1.

INTRODUCTION TO COMPANY
 TATA MOTORS:

Fig: 1.1 Symbol Of Tata Motors

 Tata Motors Limited is an Indian multinational automotive manufacturing

company headquartered in Mumbai, India, and a member of the Tata Group. Its
products include passenger cars, trucks, vans, coaches, buses, sports cars,
construction equipment and military vehicles.

 Tata Motors has auto manufacturing and assembly plants

in Jamshedpur, Pantnagar, Lucknow, Sanand, Dharwad, and Pune in India, as well
as in Argentina, South Africa, Great Britain and Thailand. It has research and
development centres in Pune, Jamshedpur, Lucknow, and Dharwad, India and in
South Korea, Great Britain and Spain. Tata Motors' principal subsidiaries
purchased the English premium car maker Jaguar Land Rover (the maker of
Jaguar and Land Rover cars) and the South Korean commercial vehicle
manufacturer Tata Daewoo. Tata Motors has a bus-manufacturing joint venture
with Marcopolo S.A. (Tata Marcopolo), a construction-equipment manufacturing
joint venture with Hitachi (Tata Hitachi Construction Machinery), and a joint

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 venture with Fiat Chrysler which manufactures automotive components and Fiat
Chrysler and Tata branded vehicles.

 Tata Motors is listed on the (BSE) Bombay Stock Exchange, where it is a

constituent of the BSE SENSEX index, the National Stock Exchange of India, and
the New York Stock Exchange. The company is ranked 226th on the Fortune
Global 500 list of the world's biggest corporations as of 2016.

 Founded in 1945 as a manufacturer of locomotives, the company manufactured its

first commercial vehicle in 1954 in a collaboration with Daimler-Benz AG, which
ended in 1969. Tata Motors entered the passenger vehicle market in 1991 with the
launch of the Tata Sierra, becoming the first Indian manufacturer to achieve the
capability of developing a competitive indigenous automobile. In 1998, Tata
launched the first fully indigenous Indian passenger car, the Indica, and in 2008
launched the Tata Nano, the world's cheapest car. Tata Motors acquired the South
Korean truck manufacturer Daewoo Commercial Vehicles Company in 2004 and
purchased Jaguar Land Rover from Ford in 2008.

 On 17 January 2017, Natarajan Chandrasekaran was appointed chairman of the

company.

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 TATA M OTORS
PASSEN G ER
ZE VEHICLE
ST

B Fig: 1.2 Tata Motors Passenger Vehicles N

O A
LT N
O

A IN
RI D IC
A A

NE IN
XO DI
N GO

SAF TI
ARI AG
O

S TI
U G
M H OR
O E
X
A

3
 Acceleration
Top Speed
Car Modal (0-100 Km/H) Cc Maximum Power
(Km/H)
(Second)

Nano 105 12.6 624 37.5bhp@5500+/-250rpm

Indica 155 14.5 1396 69.01bhp@4000rpm

Indigo 154 16.5 1396 69.01bhp@4000rpm

Tiago Diesel 150 16 1047 69bhp@4000rpm

Tiago Petrol 160 11 1199 84bhp@6000rpm

Tigor Diesel 148 16.5 1047 69bhp@4000rpm

Tigor Petrol 164 10.5 1199 84bhp@6000rpm

Zest Diesel 158 15 1248 74bhp@4000rpm

Zest Petrol 154 17 1193 88.7bhp@5000rpm

Bolt Diesel 160 14 1248 74bhp@4000rpm

Bolt Petrol 158 16.5 1193 88.7bhp@5000rpm

Nexon Diesel 158 15 1497 108.5bhp@3750rpm

Nexon Petrol 160 11 1198 108.5bhp@5000rpm

Sumo 125 27.6 2956 83.8bhp@3000rpm

Safari 160 14 2179 148bhp@4000rpm

Hexa 165 13.7 2179 147.94bhp@4000rpm

Table: 1.1 Car specifications(1)

