
Front Brakes Rear Brakes Ventilated Disc Drum

OTHERS
Seating Capacity (person) Fuel Tank Capacity (liter) 5 42

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COMFORT
Power Steering & Power windows:Front and Rear Heater Height Adjustable for Driver's Seat Rear Seat Centre Armrest Auto Drive Assist (for CR4 Engine Only) Clutch to start (for Petrol Cars only) Remote Levers for Fuel Lid/Trunk Lid (Mechanical) Air-conditioning

SAFETY
Child Safety Locks on Rear Doors Keyless Entry ABS High Mounted Stop Lamp Warning for driver Door Open/Sear Belt Not Fastened Collapsible Steering

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INDIGO MANZA

ENGINE
Engine Type/Model Displacement cc Power (PS@rpm) Torque (Nm@rpm) Cylinder Configuration No of Cylinders Valves per Cylinder (value) 4 Cylinder, Common Rail, Diesel 1248 90PS @4000rpm 200Nm @1750rpm In-line 4 4

TRANSMISSION
Transmission Type Gears/Speeds Manual 5 Gears Independent, Lower Wishbone, Mcpherson Strut with coil spring Semi-independent, Twist Beam with Coil Springs and Hydraulic Shock Absorbers Power Assisted Rack & Pinion- Hydraulic, Tilt-adjustable Standard 5.1

SUSPENSIONS
Front Suspension Rear Suspension

STEERING
Steering Type Power Assisted Minimum Turning Radius (meter)

BRAKES
Front Brakes Rear Brakes Ventilated Disc Drum

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OTHERS
Seating Capacity (person) Fuel Tank Capacity (liter) Wheel Type 5 44 Alloy Wheels

COMFORT
HVAC with electric controls One Shot power window Down movement - Driver side Lumbar support for front seats - 2-Way adjustable Rear seat with 100% foldable back Adjustable rear seat head restraint Cup holder on Rear seat Center Armrest Boot Lamp 2 DIN Music system with AM/FM/MP3/CD playback & audio equalizer Audio Controls on steering wheel Blue 5 Bluetooth connectivity Infrared remote for Audio Power windows operation up to 30 seconds after ignition 'Off' Reverse Parking Sensors (Audio) Auxiliary Input Four Speakers (Front door:2, Parcel Shelf:2) 2 Tweeters USB (MP3/WMA) playback

SAFETY
Collapsible Steering High mount LED stop lamp Child lock on rear doors Immobilizer Central locking Remote controlled keyless entry Warning buzzer for driver door open with key/headlamp/ tail lamp On Warning for seat belt not fastened ABS Dual front SRS Airbags Retractor, pre-tensioners & load limiters on front seat belts

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VENTURE

ENGINE
Engine Type/Model Displacement cc Power (PS@rpm) Torque (Nm@rpm) No of Cylinders Fuel Type 475 IDI 1405 71PS @4500rpm 135Nm @2500rpm 4 Diesel

TRANSMISSION
Transmission Type Gears/Speeds Manual 5 Gears

SUSPENSIONS
Front Suspension Rear Suspension Independent Suspension, strut type Coil Spring type with 3 link

STEERING
Steering Type Power Assisted Minimum Turning Radius (meter) Power Steering Standard 4.5

OTHERS
Seating Capacity (person) Fuel Tank Capacity (liter) 8 33

COMFORT
Air-conditioning Central locking Power steering & Power windows

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SUMO GOLD

ENGINE
Engine Type/Model Displacement cc Power (PS@rpm) Torque (Nm@rpm) No of Cylinders Fuel Type 3.0 CR4 Engine 2956 85PS @3000rpm 250Nm @1600rpm 4 Diesel

TRANSMISSION
Transmission Type Gears/Speeds Manual 5 Gears

SUSPENSIONS
Front Suspension Double Wishbone type with coil springs & antiroll bar

BRAKES
Front Brakes Rear Brakes Disc Drum

OTHERS
Seating Capacity (person) Fuel Tank Capacity (liter) Minimum Turning Radius (meter) Wheel Type 7 65 5 Aluminium Wheels

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COMFORT
Central Locking Keyless Entry Internally Adjusted ORVM Floor Console with Hand Brake Remote Fuel Lid Opener Door Trim - Fabric Stylized side Footsteps Rear Wiper & Defogger Anti-glare rear view mirror Cup holders on the glove box lid Tinted Glasses Door Ajar Warning HVAC with Demist Power Assisted Steering Soft Feel Steering Wheel 12V Outlet on Central Console

