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Detailed Report on Automobile maintenance and Role of

Engineers(Industrial Training)

Technical Report · April 2023

DOI: 10.13140/RG.2.2.31518.72009

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 KATHMANDU UNIVERSITY

SCHOOL OF ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

A REPORT ON

INTERNSHIP AT L.I. SERVICE CENTER PVT. LTD

In Partial Fulfillment of the Requirements for the

Bachelor’s Degree

Ramesh Bhandari [017092]

April 2023

i
 DECLARATION
I hereby declare that I am the sole author of the report.
I authorize the L.I Service Center Pvt. Ltd to lend this report to other institutions or
individuals for the purpose of scholarly research. I further authorize the L.I Service
Center Pvt. Ltd to reproduce the thesis by photocopying or by other means, in total or in
part, at the request of other institutions or individuals for the purpose of scholarly
research.

Ramesh Bhandari
04/15/2023

i
 CERTIFICATION OF APPROVAL
This is to certify that I have examined the internship report entitled “INTERNSHIP AT
L.I SERVICE CENTER PVT. LTD PVT.LTD” and have found that it is complete
and satisfactory in all respects and that all revisions required have been made.

Er. Sanam K.C

Senior Service Supervisor/ Warranty Officer
L.I Service Center Pvt. Ltd.

Asst. Prof. Pratisthit Lal Shrestha

Coordinator (Design and Manufacturing)

Dr. Daniel Tuladhar

Head of Department,
Department of Mechanical Engineering

i
 ACKNOWLEDGEMENT
I would like to express my gratitude to L.I Service Center Pvt. Ltd for providing me
with a platform for learning professional development. Firstly, I would like to thank HR
Natish Raut for accepting me for an intern position to train in the company. I would
like to extend my heartfelt gratitude to Service Incharge Kishor Chhetri and Intern
supervisor Er. Sanam K.C for supervising throughout the training period with his
precious guidance and support continuously.

I would like to thank all the technicians, spare parts employees and service advisors
who stood as experts during my training phase and helped me to achieve the desired
objective in industrial training.

I am also thankful to Department of Mechanical Engineering, Kathmandu University,

Dhulikhel, Nepal for providing me an opportunity to get industrial experience as a part
of academic course. I have sincere sense of gratitude towards Head of the Department
Assoc. Prof. Daniel Tuladhar, PhD, Overall Industrial Training Coordinator Asst.
Prof. Pratisthit Lal Shrestha and Design & Manufacturing subdivision Coordinator
Asst. Prof. Binaya KC, PhD for coordinating and guiding my industrial training.

i
 ABSTRACT
Industrial training is one of the requirements for the award of the bachelor’s degree in
mechanical engineering. This report illustrates the experience that I acquired during a
three-month industrial training program in L.I Service Center Pvt. Ltd. This training
aimed to provide hands-on training/experience in various aspects of vehicle
maintenance and repair. Wide range of topics has been included in this report which
includes vehicle diagnosis as well as repair procedures, and role of an engineers in
service centers. Key findings include the significance of learning and acquiring
technical as well as practical skills and need for the continuous learning in the
automobile industry. Overall, this training program provided a close insight into the
operation of automobile service center and skills required to excel in the field.

v
 TABLE OF CONTENTS
List of figures.................................................................................................................viii

List of tables......................................................................................................................x

List of abbreviation..........................................................................................................xi

CHAPTER 1 Introduction...........................................................................1
1.1 Background.............................................................................................................1

1.2 History.....................................................................................................................1

1.3 Vision......................................................................................................................3

1.4 Mission....................................................................................................................3

1.5 Internship details.....................................................................................................4

1.6 Organization structure.............................................................................................4

1.7 Objectives of industrial training..............................................................................5

CHAPTER 2 Motor vehicle technology......................................................6

2.1 Introduction.............................................................................................................6

2.1.1 The transmission system...................................................................................6

2.1.2 The electrical system........................................................................................6

2.1.3 The fuel system.................................................................................................7

2.1.4 The braking system...........................................................................................9

2.1.5 The suspension system...................................................................................10

2.1.6 The steering system........................................................................................11

2.1.7 The intake and exhaust systems.....................................................................12

CHAPTER 3 Hands-on activities carried out...........................................15

3.1 Learning methodology and task assigned.........................................................15

3.2 Introduction to various roles..................................................................................15

3.2.1 Technician......................................................................................................15

v
 3.2.2 Spare parts......................................................................................................32

3.2.3 Role as a service advisor................................................................................33

3.2.4 Global Diagnosis System...............................................................................34

CHAPTER 4 workflow and software Overview........................................35

4.1 Workflow...............................................................................................................35

4.2 Overview of software............................................................................................38

4.2.1 Benefits of SAP Business One for service centers:........................................38

4.2.2 How SAP Business One works for service centers:.......................................39

CHAPTER 5 Conclusion...........................................................................40

CHAPTER 6 References............................................................................41

APPENDIX.................................................................................................42

v
 LIST OF FIGURES
Figure 1: Google Street view of Laxmi Hyundai Service Center.....................................2
Figure 2: Organization Hierarchy......................................................................................4
Figure 3: Transmission System [2]...................................................................................6
Figure 4:Electrical System [3]...........................................................................................7
Figure 5: Fuel Injector of Tucson......................................................................................8
Figure 6: Fuel system [4]...................................................................................................9
Figure 7: Braking system and types of brakes used in passenger car [5]........................10
Figure 8: Suspension system of a vehicle........................................................................11
Figure 9: Layout of steering system [5]..........................................................................12
Figure 10: Intake manifold of Santro (old).....................................................................13
Figure 11: Exhaust manifold of I20 Active.....................................................................14
Figure 12: Air filter and AC filter...................................................................................18
Figure 13: Oil drainer, oil filter and engine oil...............................................................19
Figure 14: Brake pad and disc brake assembly...............................................................20
Figure 15: Drum brake and drum....................................................................................20
Figure 16: Friction disc and pressure plate-diaphragm assembly...................................22
Figure 17: T/O bearing and release fork.........................................................................23
Figure 18: Surface damaged flywheel.............................................................................23
Figure 19: Slave Cylinder (for hydraulic clutch system)................................................24
Figure 20: MacPherson suspension assembly.................................................................25
Figure 21: Ball joint and lower arm................................................................................26
Figure 22: Power-window switch....................................................................................26
Figure 23: Suspension assembly.....................................................................................27
Figure 24: Overhauled Gearbox and it's components.....................................................28
Figure 25: Power Steering assembly...............................................................................29
Figure 26: Steering motor, reduction gear and MDPS....................................................30
Figure 27: Yoke plug.......................................................................................................30
Figure 28: Steering rack..................................................................................................31
Figure 29: Entry of different parts into sales order.........................................................32
Figure 30: Example of Job card......................................................................................33

v
Figure 31: GDS interface and fault detection..................................................................34
Figure 32: Check sheet....................................................................................................36
Figure 33: Flowchart of workflow inside the company..................................................37
Figure 34: SAP Home screen..........................................................................................38
Figure 35: Lower arm and clock spring..........................................................................44
Figure 36: Faulty Steering Rack......................................................................................47
Figure 37: Knock sensor..................................................................................................50

i
 LIST OF TABLES
Table 1: Different Models and its vaent of Hyundai passenger car in Nepal [2]..............2
Table 2: Tools and its description...................................................................................16
Table 3: Dealer Investigation Report of Airbag Checklight and Vehicle pull.................43
Table 4: Dealer Investigation Report for Steering Noise................................................46

x
 LIST OF ABBREVIATION
OJT : On the Job Training
ABS : Antilock Brake System
T/O : Throw/Out
MDPS : Motor-Driven Power Steering
SWOT : Strength, Weakness, Opportunities, Threats
GDS : Global Diagnosis System

x
 CHAPTER 1 INTRODUCTION
1.1 Background
On-the-Job Training (OJT) is a training methodology, when freshers can learn actual
skills and knowledge required for any job by working in the actual workplace under the
guidance of supervisor or any experienced employee. It is hands-on and practical, and is
aimed at developing skills, behaviors, and knowledge which are required for an
employee to perform their job competently. It is often seen as the most effective method
for developing job-specific skills and experience in real-world settings. Good OJT
programs encourage cooperation, collaboration, and efficient communication in
addition to teaching employees’ job-specific skills. They should be customized to the
requirements and objectives of the business, the department, and the participants'
personnel.

