ACKNOWLEDGEMENT

Any work would not be complete without the mention of the people whose guidance and
encouragement led to the development of the work. I consider myself privileged to express
gratitude and respect towards all those who guided me throughout my work.

I express profound gratitude to . Principal, Indira Gandhi Institute of Polytechnic and Engineering,
Nellikuzhi, for his kind support and motivation.

I express profound gratitude to Head of the Section, Department of Automobile Engineering, for
his invaluable guidance, immense and sincere help and encouragement given during the
industrial training.

I express my sincere gratitude to our guide, Lecturer, Department

of Automobile Engineering, for his guidance and sincere help given during the industrial training.
I extend my sincere thanks to the teaching and non-teaching staffs for their co

operation, for providing very good infrastructure and all the kindness forwarded to me in

conducting the industrial training. I also thank my classmates and friends for their kind help in
industrial training within

the stipulated time. The report would be incomplete if I don't thank my parents and well-wishers
for their

moral support during the industrial training.

Above all, I bow with gratitude before God Almighty for his blessing.

1
 NO. CONTENTS PAGE NO.
1 INTRODUCTION 7

2 AUTOMOBILE INDUSTRY 8
ININDIA

2.1 INVESTMENT 8

2.2 GOVERNMENT 10
INITIATIVES

3 MUSTANG MOTORS 11
PVT.LTD
3.1 HISTORY 11

3.2 OUR MISSION 11

3.3 OUR VISION 12

3.4 OBJECTIVES 12

3.5 MILESTONES 12

3.6 QUALITY POLICY 13

3.7 SERVICE AND REPAIR 13

4 ORGANIZATIONAL 14
STRUCTURE

4.1 SERVICE STATION 15

LAYOUT
4.2 PRODUCTS & BRANDS 16-17

5 QUALITY TOOLS 18
IMPLEMENTED

6 ACTIVITIES IN THE 19
WORKSHOP FOR
SERVICING THE VEHICLE
7 SPECIAL TOOLS USED 21
DURING TRAINING

8 GENERAL VEHICLE 22
MAINTENANCE

8.1 AIR CLEANER 22

2
8.2 OIL 22

8.3 ALTERNATOR BELT 22

TENSION
8.4 COOLING SYSTEM 22

8.5 TURBO CHARGER 22

8.6 EGR 23

8.7 PROCEDURE OF CAR 23

REPAIR

8.7.1 AIR CLEANER CHANGING 23

8.7.2 OIL AND OIL FILTER 23

CHANGING
8.7.3 FRONT DISC BRAKE PAD 24
CHANGING

8.7.4 ALTERNATOR AND AC 24

BELT REMOVAL AND
REFITTING

8.7.5 TIMING CHAIN 24

REPLACING
8.7.6 SUSPENSION LOUNGE 25
REMOVING

8.7.7 CLUTCH DISC ASSEMBLY 26

REPLACING

8.7.8 TURBO CHARGER 27

REMOVAL AND
REFITTING

8.7.9 FIP REMOVAL AND 27

REFITTING

8.7.10 PROCEDURE FOR 28

ALIGNING THE WHEELS

8.7.11 PROCEDURE FOR WHEEL 28

BALANCING

3
9 MAJOR VEHICLE 30
MAINTENANCE

9.1 CYLINDER HEAD 30

REMOVAL
9.2 DISMANTLING AND 31
OVERHAULING OF THE
ENGINE
9.3 REMOVING OF THE 31
ENGINE FROM THE
VEHICLE
9.4 DISMANTLING THE 33
ENGINE

9.5 INSPECTION 34

10 CONCLUSION 35

4
 1. INTRODUCTION

An Industrial Training is a period of work experience offered by an organization for a

limited period of time. Once confined to medical graduates, internship is used practice for a wide
range of placements in businesses, non-profit organizations and government agencies. They are
typically undertaken by students and graduates looking to gain relevant skills and experience in a
particular field. Employers benefit from these placements because they often recruit employees
from their best interns, who have known capabilities, thus saving time and money in the long run.
Internships are usually arranged by third-party organizations that recruit interns on behalf of
industry groups. Rules vary from country to country about when interns should be regarded as
employees. The "INPLANT TRANING" is in connection with the syllabus of 5th semester diploma in
automobile engineering. The training duration is is 10 days this training aim of making the students
familiar with automobile servicing in direct expense.

