TRANING REPORTS ON MARUTI SUZUKI

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

Ø HISTORY OF MARUTI SUZUKI

Ø LOGO OF MARUTI SUZUKI

Ø CAR NAMES & SPECIFICATIONS OF MARUTI SUZUKI

Ø TOOLS, GAUGES & EQUIPMENT USED IN WORKSHOP

Ø DESCRIPTION OF FOUR STROKE IN PETROL AND DIESEL ENGINE

Ø ENGINE

·      DIESEL ENGINE AND PETROL ENGINE

Ø MAIN PARTS OF ENGINE

Ø TRANSMISSION SYSTEM

·      CLUTCH

·      GEAR BOX

·      PROPELLER SHAFT

·      DIFFERENTIAL

Ø COOLING SYSTEM

·      RADIATOR

·      THERMOSTAT

·      WATER PUMP

·      FAN

Ø FUEL SYSTEM IN DIESEL ENGINE

·      FUEL TANK

·      FUEL FEED PUMP

·      FUEL INJECTION PUMP

·      INJECTOR

Ø FUEL SYSTEM IN PETROL ENGINE

·      FUEL TANK

·      FUEL FILTER

·      FUEL PUMP

·      CARBURETTOR

·      SPARK PLUG

Ø MISCHELLANEOUS

·      STEERING SYSTEM

·      BRAKE SYSTEM

·      CHASSIS

Ø PARTS NAME AND ITS FUNCTI

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

                                                   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 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. 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