Aastik Chawla completed an industrial training at Honda Cars India Ltd from December 2014 to January 2015 to fulfill requirements for a Bachelor's degree in Mechanical Engineering. The training provided practical experience in design, production, administration and technical discussions. It aimed to develop leadership, innovation and management skills. Chawla acknowledges the support received from Honda officers and staff during the informative and disciplined training. A certificate confirms the successful completion of the training under guidance of the Head of Painting Department.

1. INDUSTRIAL TRAINING of Aastik Chawla
At
HONDA CARS INDIA LTD, GREATER NOIDA
In partial fulfillment for the award of the degree
of
BACHELOR OF ENGINEERING
In
MECHANICAL
Delhi Technological University
New Delhi India
December-January 2015

2. ABSTRACT
The ultimate aim of this industrial training is to learn new things,
gain practical experience, to observe the new features followed in
design, production, administration, indulge in technical discussion,
and make friends for mutual help at a future date. This training is
undertaken to learn leadership skills, for coming out with
innovative ideas for improvement etc. it also aims at learning the
skill of managing men which is very important for an engineer.

3. ACKNOWLEDGEMENT
I acknowledge that my summer training at HONDA CARS INDIA
Ltd, Greater Noida, has been very lively and informative. It was an
enriching experience while training, in sophisticated and
disciplined environment at the Honda’s passenger car
manufacturing plant in India. This has been possible only because
of support and help provided by officers and staff of HCIL during
the course of my training at Honda’s plant. I sincerely thank them
for the same. I am especially thankful to Mr. Rohan Bansal under
whom I have completed my training. I also thank all the executives
and workers in Engine Assembly who were really helpful and
supportive during the training period.

4. CERTIFICATE
This is to certify that Aastik Chawla, III Year Mechanical
Engineering Undergraduate at Delhi Technological University has
successfully completed the Winter Intern at Honda Car India
from 6th
December 2014 to 5th
January 2015 under my able
guidance and supervision.
Signature
(Head of Painting Department)

5. History of Honda
Honda is the world’s largest manufacturer of motorcycles as well as the world’s
largest manufacturer of Internal Combustion Engines measured by volume,
producing more than 14 million Internal Combustion Engines each year. Honda
was the first Japanese automobile manufacturer to release a dedicated luxury
brand, Acura in 1986. Since 1986, Honda has been involved with artificial
intelligence (AI) / robotics research and released their ASIMO robot in 2000.
They are also ventured into aerospace with the establishment of GE Honda
Aero Engines in 2004 and the Honda HA- 420 Honda Jet, released in 2011.
Honda spends about 5% of its revenues into R&D. The spirit of Soichiro
Honda, (founder) forever has been inscribed in every car and engine that Honda
builds. Once Soichiro Honda famously said, “I HAVE FAILED 99% OF MY
TRAILS, IN ORDER TO SUCCEED IN THE REMAINING 1%”.
HONDA MOTOR COMPANY LTD
In 1928, Soichiro Honda secured his first of many patents (for automobile
wheel spokes). Then, as World War II ravaged Japan, Honda cornered the
market on badly needed generator motors. His growing capital allowed him to
break ground on the Honda Technical Research Laboratory in 1946. Just two
short years later, the Honda Motor Company, Ltd. would open its doors in
Hamamatsu. The motor world would never be the same. The company initially
found its niche in the manufacture of motorcycles. Following the launch of the
company’s first success-the “C” model motorcycle-Honda and his then-twenty
employees launched themselves into motor history with the three horsepower,
two-speed transmission “D” model. The motorcycle was aptly named the
“Dream D” after jubilant employees allegedly shouted “It’s like dream!” upon
its completion. And a dream it was. The “Dream D” was like a dream come
true for the war-recovering Japanese society: it was inexpensive; it conserved
valuable fuel; and, perhaps most importantly, it provided a temporary escape
from the surrounding troubles. The overwhelming success of the “D” model
and the later “E” model helped Honda build a reputation for quality and design
supremacy, even when an early-1950s economic depression threatened to dim
the company’s shining star. By 1955, Honda had weathered the storm and saw
his dream at least partially realized when his company became the top
motorcycle manufacturer in Japan. When those top sales figures expanded to
include the world in 1959, Honda began to realize the enormous potential in a
global expansion of his empire. While his business associates encouraged him
to open a plant in either Europe or Southern Asia, Honda saw potential in
another market: the American market. Marketing experts pleaded with Honda