Mustang Motors Pvt. Ltd dealers cars provided us this in-plant training. They provided the training
faculty. This is the report of that training to understand the methods and features of a service
centre.

5
 2.AUTOMOBILE INDUSTRIES IN INDIA

2.1 INVESTMENTS

In order to keep up with the growing demand, several auto makers have started investing heavily in
various segments of the industry during the last few months. The industry has attracted Foreign
Direct Investment (FDI) worth USS 14.32 billion during the period April 2000 to December 2015,
according to data released by Department of Industrial Policy and Promotion (DIPP).

Some of the major investments and developments in the automobile sector in India are as
follows:

 Japanese two-wheeler manufacturer Honda Motorcycle and Scooter India (HMSI) has opened
its fourth and world's largest scooter plant in Gujarat, set up to initially produce 600,000
scooters per annum to be scaled up to 1.2 million scooters per annum by mid 2016.

 American car maker Ford has unveiled its iconic Ford Mustang in India and will make its debut
in second quarter of FY2016 within the price band of Rs 45 lakh (US$ 66,146) and Rs 50 lakh
(USS 73,496) in the Indian market.

 Nissan Motor Co. Ltd is in discussion with Government of India to bring electric and hybrid
technologies to India as the government plans to reduce air pollution caused by vehicles.

 Global auto major Ford plans to manufacture in India two families of engines by 2017, a 22 liter
diesel engine code named Panther, and a 1.2 liter petrol engine code named Dragon, which are
expected to power 270,000 Ford vehicles globally.

 The world's largest air bag suppliers Autolivine, Takata Corp. TRW Automotive Inc and Toyoda
Gosei Co are setting up plants and increasing capacity in India.

 General Motors plans to invest US$ 1 billion in India by 2020, mainly to increase the capacity at
the Talegaon plant in Maharashtra from 130,000 units a year to 220.000 by 2025.

 US-based car maker Chrysler has planned to invest Rs 3,500 crore (US$ 513.5 million)
inMaharashtra, to, manufacture Jeep Grand Cherokee model.

 Mercedes Benz has decided to manufacture the GLA entry SUV in India. The company has
doubled its India assembly capacity to 20,000 units per annum

6
 Germany-based luxury car maker BayerischeMotoren Werke AG's (BMW) local unit has
announced to procure components from seven India-based auto parts maker

 Mahindra Two Wheelers Limited (MTWL)acquired 51 percent shares in france-based Peugeot

Motorcycles (PMTC)

7
2.2 GOVERNMENT INITIATIVES

The Government of India encourages foreign investment in the automobile sector and
allows 100 per cent FDI under the automatic route.

Some of the major initiatives taken by the Government of India are:

 Mr. NitinGadkari, Minister of Road Transport, Highways & Shipping has announced plans to set
up a separate independent Department for Transport, comprising of experts from the automobile
sector to resolve issues such as those related to fuel technology. motor body specifications and
fuel emissions, apart from exports,

 Government of India aims to make automobiles manufacturing the main driver of 'Make in India'
initiative, as it expects passenger vehicles market to triple to 9.4 million units by 2026, as
highlighted in the Auto Mission Plan (AMP) 2016-26. In the Union budget of 2015-16, the
Government has announced to provide credit of Rs 850,000 crore (USS 124.71 billion) to
farmers, which is expected to boost the tractors segment sales.

 The Government plans to promote eco-friendly cars in the country i.e. CNG based vehicle,
hybrid vehicle, and electric vehicle and also made mandatory of 5 per cent ethanol blending in
petrol.

 The government has formulated a Scheme for Faster Adoption and Manufacturing of Electric
and Hybrid Vehicles in India, under the National Electric Mobility Mission 2020 to encourage
the progressive induction of reliable, affordable and efficient electric and hybrid vehicles in the
country.