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 No. Of Gear
Car Modal Maximum Torque Drive Type
Cylinders Box

Nano 51Nm@4000+/-500rpm 2 RWD 4

Indica 140Nm@1800-3000rpm 4 FWD 5

Indigo 140Nm@1800-3000rpm 4 FWD 5

Tiago Diesel 140Nm@1800-3000rpm 3 FWD 5

Tiago Petrol 114Nm@3500rpm 3 FWD 5

Tigor Diesel 140Nm@1800-3000rpm 3 FWD 5

Tigor Petrol 114Nm@3500rpm 3 FWD 5

Zest Diesel 190Nm@1750-3000rpm 4 FWD 5

Zest Petrol 140Nm@1500-4000rpm 4 FWD 5

Bolt Diesel 190Nm@1750-3000rpm 4 FWD 5

Bolt Petrol 140Nm@1500-4000rpm 4 FWD 5

Nexon Diesel 260Nm@1500-2750rpm 4 FWD 6

Nexon Petrol 170Nm@1750-4000rpm 3 FWD 6

Sumo 250Nm@1000-2000rpm 4 RWD 5

Safari 320Nm@1700-2700rpm 4 2WD and 4WD 6

Hexa 320Nm@1700-2700rpm 4 2WD and 4WD 6

Table: 1.2 Car specifications(2)

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2. INTRODUCTION TO DEALERSHIP

 CAMA MOTORS PVT LTD:

Fig: 2.1 Symbol Of Cama Motors

 The history of cama motors is a tale of personal conveyance in ahmedabad.This

arduous journey towards the unchartered land began nearly hundred and twenty
years ago with the opening of a bicycle shop

 The persevering zeal and the entrepreneurial vision rustom cama to Ahmadabad
the ford motors dealership in 1931.in 1945,cama motors set up their own
premises. An authorised sales and service dealership, Cama Motors Pvt Ltd in
Ahmedabad has been in the business ever since the year 1940. In a short span of
time, the place made a name for itself as well as increased its patrons base
tremendously. Ever since its inception, the showroom has always ensured that it
maintains a high standard when it comes to servicing its guests. The establishment
endeavours to achieve the highest level of customer satisfaction and improving the
buying experience for its customers. During its time in the business, the company
has constantly made evident effort to keep abreast with the needs of the customers
alongside the growing market. Understanding that options are galore, this

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 showroom makes the researching, buying and selling as well as post sales
engagements easy and uncomplicated.

 The dealer showroom is located at in Lal Darwaja. Locating it is as easy as it gets

as it stands Rustom Cama Marg - a major landmark in the area. Undoubtedly this
is one of the best Car Dealers

 Cama Motors Pvt Ltd meets all the requirements that one can possibly have in
terns of four-wheeler vehicles. Apart from ensuring the sales of these vehicles, the
outlet also offers post sale services. The sales staff employed here pays keen
attention to the requirements of the potential buyers and makes appropriate
suggestions by explaining the features, specifications and pricing of the vehicles.
Those looking to change or replace parts of their cars can approach the center as
they also deal with various authentic car accessories. It undertakes repairs and
services for a majority of the car models.

3. LAYOUT OF WORKSHOP

Fig: 2.2 Cama Motors

PARKING PARKING
CAMARRO
TRAVELS

ENTRY
SHOWROOM
NANO
SHOWROOM

SPARE PARTS
7 SHOP M.D.
OFFICE
P.A.
OFFICE
SHOWROOM T
BATTER OFFICE
SM FRONT OFFICE
GM OIL ROOM PAINT O L
Y AND
STOR
WASHING OFFCE PIT
TOOL
OFFICE
WORKE
COMPRESSOR BOOTH I I
BALAN
E
SPECIAL
BOOTH
ROOM
R'S
ENGINE
ASM L F
ROOROOM
TOILET
CING
TOOL
LIFT
E T
ROOM
ROOM
OFFICE
ROOM
M
ROOM T
 T
OI
TTGUUHJ
LE
T

