maruti services

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A

TRAINING REPORT

AT

HMT LTD, PINJORE

SUBMITTED TO :

DEPARTMENT OF MECHANICAL ENGINEERING

In the partial fulfillment for the award of

DIPLOMA IN MECHANICAL ENGEERING

As prescribed by state of board of technical education Haryana.

SUPERVISED BY: SUBMITTED BY:

Mr. V.K. Grover Rajat Khurana

Manager Roll No. 0903917068

HMT Ltd., Pinjore Mech. Engg. (5th Sem.)

Jan Nayak Choudhary Devi Lal Polytechnic

Barnala Road, SIRSA-125055


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ACKNOWLEDGEMENT

I would like to express my gratitude to all these who gave me the possibility to

complete this training. I want to thank to Department of Mechanical

Engineering for giving me the permission to commence this training in this

training in the First instance, to do necessary work for training report & to use

the Department sources.

I am further more to thank to Mr. Sanjeev Kalra, Principal, Rajendra

Polytechnic , Phulkan (Sirsa) to enurrage to go ahead.

I am deeply indefinite to my supervisor Mr. Jaswant Ray Sharma , Shakti

Motors Sirsa. Who help, inspiring suggestion and in trust help me in all the

time of training work.

Especially, I would like to give me a special thanks to my parents, whose love

enabled me to complete this training. Last but not least, I am behold to Er.

Mahabir Pansia, H.O.D. Department of Mechanical Engineering. For his

unconditional aid & ignition.

Buta Singh

Roll No. 0909717008


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CONTENTS

S. No. Title Page

No.

1 Maruti Introduction 1-2

2 Maruti Models 3-5

3 Engine 6

4 Alto Gasket 7-8

5 Alto Gear Box 9-10

6 Alto Clutch Parts 11

7 Alto Breaking System 12-13

8 Cooling System 14-15

9 Alto Clutch Plate 16-17

10 Air Filter & Battery 18

11 Carburetor Parts 19

12 Pump 19


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MARUTI SUZUKI

INTRODUCTION

The introduction of the Maruti 800 in 1983, marked the beginning of a

revolution in the Indian automobile industry. Maruti Udyog brought in the

latest technology then available, more fuel-efficient cars, and brought down the

prices of cars in India. This led to the creation of a huge market for all car

segments as the Indian middle class grew in size. This in-turn brought in more

players to this segment. A number of auxiliary car parts making units were

setup as most car manufacturers realised it was more cost effective to make

their car parts in India rather than import them. Maruti's most major influence

was in helping the component industry in the country because of its emphasis

on localization and indegenisation. As in the beginning that sector hadn't grown

much, Maruti had to start a dozen joint ventures with Indian entrepreneurs. It

got them foreign collaborations, that led to collaborations for other

manufacturers so that over a period of time the whole component industry was

able to upgrade itself and improve its quality. Leading to a major existing

export potential in vehicle components. It also brought in better methods of

financing that allowed more people, who given their income levels could not

afford to buy a car on their own, to buy cars.[6] It still remains the leader notonly in terms of market share but also in customer satisfaction surveys - it has

consistently topped J. D. Power quality surveys, including 2005.

Maruti Suzuki India is a publicly listed automakerin India. It is a leading four-

wheelerautomobilemanufacturerin South Asia. Suzuki Motor Corporation of
http://en.wikipedia.org/wiki/Automakerhttp://en.wikipedia.org/wiki/Indiahttp://en.wikipedia.org/wiki/Automobilehttp://en.wikipedia.org/wiki/Manufacturinghttp://en.wikipedia.org/wiki/South_Asiahttp://en.wikipedia.org/wiki/Suzukihttp://www.marutisuzuki.com/maruti-cars-home.aspxhttp://en.wikipedia.org/wiki/Automakerhttp://en.wikipedia.org/wiki/Indiahttp://en.wikipedia.org/wiki/Automobilehttp://en.wikipedia.org/wiki/Manufacturinghttp://en.wikipedia.org/wiki/South_Asiahttp://en.wikipedia.org/wiki/Suzuki


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Japan holds a majority stake in the company. It was the first company in India

to mass-produce and sell more than a million cars. It is largely credited for

having brought in an automobile revolution to India. It is the market leader in

India. On 17 September 2007, Maruti Udyog was renamed to Maruti Suzuki

India Limited. The company's headquarters remain in Gurgaon, nearDelhi.

