Roger Motors

A REPORT ON
INDUSTRIAL TRAINING
At:
ROGER MOTORS
Submitted To:
ATMIYA
INSTITUTE OF TECHNOLOGY AND SCIENCE
FOR DIPLOMA STUDIES
As a Part of curriculum in 5th semester
DIPLOMA
AUTOMOBILE ENGINEERING
Submitted by:
Ravani Abhishek Ashokbhai - 136030302052
Guided by:
Mr. Jenish V Bhalani
DEPARTMENT OF AUTOMOBILE ENGINEERING

ATMIYA INSTITUTE OF TECHNOLOGY AND SCIENCE
FOR DIPLOMA STUDIES - RAJKOT
2015
A REPORT ON
INDUSTRIAL TRAINING
At:
ROGER MOTORS
By
Ravani Abhishek Ashokbhai - 136030302052
Guided by:
Mr. Jenish V Bhalani
A Report Submitted to
Atmiya Institute of Technology and Science for Diploma Studies
Under
Gujarat Technological University
As a part of curriculum in
5th semester Diploma Automobile Engineering
2015
ATMIYA
FOR DIPLOMA STUDIES
Yogidham Gurukul, kalawad Road, Rajkot-360005.
II SWAMI SHREEJI II
ATMIYA
FOR DIPLOMA STUDIES RAJKOT
(Approved by AICTE, Affiliated to GTU, Gujarat)
Certificate
This is to certify that Industrial Training work embodied in this
report, was carried out by Mr. Ravani Abhishek Ashokbhai at ROGER
MOTORS as a part of curriculum Industrial training (3350201) in 5th
semester Diploma Automobile Engineering under curriculum of Gujarat
Technological University. This training work has been carried out under
my supervision.
Date:
Place:
Signature and Name of Officer Signature and Name of

(Industrial Establishment) HOD
Seal of Industry Seal of Institute

II SWAMI SHREEJI II
ATMIYA
FOR DIPLOMA STUDIES RAJKOT
(Approved by AICTE, Affiliated to GTU, Gujarat)
Examiners Certificate of Approval
The Training Report submitted by Mr. Ravani Abhishek
Ashokbhai carried out at ROGER MOTORS as a part of term work for the
curriculum Industrial Training (3350201) in the 5th semester Diploma
Automobile Engineering term ending in October 2015 at Atmiya Institute
of Technology and Science for Diploma Studies, Rajkot. The Report and
Training work submitted by student are satisfactory.
Date:
Place:
Internal Examiner External Examiner

(Signature and Name) (Signature and Name)
Abstract
Automobile Engineering is fusion of theoretical and practical knowledge,
and it demands theoretical concepts application to Real life field problems
practically, after the formation of foundation of fundamental automobile
knowledge, it was essentially important to learn the application of that
knowledge in industry, to fulfil this purpose GTU introduced Subject Industrial
Training(3350201) in curriculum of Diploma in Automobile Engineering
semester 5, and for the above mentioned reason I have chosen ROGER
MOTORS to conduct my training because of their class leading services and
Reputation as a Multi brand workshop.
During the training period from 15th June to 15th October, I went through
extensive learning process of Vehicle Maintenance, vehicle troubleshooting,
common problems driver and passengers face while travelling, standard
operation procedure to carry out most repairs, various vehicle assemblies and
subassemblies repairing procedure, important safety measures during repair
procedures, proper use of tools, significance of various essential engine fluids,
how lack of maintenance can lead to Danger to drivers life and others life on
road. Also learnt how to prolong vehicle components service life and how to
bring down Maintenance cost by keeping vehicle systems in proper shape by
carrying out periodic maintenance.
After spending four months in ROGER MOTORS for my training I could

understand how to deliver exceptional services to the customers, demands of
the industry and how to uphold service quality to bloom, and timely
transformation to match the most current scenario. And could conclude that,
without such extensive Practical experience during the Training, an Automobile
Engineer may not be able to utilize the full potential of their knowledge.
In the following report content I have tried to compile my experience,

acquired knowledge and skills related to automobile maintenance,
performance enhancement and upgradation Industry.
v
Acknowledgement
I would like to convey my Gratitude especially to Prof. M. D. Gajjar,
Prof. J. V. Bhalani and staff of Diploma Automobile Department of ATMIYA
INSTITUTE OF TECHNOLOGY AND SCIENCE FOR DIPLOMA STUDIES
and staff of ROGER MOTORS for the excellent Industrial Training which I
have undergone during 15th June 15 to 15th October 15. The skills and
knowledge which I have gained throughout my practical training I perceive
as very valuable component in my future career development. As you know
this Industrial Training was part of my educational curriculum and My
Window to had Glimpse of the Automobile Industry therefore I have to
sincerely thank you from the bottom of my heart for providing me this
Precious opportunity.
I would especially like to thank Mr Kripalsinh Jadeja(M.D), Mr

Dilipsinh Parmar(Manager HRD), Mr Kalpeshbhai Pithadiya(Works
Manager), Mr Pruthvirajsinh Gohil(Technician), & Mr Vinodbhai
Visapara(Technician) and ENTIRE ROGER MOTORS STAFF for their
generous support, coaching and companionship during my training period.
And appreciation more than words can say For letting me be the core
member of ROGER FAMILY, they shared their expertise with me very
generously, and Taught me extremely Valuable Lessons, and knowledge they
have Extracted and Mastered after Spending Many More years in the
Industry.
Thank you once again for your great support in the successful
completion of my Industrial Training.
vi
INDEX
SR NO TOPIC PAGE NO
1 TITLE PAGE I
2 CERTIFICATES II-III
3 INDUSTRY CERTIFICATE IV
4 ABSTRACT V
5 ACKNOWLEDGEMENT VI
6 INDEX VII
7 LIST OF FIGURES IX
8 LIST OF TABLES XII
TOPIC PAGE NO
CHAPTER 1 INTRODUCTION 1
1.1 INTRODUCTION TO ROGER MOTORS 1
1.2 CORE PURPOSE 2
1.3 CORE VALUES 2
1.4 MILESTONES OF THE JOURNEY 2
1.5 CONCEPT OF ROGER GALLERIA(TECHSSORIES) 3
1.6 GEMS OF THE CROWN 3
1.7 PATENTED PRODUCTS 3
1.8 AWARDS AND ACHIEVEMENTS 4
CHAPTER 2 WORKSHOP LAYOUT 6
2.1 WORKSHOP LAYOUT 6
2.2 WORKSHOP MODIFIED LAYOUT 8
2.3 MODIFIED WORKSHOP LAYOUT 9
EXPLAINATION
CHAPTER 3 HIERARCHY 10
3.1 ROGER MOTORS WORKSHOP HIERARCHY 10
3.2 ROGER HIERARCHY AND WORKFLOW 11
CHAPTER 4 TOOLS AND FACILITIES 12
4.1 TOOLS, EQUIPMENTS, AND INSTRUMENTS 12
4.1.1 MANATEC RHINO TWO POST LIFT 12
4.1.2 ELGI WHEELS FREE SCISSORS LIFT 13
4.1.3 PROFIMASTER SINGLE POST 14
MOBILE LIFT
4.1.4 CARTAR MOVE MOBILE LIFT 15
4.1.5 KENNEDY BRAKE PISTON WIND 16
BACK TOOLKIT
4.1.6 GENERIC ENGINE HOIST 17
4.1.7 BG CT2 COOLANT TRANSFUSION 18
SYSTEM
4.1.8 HUNTER ON CAR BRAKE LATHE 19
4.1.9 AUTOMATIC CAR UNDERBODY 20
vii
WASHING SYSTEM
CHAPTER 5 ENGINE AND ENGINE SUBASSEMBLIES REPAIRS 21
5.1 SKODA FABIA TDI 21
5.2 SKODA OCTAVIA TDI 23
5.3 TATA INDICA DLS DI 23
5.4 HYUNDAI I-20 CRDI 24
5.5 AUDI A4 TDI 25
5.6 NISSAN X-TRAIL 26
5.7 VOLKSWAGEN POLO TDI 27
5.8 HYUNDAI VERNA CRDI SX ABS 28
5.9 TATA SUMO GRANDE 29
5.10 CHEVROLET CAPTIVA LTZ 30
5.11 SKODA FABIA TDI 30
5.12 HYUNDAI I-20 CRDI SPORTZ 31
5.13 HONDA CIVIC I-VTEC 32
5.14 MERCEDES BENZ C250 TDI 34
5.15 AUDI A6 TDI (V6) 37
5.16 HONDA CIVIC I-VTEC 38
CHAPTER 6 TRANSMISSION REPAIRS 40
6.1 HYUNDAI I-20 CRDI ASTA 40
6.2 TATA INDICA VISTA QUADRAJET 41
6.3 TATA MANZA 42
6.5 MAHINDRA XUV-500 44
CHAPTER 7 SUSPENSION REPAIRS 46
7.2 HYUNDAI VERNA SX 46
7.3 FORD FIESTA CLASSIC TDCI 47
7.4 MARUTI SUZUKI RITZ VDI 48
7.5 CHEVROLET CRUZE 48
7.7 MARUTI SUZUKI RITZ LDI 50
7.8 AUDI Q7 V6 QUATTRO 51
CHAPTER 8 STEERING AND STEERING SUBASSEMBLIES 52
8.1 TATA INDICA DLS 52
8.2 HYUNDAI I-20 CRDI SPORTZ 53
CHAPTER 9 BRAKES REPAIR 54
9.1 TATA INDICA VISTA 54
9.2 AUDI Q7 QUATTRO 54
CHAPTER 10 MOST CHALLENGING EXPERIENCE DURING 56
TRAINING
10.1 AUDI Q7 QUATTRO ADAPTIVE AIR 56
SUSPENSION
CHAPTER 11 LIKES AND DISLIKES ABOUT ORGANIZATION 60
11.1 LIKES 60
11.2 DISLIKES 60
REFERENCES 62
viii
LIST OF FIGURES
FIGURE PAGE NO
CHAPTER 1 INTRODUCTION 1
1.1 ROGER MOTORS HEAD QUARTERS 1
1.2 BOSCH TROPHY FOR 3RD RANK IN INDIA 3
1.3 BOSCH MOMENTO FOR 1ST RANK IN GUJARAT 3
1.4 ROGERAB FITTED IN COIL SPRING 3
1.5 ROGER WIPER STAND 3
1.6 NATIONAL AWARD BY MSME 4
1.7 MR KRIPALSINH ACCEPTING MSME AWARD 4
1.8 MR KRIPALSINH ACCEPTING SSI AWARD 4
1.9 SSI ENTREPRENEURSHIP AWARD 5
1.10 MR KRIPALSINH IN CNBC AWAAZ INTERVIEW 5
1.11 MR KRIPALSINH EXPLAINING CONCEPT 5
1.12 AWARD BY TATA MOTORS 5
CHAPTER 2 WORKSHOP LAYOUT 6
2.1 ROGER MOTORS CURRENT LAYOUT 6
2.2 ROGER MOTORS MODIFIED LAYOUT 8
2.3 ROGER MOTORS WORKSHOP HIERARCHY 10
3.1 TWO POST LIFT 12
3.2 SCISSORS TYPE LIFT 13
3.4 SINGLE POST MOBILE LIFT 14
3.5 CARTAR MOBILE LIFT 15
3.6 KENNEDY BRAKE PISTON WINDING TOOLKIT 16
3.7 ENGINE HOIST 17
3.8 COOLANT TRANSFUSION SYSTEM 18
3.9 HUNTER ON CAR LATHE 19
3.10 AUTOMATIC UNDERBODY WASHING SYSTEM 20
CHAPTER 4 ENGINE AND ENGINE SUBASSEMBLY REPAIRS 21
4.1 DETERIORATED OIL PUMP SPROCKET 21
4.2 DAMAGED CHAIN TENSIONER 21
4.3 NEW CHAIN TENSIONER 22
4.4 CYLINDER WITH NEW LINERS, AND RINGS 23
4.5 PER CYLINDER TWO VALVE CONFIGURATION 23
4.6 OPENED HEAD TO REMOVE GLOWPLUGS 23
4.7 GLOW PLUG LOCATION 23
4.8 NEW GLOWPLUGS 24
4.9 GLOWPLUG LOCATION INSIDE CHAMBER 24
4.10 REMOVED INJECTORS 24
4.11 REMOVED INJECTORS AND VALVE COVER 24
4.12 REMOVED INJECTORS AND GOT THEM SERVICED 25
4.13 ACCUMULATED DIESEL 26
4.14 DETERIORATED RETURN LINE 26
ix
4.15 BULGED AND RUPTURED RETURN LINE 27
4.16 REPLACED RETURN LINE 27
4.17 TURBOCHARGER OUTLET HOSE 27
4.18 RUPTURED TURBOCHARGER OUTLET HOSE 27
4.19 RUPTURED HOSE CLOSEUP 28
4.20 REPLACEMENT HOSE 28
4.21 VGT CONTROL 28
4.22 INSTALLED TURBOCHARGER 28
4.23 DIESEL REMOVED FROM THE VEHICLE 29
4.24 SAMPLE DIESEL FOR COMPARISON 29
4.25 MALFUNCTIONING ALTERNATOR PULLEY 30
4.26 REPLACED FREEWHEELING PULLEY 30
4.27 DETERIORATED OIL COOLER 31
4.28 TRACES OF FLUIDS MIXTURE 31
4.29 REPLACEMENT OIL COOLER 31
4.30 OLD ELONGATED TIMING CHAIN 32
4.31 TIMING MARKING ON CAM SHAFT SPROCKET 32
4.32 BUCKLED AND FRACTURED CONNECTING ROD 33
4.33 CONNECTING ROD STRIKING MARKS 33
4.34 TIMING POSITION OF PISTONS 33
4.36 ENGINE REMOVAL 34
4.37 CYLINDER FILLED WITH WATER AND FUEL 34
4.38 BUCKLED CONNECTING ROD 35
4.39 BUCKLED CONNECTING ROD SIDE VIEW 35
4.40 BUCKLED CONNECTING ROD FRONT VIEW 35
4.41 BROKEN CYLINDER LINER 36
4.42 BROKEN CYLINDER LINER PIECE 36
4.43 CAMSHAFT TIMING MARKS ON LEFT END 36
4.44 METAL AMERY IN DIESEL PUMP OUTLET 37
4.45 REMOVED DIESEL PUMP 37
4.46 COROSION OF INLET VALVE DUE TO WATER 38
4.47 CUUMULATED WATE IN COMBUSTION CHAMBER 38
4.48 3RD CYLINDERS BUCKLED CONNECTING ROD 39
CHAPTER 6 TRANSMISSION REPAIRS 40
6.1 WORN OUT PRESSURE PLATE 40
6.2 REPLACEMENT PRESSURE PLATE 40
6.3 WORNOUT AND NEW CLUTCH PLATES 41
6.4 REMOVED LEFT HAND SIDE AXLE OIL SEAL 41
6.5 REMOVAL OF TRANSMISSION SIDE ENGINE 42
MOUNTING
6.6 WORN OUT CLUTCH ASSEMBLY 43
6.7 DETERIORATED CLUTCH SLAVE CYLINDER 43
6.8 AIDING IN REMOVAL OF PROPELLER SHAFT 44
6.9 DETERIORATED AND MALFUNCTIONING RIGHT 45
SIDE HALF AXLE
6.10 FRACTURED BEARING MOUNTING BRACKET 45
CHAPTER 7 SUSPENSION REPAIRS 46
7.1 DISASSEMBLING FRONT SUSPENSION 46
7.2 REAR SHOCK ABSORBER NEW AND OLD 48
7.3 FRONT REMOVED MACPHERSON STRUTS 48
x
7.4 LOWER ARM TRAILING SIDE BUSHING OLD & NEW 49
7.5 LOWER ARM 49
7.6 SPRING COMPRESSOR FITTED TO REMOVE 50
THELOWER ARM
7.7 TOP MOUNTING PLATES OLD AND NEW 50
7.8 PNEUMATIC SPRING WITH NEW UPPER ARM 51
7.9 REMOVED OLD LOWER ARM 51
CHAPTER 8 STEERING AND STEERING SUB ASSEMBLIES 52
8.1 POWER STEERING VANE TYPE PUMP 52
8.2 DETERIORATED AND WORN OUT PUMP BEARING 52
8.3 PUMP SHAFT AFTER REMOVAL OF BEARING 53
8.4 REMOVED DAMAGED AND MALFUNCTIONING 53
STEERING RACK
CHAPTER 9 BRAKES REPAIR 54
9.1 DEEP ENGRAVED GROOVE WHICH FAILED THE 54
BRAKE ROTOR
9.2 REMOVED BRAKE CALIPER 55
9.3 BRAKE CALIPER WITH NEW BRAKE PADS AND 55
WEAR INDICATOR IN FORM OF RED WIRE
CHAPTER MOST CHALLENGING EXPERIENCE DURING 56
10 TRAINING
10.1 WORN OUT BUSHING 56
10.2 WORN OUT BUSHING 56
10.3 ANGLE MEASUREMENT SENSOR ON AIRSPRING 56
10.4 VALVE TO INFLATE AND DEFLATE PNEUMATIC 57
SPRINGS
10.5 REMOVAL OF PNEUMATIC SPRING REVEALS 58
NEWLY INSTALLED LOWER ARM
10.6 GREEN AIR HOSE CONNECTING PNEUMATIC 59
SPRING TO THE INFLATION MODULATOR
xi
LIST OF TABLES
TABLE PAGE NO
4.1 TWO POST LIFT 12
4.2 SCISSORS LIFT 13
4.3 SINGLE POST MOBILE LIFT 14
4.4 CARTAR MOBILE LIFT 15
4.5 BRAKE PISTON WIND BACK TOOLKIT 16
4.6 ENGINE HOIST 17
4.7 COOLANT TRANSFUSION SYSTEM 18
4.8 ON CAR BRAKE LATHE 19
4.9 CAR UNDERBODY WASHING SYSTEM 20
xii
Roger Motors Pvt. Ltd.
CHAPTER-1 INTRODUCTION
1.1 INTRODUCTION TO ROGER MOTORS
ROGER MOTORS a National Award Winner ISO 9001 : 2000 Company founded by a car
enthusiast, racer & a scholar Automobile Engineer way back in 1992 in the city of Rajkot.
Roger Motors started as a small Garage & now flourished into a huge multi-brand car
workshop.
Figure 1.1 ROGER MOTORS HEADQUARTERS
ROGER The Organization which Overwhelmed the Expectations of those who