BSM
OFFICE
CUSTOMER
LAUNGE

WM
OFFICE

E
X
I
T

LIFT

LIFT

LIFT
LIFT
BODY SERVICE
SHOP AREA
AREA

ALIGMENT M/C

Fig: 3.1 Layout Of Workshop

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4. WORKSHOP FACILITIES
 CUSTOMER LAUNGE
 WORKER'S ROOM
 FIRST AID KIT
 ENGINE ROOM
 VALUE CARE SERVICE
 EXTENTED WARRNTY SYSTEM
 ONLINE SERVICE APPLICATION
 24*7 WORKING DAYS
 GENERAL CAMPS
 BREAKDOWN SERVICE
 HOME VISITS
 DIAGNOSTIC EXPERT
 HOME SERVICECILITY
 FIRE EXTINGUISHER
 NO SMOKING ZONE IN WORKSHOP
 PICK & DROP FACILITY
 WASHING BOOTH
 WARRNTY ROOM
 ADVANCE BOOKING SYSTEM
 EXCTING VIDEO WALL
 FREE WIFI
 TEA-COFFEE BAR
 INSURANS RENEWAL FACILITY
 PAINT BOOTH
 SPECIAL TOOLS ROOM
 GIFTS FOR SPECIAL CUSTOMER
 ONLINE JOB CARD MAKING SOFTWARE
 STORE

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 CUSTOMER LOUNGE

 An customer lounge is a facility operated at workshop. Customer lounge offer, for

selected passengers, comforts beyond those afforded in workshop itself, such as
more comfortable seating, quieter environments, and often better access to
customer service representatives. there is AC,TV,sofa in the launge for sustomers'
comfortable seating

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 Fig: 4.1 Customer Lounge

 WORKER'S ROOM

 workers room is a place where technician change there clothes, having lunch and
rest in free time

 FIRST AID KIT

 A first aid kit is a collection of supplies and equipment that is used to give medical
treatment. Medication can be a controversial addition to a first aid kit, especially if
it is for use on members of the workers

 ENGINE ROOM

 this is special room where the remove engines are safely put, engine work like
change the piston,crank,connecting rod, engine head, block is done.

 VALUE CARE SERVICE

 The AMC Service from Tata Motors Limited is known as Suraksha and it ensures
that the customer can focus entirely on his core business while leaving work
related to vehicle maintenance to the experts at Tata Motors.

 AMC or Annual Maintenance Contract is a facility provided to a Commercial

Vehicle buyer wherein TML provides maintenance and repair services to the
customer at the specified National Highways through the Service outlets of its
authorized dealers or Tata Authorized Service Stations (TASS). Under the AMC
scheme the customer has the option to choose from various AMC packages. The

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 coverage specified in each of the AMC packages may vary from a comprehensive
AMC package to coverage of only scheduled services or only labor.

Fig: 4.2 Value Care

 EXCTING VIDEO WALL

 A big colour LED tv in the customer lounge so the customer can see the
movies,music etc.so they are not boar during the car is under maintance and
waiting in lounge

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 Fig: 3.3 LED TV

 EXTENTED WARRNTY SYSTEM

 We bring to you, a program to secure your car against unforeseen breakdowns and
repair bills, even after the original warranty is over. You can extend your original
warranty by one or two more years through our Tata Motors Extended Warranty
Program. This will cover mechanical and electrical breakdown on your Tata
Vehicle and it starts immediately after expiry of the original warranty.

 24*7 WORKING DAYS

 Speed -O- Service aims to provide service to the customers with shortest
turnaround time (90 mins) for scheduled services & minor repairs of their
vehicles.and 365 working days

 ONLINE SERVICE APPLICATION

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 In order to provide convenient and hassle free service to our customers, we bring
you this facility of booking your service online. We want to make sure that you
can book your service from anywhere, anytime and at a workshop of your choice.

