Summer trainning iproject hyundai ii

SUMMER TRAINNING
AT
LALZ HYUNDAI
A REPORT Submitted by :- ANAND PRATAP
ROLL NO :- 143068
BATCH :- MECHANICAL
SESSION :- 2014-18
COLLEGE :- NETAJI SUBAHSH INSTITUTE OF TECHNOLOGY
Page 1 of 47

ACKNOWLEDGEMENT
I am truly thankful to all the guides who imparted the lectures
on various topics and took me to the machine workshops in a guided
study visit along detailed explaining about the cars and their parts
and problems.
I am indebted to respected officers and engineers:
1) Mr. Santosh kumar (HRD)
2) Mr. Tiwari (Service Manager)
3) Mr. Rahul Kumar (Asst.Supervisor)
I am thankful rather grateful for such whole hearted cooperation of
not only them but also all members of HYUNDAI like mechanics n
other staffs who helped me with their patient & friendly behaviour
throughout the Internship training tenure to demonstrate &
illustrate the work & helping us in every single step & to bring up
this report.
Page 2 of 47

CONTENTS
1) Executive summary
2) Company Profile
3) Introduction to Project
4) Departments
5) Case Study
6) Engine
7) Problems Faced By AutomobiLE
8) Bibilography
9) Conclusion
Page 3 of 47

1. EXECUTIVE
SUMMARY
Page 5 of 47

(In Pictures HYUNDAI MOTORS GROUP
CHAIRMAN Chung mong koo and his son
and vice)
Chung Ju-Yung founded the
Hyundai Engineering and
Construction Company in 1947.
Hyundai Motor Company was
later established in 1967. The
company's first model, the
Cortina, was released in cooperation with Ford Motor Company in 1968.
When Hyundai wanted to develop their own car, they hired George Turnbull,
the former Managing Director of Austin Morris at British Leyland. He in turn
hired five other top British car engineers. They were Kenneth Barnett body
design, engineers John Simpson and Edward Chapman, John Crosthwaite ex-
BRM as chassis engineer and Peter Slater as chief development engineer.In
1975, the Pony, the first Korean car, was released, with styling by Giorgio
Giugiaro of ItalDesign and powertrain technology provided by Japan's
Mitsubishi Motors. Exports began in the following year to Ecuador and soon
thereafter to the Benelux countries. In 1984, Hyundai exported the Pony to
Canada, but not to the United States, because the Pony didn't pass emissions
Page 6 of 47

standards there. Canadian sales greatly exceeded expectations, and it was at
one point the top-selling car on the Canadian market. In 1985, the one
millionth Hyundai car was built.
In 1986, Hyundai began to sell cars in the United States, and the Excel was
nominated as "Best Product #10" by fortune magazine, largely because of its
affordability.
The company began to produce models with its own technology in 1988,
beginning with the mid size Sonata. In the spring of 1990, aggregate production
of Hyundai automobiles reached the four million mark. In
1991, the company succeeded in developing its first proprietary gasoline
engine, the four- cylinder Alpha, and also its own transmission, thus paving
the way for technological independence. In 1996, Hyundai Motor India
Limited was established with a production plant in Irungattukottai near
Chennai, India.
Page 7 of 47

2.COMPANY
PROFILE
THE HYUNDAI GROUP:COMPANY OVERVIEW
Page 8 of 47

(CHUNG JU YUNG)
Hyundai is a global company with local understanding, founded by Chung Ju-
Yung in 1947.It was later established in 1967. The company was founded in
1967 and, along with its 32.8% owned subsidiary,Kia Motors ogether
comprise the Hyundai Motor Group, which is the world's fifth largest
automaker based on annual vehicle sales in 2012.
In 2008, Hyundai Motor (without Kia) was ranked as the eighth largest
automaker. As of 2012, the Company sold over 4.4 million vehicles
worldwide in that year and together with Kia, total sales were 7.12 million.
Hyundai is currently the fourth largest vehicle manufacturer in the world.
Hyundai operates the world's largest integrated automobile manufacturing
facility in Ulsan, South Korea, which has an annual production capacity of 1.6
million units.
The company employs about 75,000 people worldwide. Hyundai vehicles are
sold in 193 countries through some 6,000 dealerships and showrooms.
Hyundai is a private ,diversified company which is very well distributed all
over the parts of the world.
HYUNDAI INDIA
Page 9 of 47

