ACKNOWLEDGEMENT

I express to my sincere to all officers at HARISONS MOTOR PANIPAT who has

assisted me during my training period. I should be particularly thanks to MR.
JASVINDR 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 HARISONS MOTOR PANIPAT.

PREFACE

I worked with HARISONS MOTOR PANIPAT as training from a completion of Diploma

in AUTOMOBILE ENGG. I complete one month training under supervision. During
my training period I have learn many things such as, what happen in different types
of services.
In my training period I come to know that the specification of any vehicle can be
done by the following things Dimension, Weight, Engine, Capacity, Specification,
Servicing and Maintenance etc.

During my training, it has been put my knowledge that which part are covered
under warranty. I also to know the important of servicing and maintenance.
I am including all those things, which I have learnt during period in this project
report.

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 .

Maruti Suzuki's revenue over the years:

(Rs. in Million)

Year
Net Sales
Year
Net Sales
2006-07
2007-08
2008-09
1,45,922
1,78,603
2,03,583
2009-10
2010-11
2011-12
3,01,198
3,58,490
3,47,059

The company is listed on Bombay Stock Exchange and National Stock Exchange.

BEST THE MANNER IN WHICH WE OPERATE ,BEST IN

THE PRODUCTS WE DELIVER & BEST IN OUR.

CAR NAMES & MODEL CODES

OF

MARUTI SUZUKI
Sr.
No.
NAMES

CODES

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
MECHNICAL
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
Power steering: standard
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
COMFORT & CONEINCEE
Lock: Power lock
Windows & mirrors: Power
Sound system: Standard
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

SWIFT

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 PETROL ENGINE

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

Phosphorus

Carbon

2.2%

Silicon

1.2%

Manganese

0.63%

Sulphur

0.12%

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.

CopperAsbestos 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 doesnt 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 each cylinder, hence the difference
in power developed in each cylinder is minimum. Vibration from the engine
equipped with this system is less, due to this the life of engine components is
improved.
(2) No need to crank the engine twice or thrice in case of cold starting as happens
in the carburetor system.
(3) Immediate response, in case of sudden acceleration / deceleration.
(4) Since the engine is controlled by ECM* (Engine Control Module), more accurate
amount of A/F mixture will be supplied and as a result complete combustion will
take place. This leads to effective utilization of fuel supplied and hence low emission
level.
(5) The mileage of the vehicle will be improved.

FUEL SUPPLY SYSTEM IN DIESEL ENGINE

The fuel is stored in the fuel tank from where it is lifted by means of a fuel feed
pump if the fuel tank is place at a lower level. The fed pump supplies the fuel to the
injection pump through a filler. The fuel injection pump forces the fuel under a very
high pressure to the fuel injector .The fuel under a very high pressure is injected
into the engine cylinder in the form of a fine spray by means of the fuel injector at
proper instant .The fuel injection system consists of the following components.
4.
Fuel tank:- the fuel tank acts as a reservoir in which fuel is stored. The fuel
tank is provided with air-want so that the pressure in the fuel tank always 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. Its main components are steering wheel, steering column, steering box,
pitman arm, pull & push rod, tie rod, tie rod arm and king pin.
The main function of steering system:1.

It allowed gear wheel to turn to the right or left.

2.
The steering gear swing on piston arm to the right or left when the wheel is
turned.

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