Desire Nothing Less than Excellent Service which is Blooming with More than 140
and Still Growing Happy Employees was Founded By Three Passionate Visionaries.
Evolved From a General Workshop Established In 1992 to A Fully Equipped Modern
workshop which can is Adequately Powerful to Deal with the Most Advanced
Automobiles in the Industry.
An Organization which Transformed through Many Identities and Rested at the Best
Some of Most Popular ROGER Names or Suffixes are ROGER MOTORS,
ROGER RAPID, ROGER GALLERIA and ROGER TECHSSORIES
Found By MR KRIPALSINH JADEJA and Nourished by Passionate Trio Named
MR KRIPALSINH JADEJA, MR DILIPSINH PARMAR and MR ASHOKSINH
JADEJA The Novice Organization Initiated and Conquered its ACE status with Non
Deviating Passion and Dedication.
Department of Automobile Engineering - AITSDS Page - 1

1.2 CORE PURPOSE

To Increase Confidence and Pleasure of Driving By Providing Innovative and
Customized Solutions
1.3 CORE VALUES

Passion
Honesty
Possibility Thinker
Happiness In Hard work
1.4 MILESTONES OF THE JOURNEY

Organization with was once established on A Rented Shed in Locality called Atika
in 1992 in Rajkot, which could Handle two cars Simultaneously as a Local Garage
till 1996 can now Handle more than 30 Cars Simultaneously.
In 2000-2001, a New Place was added to the Organization which is currently known
as UNIT 3 which was ROGER MOTORS TATA AUTHORISED SERVICE
STATION which remained active till 2008 is now BODY REPAIR SHOP.
In 2002-2003 Place, currently named as UNIT 2, Which is Now Paint Shop was
Added to the Growing Organization.
In 2007 An Important Element which is Currently known as UNIT 1 got Introduced
to the world as BOSCH AUTHORISED ROGER RAPID Multi Brand car
workshop.
And A Concept which Revolutionized the industry in terms of Technical accessories
and Performance and Safety Enhancement which made Extremely positive
transformation to the industry and Safety awareness in consumer minds.
With Even more efficiency and even more Products with Dedicated R&D
Department ROGERGALLERIA is NOW ROGER CAR TECHSSORIES.
UNIT 1 is now Headquarters of ROGER MOTORS and ROGER CAR
TECHSSORIES Which Marked Dazzling and Unmatched Success with Enormous
Efficiency is Standing High with Best Possible equipments and Available Service for
Any Vehicle.
Currently, ROGER is Widespread across India and Gujarat in Form of 157 Dealers,
11 Showrooms, and 1 Franchise.
An organization which achieved the Momentum which outshined and outperformed
those who couldnt match the Higher Standards established By ROGER.

1.5 CONCEPT OF ROGER GALLERIA (Techssories)

Roger Galleria (Techssories) Concept was Arose from the Vision of M.D Kripalsinh
Jadeja, that
Safety On Road should Not be Accessible Only to the Premium or High End
Car Owners, But Every Person on the Road has Equal Right of Safety
irrespective of Brand and Variant of the Vehicle
If there are Problems and Difficulties to be faced Related to Vehicles, then there
Must be a Solution too
1.6 GEMS OF THE CROWN

Throughout the Ruthless Yet Beautiful
Journey Several Conquered Achievements
Made the Terrain Even Smoother and
Motivated personnel involved in Growth
of the Organization without which
ROGER Story can not be described with
full Potential
Among All Bosch Authorized
Workshops in India, ROGER MOTORS
Stands 3rd in India
Figure 1.2 BOSCH TROPHY

Among All Bosch Authorized
FOR 3RD RANK IN INDIA Workshops in India ROGERMOTORS Figure 1.3 BOSCH MOMENTO
FOR 1ST RANK IN WESTERN
Stands 1st in Gujarat (Western Region). REGION
1.7 PATENTED PRODUCTS

ROGERAB A Revolutionary Product which takes 900
Seconds to Get Installed in Suspension Coil Springs which
Prolongs Vehicle Suspension Life and Transforms Entire
Vehicle Character by Adding Exceptional control around the
Corners By Preventing excessive rolling and Shift of C.G to Aid
the Turning and Reduced Braking distance by Preventing C.G
Shift to Forward at those Crucial Braking Moments Hence
Reduced Braking Distance. And Prevents Vehicles Under Body
Figure 1.4
to be Brushed Against the Higher Speed breakers and Rough ROGERAB FITTED
Roads. IN COIL SPRING
ROGER WIPER STAND Another Revolutionary product

Which Keeps Wiper Blades in Lifted Position when Not in Use
but Drops Wiper Blades on windscreen when Wipers are turned
ON. This product keeps the Wiper Blade away from Heated
windshield and hence Prolongs Wiper Blades service cycle Life
Figure 1.5 ROGER

WIPER STAND

1.8 AWARDS AND ACHIEVEMENTS

2009: National Award, for Outstanding Entrepreneurship, by Special
Recognition of Outstanding Performance Award by MSME (Ministry of Micro,
Small and Medium Enterprise) First Such Award was awarded ever to the
Automobile Industry.
Figure 1.7 MR KRIPAL SINH ACCEPTING MSME

AWARD TROPHY BY SHRI DINSHA PATEL
Figure 1.6 NATIONAL AWARD BY MSME
2011: Award For Outstanding Small Scale Industry Entrepreneurship for

Passenger Cars Maintenance Service. Awarded By Former Honorable Chief
Minister Shri Narendrabhai Modi.
Figure 1.8 MR KRIPAL SINH ACCEPTING AWARD FROM SHREE

NARENDRABHAI MODI

Figure 1.9 OUTSTANDING SSI

ENTREPRENEURSHIP AWARD
Figure 1.10 MR KRIPAL SINH IN CNBC AWAAZ Figure 1.11 MR KRIPALSINH EXPLAINING
INTERVIEW SAFETY CONCEPT DURING INTERVIEW
2014: MD Er. Kripalsinh Jadeja were Interviewed By CNBC AWAAZ For the Show
CNBC AWAAZ ENTREPRENEUR.
2014: Award for Excellent Performance in 2014-15, By Tata Motors
Figure 1.11 AWARD BY TATA MOTORS

CHAPTER -2 WORKSHOP LAYOUT

2.1 WORKSHOP LAYOUT
Figure 2.1 ROGER MOTORS CURRENT LAYOUT

The workshop is Located at the Locality called Gondal Cross Roads. At the distance
of 6 Km from the State Transportation Bus Depot and 7 Km from the Bhaktinagar
Railway station.
The workshop occupies 40,000 Square Feet area, there are total of 23 Bays in which
Maintenance work can be carried out on a vehicle.
Vehicle approaches Automatic Under body washing system right after entering the
workshop
After entering the workshop, in the right side, first department is Roger techssories,
and in left side there are total Five Bays which includes oil changing bay.
There are total 4 two post lifts are in bay no 10, 11, 15, and 21, and 3 scissors type
lifts are in bay no 3, 7, and 20.
When the vehicle is brought to the workshop, service advisor Approaches the vehicle
and determines, whether the vehicle has arrived for workshop department or the
Roger techssories department.
Most of Roger Techssories jobs are performed in Bay No 1, 2, 3, 4, 22 and 23 and
some quick tyre related jobs are being performed on Bay no 3.
Mostly Vehicles with Less time consuming Jobs are strategically placed in Bay no 7
to 15 according to the Nature of Job.
Vehicles with the Job of On car brake disc turning are mostly placed on scissors lift
on Bay no 7.
Vehicles with time consuming Jobs, are placed in Bays 16 to 21 strategically
according to the Nature of Job.
Bay 12 is not used most of the times except full load conditions, as Vehicle on Bay 12
may block path for the vehicles in Bay 20 and 21.
Also Bay no 4 is very less frequently used Bay, as it blocks path for Bay no 22 and
23.
Press room, and Compressor rooms are Near to the Bay no 16.
R&D Dept, Tools room and Spares are Near to Bay no 15 and 5 respectively.
Oil and Fluid Storage Area is in the Lower Left Corner, Next to which Engine
Washing area and Toilet are Present. and Above these all areas Dining room and
Shower area along with Lockers are situated on the 1st floor.
After entering the Workshop premises, in right side after Roger Techssories, there is
Account Department and Administration department, with Adjoining Customer
Lounge, and Above all these on 1st floor, conference room, another customer lounge
and training rooms are situated.
While Moving out from the Workshop there is adequately spacious parking Lot, the
Leftmost Side of Parking Lot is allotted for Staff Parking, Middle section is allotted to
the vehicles which require service and are waiting to get serviced, and the rightmost
section of parking Lot is allotted to staff four wheeler parking and Vehicles ready to
be delivered after service and Pre delivery inspection.

2.2 WORKSHOP MODIFIED LAYOUT
Figure 2.2 ROGER MOTORS MODIFIED LAYOUT

2.3 MODIFIED WORKSHOP LAYOUT EXPLAINATION
Current Layout is Nearly Perfect and Space Utilization is Optimal according to

Availability.
Yet there can be two Suggested changes which are Highlighted by Sky Blue Colour
and Brown colour compared to Present Layout.
Suggested changes can be done easily with their Justification
Two Highlighted areas in Layout using Sky Blue Colour are Swapped or
Interchanged. Namely Research and development department has been Shifted to the
place which is currently Tyre and Alignment shop, this Interchange can be Justified
as, Research and development department is Directly associated with Roger
Techssories department and also work as quality control department, has Nothing to
do with General workshop department and due to which by switching allocated
apaces work interruption can be avoided.
By Bringing or Interchanging the Area Occupied by R&D department to Tyre and
Alignment shop, work can get much easier as due to current layout, there is no
approach to the Tyre and Alignment shop directly, hence to get any tyre related job
done, tyres need to be removed and needed to be brought to the tyre and alignment
shop by unnecessary longer path, which consumes more time and energy and also
during monsoon and heavy rain, taking tyres to the tyre shop is a cumbersome job
because of puddles, and tyres can be taken to the tyre shop by compulsorily going
outdoors which leads to getting wet during rains.
Also taking four tyres by rolling them one by one to the tyre shop reduces the
efficiency, and also leads to more chances that tyres being rolled may strike and
damage vehicle accidently.
And Another Suggested change is interchange the places occupied by Tools Room
and Engine assembly room. And the change can be justified as Tool room and all the
tools including heavy tools and equipments are used throughout working hours of
Workshop. Problem is observed when Vehicles are placed in Bay 5th and 15th and
heavy tools are needed elsewhere except Bay 5 th and 15th, taking such tools with very
less clearance between Vehicle and the wall may lead to Tools and equipments being
Struck to Vehicle and Damage the Vehicle in many manners. Also when Vehicles on
Bay 5th and 15th are Jacked or their removed assembly are kept on floor, it may lead
accidental stepping on those assemblies, which may lead to Technician Injuries,
Assembly damage and also blocks path, and sometimes Vehicle needed to be moved
in order to take out huge machines Like Coolant transfusion machine, or On car lathe.
If tools room is interchanged with Engine assembly room, there would be more
convenience to the technicians as tools room is used throughout the day during
working hours, in contrast Engine room is not used as frequently as Tools room,
hence by the suggested change, work efficiency my get increased.

CHAPTER-3 HIERARCHY
3.1 ROGER MOTORS WORKSHOP HIERARCHY
Kripal Sinh Jadeja (M.D)
Kalpeshbhai Pithadiya
(Works Manager)
Service Advisors
Jagdish Sinh Jadeja
Jayeshbhai Raiyani
Mangeshbhai Jadav
Kuldeep sinh Jadeja
Spares
Tools Room Atinbhai Workshop
Ajayraj Sinh Satishbhai Sanjaybhai (Team Leader)
Hematbhai
Technicians
Sureshbhai Pruthviraj sinh
Amitbhai Vinodbhai
Ajaybhai Krunalbhai
Eliyasbhai Vinodbhai(AC)
Pathanbhai Dharmeshbhai
Sandeshbhai Niravbhai
Mukundbhai Gopalbhai
Helpers
Divyarajsinh
Jayeshbhai
Pravinbhai
Santoshbhai
Ketanbhai
Darshanbhai
Rushirajsinh
Figure 3.1 ROGER MOTORS HIERARCHY

3.2 ROGER HIERARCHY AND WORKFLOW

Roger Motors Unit 1 is the headquarter of Roger Motors, and Roger Techssories, and
M.D Mr Kripalsinh Watches and Monitoring Workshop activities and Roger
Techssories R&D department and Are well Informed by Mr. Kalpesh Pithadiya
(Works Manager) and Mr. Ashoksinh Jadeja about every Necessary Information
Regarding Both the departments Respectively Workshop and Research and
Developement.
Four Service Advisors Reports and keep Mr Kalpeshbhai Pithadiya Informed about
Details and Progress of the works. Following was the work Pattern and work
distribution.
Mr Jayesh Raiyani : Mostly High End and Imported Vehicles with More
Sophisticated technologies as Audi, BMW, Mercedes Benz, Hyundai, Honda,
Volkswagen, Skoda.
Mr Jagdishsinh Jadeja : Mostly Handles Vehicles of Tata, and Mahindra
Mr Mangesh Jadav and Mr Kuldeepsinh Jadeja Mostly handle rest of the vehicles.
Even though the work is distributed, during peak timings and peak seasons every
Service Advisor handle every vehicle and keep Mr Kalpesh Pithadiya updated about
Latest progress.
Workshop Team Leader Sanjaybhai who was elected by casting votes by technicians,
Tool Room in charge Ajayraj sinh and Spare Department personnel Mr Atinbhai,
Satishbhai, and Hematbhai keep Service advisros Informed about work.
High end Vehicles are Being Handled by Technicians Mr Pruthvirajsinh and Mr
Amitbhai
Mr Vinodbhai is Specialist for Tata and Mahindra vehicles
And Rest of technician can deal with all kinds of jobs and services.
Mr Pravinbhai is Air conditioner system specialist.
Helpers Join Technicians according to their Nature of Job.