Hyundai Motor India Ltd is a wholly owned subsidiary of the Hyundai Motor
Company in India. It is the 2nd largest automobile manufacturer in India.
Hyundai Motor India Limited was formed in 6 May 1996 by the Hyundai
Motor Company of South Korea.
When Hyundai Motor Company entered the Indian Automobile Market in
1996 the Hyundai brand was almost unknown throughout India. During the
entry of Hyundai in 1996, there were only five major automobile
manufacturers in India, i.e. Maruti, Hindustan, Premier, Tata and Mahindra.
Daewoo had entered the Indian automobile market with Cielo just three
years back while Ford, Opel and Honda had entered less than a year back. For
more than a decade till Hyundai arrived, Maruti Suzuki had a near monopoly
over the passenger cars segment because Tata Motors and Mahindra &
Mahindra were solely utility and commercial vehicle manufacturers, while
Hindustan and Premier both built outdated and uncompetitive products.
ABOUT :- LALZ HYUNDAI (Dasaratha,Patna)
A LALZ HYUNDAI IS A HYUNDAI AUTHORISED SERVICE CENTER which is
located near sipara over bridge , Dusrattha,patna. His owner name is
MR.SANTOSH KUMAR.
My whole training period was done over here . I had learned everything related
to Hyundai services and facilities.
Page 10 of 47

picture taken during the repairment of Hyundai Eon.
Page 11 of 47

Hyundai car Models
• Hyundai Eon
• Hyundai i10
• Hyundai Grand i10
• Hyundai Xcent
• Hyundai Elitei20
• Hyundai i20Active
• Hyundai Fluidic Verna
• Hyundai Creta
• Hyundai Elantra
• Hyundai Santro XING
These are the current vehicles that are being manufactured by the Hyundai Company.
All previous models are discontinued.
The speciality of this company is that it manufactures cars for all types of economic
people and the models are in both petrol and diesel engine which gives a choice to
people to choose one as per their comfort.
These all car models are available in both petrol and diesel engine.
Page 13 of 47

New upgraded model launched in 2017 HYUNDAI ELANTRA.
Page 14 of 47

3.INTRODUCTION
OBJECTIVE
Page 15 of 47

 To understand the complexity of the problems faced by the four wheelers and to
solve it’s complexities.
 Understand the basic parts of the car and to know about everything in a very
precise manner.
 Manage the problems that are happening in the vehicle such as: Toe in/Toe out
problem, Knocking, Axle noise,Gear problems, Clutch problems etc.
 To study and learn the whole process required during serving of the vehicle.
 Resolving all the problems one by one by knowing about the material and
product use.
 To learn the way of providing the customer satisfaction.
Page 16 of 47

4.DEPARTMEN
T
The company where I did my Internship was having two major
departments :-
1. Maintenance department.
2. Repairing and Painting workshop.
Page 17 of 47

3. Office work
4. Accessories & parts storage
 Picture of Painting workshop In LALAZ HYUNDAI.
Page 18 of 47

Function of the departments: Each department was equally important
because at first what used to happen is any car or automobile is first sent to
the maintenance department, there people used to check all the probable
problems that a car is being going through after that a list of problem is to be
make so that the person doesn’t have to look again and waste time in finding
the problem.
It is a time saving
process. After the
maintenance department
the vehicle is send to the
repairing workshop
where the vehicle is first
washed up properly and
than the workers with
their impeccable skills
and work experience
solves the problem of the
automobiles. These all
repairing are all done in
different workshop that
is Repairing Workshop.
The Cars who met with
accidents and their body
parts were wrecked were
also been repaired in that
workshop some of the
automotive needed to be
painted were also done in that repairing workshop.
In this above image lalz Hyundai Mechanic named sarfaraj ahmad is working
on the parts of refrigeration system used in vechicle for cooling.
Page 19 of 47

5.Case study
THE AUTOMOTIVE INDUSTRY IN INDIA
Page 20 of 47

The Automotive industry in India is one of the largest in the world and one of
the fastest growing globally. India manufactures over 17.5 million vehicles ( 4
wheeled) and exports about 2.33 million every year.
It is the india's second largest manufacturer of cars, with annual sales
exceeding 8.5 million in 2009. India's passenger car and commercial vehicle
manufacturing industry is the fourth largest in the world, with an annual
production of more than 3.7 million units in 2010. According to recent
reports, India is set to overtake Brazil to become the sixth largest four
wheeler vehicle producer in the world, growing 16-18 per cent to sell around
three million units in the course of 2011-12.
In 2009, India emerged
as Asia's fourth largest exporter of passenger cars, behind Japan, South
Korea, and Thailand. As of 2010, India is home to 40 million passenger
vehicles and more than 3.7 million automotive vehicles were produced in
India in 2010 (an increase of 33.9%), making the country the second fastest
growing automobile market in the world. According to the Society of Indian
Automobile Manufacturers, annual car sales are projected to increase up to 5
million vehicles by 2015 and more than 9 million by 2020. By 2050, the
country is expected to top the world in car volumes with approximately 611
million vehicles on the nation's roads.
Page 21 of 47