 The Automobile Mission Plan (AMP) for the period 2006-2016, designed by the government is
aimed at accelerating and sustaining growth in this sector. Also, the well established Regulatory
Framework under the Ministry of Shipping, Road Transport and Highways, plays a part in
providing a boost to this sector

8
 3.MUSTANG MOTORS PRIVATE LTD

3.1 HISTORY

Established in 1997 as Mustang Motors Pvt. Ltd, the group has persistently grown and later we
started Elegant Automotive Pvt. Ltd in 2001 and Eminent Automotives (India) Pvt. Ltd in 2006. Our
Head Quarters is in Kochi and having outlets in major centers of Ernakulam, Thrissur &
Malappuram districts. We have a strong operational base and customer network throughout the state
of Kerala.

Mustang Motors Pvt. Ltd introduced the unique concept of an exclusive workshop for foreign and
new generation cars. We have ultra modern equipments and also able to source spare parts from any
part of the world as per customer needs. We undertake repair and spares of major premium brands
such as Benz, BMW, Audi, Toyota, Mitsubishi, Honda, Nissan, Ford, Fiat, Skoda, Volkswagen,
Porsche, Chevrolet, Hyundai, Suzuki, Mahindra etc. We carry out the repair and maintenance of
Engine, Mechanical, Electrical, Air Condition and Electronics apart from Body and Paint works.
Apart from the Service & Spares of multi branded cars, we have been associated with many branded
products as their authorised distributors.

Elegant Automotives Pvt. Ltd concentrates on wholesale, retail, import and export of foreign and
new generation car spares. The company is running its business with substantial turnover and
massive growth throughout the years.

Eminent Automotives (India) Pvt. Ltd is mainly for distribution of worldwide branded automotive
products. This company has shown its prominence and strong presence in the automobile market
since its incorporation.

3.2 MISSION

Mustang Group’s Mission is to uphold a significant stand in the growing industry through its core
values, Complete Customer Care (CCC) , Outstanding Customer Service (OCS) and Total Quality
Management (TQM). We are committed to exceed the expectations of our customers by offering
unbelievable services.

9
3.3 VISION

Our Vision is to be the most valued and unbeaten endeavor, enchanting our customers with an
extensive range of products and solutions in the automobile industry, with the best manpower and the
latest technology available across the country.

The company's progressive vision stimulates confidence among all its associates and ensures a
blooming future, built on a solid reputation of goodness, honesty and integrity.

3.4 OBJECTIVES

To establish dominant role in automobile industry and to attain maximum market share.

To provide best quality products and services to our valuable customers.

To accomplish Complete Customer Care, Outstanding Customer Service and Total Quality
Management.

3.5 MILESTONES

Shell India Ltd. extended the area of Mustang’s Shell lubricants distributorship to Ernakulam &
Iduki districts, apart from the existing Thrissur & Palakkad districts

New Products added to Mustang Group’s distribution line.

 Veedol Lubricants
 Glysantin Automotive Fluids
 Exide Industrial Batteries
 RM Brake Disc & Drums

Bosch Limited appointed Mustang Motors, Vettichira as their authorised distributor of following
categories in Malappuram district

 Bosch Main Distributor (Passenger Cars) (BMD-PC)

 Bosch Battery Distributor (BBD)
 Chassis System Control (RBIC)

The official launch of “Bosch Distributorship” in Malappuram district, formally inaugurated by

Mr.Anish Joseph, Business Manager, Bosch Limited on 19th August 2015 in Vettichira branch

10
3.6 Quality Policy

Mustang Group is dedicated to Complete Customer Care (CCC) by providing quality products and
services at reasonable rate to our esteemed customers. We assure Outstanding Customer Service
(OCS) and Total Quality Management (TQM) through our qualified and competent human resources.

We are determined to maintain our services with quality, reliability and punctuality.

Mustang group inspires enduring long-term relationships with its staff members, customers, business
associates and suppliers by the motto of ‘Quick and Quality’ Service.