CHAPTER-4 TOOLS & FACILITIES

4.1 TOOLS, EQUIPMENTS, AND INSTRUMENTS
4.1.1 MANATEC RHINO TWO POST CAR LIFT 3.2L

Table 4.1 Two Post Lift
RHINO 3.2L TWO POST CAR LIFT

No of Units 4
Maximum Lifting Capacity 3.2 Ton
Lifting Time 60 Seconds
Maximum Lifting Height 1.87 Metres
Lifting Arms Adjustment Front Rear
Minimum 685 mm 955 mm
Maximum 1020 mm 1380 mm
Power Supply 440 Volts AC, 3 Phase 50 Hz
Lifting Mechanism Motor Driven Screw Type
Figure 4.1 TWO POST LIFT
Vehicle Setup Time on this Lift is more

It Provides Full access to the Under Body, or the Bottom of the vehicle as the Vehicle
is Lifted upon the Notches beneath the Rocker Panel
It Has Complete Clearance underneath the Vehicle due to which All sort of
Instruments can be Brought Under the car to Aid the Maintenance and Support any
Assembly or Subassembly.
These types of Lifts are used for the Repairs which Requires clearer space for work,
as Engine Overhaul, Transmission Overhaul and under body damage repairs, Fuel
tank repairs, Exhaust System related repairs, Repairs which Involve Removal of Front
or Rear Sub-frames or Cross Members.
4.1.2 ELGI WHEELS FREE SCISSORS LIFT

Table 4.2 SCISSORS LIFT
ELGI WHEELS FREE SCISSORS LIFT

No OF Units 2
Lifting Capacity 3 Ton
Maximum Lifting Height 1.71 Metres
Lifting Mechanism Hydro Electric
Oil Tank Capacity 25 Litres
Oil Pump Type Gear Pump
Figure 4.2 SCISSORS TYPE LIFT
Vehicle Setup Time on this Lift is Very Less, Hence Vehicle can be Set and Removed
with Ease
It is Suitable for the Operations which are quick in Nature, Hence, Wheel and Tyre
Related Repairs and Maintenance.
For Quick Under body damage Inspection.

It is Used For Quick Pre Delivery Inspection.

It is Also Suitable for Minor Under Bodyworks and Quick assemblies as Mudguards,
Oil Filter, and Fog Lamps etc.
4.1.3 PROFIMASTER SINGLE POST MOBILE LIFT

Table 4.3 SINGLE POST MOBILE LIFT
PROFIMASTER SINGLE POST MOBILE LIFT

No Of Units 2
Lifting Capacity 1.25 Ton
Maximum Lifting Height 1 Metre
Power Supply 230 Volts, AC Single Phase 50 Hz
Lifting Mechanism Motor Driven Screw Type
Figure 4.3 SINGLE POST MOBILE LIFT
Vehicle can be Lifter either from Sides, or from the front or rear according to the
Optimum Ergonomics
This Lift is used for Quick Welding, Grinding and Painting works.
It is Used to tilt the Car safely so that Radiator, or Fuel Tanks can be Drained
completely before Removal.
It is also used to Drain out water from the Submerged Vehicle and various systems of
the Vehicle
It is Used for Quick Disassembly and Assembly of Several systems, like Oil Cooler,
and Oil Filters Etc.

4.1.4 CARTAR MOVE MOBILE LIFT

Table 4.4 MOBILE LIFT
CARTAR C-100 FL MOBILE LIFT

No Of Units 2
Lifting Capacity 2.8 Ton
Maximum Lifting Height 0.8 Metre
Power Supply 230 Volts AC, Single Phase 50 Hz
Lifting Mechanism Electro-Pneumatic
Figure 4.4 CARTAR MOBILE LIFT
Vehicle Setup time on this Vehicle is Moderate

This Lift is used when entire Workshop floor is occupied, Vehicle can be Lifted
beyond Workshop floor also
This Lift is being used in Special Purposes, as Even when the Vehicle is on the Lift,
with its Pulling Handle, Lift can be taken anywhere.
Especially during Multiple tasks to be done on Vehicle, the lift aids in Boosting up the
speed of Jobs being done, even with removed suspension and wheels, vehicle can be
taken to body shop or paint shop.
This lift aids in to bring dead engine, or Destructed Suspension vehicle to the floor,
as after mounting vehicle on the Lift, with the handle only one person can pull and
bring the vehicle as and where vehicle is to be taken.

4.1.5 KENNEDY BRAKE PISTON WIND BACK TOOLKIT

Table 4.5 BRAKE PISTON WIND BACK TOOLKIT
KENNEDY BPK-12R RIGHT HAND BRAKE PISTON WIND

BACK TOOL KIT
No Of Units 2
To Be Used By Dominant Hand Right
Threaded Length 0.15 Metre
No of Pieces in each Kit 12
Figure 4.5 KENNEDY REAR BRAKE PISTON WINDING TOOL
This toolkit is Used for High End Vehicle with Sophisticated Rear Brake System, in
which, Engaging handbrakes Rotates and Being Pressed against the Brake Pad, Unlike
Majority of Vehicles which has Drum integrated with the Disc brakes, when
Handbrakes are applied in such vehicles, Drum brakes shoes functions as a
Handbrakes and engages.
To Replace the Rear Brake pads in Such Modern, High Eng and Vehicles equipped
with such Sophisticated Rear Brakes , the Piston in the callipers Cant be simply
pushed back using Vice, instead Piston needs to be revolved also in order Push or
wind it back.
Earlier Six sided winding Dice or Cube was utilised to wind back the piston.
For Replacement of Such Brake Pads, the Kit is used.

4.1.6 GENERIC ENGINE HOIST

Table 4.6 ENGINE HOIST
GENERIC ENGINE HOIST

No OF Units 2
Maximum Height 2.38 Metres
Lifting Capacity 2 Ton
Lifting Mechanism 8 Ton Hydraulic Ram Jack
Base Width 0.91 Metres
No Of Wheels 4
Figure 4.6 ENGINE HOIST
These Engine Hosts aid in Removal and Remounting of Engine, and Transmission
system from and to the Vehicle.
They are utilised to Mobilize the Engine, and Transmission System
During Engine Overhaul once engine is suspended from the Hoist, Engine oil pan, and
such subassemblies can be removed.

4.1.7 BG CT2 COOLANT TRANSFUSION SYSTEM

Table 4.7 COOLANT TRANSFUSION SYSTEM
BG CT2 COOLANT TRANSFUSION SYSTEM

No Of Units 1
Coolant Capacity 20 Litres
Power Supply 12V DC, 6 AMP
Figure 4.7 COOLANT TRANSFUSION SYSTEM
This system Power flushes the System Using Backwards Pumping of the Coolant,
without Requirement of Running Engine
Using its suction hose connected to the Pump, It can Extract the used Coolant to the
empty can for Used coolant, once its been switched to Remove from Vehicle Mode.
Once Removed, After filling the New coolant to the New Coolant Can, and Upon
switching to the Return to the Vehicle Mode, Entire Content of coolant will be
transferred to the Cooling System very quickly.
It is Specially Used when Oil Cooler Malfunctions and Deteriorated due to Decay and
leads to Oil and coolant Mix up. To ensure thorough cleaning and Flushing of the
System.

4.1.8 HUNTER ON CAR BRAKE LATHE

Table 4.8 ON CAR BRAKE LATHE
HUNTER QCLH PRO ON CAR BRAKE LATHE

No Of Units 1
Maximum Disc Diameter 0.40 Metre
Maximum Disc Thickness (Width) 0.07 Metre
Maximum Feed Distance 0.10 Metre
Maximum Spindle Speed 0-120 RPM (Adjustable and
Automatically Variable
Power Supply 230 Volts AC, Single Phase, 50 Hz
Motor 1.5 HP @ 3450 RPM
Figure 4.8 HUNTER ON CAR LATHE
This Equipment is Used to Turn the Disc Brake Disc Surface, and to remove the
Irregularity on the disc.
It is necessary to Turn the Surface of the Disc Brakes Disc, when Brake pads are
being replaced or when Steering and Vehicle wobbles when Brakes are applied
This Equipment turns it extremely easy to Turn the Brake Disc without Getting into
the hassle to Remove the Brake Discs and to send it to the Lathe.

Without Any Disassembly, only after removing the Wheel, the Equipment can be set
on Vehicle using suitable Hub attachment and it takes merely 12 Minutes to turn a
single Brake Disc using suitable Depth of Cut.
4.1.9 AUTOMATIC CAR UNDERBODY WASHING SYSTEM

Table 4.9 CAR UNDERBODY WASHING SYSTEM
AUTOMATIC CAR UNDERBODY WASHING SYSTEM

No Of Units 1
Operating Pressure 130 PSI
No Of Water Jet Nozzles 55
Water Discharge Rate 90 Litres Per Minute (Recycled and
Processed Water)
Figure 4.9 AUTOMATIC UNDERBODY WASHING SYSTEM
This System, can be turned on and off using a Remote Switch to clean to Under Body
of the Vehicle
Especially During Monsoon, Before Bringing in the Vehicle to the Workshop Floor,
this system thoroughly cleans the Under body of the Vehicle to Prevent Workshop
floor to be soiled.
Also Before Conducting any Suspension Related Job or any Under Body Job, Vehicle
is Being Treated under this system and then Brought to the workshop floor.

CHAPTER-5 ENGINE AND ENGINE

SUBASSEMBLY REPAIRS
5.1 SKODA FABIA TDI
Problem : Engine Seizure
Cause : Insufficient or No Oil Was being Pumped
Remedy : Engine Overhaul
Received Vehicle with complaint of Engine Seizure, First of all checked the Oil Level which
was as per Manufacturers Recommendations, Upon opening the Valve cover Almost No oil
was observed on Cam shaft, Hence to check the Oil Pump condition Oil Sump was Removed,
which Revealed the Oil Pump Sprocket was Deteriorated and the Sprocket hole was Enlarged
and observed huge Clearance between Sprocket fastening Bolt and the Sprocket which Led to
the conclusion that the Oil pump was Not operational which might have triggered the Engine
Seizure, also Oil pump mounting bracket was with chain tensioner was fractured and failed.
Figure 5.1 DETERIORATED OIL PUMP SPROCKET
Due to which Engine ran without sufficient

Lubrication which caused Raised temperature
because of friction and finally the Engine
Seizure
Piston Rings, and Cylinder Liners were
Welded and Removal took Enormous Efforts,
hence reconditioning of block was required.
Using New Piston Rings, New Oil Pump,
New Head Gasket, Oil Pump Bracket, and Oil
Pressure operated Chain tensioning Figure 5.2 DAMAGED CHAIN TENSIONER
mechanism and Reconditioned Block were
used to Overhaul Engine. After Overhaul and Assembly, engine was checked on Vehicle only
as the test run cannot be done without Vehicle, as the vehicle was equipped with Immobilizer.

After Mounting the engine on the Vehicle, Engine was started without assembling exhaust
muffler, But Engine sound was not Normal according to the experienced technician, and
Informed that He was feeling as of engine was running Dry, to Check it, engine was turned
off and valve cover was opened to see whether the oil is being pumped or Not. But when
Valve cover was opened No Oil was seen on cam and oil was not being Pumped, hence
Removal of engine was Necessary to find the exact problem, Removed engine from engine
using Hoist.
When the engine was Hung in the Hoist, after opening the Oil sump, and chain cover, Oil
pump sprocket could be seen, Oil pump sprocket was Intact and was functioning as it should,
but Oil was not being pumped hence, Oil Pump was removed and checked whether its
pumping or not, Oil pump inlet was submerged in the oil and it was given drive through the
Pneumatic gun, and it could be seen that the sufficient amount of oil was being pumped.Now
Figure 5.3 NEW TENSIONER
there was only one possibility left and that was Oil passage might have been blocked
somewhere, which prevented flow of oil, to find it out Engine head was removed, and then
Using Pneumatic Jet, air was Blown in oil passage, and after a while suddenly oil was
forcefully popped out of another end, with lots of sludge and lots of Gummy substance, after
cleaning the oil passage, oil pump was installed again and given drive through Pneumatic
gun, and oil could be seen coming out from all the passages, with confirmed functionality
Engine was reassembled fixed all hoses and Wiring Harness, and Mounted engine on the
Vehicle and engine was started, and opened Valve cover to observe whether oil is being
pumped or not, Sufficient Oil was being Pumped, and Problem was resolved.

5.2 SKODA OCTAVIA TDI

Problem : Excessive Grey smoke
Cause : Worn Out Piston Rings Because of End of Rated Life of Engine
Received Vehicle with the Complaint Of Excessive Grey smoke and Engine couldnt perform
at all, Upon checking the Vehicle Odometer it shown 264079 Kms, Which Led to the
conclusion that Engine was at the end of its Rated performance Life, as Grey smoke can be
observed when Piston rings get worn out and oil instead of getting scrapped burns along with
the Fuel which causes the Grey Smoke, also No other problems were observed except smoke.
Figure 5.4 CYLINDERS WITH NEW LINERS, Figure 5.5 ENGINE HEAD SHOWING SIMPLE PER
PISTON RINGS AND NEW GASKET KEPT ON CYLINDER TWO VALVE CONFIGURATION
BLOCK
Removed Valve Cover and Engine head, Clearance was observed between piston rings and
cylinder walls, To overhaul the engine New Piston Rings, Cylinder Reconditioning, New
head Gasket, Diesel Pump overhaul, Exhaust system Overhaul was Required, Upon
Receiving the Spares and Engine Block with New Liners, Engine Overhaul was Done and
Engine was Tested after mounting on the Vehicle.
5.3 TATA INDICA DLS DI

Problem : Engine Starting Problem when Engine is Cold
Cause : Failed Glowplugs
Remedy : New Glowplugs Installation
Received Vehicle with the Problem Of Engine Took
Very Long Starting effort when Engine is Cold, This
Typical complaint Led to the conclusion that the
problem was Caused by the Malfunction of starting
Aid, that is Glowplugs.
To check Glowplugs working condition, they were
given a power
supply, closed Figure 5.6 OPENED HEAD TO REMOVE
circuit was BROKEN GLOWPLUG
observed in
cylinder 1st and 4th Glowplugs, But Glowplugs in Cylinder
2nd and 3rd Didnt pass current through them, Hence came
nd
Figure 5.7 GLOW PLUG LOCATION to the Conclusion that the Glowplugs of Cylinder 2 and

3rd were not functional and needed

replacement.
8While Removing Glowplugs, 2nd
cylinder glowplug was Broken and
might have dropped in the cylinder
and only broken Glowplug was
Figure 5.9 GLOWPLUG LOCATION INSIDE CYLINDER
Figure 5.8 NEW GLOPLUGS

observed, due to which Engine Head Removal was Necessary, Removed Glowplug from the
Cylinder and Replaced them, and then Used New Head Gasket, and Loctite Adhesive Repair
was Carried out, and Check engine, and the Problem was Resolved.
5.4 HYUNDAI I-20 CRDI