6. to change his mind, citing the low sales figures for motorcycles in the United
States. But Honda and his trusted advisor Fujisawa ignored the pleas, realizing
that America was becoming an increasingly important presence in the global
market place. In 1959, newly appointed Executive Vice President and General
Manager Kihachiro Kawashima officially introduced American Honda Motor
Company to the American public. With a $250,000 allowance, the time was
now or never for Honda America. Due to the disinterest of skeptical American
dealers, AHMC set up shop in various hardware stores and sporting good
stores. The new enterprise faced a hard sell to dealers and the public alike: the
name Japan still held negative connotations for an American society struggling
with its own wartime memories; fuel efficiency was not foremost in the minds
of much of the public; and the vehicles of America were expected to be faster
and leaner than their Japanese counterparts. However, at the same time AHMC
was experiencing the growing pains of a rookie company, Soichiro Honda was
fulfilling his lifelong dream of mastery on the racing circuit.
He won the Isle of Man in the early 1960s, and continued a steadily rising
string of successes on the race course. This publicity helped boost the Honda
image in America, and Honda’s reputation was further boosted when it was
honored with its first manufacturer’s award in 1962. The company also reached
out to a weary public through an ambitious magazine advertising campaign that
emphasized Honda’s strengths: dependability, fuel efficiency, simplicity, easy
maintenance, and a unique (rebellious?) design. AHMC struck one final blow
to the competition with its risky and expensive! Advertising onslaught during
the 1964 Academy Awards. But the ploy worked jump starting sales by
millions. Despite its slow start, AHMC was dominating sales in the same
manner as its Japanese counterpart by the end of its fifth year (matching the
original HMC’s 65%share of the market with its own impressive 62%
share).Soon, the company would become the standard bearer in the industry,
pioneering both the Motorcycle Industry Council and the Motorcycle Safety
Council. It would also solidify its image with a series of philanthropic efforts.
With the success of the American Honda Motor Company, Honda felt more
confident than ever in his next goal: dominance in the automobile industry. He
faced hurdles from the government, which delayed its approval for Honda's
entrance into automobile manufacturing. Part of the reason for this hesitation
was Honda’s subsidization of its US market, which led to questionable pricing
practices in Japan. In spite of the initial delays, Honda unveiled its first
automobile and truck products in 1962. In 1969, American Honda also
introduced its first automobile import, the N600 Sedan. The story was much the
same: initial skepticism (could a motorcycle man really make effective
automobiles?), followed by eventual success. The enormous popularity of

7. Honda’s “CB” model motorcycles helped convince the public that their faith in
Honda was well-placed. So, when Honda embarrassed the competition with his
environmental-friendly Civic automobile (in a time of growing pollution
concerns) in 1972, both the American public and the American government
were more than receptive. Soon, Honda International Trading was exporting its
now-successful American creations to Japan, closing the circle of success.
When the top-selling Accord made its way onto American streets a few short
months later, the Honda success story was finally complete: Japanese
motorcycle supremacy, worldwide motorcycle supremacy, and now automobile
supremacy. His vision finally fulfilled, Honda retired in 1973, leaving Kiyoshi
Kawashima to carry on his legacy. Honda would witness the birth of yet
another successful corporation (Honda of America Manufacturing in
Marysville, Ohio), which would revolutionize the workplace with its emphasis
on team work and cooperativeness. Honda would also be on hand for a Team
Honda first-place victory in world motocross in 1981, for the crowning of a
new American Honda president (Tetsuo Chino) in1983, for a series of honorary
distinctions (including a clean sweep of the Motor Trend Import Cars of the
Year selections), and for a most fitting 25th anniversary present of record-
setting sales. For all of his contributions and milestones, Soichiro Honda set
another standard when he became the first Asian to be inducted into the U.S.
Automotive Hall of Fame. Today, Honda’s selection of Accords, Civics,
Preludes, Passports, Acura’s, and Odysseys bear the Honda seal of excellence.
Millions of motorcycle and automobile lovers around the world can attest to
that excellence.
HONDA’S GLOBAL VISION
Soichiro’s vision was international in character. His desire was to lead the
world in technology, and make a significant contribution to the creation of a
better society. As a result, most of the products that Honda developed started
out by making a difference. Whether it was the CVCC (Compound Vortex
Control) engine in the sixties or the solar powered car of the nineties, they all
sought to challenge and overcome conventional wisdom.