As internship gives opportunities for students to work in real-world which helps in

professional development which is very important while they are part of any
organization, internship has been added as a curriculum while studying bachelor’s in
mechanical engineering in Kathmandu University. The training period lasted for 90
days. One should choose the organization and field where they have interests on and
apply for Intern position. So, according to my interest, I choose L.I Service Center Pvt.
Ltd, Dhapasi for my internship program which is authorized service center of Laxmi
Hyundai.

1.2 History
Laxmi Intercontinental Pvt. Ltd is the sole distributor of Hyundai vehicles in Nepal
since February 2009 and one of the key players in passenger car segment. Since
acquiring distributorship, it started importing and selling various Hyundai car models.
Currently, there are 12 models which are sold by Hyundai. This company has been able
to win consumers’ hearts due to its reliability, fuel efficiency, after-sales service along
with best resale value. This company also provides servicing facilities which help to
attract new consumers as well as retention of existing consumers by providing quality
services. The company’s after-sales service and part facilities follow Hyundai’s Global
Auto Servicing offers the full range of after-sales services through its high-tech

1
equipment and well- trained certified technicians [1]. And L.I Service Center Pvt.
Ltd, Dhapasi has been

2
providing all these services which are essential to function vehicle properly and well as
to solve the problem that arises in consumers’ vehicles with full dedication.

L.I Service Center Pvt. Ltd is an authorized service center of Hyundai which includes a
highly skilled workforce and is an integral part of the business division of Laxmi
Hyundai. It provides after-service to vehicles and repairing/maintenance of vehicles.
Moreover, it sells the genuine spare parts which are required to replace the
faulty/damage parts. Along with that, it provides dent/paint services to its consumers.

Figure 1: Google Street view of Laxmi Hyundai Service Center

Table 1: Different Models and its vaent of Hyundai passenger car in Nepal
[2]

SN Model Variants Capacity Fuel Price (NRS)

Era 1197cc Petrol 2,996,000
Grand i10 Nios Magna 1197cc Petrol 3,556,000
1 Magna AMT 1197cc Petrol 3,796,000
F/L
Sportz 1197cc Petrol 3,756,000
Magna 1197cc Petrol 3,996,000
2 i20 Sportz 1197cc Petrol 4,396,000
3 Aura S 1197cc Petrol 3,796,000
S(O) iMT 998cc Petrol 4,796,000
S 1493cc Diesel 4,696,000
4 Venue S 1197cc Petrol 4,196,000
S iMT 998cc Petrol 4,696,000
E 1.2 1197cc Petrol 4,096,000
S 1.2 1197cc Petrol 4,696,000
5 Venue F/L SX 1.2 1197cc Petrol 5,696,000
S(O) DCT 998cc Petrol 5,796,000
E Loaded 1197cc Petrol 4,156,000

3
6 Creta E 1497cc Petrol 5,256,000

4
 E Loaded 1497 cc Petrol 5,296,000
E Premium
1497cc Petrol 5,456,000
Loaded
S 1497cc Petrol 5,996,000
S+ 1497cc Petrol 6,496,000
SX 1497cc Petrol 6,756,000
SX CVT 1497cc Petrol 7,456,000
SX(O) CVT 1497cc Petrol 7,896,000
E 1493 cc Diesel 4,996,000
E Loaded 1493 cc Diesel 5,056,000
E Premium
1493 cc Diesel 5,196,000
Loaded
GL 2WD MT 1999cc Petrol 10,796,000
GLX 2WD AT 1999cc Petrol 13,796,000
GLX+ 2WD AT 1999cc Petrol 14,496,000
7 Tucson GLX 4WD AT 1998cc Diesel 16,096,000
GLX 4WD AT
1598cc Petrol 16,296,000
TURBO
GLS 4WD AT 2497cc Petrol 18,996,000
8 Santa Fe GL 4WD AT 2151cc Diesel 16,596,000
GLS 4WD AT 2151cc Diesel 18,896,000
9 Palisade GLS 4WD AT 2199cc Diesel 23,596,000
NS - Electric 6,096,000
10 KONA GL 100 KW 100 KW Electric 6,196,000
GLS 100 KW 100 KW Electric 6,456,000
GLS VISION
11 IONIQ 5 124.9 KW Electric 11,696,000
ROOF

1.3 Vision
To be the most successful Hyundai Automobile Dealer in the region by delivering
excellent customer service [1].

1.4 Mission
Increasing customer satisfaction by delivering Sales and Service Experience with High
Quality, Excellent Value, Integrity, and Passion [1].

5
1.5 Internship details
Name : L.I Service Center Pvt. Ltd
Location : Dhapasi, Kathmandu
Phone no. : 01-4355430/4355431
Email address: : care.service@laxmihyundai.com
Duration : 90 days
Working time : 9 am- 5pm
1.6 Organization structure
Organization structure is a systematic arrangement of human resources in an
organization to achieve business objectives. It outlines the roles and responsibility of an
individual which are assigned to them by the company so that the work and information
flow seamlessly, ensuring the smooth functioning of a company.

There are various departments in this service center which incorporate the maintenance
and repair of customers’ vehicles, sales and spare parts, accounting section of this
company and customer relation management. These various departments account for
providing proper services to customers within specified time, ensure the regular and
continuous workflow in the company, maintain the long-term customer relationship and
managing and controlling the employee to get their top-notch performance. The chain of
the organizational structure is given below.

Figure 2: Organization Hierarchy

6
1.7 Objectives of industrial training
There are various objectives that university aims to achieve by students through
industrial training. They are given below.

Primary objective
The primary objective of industrial training is:
 To become a practically oriented graduate, that meet the required job-related
competences of future employee.
Secondary objective
The secondary objectives of industrial training are:
 To get hands-on experience in real-life situations
 To understand work ethics, responsibilities, and opportunities.
 To enable to bridge the gap between theoretical and practical knowledge.

7
 CHAPTER 2 MOTOR VEHICLE TECHNOLOGY
2.1 Introduction
A motor vehicle is a self-propelled road vehicle and movement is carried with the help
of no. of wheels installed on itself. Vehicle propulsion is done by engine power or
electric motor or sometimes both (hybrid vehicle). There are several systems that
combines to function an automobile. Each system is primarily independent but is
influenced by the other system interacting with it. Some of the systems are described
below.

2.1.1 The transmission system

Transmission systems enable automobiles to transfer mechanical energy from an engine
to the wheels. It comprises of gearbox, flywheel, clutch, propeller shaft,
differential/transaxle and other various electrical units which serves as a bridge to
transfer power and energy from engine to the wheels. Cruising speed is maintained with
the help of transmission system without disturbing the performance of vehicle.

Figure 3: Transmission System [2]

2.1.2 The electrical system
The electrical system comprises of battery, starter, and alternator. When we need to start
the engine, the battery provides the required power to starter initially. After the engine is
started, the alternator gives that batter energy to power the car. The alternator is rotated
by using rotational energy from crankshaft of an engine and is inter-connected by fan
belt.

Initially, batteries provide all the required electrical current to the ignitions and fuel
system which are necessary for creating combustion necessary for the engine to
function. A starter motor serves as a bridge between battery and engine cranking

8
process. When the starter motor gets the power, a solenoid switch pushes the ring gear
which then mates with the ring gear of the flywheel, which provides cranking power to
the crankshaft of

9
the vehicle. When combustion starts alternator provides energy to the battery which
needs for the proper functioning of the vehicle until an engine is turned off. If the
alternator is not functioning properly, electrical systems of automobile will perform
inconsistently, eventually battery gets discharged and engine power will be lost.