3.7 SERVICE AND REPAIR

 MERCEDES -BENZ
 AUDI
 BMW
 LEXUS
 JAGUAR
 LAND ROVER
 TOYOTA
 VOLKSWAGEN
 SKODA
 HONDA

11
 4.ORGANIZATIONAL STRUCTURE

M.D. TONY
DIRECTOR, MUSTANG,
ELEGANT &EMINENT, FLOOR
MANAGER

MURALITHARAN JENEESH SHARAFUDHEEN

SUPERVISOR SUPERVISOR SUPERVISOR
(SERVICE AND (SERVICE AND (SERVICE AND
REPAIR) REAPAIR) REPAIR)

12
 

4.2 PRODUCTS AND BRANDS

BRANDS PRODUCTS

Zip  Oil Filters

 Air Filters
 Fuel Filters

Samvardhana Motherson  Spare Parts

ICML  Service & Spare

BASF  Glysantin Automotive Fluids

Exide Industrial  Batteries

RM  Brake Disc & Drum

Veedol  Lubricates

Shell  Engine Oil

Delight  Bulbs

13
 5.QUALITY TOOLS IMPLEMENTED

Proper Selection

Arrangement

Cleaning

Cleanliness

Discipline

What Has Been Decided

Exactly as per Standards

Must be Followed

Go to the Spot

Look at the Actual Thing

Grasp the Fact & Take Realistic Action

14
 6.ACTIVITIES IN THE WORKSHOP FOR SERVICING THE VEHICLE

1. Receiving the Customer

First the customer is received by the service advisor. Then the problems from the
customer is reported and gives possible causes and explain about the problem, net amount
excepting.

II. Initial Test Drive

The service advisor calls the worker and together they go for a test in different road
conditions, Checks the customer's problems and other problems. Gives reason or possible
reasons for the trouble.

III. Inspection

The vehicle is brought into the work shop and placed on the lift and lets it cool. After the vehicle is
cooled it is inspected for the possible causes and trouble shoots it as per Fait service procedure.
Also other activities like servicing is done as per the explained below.

IV. Second Inspection

The second inspection is done by the co-tech in the static conditions. He gives other
suggestions to the worker for good performance of the vehicle. The technician works as per
suggestions and terminate the problems.

V. Final Test Drive & Washing

Test drive is again conducted as explained above and brought the car to the washing. The
vehicle is washed thoroughly with water, diesel and car shampoo. After the vehicle is washed it
is cleaned at the inside and outside with cloth and a vacuum unit. Then the entire vehicle is
polished.

15
VI. Final Inspection

Final inspection is done by a finales inspector. In this stage the finalist checks the vehicle for
the following features,

 Level of engine coolant in the reservoir and radiator

 Level of battery electrolyte and battery water

 Level of engine oil

 Level of gear oil

 Play of all pedals

 Door pads and weather strips loose

 Door lock from inside and outside

 Fuel lead

 Functioning of all indicator lights.

 Level of water in windshield washer

 Function of all lamps

 Function of accessories

 Torque of wheel nuts

 Tyre pressure etc.

 Dashboard warning

VII. Billing

The service advisor and the technician prepare the bill of works and parts. It is checked
by the service manager and transferred to the customer.

VIII. Delivering

The Vehicle The vehicle is delivered to the customer to his house or at the office as per
is requirement. A rating card is given to the customer for knowing his satisfaction & for
suggestion and complaints.

16
 7.SPECIAL TOOLS USED DURING TRAINING

 1/4" BOX SOCKET WRENCHES: It's a small size socket wrench helps to loosen and fasten the
nut and bolts where less space to work.

 PNEUMATIC WRENCH: It is used to tighten and loosen nuts and bolts by using compressed air.

 PNEUMATIC RACHET: It is used to tighten and loosen nuts and bolts from 90° with help of
compressed air.