SAFETY
Front & Rear Fog lamps Side intrusion beam on all doors Seat belt warning Rear High Mounted Stop Lamp Engine Immobilizer

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SUMO GRANDE

ENGINE
Engine Type/Model Displacement cc Power (PS@rpm) Torque (Nm@rpm) No of Cylinders 2.2 16 Valve DOHC DiCOR 2179 120PS @4000rpm 250Nm @1500rpm 4

TRANSMISSION
Transmission Type Gears/Speeds Manual 5Gears

SUSPENSIONS
Front Suspension Rear Suspension Independent , Wishbone with Coil Springs Parabolic Leaf Spring

STEERING
Steering Type Power Assisted Minimum Turning Radius (meter) Power Steering, Tiltable & collapsible Standard 5.2

BRAKES
Front Brakes Rear Brakes Ventilated Disc brake with Twin Pot caliper Drum brake, Auto Adjusting Type

OTHERS
Seating Capacity (person) Fuel Tank Capacity (liter) 7 65

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COMFORT
Power steering HVAC (Heating, ventilation and AC) Dual Integrated Roof AC with roof mounted Ducts Power windows (All four) Key less Entry 3 Position Lumbar support for Front seats Arm rest on Driver and Co-driver Seats Foldable Hand Rest On Middle Row Seats Assist Arrangement Flat folding and Completely Tumbling and removable 3rd Row seats 12 V Power Point for front & middle Row Rear Wash & Wiper Electrical Rear Glass Demister Puddle Lamps on All doors In-car illumination: Front Roof lamp, Middle row lamp, Illuminated Ignition Key slot Adjustable light intensity on Instrument panel Magazine Pockets in the Door Pads & Bottle holder Express Down Drivers Power Window Remote fuel flap operation

SAFETY
Side Impact Bars Tiltable & Collapsible Steering Column Engine Immobilizer (ECU Controlled) Fire Resistant Seat Fabric Scotch Guard treated Stain Proof Seats Clear Lens Front Fog lamps Central Locking Door Open Warning Drivers Seat belt Unfastened Warning

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SAFARI DiCOR

ENGINE
Engine Type/Model Displacement cc Power (PS@rpm) Torque (Nm@rpm) No of Cylinders Cylinder Configuration Fuel System 2.2 L 16-Valve DOHC VTT DiCOR 2179 140PS @4000rpm 320Nm @1700rpm 4 In-line CRDi

TRANSMISSION
Transmission Type Gears/Speeds Manual 5 Gears

SUSPENSIONS
Front Suspension Rear Suspension Independent Double Wishbone with Torsion bar 5 link Suspension with coil springs

STEERING
Steering Type Minimum Turning Radius (meter) Rack & Pinion with Power Assist 6

BRAKES
Front Brakes Rear Brakes Ventilated Disc brake with Twin Pot caliper Drum brake, Auto Adjusting Type

OTHERS
Seating Capacity (person) Fuel Tank Capacity (liter) 7 65

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COMFORT
HVAC (Heating, ventilation and AC) Roof Mounted Rear A/C Power windows at front & rear with Express down feature Electrically adjustable side Rearview mirrors Electrically operated remote fuel flap Key less Entry with Parking lot car-locator On board entertainment - DVD MP3 Player Headrest mounted LCD screens on Front Seats Arm rest on Driver and Co-driver side 60:40 split and completely folding Middle row seats 12 V Power Point for front & middle Row Rear Wash & Wiper Digital Trip meter & Tachometer Digital Outside Temperature indicator Storage net in Luggage compartment area 4 Wheel Drive - Electrical Shift On Fly Mechanism Electrical Rear Glass Demister

SAFETY
Dual Airbags (for Driver & Co-driver) Anti Lock Braking System (ABS) and Electronic Brake-Force Distribution (EBD) Side Impact Bars Crumple Zones Tiltable & Collapsible Steering Column Tubeless tyres Engine Immobilizer Reverse Guide System (Rear view Camera for Reversing with LCD Display in IRVM) Motorized Head Lamps adjustment Central Locking & Child Safety Lock Antiglare Rear View Mirror Head Lamps ON Key-Out warning