Figure 4:Electrical System [3]

2.1.3 The fuel system
Three things are required for all internal combustion engines to operate: air, fuel, and
spark. The storage and delivery of gasoline or diesel engines needs to run depend
heavily on the fuel system. The gasoline pump, fuel lines, and filter are all parts of the
fuel system. The consequences of any of these fuel system failures are catastrophic for
the vehicle.

Fuel tank

This is essentially a gasoline storage tank. The gas flows down the filler tube and into
the tank when you fill up at a gas station. A transmitting unit in the tank notifies the gas
gauge how much gas is in the tank. The gas tank has gotten a little more complex in
recent years since it now frequently houses the fuel pump and has more pollution
controls to prevent vapors from seeping into the air.

Fuel pump

The fuel pump can often be found in the fuel tank of modern vehicles. In older vehicles,
the fuel pump was either linked to the engine or mounted on the frame rail between the
tank and the engine. If the pump is in the tank or on the frame rail, it is electric and is

1
powered by the vehicle's battery. fuel pumps attached to engines use the engine's
motion to pump gasoline, most often the camshaft, but sometimes the crankshaft.

Fuel filter

Clean gasoline is essential for engine durability and performance. Fuel injectors and
carburetors have tiny holes that clog easily; therefore, fuel filtration is required. Filters
can be installed before or after the fuel pump, or both. They are often composed of
paper but can also be made of stainless steel or synthetic material and are intended to be
disposable in most circumstances. Some performance fuel filters have washable mesh,
eliminating the need for replacement.

Fuel injectors

The fuel injector is a small electronic valve that opens and shuts in response to an
electric signal. By injecting fuel near to the cylinder head, the fuel remains atomized (in
tiny particles), allowing it to burn more efficiently when ignited by the spark plug.

Figure 5: Fuel Injector of Tucson

Carburetors

In a carburetor, air is mixed with incoming fuel. It is simple in operation but needs
frequent tuning and rebuilding. So, in modern cars, fuel injection is widely used.

1
 Figure 6: Fuel system [4]
2.1.4 The braking system
The car's braking system is intended solely to do one thing: safely stop the vehicle. To
do this, three main elements are required: a vehicle operator, hydraulic pressure, and
friction. When the driver depresses the brake pedal, the pedal levers and rods activate
the power brake booster. The booster multiplies the force from the operator's foot to the
master cylinder using engine vacuum or a pump. Hydraulic lines attached to the master
cylinder travel to a proportioning valve or the ABS (Antilock Brake System) module,
then to each brake caliper if the vehicle has disc brakes, or to the wheel cylinder if the
vehicle has drum brakes. The braking fluid in the lines runs into the calipers or wheel
cylinders, and hydraulic pressure pushes the brake pads against the rotors of the brake
shoes against the drums, generating friction and bringing the car to a halt.

Disc brakes

A disk brake system is made up of three parts: a rotating disk, a brake caliper, and brake
pads. When the brake pedal is depressed, pressurized hydraulic brake fluid squeezes the
brake pad friction material against the revolving brake disc's surface. As a result of this
contact, friction is created, allowing the vehicle to slow or stop.

Drum brakes

A drum brake system includes hydraulic wheel cylinders, brake shoes, and a drum.
When the brake pedal is depressed, hydraulic wheel cylinders drive two curved brake

1
shoes with

1
a friction material lining against the inner surface of a rotating brake drum. As a result
of this contact, friction is created, allowing the vehicle to slow or stop.

Figure 7: Braking system and types of brakes used in passenger car [5]
2.1.5 The suspension system
Suspension is the system of tires, tire air, coil springs, shock absorbers, and link rod that
connects a vehicle to its wheels and allows them to move relative to one another.
Suspension systems provide two functions: they contribute to the vehicle's
roadholding/handling and braking for good active safety and driving enjoyment, and
they keep vehicle passengers comfortable and relatively well isolated from road noise,
bumps, and vibrations. The suspension also protects the vehicle from damage and wear,
as well as any cargo or luggage. A car's front and rear suspension may be designed
differently. The suspension system of a vehicle is separated into two parts: front
suspension and rear suspension.

The front suspension system

The front suspension's role is to withstand the vehicle's weight. Automobiles usually use
independent front suspension, which means that if one of the tires travels over a bump,
the other is unaffected. Ball joints, control arms, lower arm bushings, coil springs,
stabilizers, shock absorbers, steering knuckle, and spindle are the essential components
of the front suspension.

1
The rear suspension system

The rear suspension system is intended to keep the back axle and wheels in their
appropriate location beneath the vehicle. To maintain alignment and effective vehicle
control, the rear suspension allows each of the back wheels to travel up and down
independently of the frame. The rear suspension is a dependent suspension system
which is connected to the torsion bar of cars.

Figure 8: Suspension system of a vehicle

2.1.6 The steering system
The steering mechanism combines steering-wheel rotation into twisting movement of
the road wheels in such a way that the steering-wheel rim turns a long distance to move
the road wheels a little distance. The rack and pinion and the steering box are the two
most popular types of steering systems. On larger vehicles, either system may be power
assisted to lessen the amount of work required to move it, especially when the vehicle is
moving slowly.

The rack-and-pinion system

A tiny pinion (gear wheel) is housed inside a housing at the base of the steering column.
Its teeth interlock with a straight row of teeth on a rack, which is a long transverse bar.

1
The rack moves from side to side when the pinion is turned. Tie rods connect the rack's
ends to the road wheels.

Its operation is accurate, and the mechanism is simple. A universal joint in the steering
column connects it to the rack without unnecessarily tilting the steering wheel side to
side.

The steering-box system

A worm gear within a box is located at the base of the steering column. A worm is a
threaded cylinder, like a small bolt. Spinning the worm moves everything that fits inside
its thread.

Figure 9: Layout of steering system [5]

2.1.7 The intake and exhaust
systems Intake system

The intake system's function is to manage the supply of clean, filtered air to the engine
at the proper temperature while also providing vacuum to run other components.
Crankcase vapors are likewise drawn into the intake stream by the intake system and
burned by the engine. Modern automobiles have a lot more intake plumbing to
accommodate smaller engine bays that have a lot more electronics packed into them.

1
 Figure 10: Intake manifold of Santro (old)
The exhaust system

The exhaust system is a component in a vehicle's engine that handles the burned gas
produced by the engine. It is made up of exhaust pipes that carry exhaust gas from one
chamber to another, a header that collects the same gas from different cylinders and
directs it to the pipes, a catalytic converter that converts pollutant gases produced during
combustion into less harmful substances, a muffler that reduces engine noise, and a
turbocharger that increases engine power. The exhaust system is critical to every vehicle
since it determines the life and performance of the engine. Back pressure in an engine
prevents it from working properly. Exhaust gas clogs an engine and prevents it from
performing useful work. As a result, the car cannot operate smoothly and quietly, and in
worst-case scenarios, it will not run at all.

1
Figure 11: Exhaust manifold of I20 Active

1
 CHAPTER 3 HANDS-ON ACTIVITIES CARRIED OUT
3.1 Learning methodology and task assigned
First, the intern date was fixed. Then, I was introduced to different departments of the
companies where engineers played a vital role in the company. At first, technicians
taught me about different components and parts of vehicles, their maintenance
procedures that we must follow, and tools used during maintenance of vehicles. The
teaching was mutual as I taught some technicians about the working mechanism of
various systems of automobile such as working process of vacuum brake boosters.
Later, I was taught about the process of looking for parts in the inventory, inventory
management, job card opening, delivery, etc. Basically, I followed the following
techniques to get trained during my internship.