Problem : High Pressure Air Release Noise
Cause : Damaged Injector
Remedy : Damaged Injector Replacement
Received Vehicle with the Complaint of Loud High Pressure Air release Noise, when engine
is Running, Upon Opening the Engine Hood, it was Observed that Diesel was Released from
the top of the Injector, Outside Cylinder Instead of Inside the cylinder From Cylinder 1 st
Injector. Removed the Injector from 1st Cylinder, and Reinstalled it in such a way that the
Figure 5.10 REMOVED INJECTORS Figure 5.11 REMOVED INJECTORS AND VALVE
COVER
Injector nozzle stays outside the Cylinder so that Spray Pattern and hence the problem can be
Observed.
Upon Starting the Engine, Almost No Diesel could be seen from the nozzle and Diesel was
being released from the Metal Pipe connecting Common rail to the Injector.
Hence Replacement of Injector Was Necessary because Diesel was Diverted to the Return
Line and was released, as The Nozzle was Clogged, Entire diesel was Being Sprayed in the
Engine room instead of Inside the Engine cylinder, thus Installed New Bosch Injector and

Fed the Injector ID code to the ECU using Bosch OBD and Programming Tool, after that
checked Engine. And the Problem was Resolved, Engine Room was Washed and Cleaned.
5.5 AUDI A4 TDI

Problem : Inconsistent Performance, Black Smoke, and Varying Engine
Revolutions
Cause : Clogged Injector Nozzles
Remedy : Injector Service, or Replacement
Received Vehicle with the Complaint of Inconsistent performance, Black Smoke, Reduced
Mileage and Varying Engine Revolutions, Upon receiving the vehicle, Checked whether the
Engine Checklight or any warning sign was illuminated or not and checked the Infotainment
System for any possible display of problem but no such warnings detected, after that the first
operation carried out was to Run a Diagnosis software VCDS to check the possible errors, but
report was Negative and vehicle could check all the reference values.
Figure 5.12 REMOVED INJECTORS AND GOT THEM SERVICED
Visually Observed and Checked the Fuel Quality, and also compared it with Standard
reference fuel, Checked the Fuel Filter, but all reports were negative, This led to the
conclusion that the problem might be triggered by the Injector related malfunction, to check
the same Valve cover was Removed and all four Injectors were removed from the engine and
were set outside the cylinder and Engine was given a start to observe the spray pattern of
Injectors.
It was observed that all four injectors displayed very poor diesel spray pattern and diesel
dripping from the nib, this led to the conclusion that the problems were triggered by the
clogged injector nozzles, each cylinder has unique Injector with their unique Numbers, the

sequence must be maintained in order to keep the engine running, hence Injector Numbers
were Written down, and sent Injectors to Bosch Authorized service centre, and those Injectors
were serviced and cross checked with the Service centre for its spray pattern, after the
Reconditioning and serviced Injectors were Installed in the car, and the Car was checked in
Road by Trial, and the Problem was resolved.
5.6 NISSAN X-TRAIL

Problem : Extremely Low Mileage (3Km/Lit)
Cause : Diesel Return Fuel Line was Ruptured
Remedy : Replacement of Diesel Return Fuel Line
Received Vehicle with the complaint of Extremely Low Mileage, Upon Checking the Vehicle
Performance On road, The Vehicle Performed well without any Problem, No Smoke was
Detected, and to Check the Actual Mileage, 1 Litre Flask of diesel was used. And Mileage
was Surprisingly Low as 4Km/Lit, Also On Board Diagnosis shown all Reference values to
be correct.
Figure 5.13 ACCUMULATED

DIESEL
To Investigate Further, the Vehicle was Brought into the workshop, and was Mounted on the
Lift and Vehicle was Lifted and Kept the Engine Running for 30 Minutes for Observation,
after Around 10 Minutes, Diesel was Observed on the Floor and Upon Checking Properly,
Diesel was Dripping off the engine. And Also Strong Smell of Diesel with minute White
Fumes were observed from the under the Hood. Due to which The Engine was turned off
without any further delay and waited for some time to Let Vehicle to cool down, After that
The Hood of Engine room was Opened and Strong
Diesel Smell was experienced, First Of all
Checked the Fuel Tank and Fuel Lines for any
possible leakage, after that Upon checking the
Common Rail, and Metal Pipes connecting
Figure 5.14 DETERIORATED RETURN LINE Common rail to the Injectors there was No
Leakage or Spillage Observed, That Further Led to

the conclusion that the Leakage Might be occurring from Diesel Return Fuel Line, To check
that Valve cover was Needed to be removed.
After valve cover removal the problem was revealed,
as it could be seen that Diesel was getting accumulated and
could be seen as puddle, and was finding its way out from oil
overflow drain. Close observation of return hose revealed
that the hose connecting 2nd to3rd cylinder, and 3rd to 4th
cylinders were ruptured, and were a bit bulged and
deterioration was seemed to be triggered by the heat, as no
mechanical damage signs were visible.
Customer refused to replace the return line assembly,
and insisted to restore and repair, the same. After that
damaged hoses
were removed from
Figure 5.15 BULGED AND the entire assembly
RUPTURED RETURN LINE and replaced the
same with new similar pipes (Hoses) which were
suitable for the intended use as a fuel line. And
restored the Assembly and reinstalled it. And before
closing the valve cover, refuelled the vehicle and
kept vehicle with engine running for 6 hours to Figure 5.16 REPLACED RETURN LINE
verify rectification of problem, and upon
confirmation that valve cover was installed vehicle was handed over to the customer.
5.7 VOLKSWAGEN POLO TDI

Problem : Sluggish Performance along with the Engine check Light Lit.
Reason : Torn (Ruptured) Turbocharger Outlet Hose
Remedy : Replacement of Turbocharger Outlet Hose
The Vehicle was Received with
the complaint of Sluggish
Performance throughout the
Revving range, and engine
check light Lit. Hence used
VCDS diagnostic software to
check the error code and hence
the reason of Engine check light
Figure 5.17 TURBOCHARGER Trigger, and Diagnosis Figure 5.18 RUPTURED
OUTLET HOSE revealed the problem as TURBOCHARGER OUTLET
HOSE
BOOST PRESSURE
MALFUNCTION, which narrowed the focus to the Turbocharger assembly, after mounting
the vehicle to the lift and thoroughly checking turbocharger assemblies and hoses, it could be
seen that the Hose was ruptured from the elbow part of hose in such a way that a thumb can
be inserted in the hole, and threads used for reinforcement were torn and could be seen easily.

This required removal of Air filter assembly to get the

damaged hose out, and Informed customer about the
fault, initially
customer insisted
to restore or repair
the part instead of
replacing, but as
the hose has to
deal with Figure 5.19 RUPTURED HOSE CLOSEUP
enormously high pressure, restoration or repair in any
Figure 5.20 REPLACEMENT HOSE means was not possible and hence replaced the Hose and
checked the vehicle for the performance, and Erased the error memory, and the Problem was
resolved.
5.8 HYUNDAI VERNA CRDI SX ABS

Problem : Whistle Kind of Loud Noise when engine in revving up beyond 2000
RPM, and Turbocharger influence could not be felt during turbocharger cut in Range.
Cause : Damaged Turbocharger Shaft which connects turbine and impeller
and was running out of the Axis
Remedy : Repairing or Replacement of the turbocharger assembly.
The vehicle was received with the problem of loud
whistle kind of noise when engine is revving up
above 2000 rpm and also the influence of
turbocharger in vehicle performance could not be
felt, which narrowed focus on the Turbocharger
assembly, upon opening the turbocharger assembly it
was observed that turbocharger was filled with
Carbon deposits in form of Soot, and narrowed the
cavity, also the vacuum assisted varying geometry
mechanism was not
functional, and play
was observed in the
shaft.
Figure 5.21 VGT CONTROL
This required Repairing or replacement of turbocharger
assembly, the turbo charger was sent to the repairing
facility, and was received after repairing, and reinstalled the
turbocharger and driven vehicle to check whether the
vehicle performance can meet the requirements and to check
whether turbocharger was repaired properly or not.
Figure 5.22 INSTALLED After extensive test drive, vehicle performance was
TURBOCHARGER satisfactory and was handed over to the customer.

5.9 TATA SUMO GRANDE

Problem : Engine Could not be started after numbers of efforts
Cause : Poor Quality Diesel was filled during Refuelling
Remedy : Fuel Tank cleaning, Fuel Lines Cleaning, Diesel Filters Replacement,
Flushing all above components.
The Vehicle was received with the problem of dead
engine, and vehicle was needed to be towed to the
workshop. After giving several starting efforts engine
did not start, Odometer shown 62000 Kms, Fuel
gauge shown tank was almost 80% full, after that
tried to check the Diesel delivery pump which pumps
diesel to the filter and Injection pump, the Pump was
working properly, after that the Fuel filters were
checked to find the possible problem, upon checking
the sediment filter assembly, fuel was not coming out
of the filter outlet, hence the sediment filter was
clogged and hence replaced, and turned on engine
after replacement, after a couple of days the same
vehicle was received with the same complaint, and
checked the sediment filter, and surprisingly again in
2 days the sediment filter was clogged again, and this Figure 5.23 DIESEL REMOVED FROM THE
led to check the quality of fuel VEHICLE
When fuel was taken out in the Glass Beaker to

observe the physical properties of fuel, it was
different in all the manners, its smell was more
like raw kerosene, and colour was much more
darker with comparison of Reference fuel in the
workshop, also used Magnet to check whether any
metallic particles are present or not, Noting god
accumulated near magnet, but after 30 minutes
clear visible layer of powdery substance was
observed. which might have clogged the sediment
filter.
Due to poor quality fuel, it was necessary to drain
and clean, fuel in the fuel tank, fuel lines and fuel
filters to prevent further contamination and
clogging. Hence the fuel was drained, and tank and
fuel lines, fuel pump and diesel pumps were
flushed and cleaned thoroughly and reinstalled, and
Figure 5.24 SAMPLE FUEL
tested vehicle for the rectification of the problem.
And the problem was resolved.

5.10 CHEVROLET CAPTIVA LTZ

Problem : Severely Loud Squeaking and rattling noise from the engine room, the
noise was too loud that nothing else can be heard except that
Cause : Alternator Pulley was Not functional full time, it worked for few seconds and
stuck, randomly, and there was a huge play in the axis of the pulley shaft, and belt
was severely damaged.
Remedy : Replacement or Repairing of Alternator Pulley, and alternator service, and
replacement of belt.
The Vehicle was received with the problem of
Severely Loud squeaking and Rattling noise,
and noise was so prominent that nothing else
could be heard no matter how loud the noise is.
And low battery.
After opening the engine hood, tried to find the
source of such noise, upon watching and
observing closely, alternator pulley was
Vibrating vigorously and after few seconds it
stopped rotating with loud belt slipping noise,
and spontaneously it started rotating again with
a loud squeaking noise and loud vibrating Figure 5.25 MALFUNCTIONING ALTERNATOR
noise. PULLEY
Which led to the conclusion that the problem

was cause by faulty Alternator assembly,
Removal of Alternator was a tough task as
alternator was in extremely confined place
where it was impossible to access fastener
without removing Radiator, Intercooler and
radiator fan assembly.
After removal of the alternator it was observed
that the pulley was malfunctioning and was not
freewheeling, and used to be freeze repeatedly,
and also a play was observed in the pulley,
Figure 5.26 REPLACED FREEWHEELING
hence the replacement of FAP was required,
ALTERNATOR PULLEY along with that the alternator was sent to get
serviced.
Reinstalled New FAP fitted Alternator and Replaced old Belt with new, and reinstalled
Radiator, Intercooler and radiator fan assembly and tested vehicle for several hours, and the
problem was resolved
5.11 SKODA FABIA TDI

Problem : Engine Overheating Light Lit
Cause : Due to Damaged Oil cooler, Coolant and Oil got mixed up and oil
started flowing through the coolant circuit.
Remedy : Replacement of Oil cooler, Flushing entire coolant circuit and
flushing entire Oil circuit.

The Vehicle was received with the complaint of

Engine Overheating Light Lit, and excessive
smoke. Due to the first complaint checked the
coolant level, But Upon opening the coolant
reservoir cap, black oil could be seen instead of
coolant, hence came to the conclusion that the
Oil and Coolant are getting mixed up and due to
which Oil travels through coolant circuit and
hence neither absorb the heat nor dissipate heat,
also because coolant is denser than oil, coolant
settled down in oil sump which ultimately raised
the oil level and because of churning effect oil
started burning and consuming which caused Figure 5.27 DETERIORATED OIL COOLER
smoke.
There might be only few locations and mechanisms whose
failure might lead to coolant and oil to get mixed up, and the
Most suspected part was Oil Cooler, as in oil cooler oil and
coolant both pass through very closely and any minor damage or
failure may lead their mixing.
After draining the oil and coolant, vehicle was lifted from one
side using Profimaster Lift and removed Oil cooler from the
front of the engine. And Upon checking closely traces of oil in
coolant hose and traces of coolant in oil hose were detected, and
when checked whether there is a failure in the assembly one side
of coolant outlet was closed and coolant was forced inside the
cooler and the next moment coolant started dripping from the oil
hose. This confirmed
Figure 5.28 TRACES OF the failure is oil cooler
FLUIDS MIXTURE assembly.
Hence replacement was Oil cooler assembly was
necessary and flushing and thoroughly cleaning
(Flushing) of Oil circuit and Coolant circuit was
necessary, to carry out that operation, coolant
transfusion machine was used which Circulates the
water in the coolant circuit continuously until the
clean water is observed. Figure 5.29 REPLACEMENT OIL COOLER
After replacing the Oil Cooler assembly oil circuit was flushed using ordinary mineral based
oil for a couple of hours. Drained the oil and again Filled Synthetic oil. And the Problem was
resolved.
5.12 HYUNDAI I20CRDI SPORTS

Problem : Decreased Performance, Decreased Responsiveness of engine and
Cluttering noise.
Cause : Elongated Timing Chain
Remedy : Replacement of Timing chain

The vehicle was received with the complaint of

Decreased performance and Decreased responsiveness
of engine, followed by the continuous cluttering noise,
Odometer reflected 82096 Km, Initial Investigation
revealed nothing suspicious, but because of cluttering
noise, came to the conclusion that timing chain must be
checked, To remove the timing chain cover, it was
necessary to remove the oil sump and hence the
draining oil was necessary, after opening the oil pump
and removal of Timing chain after removing Chain
tensioner the Chain was removed, and compared the
same with the reference hyundai timing chain,
comparison revealed that the removed chain was
elongated almost to the length of on Link, hence Figure 5.30 OLD ELONGATED TIMING
replacement of chain was necessary. CHAIN
Again before Installing the chain, all the

timing marks were set to zero and then the
new chain was installed carefully, aligning
the copper links aligned in the markings on
the sprocket. And the tensioner was released.
Installed chain cover again using Loctite
Adhesive and Installed Oil sump using
Loctite Adhesive, and the vehicle was tested
on road, and Found that the Problem was
resolved.
Figure 5.31 TIMING MARKING ON CAMSHAFT

SPROCKET
5.13 HONDA CIVIC I-VTEC

Problem : Dead Engine.
Cause : Water Ingress in Vehicle, as Vehicle was Driven through Deep
Puddle of water, and Water was Sucked in from Air Inlet Duct. Which Led
Connecting Rod Buckling
Remedy : Replacement of Connecting Rod and Engine Overhaul.
Received Vehicle with the complaint of Dead Engine, and History described by the Customer
was, the Vehicle was Being Driven through the deep water puddle, and engine stopped, after
engine was stopped Customer attempted to start engine for several times. But Engine didnt
start. And also While Operating Starter motor, metallic blows, pinging kind of noises could
be heard from the Engine.
Vehicle was Sent through Breakdown carrier vehicle from Ahmedabad. According to the
History described by the customer, First of all the Battery was removed from the vehicle and
then, The Air filter assembly was opened, and Large amount of water could be seen in the
assembly, which confirmed that the water ingress damaged the engine, and path of water was
Air inlet duct, to Air filter assembly and inlet manifold. And Because Water is