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ARIA

ENGINE
Engine Type/Model Displacement cc Power (PS@rpm) Torque (Nm@rpm) No of Cylinders Cylinder Configuration 2.2 L DICOR Compliant with Dual Mass Flywheel 2179 140PS @4000rpm 320Nm @1700rpm 4 In-line

TRANSMISSION
Transmission Type Gears/Speeds Manual 5 Gears

SUSPENSIONS
Front Suspension Rear Suspension Independent Double wish bone with coil spring 5 Link Suspension with coil spring

STEERING
Steering Type Minimum Turning Radius (meter) Rack & Pinion with Power assistance 5.6

BRAKES
Front Brakes Rear Brakes Ventilated Disc Brake with Twin Pot caliper Disc Brakes

OTHERS
Seating Capacity (person) Fuel Tank Capacity (liter) Wheel Type Mileage Highway (km/liter) 7 60 Alloy Wheels 14.7

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COMFORT
2 DIN music system with CD/MP3 player and 6 speakers Satellite navigation system Audio & phone switches on steering USB and Aux in part on center console Tata blue connect (5 phones pairing capable) Driver info system Reverse guide camera Dual AC with automatic climate control Height adjusted driver seats Rear wash, wiper & demister Key less entry with remote integrated key Cruise control Flat floor fold 2nd & 3rd row seats with sliding 2nd row Roof storage bins & Goggle cases Follow me home (Approach light) Rain sensing wiper & darkness sensing head light Glove box chiller

SAFETY
Air bags driver & passenger Side & curtain air bags (6 Air Bags) Electronic stability program & traction control system Anti-locking braking system with electronic brake forced distribution Hydroform chassis frame & reinforced body construction Engine immobilizer with perimetric alarm system All disc brakes

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DETAILS OF VEHICLES MANUFACTURED BY FIAT

PUNTO

ENGINE
Engine Type/Model Displacement cc Power (PS@rpm) Torque (Nm@rpm) No of Cylinders Cylinder Configuration Multijet Diesel 1248 93PS @4000rpm 209Nm @2000rpm 4 In-line

TRANSMISSION
Transmission Type Gears/Speeds Manual 5 Gears

SUSPENSIONS
Front Suspension Independent Wheel, Suspension with McPherson Struts, Helical Springs, Double Acting Telescopic Dampers with Stabilizer Bar Torsion Beam, Helical Springs, and Double Acting Telescopic Dampers Power Assisted Standard 5

Rear Suspension

STEERING
Steering Type Power Assisted Minimum Turning Radius (meter)

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BRAKES
Front Brakes Rear Brakes Ventilated Disc Drum

OTHERS
Seating Capacity (person) Fuel Tank Capacity (liter) Wheel Type 5 45 Alloy Wheels

COMFORT
Power Steering Tilt steering Clutch Foot Rest Central Door Locking Desmodronic Foldable Key Automatic Door Lock Rear Window (Wiper + Washer) Rear Defogger with Timer Leather wrapped Steering Wheel and Gear shift knob HVAC Speed sensitive volume adjuster for audio Remote Keyless Entry Rear foot level AC vents Power Window with 'Delay' & 'Auto Down' Function Electronically Adjustable Outside Rear View Mirrors Automatic Climate Control

SAFETY
Fire Prevention system Immobilizer with rolling code Height Adjustable Front Seat Belts Anti-lock Braking System (ABS) With EBD 3-point ELR seats belts with pretensioners & lode limiter Dual stage airbags (front) with early crash sensors Rear seat metal back Passenger Airbag deactivation Door Open Indicator

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LINEA

ENGINE
Engine Type/Model Displacement cc Power (PS@rpm) Torque (Nm@rpm) No of Cylinders Advanced Multijet (DOHC) 1248 93PS @4000rpm 209Nm @2000rpm 4

TRANSMISSION
Transmission Type Gears/Speeds Manual 5 Gears

SUSPENSIONS
Front Suspension Rear Suspension Independent Wheel, Helical Coil Springs, Double Acting Telescopic Dampers and Stabilizer Bar Torsion Beam, Helical Coil Springs, Double Acting Telescopic Dampers and Stabilizer Bar

STEERING
Steering Type Power Assisted Minimum Turning Radius (meter) Power Assisted Standard 5.5