6.ENGINE
Fig :- Picture of engine during servicing of vehicle at Lalz Hyundai
(HYUNDAI authorized service centre).
Petrol Engine
Page 22 of 47

A petrol engine (known as a gasoline engine ) is an internal combustion
engine with spark- ignition, designed to run on petrol (gasoline) and similar
volatile fuels. It was invented in 1876 in Germany by German inventor
Nikolaus August Otto. In most petrol engines, the fuel and air are usually pre-
mixed before compression (although some modern petrol engines now use
cylinder-direct petrol injection). Four-stroke engine- A four-stroke engine
(also known as four cycle) is an internal combustion (IC) engine in which the
piston completes four separate strokes while turning a crankshaft. A stroke
refers to the full travel of the piston along the cylinder, in either direction.
The four separate strokes are termed:
Page 23 of 47

1. Suction: This stroke of the piston begins at top dead center (T.D.C.) and
ends at bottom dead center (B.D.C.).
In this stroke the intake valve must be in the open position while the piston
pulls an air-fuel mixture into the cylinder by producing vacuum pressure into
the cylinder through its downward motion.
2. Compression: This stroke begins at B.D.C, or just at the end of the suction
stroke, and ends at T.D.C. In this stroke the piston compresses the air-fuel
mixture in preparation for ignition during the power stroke (below). Both the
intake and exhaust valves are closed during this stage.
3. Power: This is the start of the second revolution of the four stroke cycle. At
this point the crankshaft has completed a full 180° revolution. While the
piston is at T.D.C. (the end of the compression stroke) the compressed air-
fuel mixture is ignited by a spark plug (in a gasoline engine) or by heat
generated by high compression (diesel engines), forcefully returning the
piston to B.D.C.
This stroke produces mechanical work from the engine to turn the
crankshaft.
4. Exhaust: During the exhaust stroke, the piston once again returns to T.D.C
from B.D.C while the exhaust valve is open.
This action expels the spent air-fuel mixture through the exhaust valve.
2- STROKE ENGINE:-
Page 24 of 47

A two-stroke or two-cycle, the motor is a sort of inside ignition motor which
finishes a forced cycle with two strokes (here and there developments) of the
cylinder amid stand out crankshaft unrest. In a two-stroke motor, the end of
the ignition stroke and the start of the pressure stroke happen at the same
time, with the admission and deplete (or searching) capacities happening in
the meantime. Two-stroke motors frequently have a high energy-to-weight
proportion, for the most part in a tight scope of rotational velocities called
the “force band”. The two-stroke motor that has the in-barrel pressure is
credited to Scottish architect Dugald Clerk, who protected his outline in 1881.
In any case, not at all like later two-stroke motors, his had a different
charging barrel. The crankcase-searched motor, utilizing the range beneath
the cylinder as a charging pump, is, for the most part, credited to Englishman
Joseph Day. The primary really common sense two-stroke motor is ascribed
to Yorkshireman Alfred Angas Scott, who began creating twin-barrel water-
cooled cruisers in 1908.
Page 25 of 47

Comparison between 4-stroke engine and 2-stroke engine :-
Page 26 of 47
2-stroke engine 4-stroke engine
When the cycle is completed in one revolution of
crankshaft , it is called as 2-stroke cycle engine.
When the cycle is completed in two revolutions of
crankshaft, it is called as 4-stroke cycle engine.
One power stroke for each revolution of the
crankshaft.
One power stroke for every two revolutions of the
crankshaft.
There are inlet and exhaust ports in the engine. There are inlet and exhaust valves in the engine.
The crankshaft is fully closed and also it is air
tight. The crankshaft is not fully closed and air tight.
Both sides of piston compress the charge. Top of the piston compresses the charge.
Size of the flywheel is comparatively smaller. Size of the flywheel is comparatively larger.
Fuel is not fully consumed. Fuel is fully consumed.
Weight of engine per hp is comparatively low. Weight of engine per hp is high.
Thermal efficiency is comparatively low. Thermal efficiency is high.
Removal of exhaust gases comparatively difficult. Removal of exhaust gases easy.
Torque produced is less even. Torque produced in even.
For given weight, 2-stroke engine gives twice
power compare to 4-stroke engine.
For same weight, 4-stroke engine would give only
half power of 2-stroke engine counterpart.
Mostly high speed engines are in this type. All speed types are possible.
This engine can be operated in both the directions
i.e. clockwise and anti-clockwise. This engine can be operated in one direction only