Fig: 4.4 Online Service

 GENERAL CAMPS

 this is free general camps,in this camp cars free genersl cheke up is done and car
top washing is free

 HOME SERVICECILITY

 Tata Motors Service brings you a Unique Service experience in the form of Door
Step Service (DSS).

 The Door Step Service Van is a self-sustained standalone workshop-on-wheels

equipped with all the necessary workshop tools and equipments which are
required to perform scheduled services & minor repairs on your vehicle. To ensure
that our customers enjoy the Tata Motors Service at their convenience, the DSS
Van will actually come to a location comfortable for the customer and get the
repairs done.

 BREAKDOWN SERVICE
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 This is a pan India breakdown and towing assistance program that is serviced by a
dedicated network of over 2,700 authorized service providers and can be accessed
through a toll free helpline - 1800 209 7979. A quick response is ensured within
60 minutes in city limits and within 120 minutes on highways and other places.
This service is provided free of cost till the warranty period of your car.

 FIRE EXTINGUISHER

 A fire extinguisher is an active fire protection device used to extinguish or control

small fires, often in emergency situations.

 STORE

 TOP refers to ‘Tata Motors Original Parts’. We provide highly reliable and
competitively priced spare parts at our dealerships. We provide warranty for spare
parts for 6 months or 10,000 kms. whichever is ealier. In addition, we have also
designed variety of repair kits for the customers, which can be easily customized
according to their needs and requirements. These kits bring down the cost of parts
and also provide convenience for repair. We have 200 different repair kits
available for the customers. Tata Motors conducts checks at their authorized
dealerships to ensure that the dealers are stocking TOPs through our field team.

Fig: 4.5 Store

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 WASHING BOOTH

 In washing booth car is fully washes.thier is intriar,extriaer and tire is washing and
polishing.

Fig: 4.6 Washing Booth

 DIAGNOSTIC EXPERT

 Diagnostic Expert cum Trainers (DET) are available across our dealerships. DETs
are provided with extensive training by TATA Motors wherein they are equipped
with diagnostics skills and exhaustive knowledge of all our products. DETs are
capable of resolving both mechanical & electrical critical complaints in the best
way and shortest time possible.

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 5. WORKSHOP HIERARCHY CHART

SCS G A EE U E S RR SNS VV T I E S IIO CCR T MAEEA N E R

TTHD I A A G M N O S I C
MRA T ED SA L V E AN L IR TS A V IO GO I CR N E( S
LEE E L AE C D T E R R I C I A
MH EM I R P A A ( SN N M A A G) G E
(CLSN T A L ) )
(M( E K N R R A A( ( LNAG U P SAM TI MTG T ) E) R (
THP ( J ME U C AN H I E TN D H I C I I A
(SCP HAI R R TA EM , EZM L)A , A K NI A TL
NE I( D L E Y T )
V(P U C EA MH S G HA E H I T T E I A YL AL I )
RCR( D I S H I RA ) V A L
KS H U A AL RK) MA R A )
PAS AO T L E A L N ) K I )
N I )
N Fig: 5.1 Workshop Hierarchy

17
6. TYPES OF MAJOR AND MINOR EQUIPMENTS

ELECTRIC LIFT FOR CAR SERVICE

 A car ramp provides a simple method of raising a vehicle from the ground in order
to access the underneath of the vehicle

 The most important point of the car ramp it's safety, for cars can be kept very
stable on top of them.

 must be care that the car is properly fix in the ramp

 the ramp is go up and down so the car is on ramp is up and down,therefor we do

car's under body work easily

 the ramp capacity is about 3500 kg

 Operating controls are designed to close when released.

 Do not block open or override them.

 Never overload your lift. Manufacturers rated capacity is shown on nameplate

affixed to the lift.

 Positioning of the vehicle and operation of the lift should be done only by trained
and authorized personnel.