8. HONDA’S MISSION STATEMENT
Honda’s Mission statement is very short, simple and a pragmatic one. WE
CONVERT FUEL TO ENERGY, EFFECIENCY. GLOBALLY, Honda has
manufacturing plants all over the world. It has manufacturing units in five parts
of the globe. And its products are used in every part of the world. Globally
Honda machines are known for their reliability, efficiency and world class
quality. Honda to test their world class stands have been involved in
motorsports all over the world including Formula 1(they exited F1 in 2009 with
the sale of Honda F1 team to Brawn GP), Isle of Mann TT, Indy car racing,
Moto GP, World Super Bike and Motor Cross.
GLOBAL PRODUCT LINE: Honda has a vast list of products to its credit. It
manufactures from lawn movers to Jet engines. Honda has carried on the sprit
and legacy that Mr. Soichiro Honda has left behind in anything and everything
they build and comes out of Honda’s factory line all over the world. Here is a
list of product line of Honda machines:
* Automobiles
* Motorcycles
* Scooters.
* All-Terrain vehicles (ATV’s)
* Electrical generators
* Robots
* Marine equipment
* Jets.
* Jet engines
* Lawn and garden equipments.
INDIAN PRODUCT LINE:
* Automobiles
* Motorcycles
* Electric generators.

9. FUNDAMENTAL BELIEFS AT HONDA
I. RESPECT FOR THE INDIVIDUAL
INITIATIVE: Initiative means not to be bound by preconceived ideas, but
think creatively and act on your own initiative and judgment, while
understanding that you must take responsibility for the results of those actions.
EQUALITY: Equality means to recognize and respect individual differences
in one another and treat each other fairly. Our company is committed to this
principle and to creating equal opportunities for each individual. An individuals
race, sex age religion, national origin, educational background, social or
economical status have no bearing on the individuals opportunities.
TRUST: The relationship among associates at Honda should be based on
mutual trust. Trust is created by recognizing each other as individuals, helping
out where others are deficient, accepting help where we are deficient, sharing
our knowledge, and making a sincere effort to fulfill our responsibilities.
II. THE THREE JOYS
* THE JOY OF BUYING: The joy of buying is achieved through products
and services that exceed the needs and expectations of each customer.
* THE JOY OF SELLING: The joy of selling occurs when those who are
engaged in selling and servicing Honda products develop relations with a
customer based on mutual trust. Through this relationship, Honda associates,
dealers and distributors experience pride and joy in satisfying the customer and
in representing Honda in the customer.
* THE JOY OF CREATING: The joy of creating occurs when Honda
associates and suppliers involved in the design, development, engineering and
manufacturing of Honda products recognize a sense of joy incur customers and
dealers. The joy of creating occurs when quality products exceed expectations
and we experience pride in the job well done.