 Observation
 Questionnaires/Interviews
 Photography
 Directly involved in process with the supervision of experts
3.2 Introduction to various roles
During my training at L.I service center, I participated in different activities where I was
able to interconnect theoretical knowledge with practical and skills acquired in the class
into real world problem-solving situations. Various tasks were assigned to me during
my training period, which are listed below.

 Technician
 Spare parts
 Service advisor
3.2.1 Technician
During my time as a technician, I found that an individual job card was assigned to
individual vehicles by a service advisor which included general check-up task, periodic
maintenance task, problems that are being faced by customers while using vehicle and a
check-sheet to check different vehicle systems/components. Based on those job cards, I
was taught to perform the task slowly and gradually. During this period, I learned
various maintenance and repair practices, amount of time required to perform those
jobs, and use

1
of various tools for those practices. I am directly involved in many cases which are
detailed below.

Tools
One toolbox was assigned per two technicians. Some frequently used tools during
training are given below.
Table 2: Tools and its description

Ring Spanner
It has a closed opening that wraps bolts/nuts. There are ridge
inside the ring which are effective for hexagonal bolt heads.

Open end wrench

The two opposite ends of wrenched grip the nut or bolt.

Combine wrench
It contains both open end and closed ring with ridge inside

Rachet and extensions

Rachet provides more leverage in both directions while
tightening and loosening bolt, extension is used to extend the
distance up to which rachet can rotate easily.

Universal Joint
It is used to change the direction of force applied without
changing its magnitude.

Allen Key
It is used to turn bolt heads with a recessed hexagonal pattern.

Sockets
It has a hollow cylinder which grabs the hexagonal bolt or the
nut.

2
 Oil filter wrench
It is used for opening and tightening engine oil filter.

L-shaped extension bar

It is used for multiplying torque while using socket and mostly
used along with oil filter wrench.

General servicing
This service includes the general check-up of the vehicle like under hood check-up
which include air filter / A.C filter conditions, belt noise/alignment, brake oil, coolant,
water inside wiper tank, engine oil condition and scale and battery wiring. After that the
vehicle is lifted and inspected for brake pad thickness, axle booth, any kind of leakage
from under the body, checking if wobbliness presents in the vehicle due to some bush
failure, insulator failure, ball joint failure or tie rod failure. After that the front and rear
light is checked to see if it is lit or not. Then the vehicle is driven and checked for its
wheel movement/alignment, steering noise, and clutch hardness.

Full servicing
It is a servicing which are done periodically. When a vehicle runs a specified distance,
full servicing is required for its longevity and smooth performance. It is done by the
following procedures.

Under hood visual inspection

 Brake oil check/ refill

 Coolant check/refill
 Water level check/refill
General checkup
Tools: 17mm & 19mm spanner ring

Procedure
 Using 17mm and 19mm spanner ring, bolt of axle and mount was checked for
its looseness.

2
Air Filter/ AC filter (if available) check/change

 High velocity of air from pneumatic pump was blown onto filters to remove dust
otherwise replaced with new one.

Figure 12: Air filter and AC filter

Engine oil change
Tools: 17mm spanner ring, filter cap, L-handle

Procedure

 17mm spanner ring used to remove drain nut, oil is removed from the oil pan
and later, the bolt was fastened.
 To remove a filter cap, L-handle was inserted into filter cap which then used for
removing oil filter and new oil filter was reinstalled.
 Engine oil filler cap was removed and engine oil of 3.6 liters was poured into the
engine (10W-40 thickness of oil was used). First engine oil dip stick was
removed, cleaned, and plugged again and remove. Visual inspection was done if
oil was presented above F, oil amount is good otherwise repoured and engine oil
cap was tightened.
Note: Sometimes washer of drain nut remains attached to oil pan. In this case, we must
use screwdriver to remove it.

2
 Figure 13: Oil drainer, oil filter and engine oil
All brake check
First, the tire was removed from the wheel hub.

Tools: pneumatic gun, 21mm socket

Procedure
 A 21mm socket was installed into the slot of pneumatic gun to loosen the bolts
of the tire. The procedure was done according to requirement.
Disc brake

Tools: 14mm spanner ring, dry sandpaper

Procedure

 Using a 14mm spanner ring, bolt was unfastened. The brake pad was removed
from the caliper. The brake pad surface was scrubbed with dry sandpaper. If the
frictional surface is thin, the brake pad was replaced with new one. The brake
pad was positioned into the caliper and tire was reattached into the wheel hub by
tightening bolts.

2
 Figure 14: Brake pad and disc brake assembly
Drum brake

Tools: Impact, Hammer

Procedure
 After removing wheel, screw of drum was removed using impact. Impact was
hit with hammer to unscrew from the drum. After unscrewing, the drum was hit
with hammer with slight force to make easy to remove.
 Afterwards the braking surface was cleaned with dry sandpaper and air was
blown to clean the brake parts. If parking brake travel was too high or parking
brake was too tight brake exhauster was rotated using screwdriver
clockwise/anticlockwise (according to requirement) and all the parts was
reinstalled as it was before.

Figure 15: Drum brake and drum

Light check
• Headlights, side indicators, fog light, rear brake light, parking light were checked.
Wiper check

2
Cutch system
A clutch set is used to transmit power from the engine to the gearbox. The clutch disk is
pressed against the surface of the flywheel with the help of a pressure plate when clutch
is in engage state. In this time power is transmitted from engine to gearbox. When
clutch pedal is pressed due to the mechanism of diaphragm spring, clutch gets
disengaged, and no power is transmitted to the gearbox and hence wheel. This condition
is useful while shifting gear. There are various problems which arise due to faulty clutch
system. Some of the signs of faulty clutch system that I came to know are.
• Reduce in pick-up though engine rpm is increasing due to clutch slippage.
• Sometimes when clutch pedal is released, vehicle move late, or some time
vehicle doesn’t move at all due to damaged friction disk.
• Trouble with shifting gears
Remedy: To remove these problems, we need to change the clutch set. We also must
look for the conditions of clutch fork and replace if there are deep cuts in the forks.

The procedure is given below.

Tools: 10mm &12mm T-handle, 14mm socket, 17mm, 14mm, 21mm & 12mm socket,
14mm combine wrench, 32mm socket, Rachet, Tire lever, Support, Extension (small &
medium) Pneumatic gun, Pliers

Procedure

 Air filter case, battery, battery clamp, batter holder plate and ECU module were
removed by using 10mm and 12mm T-handle.
 Wire clamps were untied by using screw drivers.
 The gear shifter wire holder was disassembled by untying three bolts by using
12mm T-handle.
 Slave cylinder was disconnected from clutch fork using 12mm socket and rachet.
 Front tires were removed using 21mm socket and pneumatic gun, then brake
line bracket and abs sensors bolts were removed using 10mm T-handle and
brake calipers were removed using 14mm ring spanner.
 Knuckles were disconnected from suspension using 17mm socket, pneumatic
gun and 17mm combine/ring spanner.
 The axle was removed from wheel hub using 32mm socket and pneumatic gun.
 Gear oil was removed from gear box by untying bolts from gear box using
17mm combine wrench/ ring spanner and was collected in gallon and one lower
bolt was tightened and one upper bolt was just hand tied.