Incompressible, after the water entered through the inlet manifold, after the valve closure
during pistons travel towards TDC might have tried to compress the water, but waters
incompressibility didnt let the force of cranking to be absorbed and the force was released by
buckling the connecting rod.
Figure 5.32 BUCKLED AND FRACTURED CONNECTING RODS
Engine was Removed from the vehicle and Hung on the Hoist. Water was also observed in
exhaust system. Gearbox was Separated from the
engine, and then Engine Head was Removed First,
and checked it for any possible damage to the valves,
but valves seemed perfect. Also water was observed in
the Inlet manifold, and water could be seen in all four
cylinders, to check the extent of damage, First of all
the Engine crank pulley was Rotated using spanner.
Cylinder 1 and 4 were reciprocating perfectly without
any difference in their TDC, but Piston 2 wasnt
Moving at all, and 3rd Piston was Reciprocating but
there was difference in height between cylinder 4 th
TDC and Cylinder 3rds TDC, which meant that
Connecting rod of
Cylinder 2nd was Figure 5.33 CONNECTING ROD STRIKING
Failed and Broken, MARKS
and Connecting rod
in cylinder 3rd was Buckled.
Removed All hoses, And entire harness, and engine oil

sump, and disassembled entire engine. And inspected all
Figure 5.34 TIMING POSITION engine components as they were being removed. As
WHEN ALL FOUR PISTONS ARE
AT SAME LEVEL

predicted, upon opening the crankshaft and connecting rods, 2 nd cylinder connecting rod was
Broken and 3rd cylinders connecting rod was buckled badly. And Both needed replacement,
Also because of several starting attempts by the customer, Buckled connecting rods bent
edge and broken connecting rods free end struck cylinder and block several times which
ultimately damaged them, and Restoration and Reconditioning of the Engine block was
necessary, and sent for the restoration, and new Cylinder liners were installed.
Used two new connecting Rods, Old Pistons with new Piston rings and reconditioned Engine
block, Reconditioned and serviced engine head, whole engine was assembled again, and after
topping up all the essential fluids, engine was mounted on the vehicle and was started, and
engine was kept running for two days to trace any possible problem and then the vehicle was
delivered.
5.14 MERCEDES BENZ C250 TDI

Problem : Dead Engine, Dead Starter.
Cause : Water Ingress in the Vehicle through Air Inlet Duct which Buckled
the connecting rod hence Failed Engine.
Received Vehicle with the complaint of Dead Engine, and
Again the Customer described that they were passing
through the deep puddle of water, and in the middle of the
puddle, the engine was stopped and Customer tried to Turn
the engine on several times, and after several attempts, even
starter motor stopped to respond.
The Vehicle was Sent to the workshop using the breakdown
vehicle, as per standard operation procedure, Checked air
inlet duct and Air filter assembly, and upon observation,
Huge amount of water could be seen in duct and Filter itself,
hence came to the conclusion that the water Ingress Might
have damaged the Engine and water might have Routed to
the engine through the Air Inlet duct, Air filter and then
Inlet manifold, and then the cylinder. Because of waters Figure 5.35 ENGINE REMOVAL
incompressibility property, during Pistons
travel towards TDC, cranking force instead of
being absorbed by the charge, affected the
connecting rod and connecting rod might have
been buckled.
Before removal of the engine, Automatic
Gearbox and torque converter were needed to
be removed, to remove them, removal of
Headlights, Bumper assembly, Radiator,
Intercooler were Removed. After this Engine
Crank pulley was tried to be revolved using
Figure 5.36 CYLINDERS FILLED WITH WATER spanner, but the engine was Badly seized that It
AND DIESEL couldnt be rotated even a degree, hence Torque

converter and gearbox couldnt be separated, as Bolts fastening torque converter and gearbox
were not accessible from the slots, to access these fasteners Crank pulley must be revolved to
Align the fasteners to the slots from where they could be opened.
Figure 5.37 BUCKLED CONNECTING ROD
Hence the whole engine along with the Front Cross member, Steering rack, torque converter,
and Gearbox needed to be removed as a one unit without separation, Removed all the
connectors and Hoses from the Engine which are connected to the body. After placing
suitable supports properly beneath the engine, vehicle was Lifted using the Lift and engine
was separated from the Body.
Engine Hoist was used to hung the engine and two separate
supports were used to support the gearbox assembly. After
removing entire wiring harness carefully and after removing
all the hoses and all the engine auxiliaries, Engine oil sump
was removed and from the sump a Piece of Broken Cylinder
block liner was observed. After that Cylinder head was
Removed, Upon opening the cylinder head accumulated
water and rust could be seen.
Measured the Piston positions, as the firing order is 1432,
Cylinder 1st and 4th were in intermediate position and using
depth gauge, there was no height difference in piston 1st and
4th, upon measuring cylinder 2nd and 3rds height difference
in intermediate Position using depth gauge, It could be seen
that the Piston in cylinder 3rd was Lower than the Piston in
the cylinder 2nd Hence came to the conclusion that
Figure 5.39
Connecting rod in cylinder 3 has been buckled. BUCKLED
Figure 5.38 CONNECTING ROD
BUCKLED As the Crank couldnt be rotated because of the Pistons,
CONNECTING from the bottom connecting rods big end bolts were removed and hence
ROD SIDE VIEW

crankshaft was revolved and thus removed

torque converter and the Gearbox. There were
gears for timing, and to mark their timing oil
paint was used to mark each gears position with
reference to another, and after that the block was
sent for reconditioning (Repairing) as Customer
refused to buy new Engine Block. And Placed an
order for new connecting Rod and New starter.
Upon receiving Block and connecting Rod
Engine was assembled and mounted on the
Figure 5.40 BROKEN CYLINDER LINER Vehicle, after connecting all the hoses and
connectors, and topping up with the fluids,
engine was started, But even after several attempts engine didnt start, to reconfirm the timing
settings, Valve cover was Opened and Both the
camshaft had timing marks on the cam with a
clear laser mark and Crank pulley had 0 to 340
degree markings on the periphery.
Timing can be set when the 0 mark of Crank
pulley aligns with a protruding section next to
the pulley and Laser marks of Camshaft aligns
with the marking on cam supporting bearings.
But timing was wrong, to correct the timing, Figure 5.41 BROKEN CYLINDER LINER PIECE
engine needed to be removed, instead of that
Head technician Loosened the Left hand threaded nuts fastening the cam shaft sprockets as
Camshaft sprockets were not Keyed to the camshaft., hence after loosening the both the bolts
of Camshafts sprocket Positioned Both the cams to their marking, and then Revolved Crank
Pulley to its zero marking and finally tightened Both the Left hand threaded bolts to the
sprocket. And then Installed the Valve cover and then Engine was Given a starting attempt,
and the engine was started, and the Vehicle was kept in engine running condition for two
days, and then Delivered to the Customer.
Figure 5.42 CAMSHAFT TIMING LARKS ON LEFT END

5.15 AUDI A6 TDI (V6)

Problem : Engine Stopped working and from last few days engine was losing its
consistency and Performance.
Cause : Poor Quality Fuel with foreign Particles (Amery) Which Ruined the
Diesel Pump and Clogged Fuel Filter, Common Rails, and Injectors.
Remedy : Fuel tank, Fuel lines, Common rails Flushing and cleaning, and
Replacement of Diesel Injection Pump, and Injection Nozzles.
Received Vehicle with the complaint of Dead
Engine, vehicle was towed to the workshop,
First basic Inspection shown, almost Half
Fuel tank, and History described by the
Customer as From last 6 days slowly,
Gradually vehicle is Losing its consistency
and performance, and finally Vehicle engine
was stopped, according to the customer the
Problem started after previous Refuelling.
According to standard Operation Procedure,
Vehicle was checked for the Diesel quality
reacting to customers history.
Removed rear seat cushion and accessed Lid
through which Diesel Delivery Pump can be Figure 5.43 METAL AMERY IN DIESELPUMP OUTLET
accessed, Fuel could be seen from the top.
And Fuel had different colour and Lots of Foreign particles were observed to be settled down
in the Bottom of the tank. Removed the Diesel delivery pump assembly with the Level float
for inspection of the inbuilt strainer in the diesel pump. Upon Inspecting the strainer some
particles were observed but Strainer mesh was not adequately fine to filter the minute foreign
particles. Hence the inspection was narrowed to the engine room assemblies to aid fuel
filtering task.
Upon removing and checking Fuel Filter assembly, it was much heavy in weight, compared
to same size diesel filters, also it was sealed so that no cartridge or element to be inspected
was present, A fine tissue paper was Kept at the outlet of the fuel filter and fuel was extracted
from the filter, But surprisingly Fuel from the Filter outlet was Full of Foreign particles
which were being strained by the tissue paper, which meant that fuel filter was also internally
damaged that it could not prevent foreign particles to be moving ahead towards Diesel Pump,
common rails and Injectors.
After the Inspection, it was necessary to
Inspect the diesel Injection pump, to
disassemble the pump, Driving belt was
Removed, as the engine is V6 engine, there
are two outlets in the Pump, towards two
Common rails having 3 Injectors
connected to each rail. Upon Opening the
Pump Outlets, Enormous Amounts of
Metal Chips were Observed which
manifested the end of the life of the Pump
as the pump has extremely Precise Figure 5.44 REMOVED DIESEL PUMP

tolerances, and any foreign particle can be catastrophic in terms of pump Life, hence Pump
replacement was required as Repairing or restoring the Diesel Injection Pump was not
possible, Upon Opening and inspecting both Common rails and pipes connecting common
rails and Injectors were also filled with particles and Amery, due to all these, Injectors were
clogged completely, yet to take a last chance these Injectors were sent to Bosch Authorised
injector service centre, but according to Service centre authorized person informed that these
Injectors will not work, neither they can be repaired, Replacement was the only Option,
Diesel Pump for common rails could not be repaired or restored as well and needed
replacement too, and common rails, Connecting pipes, fuel tank, fuel lines and fuel delivery
pump needed to be cleaned thoroughly, Engines any other component didnt require any
other service as No foreign particle or metal Amery could have passed through Microscopic
holes of Injector Nozzle.
After receiving the Injectors, and fuel
Pump, every assembly were assembled
and tested vehicle for any possible
problem, Vehicle performed perfectly, and
the problem was resolved and vehicle was
handed over to the Owner.
5.16 HONDA CIVIC I-VTEC

Figure 4.45 WATER INGRESS LED TO CORROSION OF
Problem : Dead Engine INLET VALVE
Cause : Water ingress through Air inlet duct buckled the Connecting Rod
Received Vehicle with the complaint of Dead engine, The same Vehicle which was
overhauled three weeks ago, The Customer was Blaming Workshop for the previous Job not
done properly and thats why they are facing the problem. And History described by
customer was that the Vehicle was used properly but they were blaming workshops
workmanship, upon
inspecting vehicle properly,
there was a damp smell in the
car, to check whether vehicle
was driven in the water or not,
Used profimaster Lift to lift
vehicle from one side, and
Surprisingly Huge amount of
water was poured from the
vehicle also large amount of
water came out from the
exhaust pipe as well , after
Figure 5.46 ACCUMULATED WATER IN COMBUSTION CHAMBER that Customer was brought to
the front of the Vehicle and
Opened the air inlet duct and air filter, Water was accumulated there and air filter was totally
wet and soaked in the water, and then the Customer admitted that the vehicle was driven
through the deep water puddle which stopped the engine and after several starting attempts,
Vehicle was Finally brought to the workshop. And he agreed to Overhaul the engine.
Engine was Harnessed on the Hoist and Engine was removed from the vehicle, after that Oil
Sump was opened and Engine head was removed to check the extent of damage, upon

opening the Engine head, Large

amount of water was observed in the
Inlet manifold and also above 2nd
cylinder Inlet valves, and all four
cylinders were filled with at least
300ml of water cumulative.
Water accumulation above the Inlet
valves also rusted the face of the
valves. After removal of water from
all four cylinders, using depth gauge,
depths of 1st and 4th was measured
and Depths of 2nd and 3rd pistons was
measured, but 3rd cylinder piston was
Lower than the 2nd cylinder piston Figure 5.47 3RD CYLINDERS BUCKLED CONNECTING ROD
and hence 3rd cylinder pistons
connecting rod might have been buckled.
After opening the connecting rod big eng bolts and upon removing the connecting rods, it
was confirmed that 3rd cylinders connecting rod needed replacement as it was buckled,
reconditioning of Engine block and restoration of inlet manifold, also electronically
controlled throttle body needed replacement
Upon receiving needed spares, Engine was overhauled and reassembled and tested for two
days continuous run and the problem was resolved and vehicle was handed over to the
customer.

CHAPTER-6 TRANSMISSION REPAIRS

6.1 HYUNDAI I20 CRDI ASTA
Problem : Harder Gear shifts, Crackling sound during changing the Gears, and
Oil Leakage.
Cause : Worn out Clutch Plate and Pressure plates, and Deformed hence
Leaking Left Side Half axle oil seal.
Remedy : Replacement of Clutch plate, Pressure plate and Replacement of Left
side Half Axle Oil Seal.
The Vehicle was received with the complaint of harder Gear shifts, and Gears were not
getting engaged and changes of gear wasnt smooth. Hence following Standard operation
procedure, the vehicle was set on the Lift and was raised. The Engine was started and some
gear shifts were attempted but it was enormously difficult
to shift the gears.
Due to which to rectify the exact problem, the Gear
changing mechanism (Gear Changing knob) Mechanism
was checked and Inspected whether any cables were
deteriorated or loosened or not. Upon opening the Gear
Know Cover and trim, White plastic made gear changer
mechanism was observed and Cables were snugly fixed to
their slots, and hence there was no problem observed in the
cables, and after making some shifts, it could be concluded Figure 6.1 WORN OUT PRESSURE PLATE
that there was no problem whatsoever in the Gear

changing mechanism and was perfectly functioning,
including Reverse Gear.
After that check, the attention was focused on Clutch
Master cylinder and Slave cylinder, the vehicle was lifted
further more and located the slave cylinder to find what
degree of motion was being transmitted to the fork of
thrust bearing. Upon checking Slave cylinder, its
displacement and range of travel was adequate for gear
changing function. Figure 6.2 REPLACEMENT PRESSURE
PLATE
Hence the focus was narrowed to the thrust bearing,
Clutch plate and pressure plate, and preparation were made to remove the
Gearbox(Transaxle) also before removing the Gear box, it was necessary to find the traces of
the leaking oil and the source of leakage was essentially important. After several checks from
Engine oil drain plug, Transmission oil drain plug and transmission oil filling plug, they were
intact and no leakage was observed from there, but upon checking the Half axles, Oil was
observed coming out and dripping from the Left half axle, upon watching closely, the Oil seal
of Left half axle was deformed and Oil was coming out from there. Hence it needed
replacement.
To Check the Thrust bearing, Clutch plates and pressure plates removal of entire transmission
system was required, in order to do that, Both the wheels were removed
And the entire transmission oil was drained, and after that both the axles were pulled from
transaxle ends and were disengaged, after that these half axles were tied with a metal cable to

avoid any interruptions bye loosely opened axle, After that, Front cross member was removed
and Along with that Engine C Mount and Steering rack was removed, after steering rack
removal doors were locked to prevent any accidental steering manoeuvre which may lead to
further complications during reinstalling and fine tuning the steering rack. After the removal
suitable supports were set and adjusted to support the engine as after that task, Transmission
side engine Bracket was about to be Opened, After placing the engine supports suitably the
mounting was loosened, and Removed, also Slave Cylinder was dismounted from the
Gearbox, and Gear position sensor connector was also removed from the gearbox and
Fasteners were removed from the Gearbox and then with help of 4 Persons the Gearbox was
removed and kept on the floor.
After the removal of the gearbox,
Thrust bearing was checked and the
Bearing was performing perfectly fine,
after that the fasteners were removed
from the Flywheel which were
fastening the clutch plate and pressure
plate housing. And removed entire
assembly and checked for any possible
problem.
Upon checking Clutch Plate, it was Figure 6.3 WORN OUT CLUTCH PLATE AND NEW CLUTCH
worn out and needed Replacement, PLATE
also due to modified design Clutch plate and pressure plate both
needed to be replaced and hence they were replaced, and after
that cable condition was checked whether they were in good
working condition or not, and it was found that the cables were
perfect and were in good condition, after that the gearbox was
Lifted by 4 men, and having two dowel pins as reference, the
gear box was fixed to its place and fastened, and after that, the
slave cylinder was fitted and the connector was connected.
After the Installation of Gearbox the Left side half axle oil seal
was replaced , it was Rubber Infused metal Oil seal, was
Figure 6.4 REMOVED LEFT HAND
replaced and axles were reinserted in the Transaxle unit, and SIDE AXLE OIL SEAL
installed Front cross member, steering rack, Engine C mounting
, and reengaged the Half axles in the transaxle unit, after turning on the engine, some gear
shifts were attempted and it was observed that the gear shifting was smoother and the
problem was resolved. Also the Oil leakage problem was resolved and topped up the
Transmission oil.
6.2 TATA INDICA VISTA QUADRAJET