Diesel ENGINE:-
Diesel Engine The diesel engine (also known as a compression-ignition or 'CI'
engine) is an internal combustion engine in which ignition of the fuel that has
been injected into the combustion chamber is initiated by the high
temperature which a gas achieves when greatly compressed .
This contrasts with spark-ignition engines such as a petrol engine (gasoline
engine) or gas engine (using a gaseous fuel as opposed to gasoline), which
use a spark plug to ignite an air- fuel mixture.
The diesel engine has very good thermal efficiency (engine efficiency) due to
its very high compression ratio and inherent lean burn which enables heat
dissipation by the excess air. A small efficiency loss is also avoided compared
to two-stroke non-direct-injection gasoline engines since unburnt fuel is not
present at valve overlap and therefore no fuel goes directly from the
intake/injection to the exhaust. Diesel engines can have a thermal efficiency
that exceeds 45%. Diesel engines are manufactured in two-stroke and four-
stroke versions.
They were originally used as a more efficient
replacement for stationary steam engines.
Page 27 of 47

Difference Between Petrol and Diesel Engine in Tabular Form:-
Page 28 of 47

S.N
o
Petrol Engine Diesel Engine
1. The petrol engine works on Otto
cycle i.e. on constant volume.
The diesel engine works on diesel cycle i.e. on
constant pressure.
2. The air and petrol are mixed in the
carburetor before they enter into the
cylinder.
The fuel is fed into the cylinder by a fuel
injector and is mixed with air inside the
cylinder.
3. The petrol engine compresses a
mixture of air and petrol which is
ignited by an electric spark.
The diesel engine compresses only a charge of
air and ignition is done by the heat of
compression.
4. Compression ratio is low. Compression ratio is higher in diesel engine.
5. Less power is produced due to lower
compression ratio.
Due to higher compression ratio more power
is produced.
6. Petrol engine is fitted with a spark
plug
It is fitted with a fuel injector.
7. Burns fuel that has high volatility. Burns fuel that has low volatility.
8. They are used in light vehicles which
requires less power
Eg: car, jeep, motorcycle, scooters etc.
They are used in heavy vehicles which
require high power.
Eg: bushes, trucks, locomotive etc.
9. Fuel consumption in petrol engine is
high.
Fuel consumption in diesel engine is less.
10. Lighter Heavier
11. Petrol engine requires frequent
overhauling.
Overhauling of diesel engine is done after a
long time.
12. Lesser starting problem. Greater starting problem.
13. Lower initial cost. Higher initial cost.
14 Lower maintenance cost. Higher maintenance cost.
Page 29 of 47

CHAPTER 7.
Problems Faced By
Automobile
There are certain problems which are faced by every automobile when it is
being used for a long period of time.
Page 30 of 47

Certain Problems are :-
 Knocking
 Camber,Caster and Toe
 Engine Seizure
 Over rigid suspension
 Rough Idling or Low Idling
 Brake Seizure
 Clutch
 Accidental vehicles
These are the problems which are generally faced by all type of automobiles
either it’s a petrol engine or diesel engine. That’s why experts gives advice of
getting our car for SERVICING after 5,000 km of ride and to replace oils for
every 10,000 km of ride.
KNOCKING
Page 31 of 47

Engine-knock is among the most disturbing problems a vehicle can have, but
not many people know what it is, or how it is caused. Basically, engine knock
(also known as pinging, detonation and spark knock) occurs when the
air/fuel mixture inside a cylinder is incorrect, which makes the fuel burn
unevenly. Under normal conditions, the fuel burns in pockets, rather than in
one giant fireball within, and when each pocket of fuel burns, a shock occurs
that burns the next until all the fuel is burned in that stroke. When a knock is
present, the pockets don't burn evenly, causing shock waves at the wrong
times that can damage the cylinder wall and the piston itself. This also
creates the common "pinging" noise that is often described when knock is
present.
Engine knock can be caused by many things, however, some of the most
common are as follows:
• The fuel in your car has too low of an octane rating. - The octane rating of
gasoline is sometimes known as the AKI--anti-knock index. If you use gas that
has an AKI that is too low, you can use an octane booster, to bring it back to
levels that will allow normal function. If you use the correct rating and it still
has issues, try a different brand of gasoline.
• Carbon deposits on cylinder walls. - All fuels sold in INDIA are required to
have a certain level of carbon cleaning detergent in them, however this may
not be enough to stop deposits from forming. When deposits form, the
volume of the cylinder is effectively decreased, which increases compression
that can cause knock. To combat this, add additive detergents and then try
switching fuels. If your car is prone to knock, you may want to add the
detergent at every fill-up.
• Your vehicle has incorrect spark plugs. – There are different spark plugs for
every vehicle, and often list some alternatives. If your car is running anything
other than
Camber, Caster And Toe :-
Page 32 of 47