2
 The axle was removed from the transmission case using tire lever.
 The engine torque strut mount was disassembled from the frame using a
pneumatic gun, medium extension and 12mm and 17mm socket.
 Brackets were removed from the gear box using 14mm combine/ 14mm socket
and wrench.
 Then all the bolts were removed from the transmission assembly including the
starter motor. If bolts were too tight, pneumatic gun and 14mm sockets were
used otherwise rachet & 14mm sockets & 14mm combine were used though one
of the bolts was loosen but was kept in that transmission case to hold the gear
box and prevent it from being dropped.
 After that transmission assembly was held by long rod support and gear box
mount was removed by using pneumatic gun and 17mm long socket.
 After removing the bolt from mount, gear box was supported with hand,
remaining one bolt was also removed and gear box was pulled out. In some
cases, a tire lever was used to push gearbox.
 Clutch assembly was unattached from flywheel by untying bolt using 12mm
socket and pneumatic gun.
 Later the fly wheel was cleaned by blowing air pressure and transmission case
was cleaned by using antirust and clothes.
 Clutch fork, Throw out (T/O) bearing and spring were removed by untying
14mm bolt using ring spanner and replaced with new one.
 Grease was applied to the internal part of the T/O bearing and clutch fork before
installation.
 A new clutch set was installed, and bolts were tightened with 12mm ring by
using hand.
 All the parts were assembled by following the reverse process.

Figure 16: Friction disc and pressure plate-diaphragm assembly

2
 Figure 17: T/O bearing and release fork
Sometimes flywheel surface also gets damaged. At that time, we needed to unscrew six
bolts using a 17mm socket and torque wrench and turned the flywheel surface. Later,
flywheel was installed setting torque up to 90Nm.

Figure 18: Surface damaged flywheel

Slave cylinder
This is used for applying force in clutch fork during disengagement process of clutch. In
the case of hydraulic system, clutch pedal might get spongy or might stick to the floor.
At that time, we needed to replace the slave cylinder with a new one. The technical
procedure is given below.

Tool: 12mm socket, medium rachet, 12mm & 10mm T-handle,

2
Procedure

 The air intake line was disconnected from throttle body and air filter box was
removed using 12mm T-handle.
 Bolt of 12mm diameter was loosen using rachet and 12mm socket and new slave
cylinder was installed.
 Brake oil was added, and the bleed valve was left open until brake oil started
leaking by pumping clutch pedal. All the air was removed, and the bleed valve
was closed.

Figure 19: Slave Cylinder (for hydraulic clutch system)

Wheel wobbling
There is not one case that wheel wobbles but most of the time, it is failure in the
component which are related to suspension failure. The reasons for wheel wobbling are
given below.

 If wobbling is in vertical direction, it is failure of insulator. Insulator must be

replaced in this case.
 If wobbling is inwards and outwards according to horizontal axle, it is
because of bush failure or inner ball joint failure. Either ball joint and lower
arm bush or inner ball joint must be replaced.

2
The technical procedure to replace the shock insulator are:

Tools: 21mm, 17mm and 14mm socket, extension, pneumatic gun

Procedure

• Front tires were removed using 21mm socket and pneumatic gun, then brake line
bracket and abs sensors bolts were removed using 10mm T-handle and brake
calipers were removed using 14mm ring spanner.
• Knuckles were disconnected from suspension using 17mm socket, pneumatic
gun and 17mm combine/ring spanner.
• From the upward, using a 17mm socket and pneumatic gun, nut was loosened,
and suspension was disassembled. Two clamps were used to clamp the coil
spring and were tightened using medium extension. A nut tightening a insulator
was removed using socket and gun and insulator was replaced with new one.
• Using the reverse process assembly was done.
Shock Insulator

Figure 20: MacPherson suspension assembly

The technical procedure to replace the ball joints and lower arm bush is given

below. Tools: 17mm and 19mm combine spanner, 17mm and19mm socket,

pneumatic gun Procedure

 After removing the wheel, the ball joint bolt was disconnected using 17mm
combine spanner.
 Then two bolt screwing lower arm to the cross link was unscrewed using 17mm
and 19 mm socket with pneumatic gun.

2
  Thus, the disassembled lower arm was sent to lathe to press-fit the bushes and
ball joint and later reassembled to the vehicle.

Lower arm bush

Figure 21: Ball joint and lower arm

Power window
A power window is a car window that is lowered and raised by using an electric motor
which is controlled by switch. This has become a fundamental component of modern
vehicles replacing the older hand cranked style.

A power window switch not working is another common problem that I found out
during my training period. Most of the time carbon is collected in between the switch
which prevents the switch from completing circuit and sometimes electric motor get
jammed and doesn’t rotate.

Figure 22: Power-window switch

The solutions for carbon were to remove switch from the door panel, disassembled all
the metal part then cleaned with sandpaper. Then it started working. In case of motor
jammed, all the four screws were loosened first, then hit using mallet with small impact

3
and screws

3
were tightened using screwdrivers. Antirust was sprayed at the side of glass panel to
remove all the carbon.

Shock absorber replacement

Sometimes there is an oil leakage from the shock absorber. Due to this, when piston rod
travels downward due to the shock it takes more time to return to its initial position or it
doesn’t return at all. At that time, the shock absorber was replaced with a new one.

Shock absorber

Figure 23: Suspension assembly

Gear box overhaul and oil seal change
Problem: Gear oil leaking as one of the technicians from the local repair shop forgot to
cap the gap with gear oil seal.

Tools: 10mm T-handle and socket, 12mm T-handle and socket, 28mm socket, magnet,
tire lever

Procedure

 After dismantling the gearbox from the engine, it was taken for further
disassembly.
 The first seven number of 10mm bolts were removed and three 12mm bolts were
removed.
 Spring and balls were pulled out by using magnet.
 All the 12mm bolts of gear housing were removed.
 The gear lock pin was removed by hammering that pin with a valve.

3
  After that 5th gear along with gear shifter was dismantled using tire lever.
 Gear box housing was removed.
 By removing the 12mm bolt from shifter, we took out shifter from the assembly.
 Finally, the main shaft and layout shaft were removed along with differential by
hammering with small amount of force.
 Thus, the oil seal was replaced with a new one.
 All the components of gearbox were cleaned with petrol and re-assembled.

Figure 24: Overhauled Gearbox and it's components

Task performed: Eon era

Steering noise
Power steering comprises of an electric motor which assists the driver while steering the
vehicle. A driver can turn the vehicle by steering with less force with the help of power
steering. The additional rotation is provided by an electric motor. The power assistance
varies according to the speed of vehicle. To control the speed of electric motor, Motor-
Driven Power Steering (MDPS) is used. The force required to steer a vehicle is
inversely proportional to the speed of vehicle [6]. Therefore, when a vehicle is moving
at low speed, MDPS is designed to provide a higher amount of electric current to
electric motor and vice-versa.

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 Figure 25: Power Steering assembly
Being a mechanical part, the power steering system also faced a lot of problems and
there is not a single remedy to remove the problem. Generally, the power steering
problem was characterized by whining noise when we turned the wheel. The problem
was solved in a iterative manner. At first, the problem was tried solving by replacing
worm gear, secondly, electric motor and thirdly by replacing all the reduction part.
Sometimes, loosening the 12mm bolt of both universal joints and shaking vertically
with some force and tightening the bolt can also fix the problem. The tools required and
technical procedures that were followed for solving the power steering noise problem is
given below.

Tools: screwdriver, 14mm and 19mm combine spanner, 12mm T-handle, 12mm socket,
medium extension, rachet

Procedure

• First, the negative terminal of the battery was disconnected.

• Steering was locked by aligning front wheel in a straight line with reference to
side view of the vehicle. Different trims and column cover was removed.
• The column was disconnected from the rack by removing a 12mm bolt. This
bolt contains a spline at the end of the bolt.
• Various sensors and switches jacks were disconnected, and steering assembly
was taken out from the vehicle.
• MDPS and electric motor were removed by loosening a 12 mm bolt.
• If worm gear shaft rotates easily by rotating input shaft, then there is a

3
confirmation that there is failure in worm gear.

3
 • A special tool is required to remove the plug nut as well as lock nut and later a
bush. Similarly, 19mm nuts were removed, after that 12mm bolt were removed
and soft hammering was done to dismantle the reduction gear assembly. The
new worm gear was greased properly. There was a special white grease
available for worm gear.
• All the components were then assembled back to their original position.