10. HONDA MANAGEMENT CONCEPTS:
1. The concept of 5’S:
* Sort (Sieri):- Distinguishing between needed & un-needed items & disposing
of the un-needed items in a systematic manner
* Simplify (Seition):- Arrangement of necessary items into good order so that
they can be easily selected for use
* Shine (Seiso):- Cleaning of workplace so that there is no dust in the
workplace
* Standardize (Seiketsu):- To cultivate a disciplined workplace where everyone
does something on his/her own to maintain a clean environment & correctly
understand the 5S philosophy.
* Sustain (Shitsuke):- Sustain refers to training to all & communication to all
associates to ensure 5’s application
2. Kaizen:
Kai = Change + Zen = Good / For the better
Kaizen = Continuous Change for the betterment
3. HO-REN-SO:
HO:- Report status/ Progress to seniors
Ren:- Inform all those who may be concerned
SO:- Consult to refine one’s own thoughts/ideas

11. CONTENTS
1. Body construction – unit body & frame body
2. Manufacturing processes
A. Welding Process
B. Painting Process
 PT-Ed Line
 Sealer Line
 Mid Coat
 Top Coat
3. Air Supply Unit
4. Engine Assembly
5. Pre-Delivery Inspection

12. BODY CONSTRUCTION
Body Construction is of two types
1. Unit construction
2. Body on frame
Currently, most Honda vehicle bodies use the unit construction.
Before this technology became popular, frame constructions
widely used. With frame construction, major components such as
the engine, transmission, and suspension were mounted onto the
bare bones of the vehicle – the frame. Then the body (essentially
the skin of the vehicle) was mounted on top. This type of
construction is actually still used today for trucks and some off-
road vehicles. On the other hand unit construction vehicles, do not
have special frames. They are composed of body panels which
have been designed to provide the required body strength without
the use of a frame.

13. Rather than a separate, ladder-style frame, as is used in body-on-frame
construction, the unibody vehicle’s integral floor pan (the metal that forms
the vehicle’s underside) provides the main structural element to which the
mechanical components attach. Also known as unit body, unitized or unitary
construction, this design makes for a lighter vehicle overall and is the basis
for virtually all passenger cars.
Vehicles with unit construction use thin, press-formed steel panels
of about 1 or 2 mm in thickness. Spot welding is used at locations
where these panels overlap and a boxtype structure is created.
Certain parts of this basic structure (such as the locations where the
engine or suspension are to be mounted) are required to have extra
strength and rigidity. Common methods used to improve the
strength characteristics of the steel panels, include adding rids,
recesses, and other similar indentations. Further increases can be
achieved by welding stiffening material to the relevant areas or by
the addition of smaller, individual sub-frames

14. ADVANTAGES:
1. Structurally poor utilization of material
2. Crumple zone - lower rate of death and serious injury.
3. More resistant to torsional flexing
4. Lighter than body-on-frame.
DISADVANTAGES:
1. Complicated to design.
2. Noisier (stresses may pass into the body.)
3. Difficult to repair after accidents
From a safety point of view, the first benefit of unit construction is
that it provides increased ability to absorb impact forces. This is
achieved by efficiently distributing forces acting on the body and
not allowing them to concentrate in one area. In addition, parts of
the body have been designed to be crushable in order to improve
the ability to absorb impact forces even further. Energy from a
collision is absorbed as a section is crushed, and therefore, the
amount of energy which is directed to the driver or passengers is
reduced.

15. It would be pointless to design a body which would be completely
crushed in a collision. A survival space for the driver and
passengers must be provided. Various methods such as reinforcing
the floor of the cabin, installing door beams, and strengthening
pillars have been implemented for this purpose.
Based on the above description, Honda vehicle’s bodies are
complicated constructions that have been designed with a number
of different objectives in mind. Consequently, a much higher level
of expertise will be required when repairing these bodies than
would be required when repairing frame-type bodies.