The three major alignment parameters on a car are toe, camber, and caster.
Camber The most widely discussed and controversial of the three elements is
camber. Camber angle is the measure in degrees of the difference between
the wheels vertical alignment perpendicular to the surface. If a wheel is
perfectly perpendicular to the surface, its camber would be 0 degrees.
Camber is described as negative when the top of the tires begin to tilt inward
towards the fender wells. Consequently, when the top of the tires begin to tilt
away from the vehicle it is considered positive. (TOP RIGHT) Positive
camber: The bottoms of the wheels are closer together than the tops. (TOP
LEFT) Negative camber: The tops of the wheels are closer together than the
bottoms. (CENTER) When a suspension does not gain camber during
deflection, this causes a severe positive camber condition when the car leans
during cornering. This can cause funky handling. (BOTTOM) Fight the funk: A
suspension that gains camber during deflection will compensate for body
roll. Tuning dynamic camber angles is one of the black arts of suspension
tuning.
Caster
• It is defined as the angle created by the steerings pivot point from the front
to back of the vehicle. Caster is positive if the line is angled forward, and
negative if backward.
• Typically, positive caster will make the vehicle more stable at high speeds,
and will increase tire lean when cornering. This can also increase steering
effort as well.
• Most road vehicles have what is called cross-caster. Cross castered vehicles
have slightly different caster and camber, which cause it to drift slightly to
the right while rolling. This is a safety feature so that un-manned vehicles or
drivers who lose steering control will drift toward the side of the road
instead of into oncoming traffic.
Page 33 of 47

Toe
• Perhaps the easiest concept to visualize is toe. Toe represents the angle
derived from pointing the tires inward or outward from a top-down view –
much like looking down at your toes and angling them inward or outward. •
Correct toe is paramount to even tread wear and extended tire life. If the tires
are pointed inward or outward, they will scrub against the surface of the road
and cause wear along the edges. Sometimes however, tread life can be
sacrificed for performance or stability
• Positive toe occurs when the front of both tires begins to face each other.
Positive toe permits both wheels to constantly generate force against one
another, which reduces turning ability. However, positive tow creates
straighter driving characteristics.
• Typically, rear wheel drive vehicles have slightly positive tow in the rear
due to rolling resistance – causing outward drag in the suspension arms. The
slight positive toe straightens out the wheels at speed, effectively evening
them out and preventing excessive tire wear.
• Negative toe is often used in front wheel drive vehicles for the opposite
reason. Their suspension arms pull slightly inward, so a slight negative toe
will compensate for the drag and level out the wheels at speed.
• Negative toe increases a cars cornering ability. When the vehicle begins to
turn inward towards a corner, the inner wheel will be angled more
aggressively. Since its turning radius is smaller than the outer wheel due to
the angle, it will pull the car in that direction.
• Negative toe decreases straight line stability as a result. Any slight change in
direction will cause the car to hint towards one direction or the other.
Page 34 of 47

Engine Seizure
Many people believe that piston seizures occur when engine heat causes the
piston to expand larger than the size of the cylinder bore. This is not true. If
you could freeze your engine "in motion" in the middle of a long full throttle
pass, and disassemble it for micrometre measurement, you would find the
piston skirt to measure at a 0.0000 to 0.0005" or so press fit into the bore.
That's right, a slight press fit! The reason that it doesn't seize is because the
premix oil has such a terrific film strength that it acts as an unremovable
buffer between the piston and the cylinder. That is, the bare metal surface of
the piston never actually touches the bare metal surface of the cylinder
because the oil stays between them.
Many mechanics have experienced this phenomenon while cleaning a freshly
bored cylinder. Completely dry without cleaning solvent, the piston moves
through the bore with difficulty. After rinsing the piston glides all the way
through with no resistance at all. This is because the solvent acts as a film
between the piston and cylinder.
A piston seizure can only occur when something burns or scrapes away the
oil film that exists between the piston and the cylinder wall. Understanding
this, it's not hard to see why oils with exceptionally high film strengths are
very desirable. Good quality oils can provide a film that stands up to the most
intense heat and the pressure loads of a modern high output engine. Seizure
is a case of scoring where the oil film does not immediately return. After a
few moments of constant scoring, the piston and cylinder will scratch each
other hard enough to remove material from each other. This floating material
grinds itself into the piston and the cylinder as it continues to grow in size. As
this snowballing material grows, it will drive the opposite side of the piston
against the cylinder wall with a pressure so terrific that scoring begins to
take place. While all this is going on, your engine is still running wonderfully
at full throttle. The death blow comes when the mass of material between the
piston and the cylinder wall finds it's way to the piston ring. This nearly
molten mixture of aluminium and iron will instantly lock the ring in it's
Page 35 of 47