Figure 26: Steering motor, reduction gear and MDPS

Similarly, another cause for steering nose can be cause of overly compressed yoke plug
against the rack of steering and due to friction, it produces some noise. The yoke plugs
assembly was removed and assembled with new one. We used a special torque wrench
and a 22mm socket. It consists of yoke plug, spring, and tie nut. It required some special
tools and torque of 1.4 Nm was given while tightening the plug.

Figure 27: Yoke plug

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Faulty steering rack
A faulty steering rack also contributes to very tight steering wheel, leaking power
steering fluid (in hydraulic system), grinding noises when steering. The rack was
replaced with a new one. The tools required and technical procedures are given below,

Tools: 12mm, 17mm and 19mm socket, 14mm and 17mm combine spanner, long
extension, rachet, pneumatic gun

Procedure

• A lower universal joint was disconnected from the steering rack assembly.
• A link rod, tie rod and ball joint were detached from suspension and knuckles
respectively.
• A cross link was detached from the chassis by removing two 19mm bolts and
two 17mm bolts.
• Later, the rack was dismantled and replaced with a new one.
• After the rack was installed, all the parts were reassembled.

Figure 28: Steering rack

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3.2.2 Spare parts
During my training period, I got a chance to engage with spare parts division. It lasted
for two weeks. At first, I was introduced to the inventory that this company holds. I was
also introduced to different spare parts along with their location in the inventory. I was
familiarized with different codes of parts like air filter, A/C filter, oil filter, brake pad,
etc. I learned how I can look for part number of different items, its availability using
Inventory Master Data, no. of stocks and committed items, and their price. I learned to
make entry of different items in the sales order which are used during repair process.

Figure 29: Entry of different parts into sales order

After continuous observing, analyzing, questionnaires and exploring through different
modules of software, following are the roles of engineers in spare parts division of
automobile service center.

 Inventory Management: It is the foremost responsibility of an engineer to

organize and manage parts in the inventory and ensure that there are adequate
quantities of parts available to meet the needs of customers. This involves
forecasting demand, placing orders, and tracking levels. For example, whenever
the number of Air filters of Creta gasoline (old) reach minimum level i.e., 6,
order of Air filter was placed immediately.
 Quality assurance: Engineers need to ensure that the spare parts meet the
required quality standards. This includes inspections and tests on existing part
by comparing and verifying that the component matched the previous task and
perform function without any hindrance. Beside these, identifying defective
parts and ensuring that genuine parts are used in repair process.
 Cost management: Another responsibility was to manage the spare parts,
ensuring that they are obtained at the best possible price and that there is no

3
 wastage or misuse of parts in the service center. The price must be set according
to the company viewpoint and customer viewpoint i.e., the company can be able
to make target profit while customers can be able to buy the parts and think this
value is the best value. In this service center, there are already declared margins
that spare parts engineers need to set the retail price of parts.
 Customer service: Engineers were responsible for providing excellent customer
service by ensuring that that the right parts are available for repairs, providing
accurate information about parts, and resolving related issues to spare parts
promptly. In the case of parts unavailability, spare parts division request for
information about parts availability first at its central distributor and again if
parts were not available, then put inquiries in other Hyundai branch and
ultimately to other dealers throughout the country according to the type of order.
Some types of orders are daily order, urgent order, etc.
3.2.3 Role as a service advisor
During my role as a service advisor, I was able to acquire some focus and
communication skills. I acted as a liaison between customers and a company’s service
department, providing information and assistance regarding repairs and maintenance to
technicians. Working as technicians at first helped me a lot during this role. I was able
to describe problems to the customers, it’s probable cause and its remedy in an
understandable way to customers.

Figure 30: Example of Job card

3
I learned to prepare a manual according to the problem faced by customers in their
vehicle, create a job card of that problem, scheduling a repair and maintenance program.
Many times, I went to the floor to verify as well as learn the maintenance procedure.
When vehicles are repaired, I make delivery of some vehicle.

3.2.4 Global Diagnosis System

The Global Diagnosis System (GDS) Smart is a sophisticated diagnostic tool which is
being used by Hyundai service centers to diagnosis and repair Hyundai vehicles. It is a
hardware and software platform that uses a laptop computer or tablet and a VCI
connector to communicate with various electronic modules (ECMS) in vehicles. It
allows technicians to access and analyze data from the vehicle’s sensors, actuators, and
other components, helping them to diagnose and repair faults in the vehicle’s various
system.

During my training period I was taught and had used GDS to diagnosis the problems
like reason of engine check light on, ABS, or airbag system, cleaning of throttle,
checking data related to EVs. I detected the failure of ultrasonic sensors, misfiring of
engine, etc.

Figure 31: GDS interface and fault detection

4
 CHAPTER 4 WORKFLOW AND SOFTWARE OVERVIEW
4.1 Workflow
Laxmi Intercontinental Service Pvt. Ltd is a 2S based company i.e., this company
focuses on service and spare parts selling while many of the Laxmi Hyundai are 3S
companies i.e., service, sales, and spare parts. Services include the maintenance and
repair of faulty vehicles while spare parts refer to the sales of parts which are needed to
replace the faulty/damaged part to obtain the optimal performance of vehicles.

Servicing includes the maintenance bay and dent/paint. Maintenance is handled by

service supervisor, dent/paint supervisor, service advisor, and technicians. First
customer enters the service center who have complaint/queries/scheduled maintenance
program/parts required. Parts required are sent directly to the spare parts department,
while others remaining are considered by service advisor. The service advisor then
opens a new job card according to the requirements of customers. A sales quotation is
opened mainly for dent/paint purposes while for maintenance and repair purposes sales
order is opened. Then the vehicle is sent to maintenance bay where technicians carry out
the required and specified tasks to solve the customer problems. When a spare part is
required to repair the vehicle, in the absence of customers a phone call is made to get
permission as well to let them know about the problem with the vehicle. If parts need to
be replaced, a requisition was created to keep the record of all the parts that are sold to
individual vehicles. After replacement and repair of vehicle, a test drive is done to
check the condition of vehicle after carrying out the operation process. After solving all
the specified problems, a delivery is made in the customer’s name and an AR invoice is
created. Those AR invoices are then handled by the account section.

4
 Figure 32: Check sheet
When a customer comes directly for part, they are sent directly to spare parts and
counter sell is done for them i.e., a direct delivery is made for them by spare parts and
thus generated AR invoices are handled by account sections. The overall workflow is
demonstrated in the given flowchart.

4
Figure 33: Flowchart of workflow inside the company

4
4.2 Overview of software
A popular software called SAP Business One has been used since a few years ago. SAP
Business One is robust and flexible business management software for small and
medium-sized organizations. It offers a broad variety of tools for managing different
aspects of a business, including financial administration, sales and customer
management, inventory, and warehouse management, purchasing, and reporting [7].

Figure 34: SAP Home screen

4.2.1 Benefits of SAP Business One for service centers:
SAP Business One can assist service centers manage their operations and optimize their
workflows, resulting in enhanced productivity and profitability. The following are some
of the advantages of utilizing SAP Business One for service centers:

Improved Inventory Management: SAP Business One provides powerful tools for
managing inventory levels, tracking stock movements, and monitoring stock levels to
ensure that service centers always have the necessary parts and supplies on hand. This
can help prevent stockouts and minimize waste [7].

Customer Relationship Management: SAP Business One enables service centers to

maintain detailed customer records and track customer interactions. This information
can be used to provide better service, anticipate customer needs, and tailor marketing
efforts to specific customer segments [7].

Financial Management: SAP Business One offers robust financial management tools,
including accounts payable and receivable, cash management, and financial reporting.

4
This helps service centers track their financial performance, make informed decisions,
and plan [7].

Streamlined Workflows: SAP Business One provides a centralized platform for

managing all aspects of a service center's operations. This can help service centers
streamline workflows and eliminate redundancies, leading to increased efficiency and
productivity [7].