Maruti Udyog Limited (MUL) was established in February 1981, though the

actual production commenced in 1983. Through 2004, Maruti has produced

over 5 Million vehicles. Marutis are sold in India and various several other

countries, depending upon export orders. Cars similar to Marutis (but not

manufactured by Maruti Udyog) are sold by Suzuki in Pakistan and otherSouth

Asian countries.

The company annually exports more than 30,000 cars and has an extremely

large domestic market in India selling over 500,000 cars annually. Maruti 800,

till 2004, was the India's largest selling compact car ever since it was launched

in 1983. More than a million units of this car have been sold worldwide so far.

Currently, Maruti Alto tops the sales charts.

Suzuki Motor Corporation, the parent company, is a global leader in mini and

compact cars for three decades. Suzukis technical superiority lies in its ability

to pack power and performance into a compact, lightweight engine that is clean

and fuel efficient.

The company vouches for customer satisfaction. For its sincere efforts it has

been rated (by customers)first in customer satisfaction among all car makers in

India for seven years in a row in annual survey by J D Power Asia Pacific.

Maruti Suzuki was born as a government company, with Suzuki as a minor

partner, to make a peoples car for middle class India. Over the years, the

product range has widened, ownership has changed hands and the customer has
http://en.wikipedia.org/wiki/September_17http://en.wikipedia.org/wiki/2007http://en.wikipedia.org/wiki/Gurgaonhttp://en.wikipedia.org/wiki/Delhihttp://en.wikipedia.org/wiki/Pakistanhttp://en.wikipedia.org/wiki/South_Asiahttp://en.wikipedia.org/wiki/South_Asiahttp://en.wikipedia.org/wiki/Maruti_800http://en.wikipedia.org/wiki/2004http://en.wikipedia.org/wiki/Maruti_Altohttp://en.wikipedia.org/wiki/September_17http://en.wikipedia.org/wiki/2007http://en.wikipedia.org/wiki/Gurgaonhttp://en.wikipedia.org/wiki/Delhihttp://en.wikipedia.org/wiki/Pakistanhttp://en.wikipedia.org/wiki/South_Asiahttp://en.wikipedia.org/wiki/South_Asiahttp://en.wikipedia.org/wiki/Maruti_800http://en.wikipedia.org/wiki/2004http://en.wikipedia.org/wiki/Maruti_Alto


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evolved. What remains unchanged, then and now, is Marutis mission to

motorise India.

TYPES OF MODELS

Sales of automobiles

Maruti 800

Maruti Zen Estilo

In the order they were launched:

1. Maruti 800: Launched 1983. Largest selling car in India, until 2004.

Cheapest car in India. 3 Face-Lifts.(P)

2. Maruti Omni: Launched 1984. 2 Face-Lifts.(P)

3. Maruti Gypsy: Launched 1985.(P)

4. Maruti Wagon-R:Launched 1999, 2 Face-Lifts.(P)5. Maruti Alto: Launched 2000. Currently the largest selling car in India. 1

Face-Lift.({{Tooltip|P|Petrol

6. Maruti Versa(2003-) (P)

7. Maruti Zen Estilo(2005-) (P)

8. Maruti Suzuki Swift 1 very small face-lift(2006- ) (P & D)

9. Maruti Suzuki SX4 (May 2007- ) (P & D)

10.Maruti Grand Vitara Sports Utility Vehicle Launched in (July 2007- ).