groove. This ring locking, not the piston surface seizure, is what actually
causes your engine to quit. When the piston ring becomes locked back in it's
groove, it's incapable of providing compression sealing against the cylinder
wall. This instant loss of compression, while the engine is at speed, causes a
dramatic loss of power.
Brake Seizure
Fixing seized brakes can only be successfully completed if you can determine
what caused them to seize. A sticking or stuck calliper piston, a pad stuck in a
caliper anchor, a clogged brake hose or a frozen slide can cause seizure in
disc brakes. Over adjusted shoes, an improperly functioning parking brake
system, a frozen wheel cylinder bore or a broken or dislodged component
wedged between the shoe and drum can all be leading causes to drum brake
seizure.
How to rectify the Brake seizure problem:
• Lift the vehicle (in neutral gear) on a vehicle lift to allow the wheels to
suspend. Test each wheel to determine which wheel or wheels has drag or
will not turn by hand. Remove the hubcap, and then remove the wheel nuts
with an impact gun and socket. Remove the wheel.
• Inspect the caliper on disc brakes first. Remove the caliper bolts and pry the
caliper off the rotor and pads using a pry bar. If the caliper comes off hard
without the brakes being applied, a caliper piston is most likely to blame. To
check the piston, secure the caliper to the vehicle with a caliper hook.
Remove the pads if they are clipped to the caliper. Inspect the pads. A clear
indication of stuck brakes is premature wear of brake pads. Compress the
piston of the caliper with a caliper piston tool. A large C-clamp would work as
well. If the caliper piston does not retract back into the bore, it has seized and
needs to be replaced. Replace the caliper and bleed the hydraulic braking
system.
Page 36 of 47

• Inspect the caliper slides if the piston retracted properly. Caliper slides can
also become contaminated or the protective rubber boots may crack and
allow water, rust, sand and other corrosive elements to seize the caliper
slides. If you're able to remove the slides (it will be somewhat difficult), you
can clean them off thoroughly with the die grinder (or a bench grinder with a
wire brush wheel works well) and reapply brake lubricant to them. Reinstall
them, replace the compromised protective rubber boots and retest the
caliper after replacement.
• Pry the pads out of the caliper anchor for vehicles that use pads not clipped
to the caliper. When pads are installed, a high temperature brake lubricant is
applied to the contact points of the anchor. This allows the pads to move back
and forth when the caliper piston is applied and released. Because the brakes
are exposed to the elements of adverse weather conditions, it is common that
the lubricant washes away and rust and corrosion set in. This can cause the
tabs of the pads backing plates to seize inside the caliper anchors. Remove
the anchors and the pads. Clean the contact points of rust and corrosive
build-up with an angled die grinder and a reconditioning disc or a wire brush.
Remove the rattle clips and clean the caliper points beneath the clips. Apply
brake lubricant under and on the rattle clips. Replace the pads, replace the
anchor and then replace the caliper.
• Inspect the adjustment of the rear brakes. Remove the rubber plug (if
available) from the backing plate of the drum brakes. Insert a brake-adjusting
tool into the porthole along with a screwdriver to push the adjuster retainer
away. Turn the internal star wheel to back off the rear shoe adjuster and try
to turn the wheel. If you're able to, continue to readjust the star wheel until
you can easily remove the drum and inspect the adjuster mechanism. These
can be removed easily. Clean the threads of the adjuster, apply a liberal
amount of lubricant or anti-seize compound and reassemble.
• Inspect the rear brakes, once the drum has been removed. If a component
falls out of the drum or from the drum brakes when the drum is extracted,
the seizure of the brakes could have been caused by this part being wedged
between the drum and a shoe. Check the drum for scoring and the shoe for
Page 37 of 47

damage. Replace the component; replace the shoes if necessary. Machine the
drum or replace the drum, if needed.
• Press the bores of the wheel cylinder inward (1 at a time) with a
screwdriver to determine if the bores are stuck. The hydraulic pressure in the
braking system should allow the bore to expand back outward to contact the
horn of the shoe. If you compress the bore and it does not return or you
cannot compress the bore, then the wheel cylinder has failed and needs to be
replaced. Replace the wheel cylinder and bleed the braking system.
• Check the flow of brake fluid to the bleeder screws of the seized wheel. This
will determine if the hydraulic brake fluid is properly functioning. Have
someone pump the brake pedal 4 times and open the bleeder screw with a
hand wrench. If no fluid comes out of the bleeder screw, remove it. Have the
helper step on the brake pedal again. If fluid comes out, replace the bleeder
screw or unclog it. If fluid still does not come out, replace the bleeder screw
and disconnect the brake hose. Press the pedal again. If fluid does not come
out or barely trickles out, the brake hose should be replaced. Bleed the brake
system any time you replace a hydraulic brake component.
• Inspect the master cylinder and power brake booster.
To determine a bad master cylinder, place a brake line lock on each brake
hose at all 4 wheels. Have someone step on the brake pedal and remove 1 line
lock at a time. The pedal should remain high and hard until the lines are
removed and then slight pressure will release off each line lock removed. If
the pedal drops to the floor during the removal of 1 line lock, there's a
hydraulic problem with that particular wheel. If the pedal remains high and
hard once all the line locks are removed, the master cylinder may be the
problem. Check the vacuum line for the brake booster. Replace the master
cylinder and bleed the system.
Page 38 of 47