 ANGLE TORQUE WRENCH: It is used to fasten the bolts and nut with have specific angle torque
measurements

 SLIDING HAMMER: It is used to remove parts such as bearings wheel drums etc. It has a hook
and a sliding ram with a channel

 FILTER CUP: It is used to remove fuel filter of engine by easily fitting on a ratchet handle or
other

 Diagnostic Tool: Diagnostic is used Diagnostic tool for premium Cars.Since Suzuki Diagnostic
secured the contacts to supply OEM approved Maruthi Suzuki and Suzuki Japan. It helps to
delete the ECU memory and add new service details.

 PULLEY REMOVER: It is used to remove the key and pulley from the engine

 CLUTCH CENTER: Used to center the clutch disc

 OIL EXTRACTOR: It is a vacuum pump used to extract oils from vehicle with drain plug

 CAM LOCKER: It is used to lock the cam timing at the time of timing chain change

 BRAKE BLEEDER CAP: It is used to tighten the brake fluid reservoir tank to get vacuum inside
the brake line.

 AXLE BOOT HOSE CLIP LOCK PILER: It is used to lock the new axle boot locks.

17
 8.GENERAL VEHICLE MAINTENANCE

The performance of the engine is depended on ensure that the following maintenance carried out
as per the scheduled without fail.

8.1 AIR CLEANER

The air cleaner element should be replaced by every 20.000kms as when the element
paper is turn dark when the light bulb. For the detailed procedure refer to the air intake system

8.2 OIL

The oil filter and the oil should be changed 10,000kms. They should confirm cg4 grade
and wit a viscosity index of 15 W 40 for diesel and 5 W 20 for petrol. It should be kept in mind
that the turbo charged engine the oil has to take an additional load of lubricating and cooling the
turbo chargers shaft. If any oil of lower specification is used then it will break down under the
high thermal load end of the turbine and the shaft especially during the host shut down.

8.3 ALTERNATOR BELT TENSION

To be checked and replace if required at 30,000kms

8.4 COOLING SYSTEM

Ensure that no leakages are present. Also check the wear of water hoses and coolant
quality

8.5 TURBO CHARGER

The engine is having an exhaust gas driven turbocharger. The shat speed varies fo
4000 When engine id riding about 1700 when the engine is having full vated pen VCT
tio is also using in some model its works from the starting of engine. That is sers untical that
y shifting down, the engine is allowed to run idle for at least me mute Similarly the ge
Muld be run at idle for one minute at starting fcfue accelerating

18
 8.6 EGR

On vehicle fitted with EGR system the following additional paints check have to done during
scheduled maintenance

 Check the vacuum hoses for any damage.

 Fasten all nuts and bolts as per the recommended torque.

8.7 PROCEDURE OF CAR REPAIR

The car repairs which can be carried out are,

1. Air cleaner changing

2. Oil and Oil filter changing

3. Front Disc Brake Pad Changing

4. Alternator and AC belt removal and refitting

5. Timing chain replacing

6. Clutch Disc assembly replacing

7. Suspension Lounge removing

8. Turbo charger removal

9. FIP removal and refitting and

10. Cylinder head removal

8.7.1 Air cleaner changing

 Disconnect the battery terminals

 Remove the air cleaner box from the car

 Remove the air cleaner cover and replace the air cleaner with new one.

8.7.2 Oil and Oil filter changing

 Lift the vehicle

 Drain the oil

19
 Remove oil filter cap first for diesel vehicles else for petrol remove the oil filter using the
special tool (oil filter wrench)

 While fixing the oil filter put oil on the seal and tighten cap still its last thread.

8.7.3 Front Disc Brake Pad Changing

 Lift the vehicle

 Remove both front wheels

 Loosen the calliper bolts

 Remove the lock from the calliper

 Remove the calliper also check the disc wear if it need a skimming or replace

 Remove the old brake pad and replace with new pair

8.7.4 Alternator and AC belt removal and refitting

 Remove the under shield.

 Remove the AC belt through slipping the belt from groove by rotation the crank

 Pull the alternator belt tensioner clock wise then remove the belt

 Replace both belt by new ones

8.7.5 Timing Chain Replacing

 Disconnect the battery

 Remove the air filter

 Drain oil and coolant

 Remove both belt from pulleys

 Remove the following

 Belt tensioner

 Crank shaft pulley

 Water pump

20
  Power steering pulley

 Remove oil Sump

 Lock the Crank Flywheel timing

 Remove the main crank pulley

 Put the engine on stand

 Move the coolant and power steering tanks.

