The document is a report on a summer training project completed at Arvind Hyundai. It includes: - An acknowledgements section thanking the company and instructors for their support and guidance during the training. - An executive summary providing an overview of Hyundai Motors history and operations. - Sections on the company profile, objectives of the project, departments at Arvind Hyundai, a case study on the automotive industry in India, details on engine components and systems, and a conclusion.

1. Page:-1
SUMMER TRAINNING
AT
ARVIND HYUNDAI
A REPORT
SUBMITTED BY:- NEERAJ SIR
NAME :- SUNY KUMAR
ROLL No :- 166154
BATCH :- DIPLOMA IN AUTOMOBILE
SESSION :- 2016-19
COLLEGE :- DAYAL BAGH EDUCATION INSTITUTE AGRA

2. Page:-2
ACKNOWLEDGEMENT
The Project with ARVIND HYUNDAI has been a great learning experience. I was exposed to
the marketing system of the organization and gained firsthand
knowledge, invaluable experience which I will always recall with a sense of
satisfaction and pride.
I would like to express my gratitude and deep sense to ARVIND HYUNDAI for permitting me
to do the project in its esteemed organization.
I sincerely thank Mr. B C CHOUDHRY Sir (General Manager) who permitted me.to do a
project, and has been a great help through his constant encouragement, help and guidance.
I would like to thanks AFZAL Sir (Workshop Floor Incharge) for their support and
encouragement during this summer training. The opportunity provided by his was an
immense learning experience.
The help received from something without which the project would not have been complete.
Their insight as well as guidance helped me to understand the essentials of the Project.
I would like to thank them for their support.
I would also like to place on record my sense of gratitude to my parents and friends for their
support and encouragement, which has always guided me my entire life.

3. Page:-3
CONTENTS
1) Executive summary
2) Company Profile
3) Introduction to Project
4) Departments
5) Case Study
6) Engine
7) Engine & Its Components
8) Conclusion

4. Page:-4
1.EXECUTIVE SUMMARY:-
(In Pictures HYUNDAI MOTORS
GROUP CHAIRMAN Chung mong
koo and his sonand 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.

5. Page:-5
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 develop mentengineer.In1975,
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
ARVIND HYUNDAI BYE PASS KHANDARI ROAD AGRA

6. Page:-6
2.COMPANY PROFILE:-
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.
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.

7. Page:-7
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:-
ARVIND HYUNDAI
NH2 BYE PASS ROAD AGRA
Which is located near Bhagawan Takies over bridge, Dayal Bagh Agra.
His owner name is MR. ARVIND SIR.
My whole training period was done over here.
I had learned everything related to Hyundai services and facilities.

8. Page:-8
Picture taken during the repairment of Hyundai Creata &
Tucson

9. Page:-9
Hyundai Car Models
 Hyundai Eon
 Hyundai i10
 Hyundai Grand i10
 Hyundai Xcent
 Hyundai Elite i20
 Hyundai i20 Active
 Hyundai Fluidic Verna
 Hyundai Creata
 Hyundai Elantra
 Hyundai Santro Xing
 Hyundai Tucson

10. Page:-10

11. Page:-11
3.INTRODUCTION:-
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.
 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

12. Page:-12
4.DEPARTMENT
The company where I did my Internship was having two major
Departments:-
1. Maintenance department.
2. Repairing and Painting workshop.
3. Office work.
4. Accessories & parts storage.

13. Page:-13
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 Arvind Hyundai Mechanic named Ahmad is working
on the parts of refrigeration system used in vehicle for cooling.

14. Page:-14
5.Case study:-
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.

15. Page:-15
6.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 premixed 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

16. Page:-16
stroke refers to the full travel of the piston along the cylinder, in either direction.
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

17. Page:-17
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.
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.

18. Page:-18
2. 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 un burnt 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.
GLOW PLUG (Heating Coil) SPARK PLUG

19. Page:-19
Difference Between Petrol and Diesel Engine in Tabular Form:-
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.