Problem : Harder Gear Shifts
Cause : Worn Out Clutch plate and Deteriorated Pressure plates, worn out
thrust bearing.
Remedy : Replacement of clutch plate and pressure plate, and Thrust bearing
The Vehicle was received with the complaint of Very hard gear shifts, Reduced Mileage and
sometimes it was Impossible to Change Gears, Upon Inspecting the Vehicle, and as per
standard operation procedure, Vehicle was set on the lift and then the vehicle engine was
turned on and then some gear shifts were attempted, But Gear shift was an extremely difficult
task and couldnt be changed several times at all. Gear shifting mechanism was checked, also

Cable lines were check to inspect the

condition of the cables and to detect any
marks of wear and deterioration, but
cable was in good working condition,
hence the focus was narrowed to the
Transaxle unit, and needed removal of
transaxle.
To remove the Transaxle, initially the
transmission Oil was drained out, and
then wheels were removed and steering
knuckles were removed along with the
disc brakes assembly, after that the half
axles were pulled out and then Front
cross member was removed, and Engine Figure 6.5 REMOVAL OF TRANSMISSION SIDE ENGINE
MOUNTING
C mounting was removed. After this
used suitable supports to support engines Transmission side, as engines transmission sides
mounting was about to be removed to disassemble the transaxle unit, Slave cylinder was
removed from the transaxle unit and connectors were disconnected, when supports were
aiding to support engine, with help of four men, engines transaxle side mounting was
removed and then fastener fastening the transaxle unit to the engine were unscrewed and
finally the transaxle was removed, and was placed on the floor.
The first thing came under the observation was Thrust bearing, after removal of thrust
bearing, and upon checking it, Thrust bearing was in bad condition and was not functioning
smoothly at all, and hence it needed the replacement, after that, the Clutch housing was
dismounted and disassembled, Upon inspecting the clutch plates friction lining, it was worn
of totally and needed replacement, also Diaphragm pressure plates fingers were worn and
corroded, hence it needed replacement too. After receiving new spares these spares were
installed on engine flywheel with carefully aligning the centre of clutch plate with transaxle
shaft and with guiding aid by dowel pins, the transaxle unit was fastened to the engine, and
again slave cylinder and connectors were connected.
After Installing the transaxle unit and engine transmission side mounting front cross member
was installed along with engine C mounting, and then the Engine was started and Gears were
shifted to crosscheck the rectification of the problem, Gear shifts were smooth and the
Problem was resolved.
6.3 TATA MANZA

Problem : Harder Gear Shifts, Sometimes Clutch was not responding, gear shifts
were malfunctioning. Crackling sound when Gear shifts were attempted and also
Severe Vibrations were felt while shifting the gears.
Cause : Worn Out Clutch Plate, Pressure Plate, Clutch Master cylinder,
Clutch Slave Cylinder, and Shifting mechanism Cable Lines were deteriorated.
Remedy : Replacement of Clutch Plate, Pressure plate, Clutch Slave cylinder
and clutch master cylinder, and Shifting mechanism cable lines.
The Vehicle was received with the complaint of Harder gear shifts, sometimes irresponsive
clutch, crackling noise while changing gears and severe Gear knob vibration while changing
the gear. Following Standard operation procedure, the Vehicle was set on the Lift and was
raised to a good comfort ergonomics height, after that engine was started and clutch was

operated several times, and simultaneously the

gears were shifted to check whether clutch was
operating or not, it was observed that several times,
even when the clutch pedal was stomped to the
floor, the clutch was not operational and gear shifts
were noisy and extremely difficult, and when the
Clutch was operated, shifts were equally hard too,
with loud crackling noise and severe vibration to
the gear knob. After these initial checks, Floor
mounted gear changing mechanism was removed
to see any signs of wear and deterioration, but Figure 6.6 WORN OUT CLUTCH ASSEMBLY
Mechanism was in fairly good condition to carry
out the operation, after that upon focusing in the cables they were looking in good condition.
And upon inspecting it from outside from the transaxle unit, wear and tear was visible, hence
cables were needed to be changed, after operating clutch for several times, helper informed
that randomly clutch worked and randomly it didnt get actuated. Upon checking Master
cylinders plunger which was fastened with clutch pedal, wear and tear was observed, and
Slave cylinder was also displaying wear and
tear, Hence Replacement of Clutch master
and Slave cylinder was necessary, after this
removal of transaxle unit was necessary,
hence Slave cylinder was removed,
connector was disconnected. Wheels were
removed, axles were disengaged from the
transaxle and then removed the front cross
member and engine c mounting. After the
removal engine was supported by the
Figure 6.7 DETERIORATED CLUTCH SLAVE
suitable supports and transmission side CYLINDER
engine mounting was removed. And with
help of four men fasteners fastening transaxle unit to the engine were removed and transaxle
unit was kept on the floor. After this thrust bearing condition was checked and it was in good
condition, Clutch housing was dismounted and disassembled.
After disassembly upon checking the condition of the Clutch plate, entire friction lining was
worn off and needed replacement as well as Pressure plate needed replacement too. Upon
receiving Clutch plate, Pressure plate and its housing, they were mounted on engine
flywheel, Slave cylinder and master cylinder were installed on Transaxle unit and beneath
cowl panel respectively. And Hose were connected.
Old Cables were removed from the floor mounted shifting mechanism and new cable ties
were inserted, and cable sleeve was fastened from where old sleeve was removed. And their
other ends were fastened on the transaxle unit, according to their colour coding and also to
make the replacement easier, both the cable ends ere of different size to avoid conflict of
fitting them wrongly.
Bleeding process was done on clutch Master and Slave cylinders, after reinstalling all
assemblies and subassemblies, the vehicle was topped up with transmission oil and was tested
for the shifts to cross verify the resolution of problem, the Problem was resolved and vehicle
was taken for the test and sent for the Alignment.


Problem : Severe Vibrations, and Rattling Noises could be heard in the Cabin
and Passengers sitting in the Rear seats complained about Vibrations and Noise Only
when Vehicle Used to be In Motion and the vibrations and noise diminishes as vehicle
was stopped.
Cause : Deteriorated, Cracked and Hardened Propeller Shaft Centre Bearing
Mounting Bushing.
Remedy : Replacement of Centre Bearing Mounting Bushing of propeller Shaft.
Received the Vehicle with the complaint of severe noise, and Vibrations when vehicle is in
motion, As per Standard operation Procedure the vehicle was taken for the test, and the same
problem could be felt the moment vehicle came in to motion, and vibrations and Noises
increased linearly with the speed of the vehicle. And decreased and finally stopped as the
Vehicle was decelerated and brought to the Rest. Hence the problem was detected in
Transmission only, and specially
focus was narrowed to the
Propeller Shaft, to check whether
the Propeller shaft was intact or
not and to find the any Buckling
the Vehicle was first brought to the
workshop and then the vehicle was
set on the lift and engine was
started, after engaging gear vehicle
wheels were revolved, and
Observed the Propeller shaft, but
No Buckling was observed, but the
noise could be heard from the
centre bearing mounting. After
turning off the engine, The bearing Figure 6.8 AIDING IN REMOVAL OF PROPELLER SHAFT
was revolved manually, but
Bearing seemed to be in good condition, but the Centre bearing Mounting brackets bushing
was looking deteriorated, and cracks were visible, hence replacement was required.
For the replacement, vehicle was taken off from the lift and set on axle stand, and then the
Propeller Shaft was removed from the Gearbox, and Differential, While unscrewing the bolts,
propeller shaft was held snugly using thick shank Screwdriver, to prevent it from being
rotated, and finally centre bearing mounting bracket was removed and entire Propeller shaft
was take out. The propeller shaft had Three Universal Joints and One slip Joint, the Bushing
was removed and replaced by the New one and Again the Propeller shaft was inserted and
Mounted again on vehicle and then the Vehicle was taken for the test, and found that the
problem was resolved and Vehicle was operating smoothly.
6.5 MAHINDRA XUV 500

Problem : Squeaking Noise and Vibrations when vehicle was being driven,
periodically Metal striking and grinding Noise.
Cause : Worn out Right side Axle Bearing, due to which Broken Axle bearing
Mounting bracket, and because of Broken Mounting bracket and unrestrained half
axle movement, Worn out and malfunctioning Universal Tripod type Joint on
Transaxle side and Rzeppa Joint at wheel side.
Remedy : Installation of New Right Side Axle Bearing, Axle bearing
Mounting(Bracing) Bracket, Right side Half axle including Universal Joint.

Received vehicle with the complaint of

Severe squeaking Noise, Vibrations,
and Metal hammer blow kind of Noises
were observed, following standard
operation Procedure vehicle was taken
for the test run, during the test these
noises were heard only when vehicle
was in Motion, and the reoccurrence of
the Noise used to increase Linearly with
the Vehicle speed, and decreased and
diminished during deceleration and Figure 6.9 DETERIORATED AND MALFUNCTIONING
RIGHT SIDE HALF AXLE
when vehicle was brought to the rest. It
was also observed that even when the vehicle used to be driven through its momentum
by shifting transmission to the Neutral, there was no difference observed in the noise
occurrence. Thus came to the conclusion that the Problem was in the Axle only and
needed to be checked.
Hence the Focus was narrowed to the axle only, and vehicle was
brought back to the workshop and set on the Lift, and Inspection
was carried out, as the Vehicle was a front wheel drive vehicle it
required only two half axles, bearings, and universal joints were
to be checked. After thorough inspection, and several manual
maneuvers on front left wheel clicks were clearly audible, also
wheel play was observed in all directions and upon revolving
Figure 6.10 FRACTURED wheel manually, squeaking sound was observed as well as
BEARING MOUNTING vibrations were felt, bearing roar could be heard as well, upon
BRACKET
holding axle and shaking it, axle was displaying signs of play.
Wheels were removed, steering Knuckle was removed, including disc brakes assembly,
after that axles were clearly visible, But Left axle and all the subassemblies were looking
perfect but Left axles bearing mounting bracket shown Crack(Fracture) and Bearing was
totally worn out, Bearing balls were not visible, instead thin metal chips were observed.
hence, New bearing had to be installed, also Bearing mounting bracket needed
replacement, and Upon checking the Axles universal Joints they were not operating
silently, and operation was full of squeaks and Jolty, Hence replacement of entire Right
side axle needed replacement.
First of all Axle was disengaged along with the Universal Joints, and New bearing was
Installed on the Axle Using Hydraulic Press and After Installing the Bracket, Axle was
Installed, After Installation of new Axle along with universal constant velocity Joints,
Bearing, and Bearing Mounting Bracket, Vehicles remaining subassemblies were
installed and The Vehicle was taken for a Long trial to verify rectification of the Problem.
The Vehicle marked all the checkboxes and then Vehicle was sent for Alignment and the
Problem was resolved.

CHAPTER-7 SUSPENSION REPAIRS

Problem : Rattling Noise when vehicle passes over the Pothole
Cause : Worn out Lower and Upper wishbones (Lower and Upper Arms)
Bushings
Remedy : Replacement of Bushing Kits
Received Vehicle with the complaint of Rattling Noise when Vehicle passes over the Pothole,
as per standard operation procedure Vehicle was taken for the Test run on rough patch of
road. And Observed the pattern of the noise, the source of noise was from the front
suspension, especially while passing over the road irregularity. Which led to the conclusion
that the problem was caused by faulty
suspension components. After the test
run the vehicle was set on the Lift to
inspect the Lower and upper
wishbones bushings condition. Upon
Inspection, Bushings were found to be
completely worn out and needed
replacement.
Hence Started Replacing Entire
Bushing Kits, Before Removing the
two Fasteners which fasten the Lower
Arm, Special Spring holding Bracket
is used to ease the removal of the
Lower arm. This special bracket has
two removable anchors, and a Nut. Figure 7.1 DISASSEMBLING FRONT SUSPENSION
After inserting the bracket from one
side of spring, another anchor is reinserted and is backed up by the Nut, upon tightening the
Nut, coil spring compresses and releases the load from Lower arm, After this the Lower arms
Bolts can be removed
As these bolts has self Locking Nut, there is no need to use other wrench to prevent nut from
rotating. Once the Arm is removed from the vehicle, it needs to be sent to the Press Room in
cases where fit type is interference fit, and sometimes applying grease is adequate to slide the
bushing in the eye of the Lower wish bones and after that Wishbones were reinstalled to the
Vehicle, same steps were repeated for upper arm bushing kits too. After the replacement the
vehicle was taken for the trial on same rough patch of road, and the vehicle performed great,
and then the Vehicle was sent for the Alignment.
7.2 HYUNDAI VERNA SX

Problem : Continuous Rattling noise even with small road Irregularity
Cause : Leaked Strut assembly, which were not providing any damping
Remedy : Replacement of Struts
Received Vehicle with the complaint of Continuous Rattling Noise from the front side of the
Vehicle and a kind of Rough Ride, As per standard operation procedure, the vehicle was

taken to the test run, and even on the Asphalt road, small irregularity caused rattling noise
which was prominent
Brought Vehicle back to the workshop and set on the Lift, and checked front suspension
struts, upon inspection it was revealed that the struts were bleeding and Leaking and oil could
be easily seen in both the struts, stabilizer Links and sway bar bushings were in good shape,
as well as Lower wishbones bushings were intact and were not worn, Hence came to the
initial conclusion that front struts needed replacement.
It needed removal of wheels, Disc brakes assembly, Steering Tie rod, Half axles, and
separation of Steering knuckle having caution to the disc brakes Hydraulic Lines. After
removal of these subassemblies, Nut is loosened from the top of the strut which is fastened
with the Body. Which ultimately removes the struts of both the sides. Strut assemblies are
sold without coil springs, hence Old coil springs were supposed to be used, and to handle
hazardous element as suspension springs and to Aid in Safe removal, Specially designed
Spring compressing and holding brackets are used. These brackets have upper and lower Jaw
which grapples the spring and both the jows are interconnected with a threaded bar, and end
of the upper jaw is also threaded, and on the top of threaded bar, there is a hexagonal m18
head, which can be tightened to compress the Spring. And springs were compressed to
remove the strut assembly and mounting plate (Buffer plate), Mounting plates were in good
condition, and didnt need replacement.
Once the strut is inserted and the nut is fastened moderately, the Spring grappling bracket is
opened to apply compression to the top mounting plate due to which nut can be tightened
firmly without rotating the strut assembly, after the replacement reinstalled all the
subassemblies and tested vehicle on the road, and the problem was rectified. And then the
Vehicle was sent for the Alignment.
7.3 FORD FIESTA CLASSIC TDCI