4.2.2 How SAP Business One works for service centers:

SAP Business One is a modular software solution that may be adjusted to a service
center's individual requirements. It is often made up of numerous modules, including:

This module includes tools for managing sales operations, making bids and orders,
recording client interactions, and evaluating customer data.

Inventory and Warehouse Management: Using this module, service centers may
control inventory levels, track product movements, and optimize warehouse operations
[7].

Financial Management: This module includes tools for managing financial

transactions, keeping track of spending, and creating financial reports [7].

Purchasing: This module allows service centers to manage their purchasing activities,
make purchase orders, and track the performance of their suppliers [7].

Reporting and Analytics: With this module's extensive reporting and analytics
capabilities, service centers may produce thorough reports and obtain insights into their
operations [7].

4
 CHAPTER 5 CONCLUSION
In conclusion, the industrial training at Laxmi Intercontinental Pvt. Ltd provided me
with valuable hands-on experience in the field of automotive engineering. My
internship lasted for 90 days. During my internship, I had a lot of opportunities to work
on various tasks, including technical work, spare part, and service advisor. Through this
experience, I was able to apply theoretical knowledge gained in my academic into real-
world situations.

Additionally, the internship provided me with the opportunity to develop important

technical skills and soft skills such as problem-solving, teamwork and communication.
These skills will undoubtedly benefit me in my future academic pursuits and career
aspirations.

Overall, my internship was a positive and rewarding experience. I am grateful for the
opportunity to have worked with skilled professionals in the company and for the
knowledge gained during internship. I believe that this experience has prepared me and
given me some extra confidence for future challenges in the field of mechanical
engineering.

4
 CHAPTER 6 REFERENCES
[1] [Online]. Available: https://laxmihyundai.com/about.
I. Y. Suleyman Tasgetiren, "Two cases of failure in the power transmission systems
[2] on vehicles: A universal joint yoke and a drive shaft," Engineering Failure Analysis,
vol. 14, no. 4, pp. 716-724, 2007.
[3] [Online]. Available: https://repairpal.com/electrical-lights.
I. Y. M. AUTOMOTRIZ, "INGENIERÍA Y MECÁNICA AUTOMOTRIZ," 01 April
[4] 2019. [Online]. Available: https://www.ingenieriaymecanicaautomotriz.com/fuel-
system-components-working-principles-symptoms-and-emission-controls/.
S. Thorat, "Learn Mech," [Online]. Available: https://learnmech.com/types-of-brakes-
[5]
different-types-of-braking-system/.
[6] H. M. co, "Motor-driven power steering system". USA Patent US7374015B2, 2004.
"SAP Business One," [Online]. Available:
[7]
https://www.sap.com/products/erp/business-one.html.
[Online]. Available:
[8]
https://www.ngkntk.co.jp/english/product/sensors_plugs/knock.html.
27 October 2021. [Online]. Available:
[9]
https://www.utmel.com/blog/categories/sensors/what-is-a-knock-sensor.
[Online]. Available: https://www.hella.com/techworld/uk/Technical/Sensors-and-
[10]
actuators/Car-knock-sensor-troubleshooting-4012.

4
APPENDIX

4
 A CASE STUDY ON AIRBAG CHECKLIGHT AND VEHICLE
PULL IN A STRAIGHT LINE

Table 3: Dealer Investigation Report of Airbag Checklight and Vehicle pull

Dealer Investigation Report

REG. No.:
Vehicle Model Creta Gasoline Dealer Name Laxmi Intercontinental
Chassis No. Vehicle Sold
Engine No. DIR date
Kilometer DIR Made By

Customer Complaint Details:

1. The airbag sign was displayed on dashboard and steering wheel function keys doesn’t work
properly.
2. Vehicle pulls in one side
Symptoms: Observations / Verification of Complaint:
What happened Vehicle pulls in one direction on driving and there was airbag sign in dashboard

Where it Kathmandu Nepal

happened

When it happened February 2023

How does it Air bag sign was due to faulty clock spring, and vehicle was pulled in one
happen direction while travelling in a straight line was due to tie rod was screwed a bit
inside.
Diagnosis Procedure
1. GDS was used to scan for Airbag Sign in dashboard.
2. Tire pressure was checked.
3. Test drive was done to verify the complaint.
4. Under body inspection was done to check if the suspension system is in good condition.
Diagnosis Decision
1. Airbag sign was due to the failure in clock spring and due to same issue function keys on steering
wheel were not working properly.

4
 2. Tire pressure was correct.
3. On under body inspection we found that front right lower arm was hit badly by local repairs
when they tried to solve wheel alignment issue. There was no option other than changing it. It
was changed.
4. Wheel alignment was done at last.
Part / Aggregate involved
PART NO PART NAME QUANTITY
1 PC
CLOCK SPRING

LOWER ARM RH 1 PC

Summary of the Case

The clock spring at one end of the conductive ribbon serves as the connection between
the electrical systems for the steering wheel and airbag. The systems required to run
turn signals, the horn, cruise control, and other devices are operated by clock springs.
Circuitry is engraved on the conductive ribbon, allowing currents to freely flow through
the channels as the wheel revolves. Electrical ribbons and their connections can wear
out with time, which can lead to clock springs being unreliable. If they are not changed
following a car collision in which the airbag was deployed, they are also susceptible to
failure.

Figure 35: Lower arm and clock spring

Common signs of faulty clock spring include:

5
 Illumination of the SRS/Airbag light.

5
  No sound when hitting the horn.
 Noises coming from the steering column.
Lower arms are hinges that hold the wheels to the frame and connect the steering to the
wheels. They basically hold the wheels in the right place. All a car’s weight other than
the wheels (and things mounted on them, like the brakes) is suspended by a series of
levers and springs - it ‘floats’ above the wheels. The lower control arms determine the
actual location of the wheel's bottom bearing in relation to the rest of the vehicle. This
arm controls the camber angle, as well as the longitudinal and lateral positions of the
wheel. It resists three types of forces: longitudinal forces brought on by changes in the
road's surface or by the vehicle's acceleration and deceleration; cornering forces
resulting from turning; and vertical forces brought on by the weight of the suspended
body. A flaw in the lower arms impairs wheel alignment because it retains the wheels in
the proper position. Local repairs shouldn't have been too hard on the lower arm. They
were unable to resolve the wheel alignment issue as a result.

5
 A CASE STUDY ON STEERING NOISE

Table 4: Dealer Investigation Report for Steering Noise

Dealer Investigation Report

Reg. NO.:
Vehicle Model Creta Petrol Base Dealer Name Laxmi
Intercontinental
Chassis No. Vehicle Sold
Engine No. DIR date
Kilometer DIR Made By

Customer Complaint Details:

1. Steering Noise
2. Vehicle pulls right on straight driving
Symptoms: Observations / Verification of Complaint:
What happened While driving, the vehicle pulled right and there was steering noise.

Where it happened Kathmandu, Nepal

When it happened January 2023

How does it happen Most common reason for vehicle pull is unbalanced tire pressure in all tires. There
might also be reasons related to bushes, steering, tie rods, joints etc. which are to be
investigated.

Diagnosis Procedure
1. A test drive was done first to verify the complaint.
2. There was a noise on steering and vehicle was right pulled.
Diagnosis Decision
1. The noise was from the steering rack. As it is not repaired in the service center, It was changed
and calibrated.
2. Front Right tire has less pressure. It was pressurized.
Part / Aggregate involved Supplier

PART NO PART NAME QUANTITY SPECIFICATION

GEAR
1
**600 - 0X570 STEERING

5
Summary of Case Study
The rack and pinion steering system might have one or more issues over time, just like
any other part of a car. Any rack and pinion steering issue must be identified and fixed
as soon as feasible because this component is essential for efficiently steering and
controlling our car. Over time, some rack and pinion systems will deteriorate. As they
are regularly engaged during driving and steering, the gears are subject to wear and tear
over time. These gears eventually develop loose fits due to the metal's deterioration with
use.