20. Page:-20
Engine & Its Components:-
Engine Block:-
• Generally manufactured
from cast iron or Aluminium alloys.
The major parts installed in or on the
block are the pistons, crankshaft,
camshaft, cylinder heads and manifolds
Cylinder Heads:-
•The cylinder head contains the
combustion chamber for each cylinder
and forms the top of the cylinder.
•Cylinder heads contain the intake and
exhaust valves and, in some cases, the
camshaft and lifters.
•They also contain oil galleries, coolant
passages, and openings to allow the flow of
intake and exhaust gases.
•Cylinder heads are made from either cast
iron or aluminum. A sheet metal, cast
aluminum or plastic valve cover is installed
over the upper valve train components.
Different Cylinder Head Designs:-

21. Page:-21
CRANKSHAFT:-
• Crankshaft is produced from
forged steel or machined steel.
• It is supported on block from
main journals and carrying
connecting rods and flywheel
assembly.
• The crankshaft converts the
straight-line force from the piston
and connecting rod into rotary force.
Connecting Rod:-
•Connecting rods are prepared from
steel, Aluminium or titanium by casting or
forging techniques.
• The connecting rods are forged steel
rods that connect the piston to the
crankshaft. They transfer the force from
the piston to the crankshaft.
• Each connecting rod is connected to a
piston by a piston pin.
Piston:-
•Pistons transfer the force of
expanding combustion gases
to the connecting rods.

22. Page:-22
•They are made of aluminium to reduce weight.
Piston Rings:-
• Most automotive pistons have two
compression rings and one oil ring.
Usually made of cast iron.
COMPRESSION RING:
It acts as a seal between the piston and
cylinder wall to prevent escape of
combustion gases.
OIL RING:
Scrapes excess oil from the cylinder walls.
Piston And Connecting Rod Assembly:-

23. Page:-23
Camshaft:-
• Camshafts are produced
from forged steel.
• Changes reciprocating
motion of pistons into
rotating motion to drive
propeller
Valves:-
Valves are produced from
forged steel. There are two types;
1. Inlet valves
2. Exhaust valves
• Valves control the flow of gases inside the
engine.
Valve Assembly:-

24. Page:-24
Manifolds:
They are generally of two types:
1. Intake Manifold
2. Exhaust Manifold
Intake Manifold:
It is manufactured of aluminium or cast
iron. The reason is that both of these metals resist heat without warping or
melting.
Exhaust Manifold:
Some exhaust manifolds are constructed of
cast iron. Others are made from stainless
steel and still others are made of ceramic
which does not have the durability of steel
and is more likely to crack.
Cooling System:-
Cooling system is
composed of radiator,
water pump, water
hoses, water jackets,
thermostat and
cooling fan.

25. Page:-25
Lubrication System:-
•Lubrication reduces unwanted friction, and controls where it is useful.
•It reduces wear on moving parts.
•Clearances fill with oil so that engine parts move or float on layers of oil instead
instead of directly on each other. Much less power is needed to run them.
•It helps to cool the engine. It collects heat from the engine, then returns to the sump
where it cools it.
• It helps to absorb shock loads. A power stroke can put as much as 2 tonnes force on
main bearing.
Layers of oil cushion this loading.
• Oil is also a cleaning agent. It
collects particles of metals and
carbon and carries them back to
the sump. Larger pieces falls to
the bottom.
Oil Pump:
Oil pump may be driven rom camshaft
or crankshaft.
In a rotor type oil pump, an inner rotor
drives an outer one. As they turn, the
volume between them increases. This
larger volume lowers the pressure at
the pump inlet.
Outside atmospheric pressure is then
higher. This then forces oil into the

26. Page:-26
pump, and it fills the spaces between the lobes and the rotor.
Oil Filter:-
The oil filter helps to clean
the oil in the system.
If the filter clogs, a valve opens and directs
unfiltered oil to the engine.
Most oil filters on diesel engines are larger than
those on similar gasoline engines.
Air and Fuel Filter:-
Air filter is used to filter coming air to
protect engine components against
excessive wear.
Technology that are used in the engines of Hyundai
cars:-
1.CRDI - Common rail diesel injection
2.VGT - Variable-geometric
turbochargers
3.VVT - Variable valve timing
4.WGT - Waste gate turbochargers
5.VTVT - Variable timing valve train
6.MPFI - Multi point fuel injection