Imported(P)

11. Maruti DZiRE Sedan Version of swift launched in (March 2008- ) (P)

Upcoming models in 2008
http://en.wikipedia.org/wiki/Maruti_800http://en.wikipedia.org/wiki/Indiahttp://en.wikipedia.org/wiki/Maruti_Omnihttp://en.wikipedia.org/wiki/Maruti_Gypsyhttp://en.wikipedia.org/wiki/Maruti_Wagon-Rhttp://en.wikipedia.org/wiki/Maruti_Altohttp://en.wikipedia.org/wiki/Indiahttp://en.wikipedia.org/wiki/Maruti_Versahttp://en.wikipedia.org/wiki/Maruti_Zen_Estilohttp://en.wikipedia.org/wiki/Maruti_Suzuki_Swifthttp://en.wikipedia.org/wiki/Maruti_Suzuki_SX4http://en.wikipedia.org/wiki/Maruti_Grand_Vitarahttp://en.wikipedia.org/wiki/Maruti_DZiREhttp://en.wikipedia.org/wiki/Maruti_800http://en.wikipedia.org/wiki/Indiahttp://en.wikipedia.org/wiki/Maruti_Omnihttp://en.wikipedia.org/wiki/Maruti_Gypsyhttp://en.wikipedia.org/wiki/Maruti_Wagon-Rhttp://en.wikipedia.org/wiki/Maruti_Altohttp://en.wikipedia.org/wiki/Indiahttp://en.wikipedia.org/wiki/Maruti_Versahttp://en.wikipedia.org/wiki/Maruti_Zen_Estilohttp://en.wikipedia.org/wiki/Maruti_Suzuki_Swifthttp://en.wikipedia.org/wiki/Maruti_Suzuki_SX4http://en.wikipedia.org/wiki/Maruti_Grand_Vitarahttp://en.wikipedia.org/wiki/Maruti_DZiRE


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1. Suzuki Splash

2. Suzuki A-Star

Future Maruti Suzuki Plans

1. Maruti Omni Face-Lift in 2009

2. New Mini-SUV in 2010 Likely to be a four-door Jimny.

3. New Luxury Sedan in 2010 Likely to be a production version of the

Kizashi.

4. New Swift in 2011

5. New Alto
http://en.wikipedia.org/wiki/Suzuki_Splashhttp://en.wikipedia.org/w/index.php?title=Suzuki_A-Star&action=edit&redlink=1http://en.wikipedia.org/w/index.php?title=Maruti_Omni_Face-Lift_in_2009&action=edit&redlink=1http://en.wikipedia.org/w/index.php?title=New_Mini-SUV_in_2010&action=edit&redlink=1http://en.wikipedia.org/w/index.php?title=New_Luxury_Sedan_in_2010&action=edit&redlink=1http://en.wikipedia.org/w/index.php?title=New_Swift_in_2011&action=edit&redlink=1http://en.wikipedia.org/wiki/Suzuki_Splashhttp://en.wikipedia.org/w/index.php?title=Suzuki_A-Star&action=edit&redlink=1http://en.wikipedia.org/w/index.php?title=Maruti_Omni_Face-Lift_in_2009&action=edit&redlink=1http://en.wikipedia.org/w/index.php?title=New_Mini-SUV_in_2010&action=edit&redlink=1http://en.wikipedia.org/w/index.php?title=New_Luxury_Sedan_in_2010&action=edit&redlink=1http://en.wikipedia.org/w/index.php?title=New_Swift_in_2011&action=edit&redlink=1


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Maruti Alto Engine

All the Suzuki Alto's sold in the Netherlands have the same engine/platform. So

it is very cheap to maintain, because second hand parts can be found at almost

any junkyard and are cheap! The same car and engine are also sold as the

Daewoo Tico and in India as the Maruti 800. The F8B engine is also mounted

in the Suzuki Mightyboy and Suzuki Hatch.