BRAKES
Front Brakes Rear Brakes Ventilated Disc Drum

OTHERS
Seating Capacity (person) Fuel Tank Capacity (liter) 5 45

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COMFORT
Tilt Steering Driver Seat height Adjust Electrically Adjustable Outside Rear View Mirrors Remote tailgate open Electric Double Folding Rear Back Seat Internal roof light with dimming effect Night Panel in front roof lights Rear Roof Light Vanity Mirror Both side Illuminated Automatic Climate Control Integrated CD / MP3 & FM Player Steering Mounted Audio, Blue & Me Controls External Temperature display Blue & Me with USB port Desmodronic Foldable Key with boot release Collapsible Rear Sun Curtain All 4 One Touch Auto Down Power Windows Remote Keyless Entry Rear AC Vents (Foot & Knee Level) Rear Armrest With Glove Box & Cup Holders

SAFETY
Fire Prevention System (FPS) Anti-lock Braking System (ABS) with EBD Immobilizer With Rolling code (FCS) Central Door Locking Double Crank Prevention System Exact Door Open Indicators Automatic Door Lock Dual Stage Front Driver & Passenger Airbag 3- Point ELR Seat Belts with Pretensioners & Load Limiters Driver Seat Belt Warning Light (with buzzer)

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PROCEDURE FOR RECEIVING & DELIVERING THE VEHICLE

1. RECEIVING THE VEHICLE Firstly the customer is received by the service advisor. The problems are reported and give possible causes. Explain about the problem and net amount expecting. 2. INITIAL TEST DRIVE Both service advisor and technician go for test drive in different road conditions. Check the problems. Give possible reasons for the trouble. The service advisor adds the problem into the job card and gives to the supervisor. The supervisor gives the job card to the technician. 3. INSPECTION The vehicle is brought into the bay by the technician. After the engine is cooled, inspect the problems and troubleshoot as per the Tata service procedure. The technician works as per suggestions and clear the problems. The supervisor enters the details of replaced parts and the works done into the sheet. 4. FINAL TEST DRIVE & WASHING The test drive is conducted by the service advisor and the supervisor. The vehicle is brought into the washing bay. The vehicle is washed neatly with vehicle shampoo by the service man.

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5. BILLING The service advisor prepares the bill of works and changed parts as per the details sheet given by the supervisor. It is checked by the works manager and transferred to the customer. 6. DELIVERING OF THE VEHICLE The vehicle is delivered to the customer. A rating card is given for knowing his satisfaction and for suggestions and complaints.

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MARINA MOTORS (INDIA) PVT.LTD.

Bypass road, Pantheerankavu, Calicut

TATA MOTORS

JOB CARD (example)

Job card No. JC-MarinM-CP1-1213001852
Customer arrival time at WS gate:

Job Card Open Date/Time: 5/22/2012 03:44:04 PM

Attended by Service Advisor at: 5/22/2012 15:42:59

S.R.No. SR-MarinM/CP1-1213002171
Estimated Delivery Date & Time: (After Revision) Estimated Cost (After Revision): 0

SR Type: First Free Service

Actual Delivery Date & Time: Actual Cost (Labour+Parts):

Vehicle Reg No: KL 18 F 2058

Current KMs: 1277

Customer Details
Mr. JINEESH 6/199(253), ERANJIKKAL, VADAKARA BEACH P.O. KOZHIKODE-673103 KL India Ph. No.-9249729283

Vehicle Details :
Model : Indica Vista ; Variant : Indica Vista LX QJT Colour : PORCLN_WHITE JDP Customer : Y Sold By : MARINA MOTORS (INDIA) PVT.LTD. Sold On : 14-May-12 Extd Warranty : N Chassis No. : MAT611425CPB11861 Operation Type : Personal Engine Number : 100A2000-0209928 Last Attended At : MARINA MOTORS (INDIA) On : 18-May-12 Road Test Done : Y / N

Last RC SR Number
Job Code Compl Code Description

Last RC SR Date
Diagnosis Root Cause

Last PSF CSI Data

Overall RQ WQ Time Cost Courtesy Waiting time JCE

Service Advisor : NOUFAL A.