27. Page:-27
CRDI-COMMON RAIL DIRECT INJECTION
• Common rail direct fuel
injection is a direct fuel injection
system for petrol and diesel engines.
• On diesel engines, it features a high-
pressure (over 1,000bar or 100MPa or
15000 psi) fuel rail feeding individual
solenoid valves, as opposed to a low
pressure fuel pump feeding unit
injectors.

28. Page:-28
VGT -VARIABLE GEOMETRY TURBO CHARGERS
• Variable – geometry
turbochargers (VGTs) are a
family of turbochargers,
usually designed to allow the
effective aspect ratio (A:R) of
the turbo to be altered as
conditions change.
• Variable-geometry turbo
chargers are also known as
variable nozzle turbines
MPFI- Multi point fuel injection system
• So in case of an MPFI engine,
there is one fuel --injector
installed near each cylinder,
that is why they call it Multipoint (more than
one points).
• This is the multi point fuel injection rail
used in petrol engines, the other one is multi
point fuel port.
BRAKING SYSTEM
Purpose of Braking System:-

29. Page:-29
• Stop the vehicle by converting the kinetic energy of the vehicle to heat energy.
• Heat energy is created in the brakes by friction.
• Friction is created between a moving and a nonmoving surface at each wheel to
generate the heat.
• Disc and drum brakes are the most common type of
braking systems used.
Factors Effecting Braking:-
Types of Braking System:-
• Service brakes. It’s the
primary braking system
using a the pedal
connected
to a hydraulic system
causing it to operate.
• Parking brakes. It’s
mechanically applied by a
lever or pedal.
• Pedal assembly
• Hydraulic system
• Power booster
• Disc brake

30. Page:-30
assembly.
• Drum brake assembly
• Parking brake
Drum Brake Action:-
Disc Brakes:-
• Disc brakes use a rotating
disc with two stationary
friction pads that are
pressed against to rotor by
the caliper to create friction
and heat.
• Disc brakes are more
effective at dissipating heat

31. Page:-31
Disc Brake Pads:-
Asbestos
Metallic
Semi-Metallic
Organic
Anti-lock Braking System:-
Anti-lock brake systems (ABS) -
generally also referred to as antilock
systems (ALS) - are designed
to prevent the vehicle wheels
from locking as a result of the
service brake being applied with
too much force, especially on
slippery road surfaces.
Components of ABS:-
Major components of the anti-lock brake system consist of a
◦ Brake control module,
◦Solenoid valve assembly,
◦ Speed sensor's
◦ Wiring, and the amber ABS brake warning light.

32. Page:-32
Air Conditioning System in CARS:-
Different Parts in Air Conditioning:-
Your A/C system is nothing more than a heat exchanger. There
are only 6 major parts to the system.
The Compressor
The Condenser
The Receiver or Dryer.
The Thermal Expansion Valve or Orifice Tube
The Evaporator
The Refrigerant
V

33. Page:-33
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:-
Maintenance tasks
commonly
carried out during a
motor vehicle
service include:
Change the engine oil
Injector cleaning.
Replace the oil filter

34. Page:-34
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
CONCLUSION:-
This effort for the innovation in sales promotion of Hyundai car
will help the road shows, TV Advertisement, Mouth publicity etc.
And other thing is provide some offers like Discount, Diwali offers, Free Gift like
music system, Accessories etc. My project is a key to open the door of greater comfort
to the all segment.
The customers of Hyundai are brand loyal with only a small percent want to shift
over to other brands. Trying of other brands by customers is mainly because the
customer wants to try something new.

35. Page:-35
The performance of Hyundai is good in comparison to other brands.
After sales service is the basic feature influencing brand loyalty.
THANKING YOU