 Lock the cam timing with the special cam locking tool

 Remove

 Engine mounding holder from the engine

 Pipes from the timing chain cover and pull out the timing chain cover.

 Chain tensioner, pads and chain.

 Replace the parts that have to replace and do this list vice versa.

8.7.6 Suspension Lounge removing

 Lift the vehicle

 Remove following items

 Protective Shield

 Both wheels

 Lower arms from the hub

 Steering box from the lounge

 C gear box mound

 Silencer joint

 Link rod

 Loosen the lounge bolts and jack a stand on lounge

 Up the life and pick the lounge with a help of one another and place on floor

21
 Check all the suspension bushes

 Replace if any needed.

8.7.7 Clutch disc assembly replacing

 Disconnect the battery terminals.

 Remove the following items

 Air filter assy

 Battery and battery tray.

 Clutch sleeve cylinder from the gear box.

 Gear selecting cables

 Speedo gear

 Loose the B. (Gear box mound) mound.

 Remove the suspension lounge and C gear box mound.

 Loose and remove all gear box bolts

 Jack the engine with a stand.

 Shake the gear box and remove the box from the engine.

 Grease the shafts.

 Replace the clutch assembly

 When fasten the pressure plate use the special tool "clutch centre" for centring the clutch dise.

 Do this step vice versa for finishing the job.

22
8.7.8 Turbo charger removal and refitting

 Disconnect the battery terminals

 Remove

 Air cleaner to turbocharger hose.

 Parts that make the work tough

 Turbocharger oil supply pipes and vacuum pipes from manifold

 Disconnect the exhaust pipe from the turbocharger

 Remove the exhaust manifold along with turbocharger

8.7.9 FIP Removal and refitting

 Disconnect the battery terminals

 Remove the battery from its tray.

 Disconnect the wiring from FIP

 Remove the high pressure pipe from the injector and FIP

 Remove the three bolt that fix the FIP in engine.

 Rotate the FIP and slowly push the out FIP with care.

23
8.7.10 PROCEDURE FOR ALIGNING THE WHEELS

 The wheel must have proper camber, caster angles and toe. It will change due to the use. So
the alignment must be checked properly. Check the tyre pressure and bring it to correct as per
specification.

 Bring the vehicle to the ramp

 Make sure that the front wheels are on the disc provided.

 Attach the sensors on all the wheels

 By operating the computer which has pre recorded data's of vehicles, select the vehicle

 Jack up the front wheels and press the run out of each wheel and check it

 After that jack up rear wheels and set the run out.

 Rotate the steering wheel to left, right and centre

 Set the steering wheel correctness if not adjust it properly.

 Go under the vehicle and loosen the nuts of steering tie rod.

 Turn it and check the toe.

 Bring it to proper specification and tighten nuts.

8.7.11 PROCEDURE FOR WHEEL BALANCING

The wheels of the vehicle may not be perfectly balanced weight form the axle to the outer
part is not same at all points. It is balanced with the help of a machine called wheel balancer. It
determinates the position and weight to be added to balance the wheel. Sticker weights are added
in alloy wheels and clip in weights are added in normal steel wheel.

 Make sure that the disc is proper and not bended

 Check the tyre pressure and make it as per manufacturer

 Remove the weights from the wheel.

 Place it on the axle and tighten it.

 Set the dimensions of wheel and rim tyre.

 After setting press the rotation key

24
 After the process stop the wheel from rotation by pressing the brakes

 Determine the position to ass the weight and amount with the machine

 Stick or clip the weight

 Repeat it until the machine indicates OK

25
 9.MAJOR VEHICLE MAINTENANCE

9.1 CYLINDER HEAD REMOVAL

 Disconnect the battery terminals

 Remove the battery from its tray.