Customer Complaint Details Compl Code SSC Scheduled Service Total Operation Time : Repeat Y/N N Top RC Job Code

Labour Rate Per hour :

Repair Details First Free Service Std Parts Labour hrs Estim. Estim. 2.5 0

Total Scheduling Time : Estimate Delivery Bill : Rs.0.00

Estimate Delivery Date & Time : 5/23/2012 06:44:00 PM

Description : Revision in the job : Add on Jobs : 1) Customers Signature : Time : 2)

All delivers against payment by cash or card only. Please fill in the correct timings above in order to help us serve you faster. Thank you !

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SPECIAL TOOLS USED

VEHICLE ERROR DETECTOR It is used to detect the errors occurred in vehicle by using software. It is done by plugging the laptop into the ECU. SLIDING HAMMER It is used to remove parts such as bearings, wheel drums, etc. OIL EXTRACTOR It is a vacuum pump used to extract oil from vehicle without opening the drain plug. PNEUMATIC GUN It is used to tighten and loosen nuts and bolts by using compressed air. TORQUE WRENCH It is used to tighten and loosen nuts and bolts at specified torque according to manufacturers specification. AUTOMATIC TYRE INFLATER It is used to inflate tyres of vehicles according to the required pressures. It can clamped to the valve of the tyre instead of holding the cable all the time.

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COMMON WORKS DONE IN THE WORKSHOP

PROCEDURE FOR REPLACING THE ENGINE OIL AND COOLANT Bring the vehicle to the bay. Drain out the engine oil. Collect oil in tray and remove the oil filter with a filter wrench. Replace a new filter and fit the drain plug. Fill the engine with new oil. Drain out the radiator coolant. Fill the radiator with new genuine coolant. Start the engine and watch the performance.

PROCEDURE FOR ADJUSTING BRAKES Bring the vehicle to the bay. Jack up the vehicle to a small height. Remove all wheels using box spanner or pneumatic gun. Loosen the rear axle nuts and remove the brake drums Clean the brake drums using compressed air. Check the condition of brake shoes, working of wheel cylinder and replace it if necessary. Clean the brake drum and brake shoes properly. Adjust the brakes by turning the adjusting screw. Refit the brake drum; tight the axle nut with specified torque. In the case of front brakes (Disc brakes), remove the caliper body by removing the two bolts. Loosen the brake pad and check for any damages. Clean the parts; check condition of brake pads and replace it if necessary. Refit all parts of disc brakes. Refit the tyres and check the brakes.

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PROCEDURE FOR AVOIDING SPINDLE SHAKE Loosen the bolts of front wheels. Remove the tyres. Loosen the nuts of brake pad and remove it. Remove the steering knuckle by loosening the bolts. Remove the retaining pin using circlip plier. Remove the upper and lower grease nipples. Remove the cotter pin by using hammer and punch. Remove the king pin also. Take the thrust washer. Remove the disc with stub axle assembly. Clean the bushes and all parts properly. Refit the stub axle with disc by inserting new king pin and cotter pin with new shims and thrust washer. Refit the grease nipples with new O-rings. Refit the brake pads correctly. Refit the steering knuckle properly. Apply grease through the nipples. Refit the tyres with box spanner or pneumatic gun.

PROCEDURE FOR AVOIDING BEARING SHAKE Loosen the bolts of front wheels. Remove the tyres. Loosen the nuts of brake pads and remove it. Loosen the nuts of cap and remove it. Loosen the nut by removing the split pin. Remove the disc from the stub axle and dismantle it. Remove the oil seal, outer bearing, inner bearing etc. Refit the disc on stub axle with new inner, outer bearings and oil seal by applying grease thoroughly. Fix the nut with new split pin. Refit the cap with grease. Refit the wheel on hub. Check for bearing noise.

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PROCEDURE FOR AVOIDING OIL LEAKAGE Bring the vehicle to the bay. Remove the battery terminal. Drain out the engine oil to the tray by loosening the drain plug. After the completion of the drain out, loosen the bolts of valve cover and its gasket. Then remove the oil sump and its gasket by loosening the bolts. Clean the oil sump and valve cover neatly with water and compressed air properly. Then refit the valve cover and oil sump with new gasket by applying the Anabond rigidly. Refill new engine oil. Reconnect the battery terminals. Start the engine and watch the performance.

OTHER WORKS DONE Park light changing. Brake light changing. Reverse light changing. Steering box replacing. Re-circulating ball type steering box changing.

