HYUNDAI-Internship

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ME1047 INDUSTRIAL TRAINING-1
A REPORT
Submitted by
Amit Kumar Mandal [Reg No:1021310340]
In submission for assessment
and award
of Grade for the course
BACHELOR OF TECHNOLOGY
In
MECHANICAL ENGINEERING
Of
FACULTY OF ENGINEERING & TECHNOLOGY
S.R.M.Nagar ,Kattankulathur,Kancheepuram District
AUGUST 2015

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SRM UNIVERSITY
(Under Section 3 of UGC Act, 1956)
BONAFIDE CERTIFICATE
Certified that this report titled “ME1047INDUSTRIALTRAINING is the
bonafide work of “AMIT KUMAR MANDAL”, who carried out the training
in(HYUNDAI FAIRDEAL,Ltd,JAMSHEDPUR).Certified further, that to
the best of my knowledge the work reported herein does not form any other
training report on an earlier occasionon this or any other candidate.

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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. P.R Singh(HRD)
2) Mr. Arvind Babu(Service Manager)
3) Mr. Santoh Kumar(Service Manager)
I am thankful rather grateful for such whole hearted cooperation of not only them but also
all members of HYUNDAI 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

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CONTENTS
CHAPTER NO. PAGE NO.
1. Executive summary 1
2. Company profile 4
3. Introduction to project 8
4. Departments 10
5. Case study 12
6. Engines 14
7. Problem faced by automobiles 18
8. Bibliography 31
9. Conclusion 33

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CHAPTER-1
Executive Summary

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Executive Summary
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 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.

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In 1998, Hyundai began to overhaul its image in an attempt to establish itself as a world-
class brand. Chung Ju Yung transferred leadership of Hyundai Motor to his son, Chung
Mong Koo, in 1999.
Hyundai's parent company, Hyundai Motor Group, invested heavily in the quality, design,
manufacturing, and long-term research of its vehicles. It added a 10-year or 100,000-mile
(160,000 km) warranty to cars sold in the United States and launched an aggressive
marketing campaign.
In 2004, Hyundai was ranked second in "initial quality" in a survey/study by J.D. Power and
Associates. Hyundai is now one of the top 100 most valuable brands worldwide. Since
2002, Hyundai has also been one of the worldwide official sponsors of the FIFA World
Cup.
Hyundai has 6 centres worldwide, located in Korea (three
offices), Germany, Japan and India. Additionally, there is an American design centre
in California that develops designs for US markets.
In 2006, Hyundai hired Thomas Bürkle as head of the company's design center
in Russelsheim, Germany. Bürkle had previously worked for BMW, having designed
the BMW 3 Series (E46), and the BMW 6 Series (E63).Hyundai's current design philosophy
is known as Fluidic Sculpture,which is heavily inspired by nature.

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CHAPTER-2
COMPANY PROFILE

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THE HYUNDAI GROUP: COMPANY OVERVIEW
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 , together 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.

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HYUNDAI INDIA
Hyundai Motor India Ltd is a wholly owned subsidiary of the Hyundai Motor Company
in Indai. 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.

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Hyundai Car Models
 Hyundai Eon
 Hyundai i10
 Hyundai Grand i10
 Hyundai Xcent
 Hyundai Elitei20
 Hyundai i20Active
 Hyundai Fluidic Verna
 Hyundai Creta
 Hyundai Elantra
 HyundaiSantaFe
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.

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CHAPTER-3
INTRODUCTION

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OBJECTIVE
 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.
 Resolving all the problems one by one by knowing everything about the material and
product used.

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CHAPTER 4
DEPARTMENT

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The company where I did my Internship was having two major departments :-
1. Maintenance department.
2. Repairing and Painting workshop.
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.

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CHAPTER5
CASE STUDY

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THE AUTOMOTIVE INDUSTRY IN INDIA
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.

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ENGINE
Petrol Engine
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:
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.

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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.

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Difference Between Petrol And Diesel Engine

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CHAPTER 7
Problems Faced By
Automobiles
Z ```````````````````

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Problems Faced By Automobiles
There are certain problems which are faced by every automobile when it is being used for a
long period of time.
Certain Problems are :-
o Knocking
o Camber, Caster and Toe
o Engine Seizure
o Over rigid suspension
o Rough Idling or Low Idling
o Brake Seizure
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.

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KNOCKING
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

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what is suggested, you may have knock. The heat range of a spark plug is often in its
part number, and the spark plug is designed to run at that range. Its job--other than
producing spark--is also to withdraw heat from the combustion chamber and into the
head.

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Camber, Caster And Toe
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.

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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.

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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.

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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 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.

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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.
 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

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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 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

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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.

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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.

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7. 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:
1. If you have a carburetor (gramps), you may have a bad accelerator pump or power circuit.
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.
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 engine condition.
9. The fuel injectors may be dirty.
The Fix: Clean or replace fuel injectors.

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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.
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.
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:

36 | P a g e
1. There may be a serious vacuum leak.
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.

37 | P a g e
CHAPTER 8
BIBLIOGRAPHY

38 | P a g e
BIBLIOGRAPHY
1. HYUNDAI MOTOR INDIA
2. SOCIETY OF INDIAN AUTOMATIVE MANUFACTURER.
3. AUTOMATIVE COMPONENTS MANUFACTURERS ASSOCIATION.

39 | P a g e
CHAPTER 9
CONCLUSION

40 | P a g e
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. 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.

HYUNDAI-Internship

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