Problem : Rattling Noise During normal driving and even when the vehicle is
passing through the pot hole.
Cause : Strut was not damping at all, and Stabilizer Links ball joint was
ripped off.
Remedy : Replacement of Struts and Stabilizer Links.
Received Vehicle with the complaint of Rattling Noise and very rough and bumpy ride, As
per standard operation procedure the vehicle was taken for a test on Rough patch of road to
decode the character of the problem, Ride was harsher, and Noisy and click kind of noise
could be heard when steering was operated, After the trial the vehicle was brought to the
workshop and was set on the Lift, and Usual test of giving some thrusts or pushes to the
wheel in Horizontal, vertical and Lateral Direction to check any play. While fiving Vertical
play clicks were observed, and after holding the stabilizer link and by shaking it, it was
moving with clicking noise, Hence came to the conclusion that the Stabilizer links needed
replacement as upon observing closely, stabilizer Links Ball joint was Ripped off. No
leakage was observed in the strut assembly, hence to inspect the strut condition, strut was
removed from the vehicle, after Removal of strut, and during tests strut was rigid and wasnt
provide any damping effect, not it got compressed, Hence it was necessary to replace the
struts, In new strut assembly old coil springs needed to be installed.
After securing springs properly in the Jaws of Spring compressing and grappling bracket,
strut was removed and new strut was inserted in the assembly, after tightening the nut

moderately, the spring grappling brackets were removed to apply compression load to the top
mounting plate component so that it can be tightened without using any additional wrench.
After strut replacement, stabilizer links were also replaced, as the Ball joint was ripped off, to
open the nut of Stabilizer link, additional tools were used to Aid the ease of opening the nut,
Lock wrench was used to hold the Strut of stabilizer link. And Both Links were replaced.
After the replacement vehicle was taken for the trial and upon checking all the parameters
and confirming the resolution of problem, the vehicle was sent for the Alignment.
7.4 MARUTI SUZUKI RITZ VDI

Problem : Severe Squeaking voice when vehicle was being driven, Severe rattling
noise, rough ride, and rattling noise from the rear too.
Cause : Leaked Macpherson struts, and rear Shock Absorbers were not functioning
normally in terms of compression.
Remedy : Replacement of Front Macpherson Struts, and Rear Shock absorbers
Received Vehicle with the complaint of Rattling, and
squeaking noise all around, also Ride was bumpy and
noisy with all the road irregularities felt in the car
cabin, as per standard operation procedure, vehicle was
taken for test on rough patch of Road, and observed
that source of squeaking an rattling noises were from
front and rear both. After the test the vehicle was taken
in the workshop and was set on the Lift, Upon
checking closely, both the struts were leaking, hence Figure 7.2 REAR SHOCK ABSORBER NEW
their replacement was required, and also Noises were AND OLD
audible from the rear of the vehicle too, To check the rear shock absorber, a trim was
removed from the boot area and the Nut was revealed through which the Shock absorber
could be removed, after removal of Right the shock
absorber, it was surprising to see that shock absorber
wasnt moving and wasnt compressing at all, hence it
needed replacement too, Upon checking Left shock
absorber, it was functioning but the length through which It
could travel was very less compared to the Normally
functioning shock absorber, hence, both rear left and right
shock absorbers were needed replacement.
Also Front Macpherson strut needed replacement, In new Figure 7.3 FRONT REMOVED
Macpherson struts there was no need to use the old springs MACPHERSON STRUTS
and the new struts had springs preinstalled, hence new struts were installed and the vehicle
was taken for the test run, and the problems seemed to be resolved, after the test the vehicle
was sent for the Alignment.
7.5 CHEVROLET CRUZE

Problem : Rough and Noisy ride
Cause : Worn out Front Macpherson suspension lower Arms Bushings
Remedy :Replacement of Lower arms, as No separate full bushing kits
available, Bushings are fused in the Lower arms mounting bracket assembly only

Received Vehicle with the

complaint of Rough and Noisy
ride, No prominent rattling or
squeaking was observed. after
taking the test run, vehicle was
set on lift, as there were no
severe rattling noise problem
could not be in Macpherson
strut or Mounting
(Bracing)plate, after observing Figure 7.4 LOWER ARM TRAILING SIDE MOUNTING BUSHING OLD
AND NEW
Lower arms Bushings, Cracks
and damage in Bushings was Visible, due to which
Replacement of Bushings was necessary.
But in that Vehicle, Full Bushing kits were not Available
instead of that, Separate bracket (Bracing) fused with
Bushing were available and another bushing s were available
as replacement kit.
The Lower arm of the Vehicle needed a separate bracing
assembly to mount the Lower arm fully, after replacing those
brackets, Old bushes were Replaced with New Bushings
Using Hydraulic Press, and after greasing the Bushings, they Figure 7.5 LOWER ARM
were fitted in eyes of Lower wishbone and vehicle was taken for test drive. Problems were
rectified, and then the vehicle was sent for Alignment.

Problem : Rough Ride, Severe Rattling, and squeaks noise and reduced steering
feedback.
Cause : Worn Out Bushings of Sway Bar, Upper wishbones and Lower
Wishbones, and Wheel bearings needed Greasing.
Remedy : Replacement of Worn out Bushings, Greasing the Wheel Bearing
Received the vehicle with the complaint of Rough and Bumpy ride, severe Rattling noise and
squeaks, also during smooth roads Tyre noise was transmitted to the cabin, and reduced
steering feedback, as per standard operation procedure, the Vehicle was taken for the trial,
noise was observed from both the sides of the front wheel, after the trial the vehicle was
brought back to the Workshop and was set on the Lift for thorough checking of suspension
system, Upon checking the Upper and Lower Arms Bushings condition, Bushings were
completely deteriorated and Cracks were visible on the Bushings, hence came to the
conclusion that Entire Bushing Kit Needed to be replaced. Vehicle was then taken off from
the lift and was set on the Jack and then axle stand, Both front wheels were removed and then
Steering Knuckle along with disc brakes assembly was removed and Disc brakes callipers
were removed and using flexible metal Bar, they were Hung carefully. To release the Load
from Upper and Lower Wishbones (Arms) Spring compressing Bracket was utilized,
Removed one Anchor from the Bracket. Penetrated the threaded bar through the spring, then
another Anchor was inserted which was backed up by the Nut, after tightening the Nut the
spring was compressed and Load was released from the Wishbones, Once the Load was
released, Wishbones could be removed using pneumatic gun.

After the removal of the wishbones, using suitable sized

shaft taken the bushing off the Arms (Wishbones), after
Inspecting the wishbones, New Bushings were Greased
properly before insertion in the Wishbone eye, after
several hammer blow on the shaft pushing bushing inside
the eye, Bush was properly fit and the same steps were
repeated on both sides, and after that, steering Knuckle
was installed, and slotted nut was cocked by deforming the
secure pin.
After the installation, wheel hub cover bolts were opened,
and removed all the accumulated grease and replaced the
grease with new.
After the installation, vehicle was taken for the test drive
and upon confirming the resolution of the problem, vehicle was Figure 7.6 SPRING COMPRESSOR
FITTED TO REMOVE LOWER
sent for the Alignment. ARM
7.7 MARUTI SUZUKI RITZ LDI

Problem : Vibration and Noise while negotiating the turn and knocking kind of
noise when Vehicle used to pass over speed breakers or potholes
Cause : Deteriorated Strut Top Mounting Plates
Remedy : Replace worn out and deteriorated top mounting plates
Received Vehicle with the complaint of Vibration and Noise when steering was being
Operated, and Knocking kind of Noise when vehicle used to pass over the Pothole or speed
breaker, according to the customer provided history, Vehicle was first set on the Lift and
Lifted, after that Bu Holding tire
firmly, tyre was pushed towards up
and down several times, Laterally,
and horizontally. But when tyre
was being pushed upward and
downward the same knocking noise
was observed, Lower arms
bushings were appropriate in
condition, Stabilizer links were in
good condition, Hence Focus was
Figure 7.7 TOP MOUNTING PLATES OLD AND NEW narrowed to the Strut top mounting
plate.
Removed wheels, Steering Knuckle, Stabilizer links, and removed Half axle, and then Nut
was unscrewed from the top to remove the Strut. Once the strut was removed, the strut top
mounting plate was revealed and it displayed signs of extensive wear and deterioration, hence
the plates were Replaced and reinstalled all removed subassemblies, after the trial went well,
the vehicle was handed over to Alignment department, and the problem was resolved.

7.8 AUDI Q7 V6 QUATTRO

Problem : Rough Ride, Squeaking noise when vehicle passes over the Road
Irregularity
Cause : Worn out and Deteriorated Bushings of Adaptive Air Suspensions
Upper and Lower Wishbones.
Remedy : Replacement of Suspensions Upper and Lower wishbones as No
Separate Bushings were Available, Bushings were Fused in the Lower and Upper
Arms.
Received the Vehicle with complaint of harsher and noisy ride, As Per standard operation
procedure, vehicle was driven in the Rough Road patch, and all the unnecessary noises were
observed, after the trial, the vehicle was brought into the workshop, and set on the lift for the
check. After inspecting carefully, Bushings in front suspensions upper and Lower arms were
found to be completely deteriorated and Visible cracks were observed in the Bushings.
To Replace the Upper and Lower arms, Wheel was removed, along with the Axle, Steering
Knuckle and Disc brakes assembly were removed, Because the Suspension was Adaptive Air
Suspension, there were no springs but there were Pneumatic springs or Pneumatic Struts
which used to inflate of deflate according to the requirement.
Figure 7.8 PNEUMATIC SPRING FITTED WITH NEW UPPER ARM
For height variation, Air hose were connected to the Pneumatic spring Valve. First the
Vehicle was Set in Jacking mode, which releases Air from the pneumatic springs and after
that the Pneumatic springs could be removed. After Jacking
mode execution, Air hose was carefully disconnected from the
Pneumatic springs, there was a Angle measurement sensor
connected to both Upper arm and Pneumatic spring both,
Removed that sensor carefully
After removal, New Arms were installed which were brought

by the customer, Installed the sensor and all subassemblies,
and vehicle was Taken for the test and No noise could be Figure 7.9 REMOVED OLD LOWE
heard, and then the vehicle was handed over to the alignment ARM
department.

CHAPTER-8 STEERING AND STEERING

SUBASSEMBLIES
8.1 TATA INDICA DLS

Problem : Harder Steering
Cause : Vane Type Hydraulic Power Assisted steering Pump Bearing
was Deteriorated and was not functioning at all.
Remedy : Pump Replacement, or Pump Overhaul
The Vehicle was received with the complaint of Extremely hard steering, and according to
the customers description, he described as there was no power assistance at all, As per
standard operation procedure in such scenario,
vehicle was set on the Lift and Steering was
operated to check the degree of Power assistance,
but even though the vehicle was in Lift there was
no power assistance at all.
After turning off the engine, underbody trims were

removed to access the Power assisted steering
hydraulic pump, engine was started to see whether
the pulley rotates or not, but the pulley was
rotating, and also it could be observed that there
was some oil was dripping, and dripping fluid was
the power steering fluid. Hence the fault was
Figure 8.1 POWER STEERING VANE TYPE detected in the Pump
PUMP
To remove the pump, Belt was removed and
then after extracting the hydraulic fluid the
pump was removed from the engine, and
started disassembling the pump, the Pump
being used was Vane type Pump. Meanwhile it
was observed that there were some metal chips
in the pump body, after doing further
investigation, entire pump bearing was
deteriorated and was destroyed, oil seal and o
ring were deteriorated.
Hence either Bearing or the entire pump was
supposed to be replaced, but upon checking the Figure 8.2 DETERIORATED AND WORN OUT
specifications of the bearings on spares PUMP BEARING
department, the same bearing was available, hence only overhaul of pump was required, To
remove the Old worn bearing, the shafting of the pump was brought into the press room and
using hydraulic press the bearing was removed from the shafting. Also the pump rotor with
vanes were thoroughly washed by diesel and then the same grade of hydraulic fluid to ensure
all metal chips were washed away.

After the Installation of Bearing, new

Oil seal and new O ring were installed
after assembling whole pump, it was
mounted on the engine using loctite
adhesive and again the belt was applied
on the pulley
Figure 8.3 PUMP SHAFT AFTER REMOVAL OF BEARING After the installation, the vehicle
engine was started and steering was
checked to ensure the problem was resolved, after the installation vehicle was taken for a test
run, and the problem was resolved.
8.2 HYUNDAI I20 CRDI SPORTZ

Problem : Harder steering, no power assistance.
Cause : Burnt Electric motor in Electronic motor assisted steering Rack
Remedy : Replacement of Steering Rack And Burnt Power assistance Motor
Received Vehicle with the complaint of no power assistance during handling the steering, and
steering was extremely hard to Operate. The vehicle was set on the Lift to check the
Condition of steering Rack.
After checking the Physical condition of the rack, and as the rack was looking Intact, but
upon holding and shaking tie rod, there was clear clicking sound and also there was a play,
hence rack replacement was required, after this power supply was checked whether Steering
power assisting motor was receiving power or not, after the check it was observed that the
Power was being supplied. After this intensive check of steering rack was required, to access
and to remove the Electronically Motor Operated Power assisted steering rack, Removal of
Front Cross member was required, and Hence the Front cross member was removed and
Steering rack was Dismounted from the Cross member, Also removed Engine C mounting
Figure 8.4 REMOVED DAMAGED AND MALFUNCTIONING STEERING RACK
After removal of the steering Rack, and removal of Motor, upon opening the motor it was
observed that the motor was Burnt and needed replacement too. The Rack was sent to get
checked by Specialist person for the possible problem, and the person informed that the
steering was operated without motor assistance and also due to deteriorated rack and tie rod
rack assembly was damaged beyond any repairing hence entire rack replacement along with
the motor was needed, after customers consent entire steering Rack was Replaced. After
removal of steering Rack doors were kept locked as steering must not be moved at all else It
might lead to fine tuning problem, again front cross member along with the Engine C
mounting were installed and vehicle was tested on road, and after the confirmation of
resolution of problem the Vehicle was handed over to the Alignment department.

CHAPTER-9 BRAKES REPAIR

9.1 TATA INDICA VISTA
Problem : Severe Squeaks, Rattling sound, and Irresponsive brakes.
Cause : Completely worn out Brakes Pads and Deep Grooves on Brakes
Discs
Remedy : Replacement of Disc Brakes Pads and Brakes Disc
The Vehicle was received with, continuous Severe and Loud squeaks, Grinding Noise and
Rattles when brakes were applied, and also brakes were completely irresponsive.
There was no further investigation needed as Problem was appeared to be in the Brakes only.
Because The Vehicle was fitted with the Regular Steel Rim, it was necessary to remove the
wheel in order to inspect and observe brake disc surface clearly.
Upon Removing the Wheel, the first thing observed was a Deep Groove was formed around
the middle of the disc width, and the groove was adequately deep, and upon observing Brake
Pads condition, it was clearly visible that Brake pads Friction
Lining was worn out totally, due to which protruded metal
and remaining Pad with No brake Lining used to get in
contact with the Brake Disc, and hence disc was worn out
and also needed replacement because turning Brake disc
surface was not possible because to Nullify the effect of
groove, large amount of material removal was necessary,
which lead to excessively thin brake disc, which may not
function properly and can lead to danger to lives. Hence
replacement of Both the discs was necessary.
Hence Brake caliper Mounting Bolts were Removed, and the
caliper was Lifted Up and was fastened with metal cable, and Figure 9.1 DEEP ENGRAVED
cleaned the caliper sliding bolts. Pads were removed, after GROOVE WHICH FAILED THE
BRAKE ROTOR
this two bolts from the knuckle fastening caliper, and after
the removal the Disc assembly came off the Hub and new brake disc was fixed
Both the caliper pistons were compressed using a clamp and then placed both the pads on
either side of the brake disc and swiveled the Caliper back to its original place and tightened
the Mounting Sliding Bolts.
9.2 AUDI Q7 QUATTRO

Problem : Brakes Check warning appeared on the Infotainment system.
Cause : Worn Out Rear Brakes Pads.
Remedy : Replacement of Worn out brake pads.
The Vehicle was Received with Multiple complaints Including Brake check warning on
Infotainment system. Upon turning on the vehicle, it was visible on the Infotainment system
that rear brakes Needed attention, as rear brakes were being reflected in check system.