General specification:

Engine code: F8B

Capacity: 796cc

Nominal bore: 68.5mm

Stroke: 72.0mm

Compression ratio: 8.7:1

Max power output: >29.5kW/39.5bhp @ 5500rpm


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Power output per litre: >37kW/49,7bhp

Power to weight ratio: 64,1bhp/ton (616Kg)

Max torque: 59 Nm @ 3000rpm

Torque per litre: 74,1Nm

Torque to weight ratio: 95,8Nm/ton

Intake 31.6mm Exhaust 27.6 (valve head diameter)

Rocker ratio: about 1.48


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Alto Gasket

In my earlier post, I did mention on the K6A engine that is install on Japan

Suzuki Alto (Please note that the Malaysia Suzuki Alto which is assemble from

India Suzuki factory is in difference engine), as it seem like this engine is

mainly for Japan domestic market requirement only, I'm not really expect to

find such an engine in Malaysia.

Than I found a post in a local auto forum, that one guy had swap this 2003

Suzuki Alto K6A engine to 1993 Suzuki Alto, which it originaly carry F6A

engine.
http://3.bp.blogspot.com/-9bAZQFZfwXg/TiOZbJyNAtI/AAAAAAAAA0U/ik625QdRr1s/s1600/K6A.jpghttp://3.bp.blogspot.com/-_M7YJPMgWws/TiOZgpRraHI/AAAAAAAAA0c/QPCU63lbJfI/s1600/p1070201l.jpg


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And also some fact of K6A engine driven Suzuki Cappuccino.

The Suzuki Cappuccino is a small 2-door, 2-seater demountable hardtop

roadster produced by Suzuki Motor Corporation. The vehicle was designed to

meet Kei car specifications for lower tax and insurance in Japan. Weighing just

725 kg (1,598 lb), the Cappuccino is powered by a turbocharged, three-

cylinder, 657cc DOHC engine (just under the 660cc maximum displacement

allowed for a Kei car). Its dimensions also conformed to Kei car regulations on

length and width, being 3,295 mm (129.7 in) long and 1,395 mm (54.9 in) wide.

Front-rear weight distribution is claimed to be 50/50% when both seats are

occupied. Layout is front mid-engined and rear-wheel drive. The hood, roof,

roll bar and lower front guard panels are aluminium.


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Maruti Alto Gear Box

n an awe inspiring reflection of how popular Volkswagens award winning dual

clutch gearbox has been, Volkswagen has just sold its three and a half

millionth DSG Gearbox worldwide. DSG, is an acronym for Direct Shift

Gearbox, with Volkswagen being the very first manufacturer to introduce the

dual clutch system in a car gearbox which made gear shift times quicker, to suit

todays high performance car just fine.

The Direct-Shift Gearbox commonly abbreviated to DSG is an electronically

controlled dual clutch multiple-shaft manual gearbox, in a transaxle design -

without a conventional clutch pedal,and with full automatic, or semi-manualcontrol. The first actual Dual Clutch transmissions derived from Porsche in-

house development for 962 racing cars in the 80's.

Now, what exactly do the two clutches in the DSG gearbox do? The two

clutches let two gears to be selected at a single shot so that when the

transmission shifts, it needs only open one clutch and the other clutch can

remain closed, thus saving time. Quicker shifts means more rapid acceleration

and also a less jerky movement during gear shifting.

Also, since Dual Clutch gearboxes are lighter than conventional automatic

gearboxes, they are inherently more efficient, thus delivering fuel savings. In

India, models such as the Skoda Laura, Skoda Superb, the Altoi A4, the 2011


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Volkswagen Passat are a few models where Volkswagens DSG gearbox is

being used currently. In due course of time, smaller Volkswagen group cars in

India like the Volkswagen Polo and the Skoda Fabia may also get the DSG

gearbox.


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Alto Clutch parts

We have wide range of clutch plate items available for American , European ,J

apanese,and Korea Vehicles,

O,D range from 160mm-430mm.