16. MANUFACTURING
WELDING PROCESS
Primary function of welding is to assemble and weld all parts to
form the basic structure of a car. Assembly of parts in welding
takes place in specially designed fixtures.
The type of welding employed to weld the parts is known as spot
welding. The process of part fixing and metal finishing is also
carried out in the welding department.
Welding is divided into four sections.
* Floor spot line – A zone
* The GW line – B zone
* The metal finish line – C zone
* Hemming line – D zone
The parts supplied by the material department are welded into sub
assemblies which are later welded to form the basic structure of a
car. In different sections different sub assemblies are welded. In
floor line the structure of the floor of the car is welded from
different sub assemblies.
RESISTANCE WELDING
In this process electric current flows through a resistive circuit to
generate enough heat between two pieces of sheet metal so that the
metal reaches molten stage. The resistance to the flow of current is

17. provided by work piece. The maximum heat is generated at the
point of maximum resistance.
The commonly used electrodes shapes are p and cr types.
SPOT WELDING
Spot welding is a resistance welding method used to join two to
three overlapping metal sheets, studs, projections, electrical wiring
hangers, some heat exchanger fins, and some tubing. Usually
power sources and welding equipment are sized to the specific
thickness and material being welded together. The thickness is
limited by the output of the welding power source and thus the
equipment range due to the current required for each application.
Care is taken to eliminate contaminants between the faying
surfaces. Usually, two copper electrodes are simultaneously used
to clamp the metal sheets together and to pass current through the
sheets. When the current is passed through the electrodes to the
sheets, heat is generated due to the higher electrical resistance
where the surfaces contact each other. As the electrical resistance
of the material causes a heat buildup in the work pieces between
the copper electrodes, the rising temperature causes a rising
resistance, and results in a molten pool contained most of the time
between the electrodes.
As the heat dissipates throughout the workpiece in less than a
second (resistance welding time is generally programmed as a
quantity of AC cycles or milliseconds) the molten or plastic state
grows to meet the welding tips. When the current is stopped the
copper tips cool the spot weld, causing the metal to solidify under
pressure.
The water cooled copper electrodes remove the surface heat
quickly, accelerating the solidification of the weld. since copper is
an excellent conductor. Resistance spot welding typically employs
electrical power in the form of direct current, alternating current,

18. medium frequency half-wave direct current, or high-frequency half
wave Direct current.
If excessive heat is applied or applied too quickly, or if the force
between the base materials is too low, or the coating is too thick or
too conductive, then the molten area may extend to the exterior of
the work pieces, escaping the containment force of the electrodes
(often up to 30,000 psi). This burst of molten metal is called
expulsion, and when this occurs the metal will be thinner and have
less strength than a weld with no expulsion. The common method
of checking a weld's quality is a peel test. An alternative test is the
restrained tensile test, which is much more difficult to perform, and
requires calibrated equipment. Because both tests are destructive in
nature (resulting in the loss of salable material), non-destructive
methods such as ultrasound evaluation are in various states of early
adoption by many OEMs. The advantages of the method include
efficient energy use, limited workpiece deformation, high
production rates, easy automation, and no required filler materials.
When high strength in shear is needed, spot welding is used in
preference to more costly mechanical fastening, such as riveting.
While the shear strength of each weld is high, the fact that the weld
spots do not form a continuous seam means that the overall
strength is often significantly lower than with other welding
methods, limiting the usefulness of the process. It is used
extensively in the automotive industry— cars can have several
thousand spot welds. A specialized process, called shot welding,
can be used to spot weld stainless steel.

19. PAINTING PROCESS
At PA-ON, the white body is received from the weld shop and
inspected for the following welding defects:
1. Black sealer
2. Metal dust
3. Dent and ding
4. Sanding marks
5. Rust
6. Spatter
7. Burrs
8. Scratch
Also the body is earthed to eliminate any static charge on the car
body.
The entire painting process is divided into four lines. Each line has
a specific purpose.
These lines are
* PT-ED line
* Sealer line
* Mid coat line
* Top coat line