ENGINE IDLE
Engine idle is a good measure of your engine's health. If anything is going
wrong under the hood, there's a good chance it will be affecting your car's
idle speed and quality. Problems with idle speed, things like slow idle, low
idle, bad idle, lumpy idle, fast idle -- these are symptoms that should be
investigated, troubleshooted, diagnosed and repaired. The following
symptoms and related problems should act as a guide in helping you
troubleshoot your idle issues. Symptom: The engine will not idle smoothly, or
it stalls during idle when the engine is cold. When the engine is cold and you
take your foot off the gas pedal, the engine runs very rough and may even
stall. When you run the engine at higher speeds, it seems to run fine. Or at
least it runs more smoothly.
Possible causes:
1. If you have a carburetor (grandpa), you may have a bad accelerator pump
or power circuit. The Fix: Replace accelerator pump or replace carburetor.
2. There may be a vacuum leak. The Fix: Check and replace vacuum lines as
required.
3. There may be some type of ignition problem. The Fix: Check and replace
distributor cap, rotor, ignition wires and spark plugs.
4. The ignition timing may be set wrong. The Fix: Adjust ignition timing.
5. There may be a fault in the computerized engine control system. The Fix:
Check engine control systems with a scan tool. Test circuits and repair or
replace components as required. (Generally not a DIY job)
6. The EGR valve may be bad. The Fix: Replace EGR valve.
The engine may have mechanical problems.
The Fix: Check compression to determine engine condition.
1. Idle speed set incorrectly. The Fix: Set idle speed to specs.
2. The fuel injectors may be dirty. The Fix: Clean or replace fuel injectors.
Symptom: The engine will not idle smoothly, or it stalls during idle when the
engine is warm. When the engine is warm or hot and you take your foot off
the gas pedal, the engine runs very rough and may even stall. When you run
the engine at higher speeds, it seems to run fine.
Possible causes:
Page 39 of 47

1. If you have a carburetor (gramps), you may have a bad accelerator pump
or power circuit. The Fix: Replace accelerator pump or replace carburetor.
2. There may be a vacuum leak. The Fix: Check and replace vacuum lines as
required.
3. The fuel pressure regulator may be operating at too low a pressure. The
Fix: Check fuel pressure with a fuel pressure gauge. Replace fuel pressure
regulator.
4. Idle speed set incorrectly. The Fix: Set idle speed to specs.
5. There may be some type of ignition problem. The Fix: Check and replace
distributor cap, rotor, ignition wires and spark plugs.
7. The EGR valve may be bad. The Fix: Replace EGR valve.
8. The engine may have mechanical problems. The Fix: Check compression to
determine engThe fuel injectors may be dirty. The Fix: Clean or replace fuel
injectors.
Symptom: The engine idles too fast. After the engine has run long enough to
be warm, the idle speed does not come down to normal. You really notice it
when you come to a stop and must have to push hard on the brake pedal to
keep the car from moving.
Possible causes:
1. If you have a carburetor, you may have a bad accelerator pump or power
circuit. The Fix: Replace accelerator pump or replace carburetor.
2. The engine may be overheating. The Fix: Check and repair cooling system.
3. The fuel pressure regulator may be operating at too low a pressure.
The Fix: Check fuel pressure with a fuel pressure gauge. Replace fuel
pressure regulator. (Generally not a DIY job)
4. The ignition timing may be set wrong.
The Fix: Adjust ignition timing.
5. There may be some type of ignition problem.
The Fix: Check and replace distributor cap, rotor, ignition wires and spark
plugs.
6. There may be a fault in the computerized engine control system.
Page 40 of 47

The Fix: Check engine control systems with a scan tool. Test circuits and
repair or replace components as required. (Generally not a DIY job)
7. There may be a vacuum leak.
The Fix: Check and replace vacuum lines as required.
8. You have a bad idle speed control unit.
The Fix: Replace idle speed control unit.
9. The alternator may not be working properly. The Fix: Replace alternator.
Symptom: Car stalls when stopped quickly. You are driving along and
everything is just fine ... until you let off the gas pedal and apply the brakes.
The engine starts shaking and may even stall. Not a good thing to happen
because you lose power steering when the engine dies.
Possible causes:
1. There may be a serious vacuum leak. The Fix: Check and replace vacuum
lines as required.
3. Broken linkage.
The Fix: Repair or replace as required. Idling issues can be very frustrating,
but with some patient troubleshooting, you'll have a real chance at figuring it
out. Remember to always check engine idle with the air conditioning and
defroster in the OFF setting, both of these systems are designed to change the
idle when they are on due to the air conditioning system's demands on the
engine.
Page 41 of 47