2,More than 1,000 kinds of models, if you require by OEM No.,or Dakin No.,V

aleo No.,Sachs No.,Asco No.,

LUK No., etc. We can quote you in no time, we can guarantee our clutch disc t

o be high standard.

3,We can develop according to customers' drawings or samples.

4,Material:High quality non-asbestos clutch facing. High quality toque spring

with material 60 Si2Mn,Forged clutch hubs , Anti-rust paper and oil.

5,High standard heat treatment system for progressing.

6,Steady force transmission , Reliable transfer torque.

7,Excellent radiative performance.

8,Long service life , low wear and tear , Noiseless.


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Alto Braking System

Differential & Gear Parts

One of the most important car parts, these axles join the front two

wheels of your car. The positioning of the front axle can significantly change

the wheel base, for example if it is mounted under the cab instead of ahead the

cab, as most commonly done in commercial vehicles, the wheel base can be

reduced to quite an extend. Our front axles designed for cars like tata indica,

maruti suzuki and other cars are made to fit all the models and can also be made

to your exact specifications. Some of the axle types are shaft assembly ( both

for rh and lh drive), joint assembly wheel side and joint assembly differential

side.


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Our company is also engaged in the manufacturing of rim, web & welded shoe

for various automobiles.

6 types of rims & 7 types of webs are manufactured for different leading

vehicles viz. Maruti800, Zen, Alto, Van, Swift, Esteem, Tata Indica,

Bajaj Rickshaw, Mahindra Logan, Tata Economy Car (Rs. 1 lacs) & etc. .

Web developed for Mahindra Logan has full shaving as like fine blanked

component on its welding face & anchor point. .

Pad plate developed for Maruti 800 for its front disk brake is having full

shaving on its two lugs with dimension between the two maintained

within +/-0.05mm. .

Each rim has lancing, dimpling & radius bending operations which are to

be maintained within close dims. .

Progressive tools have been developed for four types of rims and four

types of web. .

Shoe welding can be done in house on projection welding machines. .

A fully developed & tested set-up for shoe welding, coining & piercing is

ready with CSPL.

Our company is one of the main sources to supply these items in quantities to

Bosch. Currently, our company is short-listed supplier by Bosch for supplying

Rim, Webs for Alto.


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The Car Cooling System

When a car engine is running there are continuous explosions in the cylinders of

the engine. We know for a fact that fire creates heat, these explosions create a

lot of heat within the engine. If the heat is not controlled it can damage the

engine and cause it to cease. For this reason every car has a cooling system. The

cooling system on a car is managed by a radiator and some other components.

All cars today are liquid cooled. There are passages around the engine and thecylinders. The cooling system circulates coolant through those passages in the

engine. The liquid absorbs the heat from the engine as it passes through.


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In earlier times cars were cooled by passing water around those passages. Cars

operate in very different conditions across the world. From well over 100 F in

desserts to below freezing temperatures in snow. The liquid that is used to cool

the engine cannot evaporate or freeze because if it does the cooling system will

not work and the engine will overheat until it ceases. As a result the fluid used

to cool the engine is a mixture of water and ethylene glycol which is called

coolant. This mixture has a boiling point that is much higher than that of water

at 235 F, and has a freezing point that is well below that of the freezing point of

water at -55 C. In addition to this there is a pressurised radiator cap. The boiling

temperature of any liquid goes up when it is pressurised, as a result the

pressurised radiator cap increases the boiling point of the coolant. If the

temperature exceeds the boiling point the fluid will flow out of the radiator cap

through a valve. The spring pressure of the cap determines how much

maximum pressure of the cooling system. The coolant flows through the

overflow pipe into the bottom of the overflow tank. Once the radiator cools

back down vacuum is created in the cooling system that opens another spring

loaded valve that pulls the coolant back into the system.