 Never raise vehicle with anyone inside it. Customers or bystanders should not be
in the lift. During operation.

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 ALIGMENT MACHINE

 Wheel alignment, sometimes referred to as breaking or tracking, is part of

standard automobile maintenance that consists of adjusting the angles of wheels
so that they are parallel to each other and perpendicular to the ground.

 The purpose of these adjustments is to reduce tire wear, and to ensure that vehicle
travel is straight Alignment angles can also be altered beyond the maker's
specifications to obtain a specific handling characteristic.

 Wheel Alignment is often confused with Wheel Balancing.

 The two really have nothing to do with each other except for the fact that they
affect ride and handling. If a wheel is out of balance, it will cause a vibration at
highway speeds that can be felt in the steering wheel and/or the seat.

 If the alignment is out, it can cause excessive tire wear and steering or tracking
problems

 The primary angles are the basic angle alignment of the wheels relative to each

Fig: 6.1 Electric Lift

other and to the car body. These adjustments are the camber, caster and toe.[1] On
some cars, not all of these can be adjusted on every wheel.

19
 These three parameters can be further categorized into front and rear (with no
caster on the rear, typically not being steered wheels)

Fig: 6.2 Alignment Machine

ENGINE CRANE

 The engine crane is commonly used in combination with the engine stand so that
the removed engine can be rotated in midair to provide access to underside
surfaces of the engine

 An engine crane is a common repair tool used in vehicle repair shops to remove or
install gasoline or diesel engines in small and crowded vehicle engine

compartments.

 It uses a heavy cantilevered support structure to hold the engine in mid-air so that
the mechanic can carefully connect or disconnect fragile hoses and wires on the
engine to the frame of the vehicle.
 Engine cranes are typically mounted on large casters so that an engine can be
lifted straight up out of an engine compartment and then rolled away from the
immobile vehicle frame.

20
 Engine cranes are typically mounted on large casters so that an engine can be
lifted straight up out of an engine compartment and then rolled away from the
immobile vehicle frame.
 Most engine cranes are equipped with a telescopic boom which can be extended to
reach engine blocks located further into the engine compartment. At the end of the
boom there is a grab hook where lifting chains, slings or a load level can be
attached for lifting purposes.
 The engine crane is commonly used in combination with the engine stand so that
the removed engine can be rotated in midair to provide access to underside
surfaces of the engine.

Fig: 6.3 Engine Crane

ROBINER

 R-12, the Freon that was commonly used in cars up to the mid-'90s, was
dangerous to the ozone layer.
 For the above reasons, a new refrigerant that is less harmful to the environment
was needed because of the unintentional leaks (such as a blown hose in a vehicle's
air conditioning system).
 A new refrigerant called R-134 was produced. R-134 is far less harmful although
still not totally safe.

21
 This is the refrigerant that is used in vehicles to date.
 The race is still on to find something better.
 All types of liquids have been tested--even propane.
 So far they all have significant disadvantages--not so much to the environment,
but for safety issues or cost factor.

AC gas charge machine(robiner)is use for following function:

 refrigerant recovery vacuums

 with oil charge/drain function

 pressure/weight protection, safe operation

 lcd displayer offer operation & service prompt

 charge with high and low side gauge, cylinder gauge, etc.

 precise weight scale to ensure precise recovery & charge

 BALANCING MACHINE

Fig: 6.4 Robiner

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 As the part is rotated, the vibration in the suspension is detected with sensors and
that information is used to determine the amount of unbalance in the part.
 Along with phase information, the machine can determine how much and where
to add or remove weights to balance the part
 Unbalance correction is achieved by means of graded lead weights with integral or
separate clip, or by means of graded or infinitely variable adhesive weights.
 The machines are used in large volume production in mixed or batch mode.
 The machines can be interlinked with other plant components such as: valve
insertion systems, tyre mounting, inflating and matching machines, tyre bead seat
stabilisation machines, additional residual unbalance checking machines, etc.