SERVICING :-
Motor vehicle service is a series of maintenance procedures carried out at a
set time interval or after the vehicle has travelled a certain distance. The
service intervals are specified by the vehicle manufacturer in a service
schedule and some modern cars display the due date for the next service
electronically on the instrument panel.
The completed services are usually recorded in a service book which is
rubber stamped by the service centre upon completion of each service. A
complete service history usually adds to the resale value of a vehicle.
The actual schedule of car maintenance varies depending on the year, make,
and model of a car, its driving conditions and driver behavior.
Car makers recommend the so-called extreme or the ideal service schedule
based on impact parameters such as
• number of trips and distance traveled per trip per day
• extreme hot or cold climate conditions
• mountainous, dusty or de-iced roads
• heavy stop-and-go vs. long-distance cruising
• towing a trailer or other heavy load
Experienced service advisors in dealerships and independent shops
recommend schedule intervals, which are often in between the ideal or
extreme service schedule. They base it on the driving conditions and
behavior of the car owner or driver.
COMMON MAINTAINANCE:-
Page 42 of 47

Maintenance tasks commonly
carried out during a motor vehicle
service include:
• Change the engine oil
• Injector cleanising.
• Replace the oil filter
• Replace the air filter
• Replace the fuel filter
• Replace the cabin filter
• Replace the spark plugs
• Tune the engine
• Check level and refill brake fluid/clutch fluid
• Check Brake Pads/Liners, Brake Discs/Drums, and replace if worn out.
• Check level and refill power steering fluid
• Check level and refill Automatic/Manual Transmission Fluid
• Grease and lubricate components
• Inspect and replace the timing belt or Timing
chain if needed
• Check condition of the tyres
• Check for proper operation of all lights, wipers etc.
• Check for any Error codes in the ECU and take
corrective action.
• Wash the vehicle and clean the interiors.
 CHANGING AIR FILTER
Page 43 of 47

 CHECKING COOLANT
 CHANGINGENGINE OIL
Proper maintenance will extend the life of your car and prevent costly
repairs. A little time and expense spent on maintenance can save big bucks
and time in the repair shop. Regular maintenance will also keep your car
safer to drive. You can prevent an accident or breakdown by keeping
everything in working order. That may even save you a trip to the hospital,
where the repairs will be even more costly!
ACCIDENTAL :-
As we know about the risk of accidents, it was takes place any time with own
mistakes or other mistakes while driving on roads. To avoid this we have to
follow the safety measures.
An accidental vehicles also brought in lalz hyundai for repairments.
Here vehicles are categorized in 2 differents ways before repairment:-
1. In insurance claims
2. Non-insurance claims
Page 44 of 47

BIBLIOGRAPHY
 HYUNDAI MOTORS INDIA
 LALZA HYUNDAI AUTORISED SERVICE CENRE,PATNA.
 SOCIETY OF INDIAN AUTOMATIVE MANUFACTURER.
 AUTOMATIVE COMPONENTS MANUFACTURERS ASSOCIATION.
 BOOKS- AUTOMOBILE ENGINEERING BY ER. SK GUPTA etc.
Page 45 of 47

CONCLUSION
 The automotive industry has faced major trend changes in the
concentration of the market. It has shifted from a domestic market to a
monopolistic to a global market to a perfectly competitive market
scenario. All these changes were accompanied by growth and
development of the industry and overall economy as well. India has
finally emerged as a world class entity in the global market for
automobiles and has made its presence felt by the other nations. The
future of Indian Auto Industry is bright as more and more companies
are getting attracted towards the Indian Market and are setting up their
manufacturing units in India. After going through Internship Program,
the current company position, capabilities, facilities and objectives and
taking care of the customers and developing great service. Customer
satisfaction was at top priority of this company.It is concluded that
there is a viable increase in production and management. This
Internship Program was approved by the H.R Manager of the Fair Deal
Hyundai Company for letting me explore the company and know about
Automobiles.
Page 46 of 47

SUBMITTED BY –ANAND PRATAP
ROLL NO. 143068
PROJECT NAME-HYUNDAI WORKSHOP
YEAR-2017
COLLEGE-NSIT ,AMHARA,BIHTA
Page 47 of 47

Summer trainning iproject hyundai ii

Recommended

Recommended

More Related Content

What's hot

What's hot (20)

Similar to Summer trainning iproject hyundai ii

Similar to Summer trainning iproject hyundai ii (20)

Recently uploaded

Recently uploaded (20)

Summer trainning iproject hyundai ii