Specifications

1.Radiator fan motor, Fan motor, Blower motor, Electrical fan motor for

MARUTI ESTEEM FM35

2.OE N/D

NAME:Radiator fan motor, Fan motor, Blower motor, Electrical fan

motor

1.Application: MARUTI ESTEEM FM35

2.OE N/D

3.Volt: 12V

4.Certification:ISO9001:2000


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Alto Clutch

We provide clutch plates that are forged out of high grade materials. These

clutch plates are supplied with asbestos based or asbestos free clutch facings, to

suffice you requirements. A wide orange of clutch plates are available for

different makes of cars. There is also a provision to cater to the customized

requirements for individual needs. Along with it, we also have a complete range

of clutch parts, namely bearings, clutch arms and clutch fork.

automobile clutch release bearingclutch bearing,automotive bearingclutch

partstruck bearing ,With Car Maruti Alto.


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Various types and sizes of automobile clutch release bearings available for

Europe, Japan,

Korea and America automobiles .

Capable of developing customer's designation and samples.

We offer SKF number for you .

our company fully introduces ISO9001 and TS16949 international standard.

By the past years efforts, we have already established a comprehensive

integrated quality control system, with QC engineers inspecting goods at every

stage of the manufacturing process.

With high-quality material and advanced technology,the qualities of the

products have get continuous promotion and have got the praise of customers.

We offer our customers:

1) High quanlity bearing

2) competitive price

3) prompt delivery

4) good service

In addition, special bearings are also produced as per customers requirements


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Air Filter and Battery

A few car upkeep work tend to be not so difficult to become carried out through

somebody along with fairly small specialized understanding. Car restore

providers that may be carried out along with no less than resources as well as

knowhow consist of altering the fatigue, changing a good air conditioning filter,

looking at as well as altering essential oil, looking at as well as leading upward

tranny liquid, as well as looking at electric battery, ignite attaches along with

other electric products.

A few of these points seem very complex in order to somebody who has in no

way done an automobile prior to. However, dont allow the actual unfamiliar

frighten a person. Determining the issue is the toughest a part of carrying out

car restore providers; maintaining an automobile taken care of is usually easier.
http://www.forerunner405gps.com/maintaining-car-air-filter-battery.htmlhttp://www.forerunner405gps.com/maintaining-car-air-filter-battery.html


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Carburetor Parts

To cater to the segment, which has cars that were launched with carburetors

(maruti suzuki 800, Alto, omni, gypsi, zen/ alto), we supply a complete

range of parts. Some of them are: needle valve assembly, float, jet

(primary and secondary), gasket kit, membrane assembly accelerator

pump, float chamber cover, throttle body, spring, carburetor repair kit,

pump body accelerator, power valve kit, insulating gasket, washer and

valve assembly solenoid (solenoid watch).

Pumps 01

Our range of auto pumps viz water pump assembly, pulley water

pump, belt water pump, fuel pump assembly (along with diaphragm) and oil

pump assembly are carefully manufactured and thoroughly tested, in oder to

prevent any leakage or over heating of the engine. These components not only

prevent accidental damage but if properly maintained, also enhance the

efficiency of the vehicle.


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CONCLUSION

On an average more than 73% people feel that the prices are affordable whereas

17% do not agree, 74% believe that attractive discounts are offered whereas

26% are not satisfied with the discounts offered. 20%

said that the test drives are not offered and 15% said that post sales follow ups

are not done regularly whereas 85% said that they were done regularly, but

people feel that Maruti Suzukis the peoples car as it is satisfactory on all other

parameters: knowledgeable sales persons, employees spent enough time before

and during sales, display of merchandise is attractive, availability of product,

variety of merchandize, vehicle in good condition, affordable prices, attractive

discounts are offered, dcor of the waiting area is pleasing, responds to

complaints quickly, service at Maruti service station is excellent, careful with

personal information and is value for money .

The overall opinion about Maruti is very good.

maruti services

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