Figure 36: Faulty Steering Rack

An automobile should be inspected as soon as possible if a rack and pinion steering
issue is detected. A malfunctioning system not only puts the car's safety in jeopardy, but
the early issues can develop much worse very rapidly. The entire system could need to
be rebuilt or replaced, depending on elements like age and the gravity of the issue.
Drivers may notice the several issues when driving like:
• The steering wheel feels looser than normal.
• it takes more effort to keep the car driving in a straight line down the road.
• noises such as squeals, hisses, and knocks are present.
• the steering wheel feels unusually stiff.
5
• inability of the steering wheel to return to its normal position when turned.

5
SWOT ANALYSIS OF THE COMPANY

SWOT stands for Strengths, Weaknesses, Opportunities, and Threats. So, it deals with
these aspects. It is used to evaluate the company’s competitive position and to develop
strategic planning. Analyzing and identifying internal and external factors that will
influence the future direction and success of the organization and its business comprises
strength and weakness which are internal factors and opportunities and treats which are
external factors. It helps managers in strategic planning.

Strength Weakness
 Strong Brand name  Unavailability of spare parts
 Skilled workforce  High operation cost
 Modern diagnosis methods and  Limited hours of operation
technologies  Competition

Opportunities Threats
 Expansion of services  Changing in customer preferences
 Online presence  Price competition
 Green initiatives  Technological advancement

Strength

 Strong brand name: Hyundai is a world-recognized brand. So, it can attract

customers because of its name too.
 Skill workforce: L.I service center has a team of skilled manpower with in-
depth technical knowledge which helps to address the issue in short period of
time.
 Modern diagnosis method and technologies: Due to changes in the technology
that is used in the car this service center can keep up to date in the market.

Weakness

 Unavailability of spare parts: Sometimes customers don’t get the right parts
and supplies as this service center depends on suppliers which lead to delays in
service.
 High operation cost: Running an automobile service center can be expensive
due to the high cost of equipment, supplies, and skilled labor.
 Limited hours of operation: Service centers may have limited hours of
operation, which can limit their ability to serve customers.

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  Competition: There may be other automobile service centers nearby, which can
make it difficult to attract customers.

Opportunities

 Expansion of services: Service centers can explore new service offerings, such
as car detailing or mobile repair services, to increase their revenue and attract
new customers.
 Online presence: Establishing an online presence, such as a website or social
media accounts, can help service centers reach new customers and promote their
services.
 Green Initiatives: Implementing eco-friendly practices, such as using energy-
efficient equipment and recycling materials, can attract environmentally
conscious customers.

Threats

 Changing customer preferences: Changes in consumer preferences, such as a

shift towards electric cars or ride-sharing services, can reduce demand for
traditional automobile services.
 Price Competition: Other service centers may offer lower prices, which can
make it difficult to attract customers.
 Technological Advancements: Advancements in technology may make it
difficult for service centers to keep up with the latest diagnostic and repair
techniques, which can impact their ability to provide quality services.

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 A CASE STUDY ON KNOCK SENSOR, IT’S FAILURE AND
TROUBLESHOOTING

Prepared by: Ramesh Bhandari

Group: ME (Design and Manufacturing)
Department of Mechanical Engineering, Kathmandu University

INTRODUCTION
A knock sensor is a crucial component that is being used in automobiles. This sensor is
in the head of the cylinder of an engine. The primary function of this sensor is to
produce a voltage indication in response to explosion-related vibrations. Pre-ignition
occurs when we see or hear a knocking or pinging sound along with the noise of an
engine in a vehicle. This ignition can occur because the air mixture or fuel pocket
sparked in front of the flame from the flash plug. So, a small shock wave generated
around the ignition, which causes pressure to increase within the cylinder. In some
cases, it might lead to damage to the engine.

Figure 37: Knock sensor

WORKING PRINCIPLE OF KNOCK SENSOR
Piezoelectric ceramics are commonly used material in knock sensors. Piezoelectric
ceramics are those materials which can turn mechanical effects such as pressure,
motion, or vibration into electrical vibration or vice-versa. Thus, knock sensors detect
those effects and convert them into AC signals when engine knocks. Engine damage
can be caused by engine knock, which is triggered by early ignition, poor exhaust gas

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recirculation, low-graded fuel, and other factors. The knock sensor sends a knock signal
to the ECU which allows the computer to modify ignition timing to prevent future
knocks. They are often built to measure frequencies in the range of 5 to 15 Khz.

A pressure wave having frequency of 1- 10 KHZ is produced when engine knocks.

Thus, the produced pressure wave is transmitted to the cylinder block, creating vibration
acceleration in the metal particles. This knock pressure is detected by accelerometer
knock sensor, which measures the vibration acceleration on cylinder block’s surface.

SYMPTOMS OF FAULTY KNOCK SENSOR

A faulty sensor can be detected in different ways during fault discovery through control
unit, which includes the following.

 Engine check light is on

When Powertrain Control Module (PCM) detects a faulty knock sensor or
circuit, it will turn the engine check light on and trigger a related diagnostic
trouble code (DTC).
 A pinging noise from the engine
In the case of knock sensor failure, the PCM may not be able to recognize or fix
the spark knock. The failed sensor can result in a metallic pinging noise from the
engine. We can also notice that sounds get prominent when engine is under a
heavy load.
 Bad engine performance
A malfunctioning knock sensor can cause the PCM to wrongly adjust the
ignition timing, resulting in inadequate engine performance.
 Poor acceleration
Vehicle will not accelerate properly when there is a faulty knock sensor, which
ultimately causes reduced fuel economy.
 Power loss
Once the Engine Control Unit realizes the knock sensors is not working
properly, car is most likely to lose power. The amount of power lost depends on
the octane lime of the engine and how heavily it depends on knock sensor input.
High compression engine (i.e., Diesel engine) is mostly like to lose its power.

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CAUSES OF KNOCK SENSOR FAILURE
There are various causes which cause failure of knock sensors. The few potential causes
are illustrated below:

 Short circuit inside the engine or damage in wiring

 The spark ignition doesn’t occur in timely.
 Improper air and fuel mixture ratio
 Deposits like dirt/ contaminants entering the cylinders.
 Faulty spark plugs/ Incorrect spark plugs gaps.
 Low octane fuel
 Incorrect mounting of knock sensor
 Abnormally high engine operating temperatures
 Carbon buildup inside the combustion chambers
CHECKING THE CAR KNOCK SENSORS
Troubleshooting of knock sensor

 Read out the stored fault code.

 Check the sensor for correct fit and tightening torque.
 Check the electrical connections of the sensor wiring, the plug, and the sensor
for correct connection, breaks, and corrosion.
 Check the ignition point (older vehicles)
Testing with the multimeter

Check the wire which is connected to the control unit by checking continuity and short
circuit to frame for every wire to the control unit plug.
Connect the
ohmmeter. Setpoint: <
1 Ohm
Connect the ohmmeter between the knock sensor connector and the removed control
unit connecter.

Check the pin against ground using an ohmmeter

Check the respective pin at the wiring harness connector against ground using an
ohmmeter and with the control unit connector removed.
Setpoint: at least 30 mOhm
Note: A connection pin can act as shielding and thus have continuity to ground.

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 CONCLUSION
This case study examines the various topics related to knock sensors. As modern
vehicles comprise many sensors and knock sensor is found to be one of the important
sensors inside vehicle. Knock sensors help to prevent knocking inside the engine by
adjusting ignition time with the help of control unit. So, to prevent engine failure and
get the engine performance continuously for longer periods of time as well as to get the
indicated mileage, it is suggested to inspect the knock sensors wiring time to time or
troubleshooting can be done regularly. It is suggested to replace the knock sensor
immediately when knock sensor failed.

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