20. PT-ED Line
Jet spray
At this station the body is spray washed with RO water in order to
remove loose dust, metal particles and excess oil and grease from
the body surface.
Also the body holding jigs are fitted to lift the car and carry out the
PT-ED process.
Pretreatment
The purpose of coating and plating is to form a dry film on the
automobile body using various methods of coatings and plating so
that the body is resistant to weather, rust and contamination and
also looks beautiful with colored, glossy and smooth surface giving
cubic effect. Therefore coating and plating are final methods of
finishing. Automobile bodies are very important because they can
greatly affect the grade and value of the product.
Predegreasing and degreasing
This is mainly done to remove the oil and grease particles that
come attached to the car’s body after the welding process. This
step is basically a cleaning step that removes dust and oil particles
from metal surface and makes the body more suitable for paint
adhesion.
In this the body is dipped for 3-5 minutes in an alkali solution as a
result of this the oil and dust particles get stuck to the degreasing
alkali particles and get off the surface.
After this step the white body is thoroughly rinsed in water tanks to
remove excess alkali on body to carry out further steps.

21. Surface conditioning and zinc coating
The surface of body is activated for zinc phosphate coating.
Phosphating is done to improve corrosion and adhesion of the
electro deposit coat.
Rinsing & Electrode deposition process
In this step excess phosphate sludge formation, if any, is removed
during 2 stage rinsing. Further the car body is manually washed &
prepared for ED coat.
ED paint dispersed in water is electrically deposited on surface of
substrate (body) to form a uniform and water insoluble film.
Deposition of film takes place by increase in pH.
Paint gets deposited continuously through concurrence of four
different phenomenon:
1. ELECTROPHORESIS
2. ELECTRODEPOSITION
3. ELECTROLYSIS
4. ELECTROSMOSIS
Rinsing, baking and defect inspection
It’s a 5 step rinsing in which excess ED coat/ drop/ paint gets
removed from the car body to avoid any carry forward of the ED
paint.
Further the body is sent to baking oven where it’s heated at 160o
for around 35mins. Then thinner is applied to remove oil and dust
to avoid paint peel off from that area later.

22. Also the body is checked for any defects like ED drop, jig marks,
metal dust & deformity.
ADVANTAGES OF ED COATING
 Corrosion resistance of car body increases.
 Paints are deposited even on surfaces inaccessible to
conventional methods of painting.
 Uniform film of desired thickness is obtained easily by
adjusting voltage.
 Quantity of drag out solids is small since bath paint being
diluted with water is low in solid content.
The voltage application is 220-260 v (per unit area).
Sealer Line
 Sealer application and cleaning
Sealers are used in Honda vehicles for the following purpose
* It fills a gap between two or more substrates.
* It forms a barrier through the physical properties of the sealant
itself and by adhesion to the substrate.
* It maintains sealing properties for the expected lifetime, service
conditions and environments.
 PVC application & baking
After applying the sealer at the joint areas PVC is sprayed under
body to give the protection to the body against any rust and
damages from underneath.

23. Later the body is baked at 160 degrees for 8mins.
Mid Coat Line
Sanding paper is used to clean hood, fender, door, roof, trunk, door
inside, quarter panel, trunk inside. Then the surface is blown with
pressurized air to clean the surface and then it is cleaned with tag
rag before applying mid coat.
MID COAT COLOURS – mid coat is applied in 3 stages and there
are 3 colors for mid coat. White for white color, light grey for light
colors and dark grey for dark colors.
Then the body is sent to oven and heat treated at 160o
for 24mins.
Top Coat Line
Body is inspected for mid coat defects like MC sag, dust, wiping
marks, ED marks, sanding marks, film thickness, popping. Sanding
paper of 800/ 1500/ orbital sander is used to remove the defect.
Wipe with tag rag and air is blown to keep the surface clean.
For solid white color only base coat is applied and for metallic
colors top coats and clear coats are applied in layers. Then it’s sent
to oven for baking at 180 degrees.