Upon checking the Rear Brakes, It was Clearly Visible

that Rear brakes pads were completely worn out and
needed replacement. Hence Started removing rear brakes
callipers, after opening the mounting sliding bolt, the
calliper could be swivelled and the pads were removed,
But the Pads had a sensor to Monitor the brake lining
wear, unlike ordinary brakes pads which are fitted with
wear indicator in form of metal protruded section which is
being brushed against the Brake disc and makes the Noise,
here the sensor in form of a wire or a cable could be seen,
and understood its function also, as the pads brake lining Figure 9.2 REMOVED BRAKE
wears off, the sensor gets close to the disc, and after the CALIPER
maximum recommended Wear, the sensor comes in contact
with wear and generates the warning signal to check the brakes
system with the information of a particular wheel also.
The rear brakes pistons could not be compressed using Normal
clamp. As these brakes are parking brakes, or handbrakes, and
they needed to be Revolved to get compressed and to compress
the while revolving, earlier six sided dice was used but here
Kennedy Right hand Brake winding toolkit was used. One or
its flange was penetrated with the threaded bar, and was kept
against the opposite side of brakes piston, and the once the
adaptor attachments projected parts set in the slots of the
brakes piston, winding them clockwise with Right hand was
done and finally pistons were compressed and the pads were set
in with the Sensor wire and again the calliper bolt was cleaned Figure 9.3 BRAKE CALIPER
and greased and was fitted again on both the sides and the WITH NEW BRAKE PADS AND
WEAR INDICATOR IN FORM
problem was resolved. And the brake check warning sign was OF RED WIRE
no more reflecting.

CHAPTER-10 MOST CHALLENGING

EXPERIENCE DURING TRAINING
10.1 AUDI Q7 QUATTRO ADAPTIVE AIR SUSPENSION
This Vehicle was Received with the Complaint of Severe Squeaks and Rattles during the ride
and when the Vehicle used to Pass over the pot hole or the Road Irregularity. Upon initial
Test Drive and Initial inspection, worn out Bushings of Adaptive Air suspensions Pneumatic
struts Upper and Lower Wishbones with Clear Cracks and Deterioration were Observed,
hence the Replacement of
these Worn out Bushings
was necessary.
But Separate Bushing

Kits were Not available
for these wishbones,
instead of that, Entire
Wishbones along with the Figure 10.2 WORN OUT BUSHING
bushings were needed, as
Figure 10.1 WORN OUT BUSHING bushings were Integrated and infused in the wishbones
itself, hence the conclusion was forwarded to the
customer, along with the Price of replacement Spares.
But customer did not agree to spend Large amount on Audi Provided genuine parts, instead
of that customer informed workshop that they will arrange these spares and after that the job
should be initiated. The next day customer visited the workshop and taken removed spares as
a reference to get new aprs. And after 5 days the Customer Visited the workshop along with
the Required Spares and informed workshop staff that He arranged these spares from
Mumbai, and these spares are not Genuine from Audi but these Spares are Manufactured by
the manufacturer who supplies spares to the Audi and then Audi after Branding these spares,
introduces to the market.
Figure 10.3 ANGLE MEASUREMENT SENSOR MOUNTED BETWEEN UPPER ARM AND AIR SPRING
After receiving these spares, the work was resumed on the vehicle and after 5 hours, the
vehicle was fitted with new Lower and Upper wishbones. And was ready to be taken for the

test drive. And there was no noise at all when the vehicle was being tested on Rough patch of
Road after Setting Vehicle to the Off Road Mode. The Vehicle was driven for several
kilometers with new Front suspension wishbones, and after ensuring totally noise free Drive,
the Vehicle was brought back to the workshop.
Figure 10.4 VALVE TO INFLATE AND DEFLATE PNEUMATIC SPRING
After Almost a Couple of Hours the some technicians Observed that the Vehicle was High in
Rear and the Vehicle was Low in Height from the Front. And it was Observed that the Rear
Pneumatic Springs were Inflated but front Pneumatic Springs were deflated, and were much
shorter compared to rear pneumatic Springs. After turning on the engine and again selecting
Off Road mode using Dial, slowly the front of the Vehicle gained height and became equal to
the rear. And all four springs were then equal in length. And then the vehicle was kept for a
couple of hours
After the couple of Hours, again the same problem was observed as front two pneumatic
springs Couldnt retain their Height, and Vehicle was Lowered in Height from front
compared to the rear. To verify whether it was a Normal phenomenon or not, upon calling
and knowing from the customer, this was the Problem after Wishbones replacement only,
Earlier this Problem never used to take place. Hence it was necessary to address and trace the
Problem started after the Replacement.
Hence to check any possible Problems or error codes, and to check the reference values,
Bosch KTS 570 Diagnostic System was Utilized but there were no Problems observed there
and No error Codes were Generated, after that VCDS Diagnostic System was used to check
any possible problem but No problems were observed there also and No error code could be
seen and all the reference values were within their limits.
After that, thorough checking was done to the Air Hoses, which connected Air Pump under
the Driver sear underneath the body and Modulator to the Pneumatic Strut(Spring)(Shock
Absorber) for Any possible Damage upon Observing that there was No Damage, hoses were
fixed again and again the Off road Mode was activated and front suspension Gained the
Height. And then the Engine was turned off, and after checking the suspension system

condition after a couple of Hours, front pneumatic springs(Shock absorbers) couldnt retain
their Height and were dropped down in Height.
After this to check the possible Air leakage, a Special Mixture of Liquid soap and Water was
prepared, and was Sprayed on entire Strut assembly, and also to the crucial Joints and hose
connections. To verify that These assemblies were Intact. After sprinkling and covering all
hoses and connections and Valves with Mixture, no bubbles were Observed hence there was
no Leakage at all.
After this again newly fitted Upper and Lower wishbones were Removed and Both
Pneumatic Springs were removed. And Checked for the Leakage. No other parts except
Pneumatic Springs, Wishbones, And Outer end of Air Hose and Sensor Mounted on the
Upper wishbone which has got its other end connected to the Strut, Steering Knuckle, Disc
brake assembly. Hence attention was focused in these parts only especially, Strut, Air Hose,
and Strut Valves, Upper and Lower wishbones and Angle measurement sensors on the
suspension assembly.
Removed all Subassemblies and
checked every single component
thoroughly, and fitted them
Properly, and after that again
activated the Off road Mode and
Checked whether front
suspension could retain their
Height or Not, But again after an
Hour, front suspension couldnt
maintain its height and was
dropped down. Meanwhile the
customer Visited the workshop
and scolded for the persisted
problem.
Again Removed entire front
suspension Subassemblies
,removed front Struts, and
Decided to Check Entire
Figure 10.5 REMOVAL OF PNEUMATIC SPRING REVEALS Pneumatic Spring By
NEWLY INSTALLED LOWER ARM Submerging in water completely,
to trace even the tiniest Leakage,
strut were filled with air and were submerged in water and checked for their Leakage, But
there was No Leakage at all. After this the suspension was Installed again, and Kept the
Angle measurement sensor loose, same result acquired and height was lost.
But then the angle measurement sensor was kept at smaller angle than where it used be
Mounted by using duct tape. And that was Bulls eye, even after Many Hours suspension
retained its height and didnt lose its height, hence arrived to the conclusion that the problem
was with the sensor Angle. And it led to the conclusion that New arms might be different in
dimensions due to which the angle was varied to which sensor should be mounted, and the
sensors base position angle was changed, due to which Suspension Control Module might
have received varied reference value and due to which system Might have considered that

Pneumatic Springs were over Inflated, and as a

correction it used to Remove the Air, and deflate
the Strut.
When the problem was shared with the Customer
He was Not ready to accept it, hence he was
informed from the workshop to Bring those
replaced arms which he took for as a sample which
he didnt bring back instead he brought new Spares
only, after 4 days those Old replaced arms were
received, and they were compared with new Arms,
and it was found that New upper arm was shorter
than the old arm. Also compared the Camber value
to the Manufacturer recommended value, but after
installing these new arms, there was as large as 2
was observed. hence theoretical reason seemed to
be correct, and to verify the same, The Vehicle was Figure 10.6 GREEN AIR HOSE CONNECTING
fitted with Old Upper and Lower Arms, to check PNEUMATIC SPRING TO THE INFLATION
MODULATOR
whether vehicle front suspension Retains and
sustains its height or not, but after application of
Old arms, Vehicle was perfectly alright and didnt lose its height from Front, and after as
Long as 16 days the Vehicle Problem was resolved.

CHAPTER-11 LIKES AND DISLIKES

ABOUT ORGANIZATION
11.1 LIKES:
Healthy Working environment, and Daily motivation towards work and new
information every morning during morning meeting
Availability of All the necessary Spares, Never had to use any other Spares for any
particular use for which it was not intended.
Extra ordinary discipline, of entire staff as MD himself was grown up and Belongs to
the defence background, under the Discipline of defence.
Amazing exposure to the Vehicles, because of established higher service standards,
and workshops reliability, car owners used to bring their extremely expensive vehicles
without any hesitation
Incentive and Penalty system, First time observed Implementation of system
effectively and saw miracles.
Extremely friendly staff, and warm greetings to the customer. And Vigorous follow
ups by service advisors to ensure work is being carried out according to calculated
schedule.
Freebies to customers to ensure their safety and peace of mind as Anti rain windshield
coating to ensure crisp vision in rain, and Battery terminal coating to prevent
formation of scale.
Complete transparency by Returning the replaced parts to the customer, considering
the value of these parts in terms of their weight as scrap if not returned to the
customer, it can generate huge amount of revenue at the end of the year. But instead
its returned to the customers.
Extra ordinary cleanliness in entire workshop.
Ethical Repairing and Maintenance. As never observed any service advisor
misleading customer or exaggerating the problem to overcharge the simple job.
Restoration culture, as and when it was possible to restore the spares or assemblies
without compromising on passengers safety, restoration was done to reduce the cost
and to make repairing affordable.
Zero compromise policy in repairing and spares quality, and only genuine spare
boosts up repairing reliability.
Never seen before, 6 months warranty of fitted spares, even Manufacturer authorized
workshops dont provide such warranty, which increases confidence in Customer and
leads to peace of Mind
11.2 DISLIKES:
Poor ambient Lightning in the workshop except the bays next to natural source of
light like bays near main entrance.
Poor air Ventilation, this problem was felt quite a few times as suffocation.
Although availability of all the required and modern spares, it was observed that most
of pneumatic guns and electric guns were not functional because of some of the
technicians who were observed to use the tools in the manner they must not be used or
handled. and no one was bothered to get them repaired also.

Even though regular updates, and informative tips were forwarded to the service
advisors and technicians, in many cases it could be seen that they were using wrong
grade of fluids, and coolant in wrong proportion of dilution.
In many cases it was observed that Vehicle lifts were occupied wrongly. Sometimes
without calculation and estimation of time vehicle used be mounted on lift and
remained idle for whatsoever reasons, but this could have been avoided if Smarter
planning could have been done. And productive working hours could have generated
more revenue.
For a Phase of 15 days, it was observed that there was a huge problem of wiring
which led to electric shock every now and then, that kept everyone on threat and due
to which technicians were cautious, and no earth leakage protection was observed
during these 15 days.
Sometimes just to keep the Vehicle lift occupied, and to avoid further waiting for
technicians turn to use the lift, many technicians occupied lift wrongly by placing
vehicle on lift and disassembling assemblies and then they used to wait for the spares
and this way they didnt utilize their resources efficiently.
Spares were often received late and almost 4o% of times, in case of requirement of
any special spare, spare either used to get late or wrong spare used to be received.
Sometimes it was observed that in presence of all necessary tools, some non scientific
ways and mishandling of tools were observed, for example, to remove the door trims,
clips and plugs, in presence of their removers some technicians removed them with
screw driver or any such tools which were not meant for that purpose and hence
damage to the finishing.
No in house washing facility.
Many times, vehicles with the problem of smoke, emission or any such issues were
kept inside workshop with Running engine, that led to severe suffocation, and that
was extremely hazardous to the health. A rule should be introduced to avoid such
incidents
Though seat covers and steering covers are provided to each technician, some
technicians didnt use them at all, which led to staining and soiling of seat cover,
interiors, upholstery and steering, this could have been avoided.

REFERENCES
AUTOMOTIVE MECHANICS
WILLIAM. H. CROUSE & DONALD. L. ANGLIN
ISBN : 978-0-07-063435-0
A TEXTBOOK OF AUTOMOBILE ENGINEERING

P. S. GILL
ISBN : 978-9-35-014276-9
AUTOMOBILE ENGINEERING
R. B. GUPTA
ISBN : 817-7-68-4858-1

R. K. RAJPUT
ISBN : 81-7008-991-3

ER. S. K. GUPTA
ISBN : 978-93-83746-91-0

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A REPORT ON

As a Part of curriculum in 5th semester

DEPARTMENT OF AUTOMOBILE ENGINEERING

This is to certify that Industrial Training work embodied in this

report, was carried out by Mr. Ravani Abhishek Ashokbhai at ROGER

MOTORS as a part of curriculum Industrial training (3350201) in 5th

semester Diploma Automobile Engineering under curriculum of Gujarat

Signature and Name of Officer Signature and Name of

Seal of Industry Seal of Institute

Examiners Certificate of Approval

The Training Report submitted by Mr. Ravani Abhishek

curriculum Industrial Training (3350201) in the 5th semester Diploma

Automobile Engineering term ending in October 2015 at Atmiya Institute

Training work submitted by student are satisfactory.

Internal Examiner External Examiner

After spending four months in ROGER MOTORS for my training I could

In the following report content I have tried to compile my experience,

I would especially like to thank Mr Kripalsinh Jadeja(M.D), Mr

Figure 1.1 ROGER MOTORS HEADQUARTERS

ROGER The Organization which Overwhelmed the Expectations of those who

Department of Automobile Engineering - AITSDS Page - 1

1.2 CORE PURPOSE

1.3 CORE VALUES

1.4 MILESTONES OF THE JOURNEY

Department of Automobile Engineering - AITSDS Page - 2

1.5 CONCEPT OF ROGER GALLERIA (Techssories)

1.6 GEMS OF THE CROWN

Figure 1.2 BOSCH TROPHY

1.7 PATENTED PRODUCTS

ROGER WIPER STAND Another Revolutionary product

Figure 1.5 ROGER

Department of Automobile Engineering - AITSDS Page - 3

1.8 AWARDS AND ACHIEVEMENTS

Figure 1.7 MR KRIPAL SINH ACCEPTING MSME

Figure 1.6 NATIONAL AWARD BY MSME

2011: Award For Outstanding Small Scale Industry Entrepreneurship for

Figure 1.8 MR KRIPAL SINH ACCEPTING AWARD FROM SHREE

Department of Automobile Engineering - AITSDS Page - 4

Figure 1.9 OUTSTANDING SSI

Figure 1.11 AWARD BY TATA MOTORS

Department of Automobile Engineering - AITSDS Page - 5

CHAPTER -2 WORKSHOP LAYOUT

Figure 2.1 ROGER MOTORS CURRENT LAYOUT

Department of Automobile Engineering - AITSDS Page - 6

Department of Automobile Engineering - AITSDS Page - 7

2.2 WORKSHOP MODIFIED LAYOUT

Figure 2.2 ROGER MOTORS MODIFIED LAYOUT

Department of Automobile Engineering - AITSDS Page - 8

2.3 MODIFIED WORKSHOP LAYOUT EXPLAINATION

Current Layout is Nearly Perfect and Space Utilization is Optimal according to

Department of Automobile Engineering - AITSDS Page - 9

Kripal Sinh Jadeja (M.D)

Figure 3.1 ROGER MOTORS HIERARCHY

Department of Automobile Engineering - AITSDS Page - 10

3.2 ROGER HIERARCHY AND WORKFLOW

Department of Automobile Engineering - AITSDS Page - 11

CHAPTER-4 TOOLS & FACILITIES

4.1.1 MANATEC RHINO TWO POST CAR LIFT 3.2L

RHINO 3.2L TWO POST CAR LIFT

Figure 4.1 TWO POST LIFT

Vehicle Setup Time on this Lift is more

Department of Automobile Engineering - AITSDS Page - 12

4.1.2 ELGI WHEELS FREE SCISSORS LIFT

ELGI WHEELS FREE SCISSORS LIFT