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FIRST FREE SERVICE

Conduct the road test before entering to the bay. Check : Wheel bearing noise. Spindle shake and bearing shake. Steering tight and noise. Suspension system noise. Brakes and all lights. Performance of gear, clutch, speedometer etc.

WORKS
Drain out engine oil Replace engine oil filter Inspect master cylinder, wheel cylinder leakage Inspect brake hoses and pipes Inspect all steering rods and arms Inspect leaf spring damage Inspect engine coolant level and leakage Inspect shock absorber oil leakage and damage Inspect coolant pump drive belt Inspect clutch pedal play Inspect gear changing performance Inspect gear oil level and leakage Inspect brake pedal play Inspect brake fluid level Inspect differential oil level and leakage Clean air filter with compressed air Remove spindle shake Remove bearing shake Inspect lighting system working Inspect horn operation Change all worn-out parts and refit correctly.

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SECOND FREE SERVICE

Conduct the road test before entering to the bay. Check : Wheel bearing noise. Spindle shake and bearing shake. Steering tight and noise. Suspension system noise. Brakes and all lights. Body and chassis noise. Performance of gear, clutch, speedometer etc.

WORKS
Drain out engine oil Replace engine oil filter Inspect master cylinder, wheel cylinder leakage Inspect brake hoses and pipes Inspect all steering rods and arms Inspect leaf spring damage Inspect engine coolant level and leakage Inspect shock absorber oil leakage and damage Inspect coolant pump drive belt Inspect clutch pedal play Inspect gear changing performance Inspect gear oil level and leakage Inspect brake pedal play Inspect brake fluid level Inspect differential oil level and leakage Clean air filter with compressed air Remove spindle shake Remove bearing shake Inspect lighting system working Inspect horn operation

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Inspect disc brake pad Inspect wheel drum and brake shoes Inspect front and rear wheel bearings Replace exhaust system Inspect cooling system hoses Replace fuel filter Inspect battery electrolyte Inspect tyre pressure Inspect wheel damages Inspect steering wheel play Inspect A/C operations Inspect all chassis nuts and bolts Inspect brake pedal Inspect F.I.P operation and leakage Inspect radiator cap Inspect colour of exhaust gas Inspect mileage Inspect engine jerking Inspect engine sound Inspect windshield wiper Change all worn-out parts and refit correctly.

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THIRD FREE SERVICE

Conduct the road test before entering to the bay. Check : Wheel bearing noise. Spindle shake and bearing shake. Steering tight and noise. Suspension system noise. Brakes and all lights. Body and chassis noise. Performance of gear, clutch, speedometer etc.

WORKS
Drain out engine oil Replace engine oil filter Inspect master cylinder, wheel cylinder leakage Inspect brake hoses and pipes Inspect all steering rods and arms Inspect leaf spring damage Inspect engine coolant level and leakage Inspect shock absorber oil leakage and damage Inspect coolant pump drive belt Inspect clutch pedal play Inspect gear changing performance Inspect gear oil level and leakage Inspect brake pedal play Inspect brake fluid level Inspect differential oil level and leakage Clean air filter with compressed air Remove spindle shake Remove bearing shake Inspect lighting system working Inspect horn operation

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Inspect disc brake pad Inspect wheel drum and brake shoes Inspect front and rear wheel bearings Replace exhaust system Inspect cooling system hoses Replace fuel filter Inspect battery electrolyte Inspect tyre pressure Inspect wheel damages Inspect steering wheel play Inspect A/C operations Inspect all chassis nuts and bolts Inspect brake pedal Inspect F.I.P operation and leakage Inspect radiator cap Inspect colour of exhaust gas Inspect mileage Inspect engine jerking Inspect engine sound Inspect windshield wiper Tighten engine bolts according to manufacturers specification Inspect accelerator cable Tighten engine mounting bolts and nuts Inspect injectors spraying patterns Inspect fuel tank cap and its leakage Inspect all gauges and meters Inspect all universal joints

A/C
Inspect belt tension Tighten compressor mounting bolt Clean condenser with water Inspect all hose joints

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CONCLUSION
From the training, I understood most of the possible complaints about Tata & Fiat motor cars and works to be done in an automobile workshop. The staff and technicians are so talented to complete their works in time. I think the staff and technicians play a major role in making Marina Motors, the best service centre and thereby fulfilling customer satisfaction. I conclude that the interactions with them would help a lot in my future career.

THE END