 Disconnect all wiring connections in head

 Drain the oil

 Remove

 All belts

 Water hoses from the head and thermostat

 Hose turbocharger to inlet manifolds

 Egr pipe to exhaust manifold

 Oil supply line to turbocharger

 High pressure pipe from the injector and fip

 Injector from head

 Timing chain.

 Top cover that have rocker arm

 Injectors

 Exhaust manifold from the head

 Cylinder head bolts

 While fitting the cylinder head gasket. Ensure that the blockhead and gasket are dry

 If the cylinder head gasket was skimmed, the please cross check the injector protrusion

26
9.2 DISMANTLING AND OVERHAULING OF THE ENGINE

If comprises of 5 steps

1. Removal of the engine

2. Dismantling

3. Inspection

4. Assembling

5. Testing

9.3 Removing of the engine from the vehicle

 Disconnect the battery terminals

 Check the wheels

 Drain the oil andcoolant

 Remove

 Air cleaner

 The hose air cleaner to turbochargers

 + Starting motor

 The electrical connection to starter, alternator, FIP injectors and all sensors.

 The fuel lines to FIP as well as the return line going to tank

 Disconnect the exhaust pipe from the turbocharger

 Disconnect the hose from the radiator end

 Remove the front grill along with the radiator

 Disconnect the clutch slave cylinder

 Support the transmission system security

 Support the engine using the lifting hook

 Check once more if any connections to be disconnected or removed.

27
 Remove transmission mounting bolt in the engine block

 Using a crane, pull the engine out of vehicle

28
9.4 Dismantling The Engine

 Remove

 Turbocharger hose to inlet manifold

 Egr pipe to exhaust manifold

 Oil supply line to turbocharger

 Dipstick guide

 High pressure pipe at the injector end and flip

 Loosen the alternator brace at the top

 Loosen the alternator mounting bolt at bottom. Move the alternator towards inner

 Take off the belt

 Remove the alternator

 Rocker arm cover.

 Injector and fip.

 Water pump.

 Damper mounting bolt and damper.

 Rocker aim cover.

 Loosening the camshaft mounting bolts

 Remove

 Flywheel mounting bolts.

 Oil sump.

 Timing cover and chain.

 Camshaft along with the thrust plate.

 Camshaft mounting bolts.

29
  Connecting rod nuts.

 Rear-end oil seal along with the carrier.

 Crankshaft.

 Piston along with connecting rod.

9.5 Inspection

All the components should be inspected for wear. Any components, which are beyond the
wear limits, have to be replaced. Over and above the near limits, the following paints also need to
be ensured.

Piston

Check for stifling scaring on a head think larger of carbon acquire on top land is acceptable.

30
 10.CONCLUSION
This report is based on industrial training at MUSTANG MOTORS Pvt,Ltd,
MARATHAKARA,THRISSUR. The Mustang Motors is the leading service and repair of premium cars
in Kerala. During 10 days of training through exposure was created in management function of
various department of the company. There was also opportunity to go through real hand
maintenance activities. The meaning of Training is to learn a skill. Training is the act of increasing
the knowledge and skill of a person for doing a particular job. Training enables to acquire latest
skills, thus increase versatility for qualification for busting carrier. It provides better safety,
remuneration and security. It also enables to drive greater satisfaction and utilize the full skills and
capacity. Proper training teaches proper operation and changes the wrong attitude and also tells
the safe points. In-plant training for diploma automobile engineering students is important because
it is the time to obtain as much knowledge about their field. As a diploma student, training helps
me to implement the concepts I learned at my classes. Actual challenges only appear when I work
in real-world of automobile. All the automobile subjects based on the theories already I learned
during my diploma course, but there are lot more things involved in developing a live application
and those things can be learned only from a good service centre environment and that never
taught me at classes. Training increases the confidence in my field that I learned. After completing
training I feel much confident about me field. If my Concepts not clear or I have any confusion with
them, then at the time of interview, exams or in professional life I may face many problems. All
experienced people always like to hear accurate to the point solution to every problem, my carrier
depends on my sharpness, intelligence and of course in my confidence. So as much as possible, I
cleared my confusion and got the new ideas from the fields with the help of In-plant training and
become confident and sincere in this field.

31