24. CHECK AND REPAIR DEFECTS
After the top coat, the sealer defects are checked with soap
solution. Then the body is thoroughly inspected from outside and
inside for paint defects like sagging, DUP, crater, film thickness,
lint dust, sanding marks, orange peel, dent, ding.
POLISHING AND WAXING
After removing the defects the body is sent for polishing that is
done in 3 stages:
1. glaze paste on sanded areas + wool pad
2. grey polish + orange pad
3. fine polish + swirl mark pad

25. AIR SUPPLY UNIT
Air Supply Unit (ASU) is equipment used to circulate, supply
or replace air from spray paint booth. Air Supply Unit is
commonly known as Air Replacement Plant (ARP), Air
Handling Unit (AHU), and Air Makeup Unit (AMU) etc. Air
Supply Unit or Air Handling Unit was very popular in areas
where the air has low humidity, and hotter climate, mainly to
comfort the human conditions in such climate. As technology
has changed for better development, even in the field of paint
and painting equipment, more and more expansions have
added up to make a dust free painted product .To attain such
a clean paint film on the product free from dust above 5
micron, Air Supply Units and Air Handling have become a
necessity of today’s market.
Air Supply Unit (ASU) comprises of series of filters &
eliminators. Air Supply Unit (ASU) uses the atmospheric air
from outside, refines the air, and supplies it to the Paint booth
via ducting, thus creating a constant flow of dust free air into
the paint booth. The volume of air supplied from the Air
Supply Unit (ASU) also helps to maintain a positive pressure
in the paint booth, thus not allowing external dust around the
paint booth to enter into the paint booth. Air Supply Unit
(ASU) creates an enclosed environment safer for workers by
facilitating the elimination of toxic fumes.
Air Supply Unit (ASU) are not only used to provide make up
air for the paint booth, but also used as a spot cooling device
for the workers in molding shops, assembly shops and other
hotter areas. It is capable to manufacture customized Air
Replacement Plants (ARP), in metallic & civil constructions.

26. ENGINE ASSEMBLY
Honda vehicles in India use various four stroke petrol engines.
Engines based on the four-stroke ("Otto cycle") have one power
stroke for every four strokes (up-down-up-down) and employ
spark plug ignition. Combustion occurs rapidly, and during
combustion the volume varies little ("constant volume"). They are
used in cars, larger boats, some motorcycles, and many light
aircraft. They are generally quieter, more efficient, and larger than
their two-stroke counterparts.
The steps involved here are:
1. Intake stroke: Air and vaporized fuel are drawn in.
2. Compression stroke: Fuel vapor and air are compressed and
ignited.
3. Combustion stroke: Fuel combusts and piston is pushed
downwards.
4. Exhaust stroke: Exhaust is driven out. During the 1st, 2nd, and
4th stroke the piston is relying on power and the momentum
generated by the other pistons. In that case, a four-cylinder engine
would be less powerful than a six- or eight-cylinder engine.
Major components of a four stroke petrol engine are * Cylinder: A
cylindrical vessel in which a piston makes an up and down motion.
* Piston: A cylindrical component making an up and down
movement in the cylinder * Combustion chamber: A portion above
the cylinder in which the combustion of the fuel-air mixture takes
place
* Intake and exhaust ports: Ports that carry fresh fuel-air mixture
into the combustion chamber and products of combustion away *

27. Crankshaft: A shaft that converts reciprocating motion of the
piston into rotary motion * Connecting rod: A rod that connects the
piston to the crankshaft * Spark plug: An ignition-source in the
cylinder head that initiates the combustion

28. PRE-DELIVERY INSPECTION
Vehicle quality check
PDI is the final inspection prior to the delivery to the customer.
The customer expects a very high level of quality from the product
being purchased.
The following checks are done on the car in the final step:
 Exterior inspection – alignment inspection, parts gap
inspection, fitment inspection, flushness inspection
 Paint inspection – dent and ding inspection, dust inspection,
crater inspection, sag inspection
 Interior inspection – parts fitment inspection, parts gap
inspection, parts model mismatch inspection
 Function check – door glass operation, center locking
inspection, keyless function inspection
 R swat & head light – toe angle adjustment, headlight
profile adjustment.
 Turning angle – turning angle check, hazard operation
check, side indicators check, and fog lamp inspection.
 Multi drive test – speed check, speedometer check, brake
force check, ABS & VSA inspection
 Side slip inspection
 U/B & eng room – oil leakage inspection, torque marking,
pipe fitment inspection, oil level inspection.