 Keep your hands and the other parts of your body from the location with the
potential danger. Before starting the machine, you must check it there existing the
damaged part. If any break or damage, the machine will not be used.
 Before balancing, operators should check all the tires and wheels to find the
possible faults. Do not balance the tires and wheels with fault.
 Before balancing, you must confirm the installation of the wheel suitable. Before
rotation, be sure the nut turn 4turns around the thread shaft and firmly locked on
the main shaft.

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 Fig: 6.5 Balancing Machine

 BATTERY CHARGER MACHINE

 battery charger machine is a instrument which is externally charge the battery

 there are 2 regulator is given in the machine
 one is for voltage regulator and second is for current regulator
 There are two basic types of lead-acid battery charger: FLOAT chargers and 3-
STAGE CHARGERS.
 Float chargers also come in two versions - good ones and bad one A good FLOAT
charger charges the battery at a constant current until the 'FLOAT' voltage (13.8V
or 27.6V) is reached, then it progressively reduces the current to maintain that
voltage.
 A bad FLOAT charger commences charging at the rated current but as the battery
takes the charge, its voltage rises and the current drops off long before the float
voltage is reached.
 Thus, even 75% capacity takes a long time to restore and full charge takes forever.
By far the best type of charger is the 3-STAGE CHARGER.
 This starts charging like a good float charger but continues charging at constant
current until the 'BOOST VOLTAGE' (14.4V or 28.8V) is reached.
 Then, the current is progressively reduced until it drops to one quarter of its
maximum. This corresponds to 90% capacity in the battery.

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 The charger voltage now changes automatically to the float voltage where it then
remains, slowly restoring the last 10% capacity.

COMPRESSER

 An air compressor is a device that converts power into potential energy stored in
pressurized air.
 an air compressor forces more and more air into a storage tank, increasing the
pressure.
 When tank pressure reaches its upper limit the air compressor shuts off.
 When tank pressure reaches its lower limit, the air compressor turns on again and
re-pressurizes the tank.
 An air compressor must be differentiated from an air pump which merely pumps
air from one context (often the surrounding environment) into another (such as an
inflatable mattress, an aquarium, etc.).
 Air pumps do not contain an air tank for storing pressurized air and are generally
much slower, quieter, and less expensive to own and operate than an air
compressor.

 Compressors can be classified according to the pressure delivered:

Fig: 6.6 Battery Charger Machine

25
 Low-pressure air compressors (LPACs), which have a discharge pressure of 150
psi or less
 Medium-pressure compressors which have a discharge pressure of 151 psi to
1,000 psi
 High-pressure air compressors (HPACs), which have a discharge pressure above
1,000 psi

Fig: 6.7 Compressor

HYDRAULIC PRESS

 A hydraulic press is a device using a hydraulic cylinder to generate a compressive

force
 The hydraulic press depends on Pascal's principle: the pressure throughout a
closed system is constant.
 One part of the system is a piston acting as a pump, with a modest mechanical
force acting on a small cross-sectional area
 A fluid, such as oil, is displaced when either piston is pushed inward.
 Since the fluid is incompressible, the volume that the small piston displaces is
equal to the volume displaced by the large piston. This causes a difference in the
length of displacement, which is proportional to the ratio of areas of the heads of
the pistons, given that volume = area × length.

26
 Therefore, the small piston must be moved a large distance to get the large piston
to move significantly.
 The distance the large piston will move is the distance that the small piston is
moved divided by the ratio of the areas of the heads of the pistons.
 This is how energy, in the form of work in this case, is conserved and the law of
conservation of energy is satisfied.
 Work is force applied over a distance, and since the force is increased on the larger
piston, the distance the force is applied over must be decreased.

HYDRAULIC JACK

 Hydraulic jacks are typically used for shop work, rather than as an emergency jack
to be carried with the vehicle

 Use of jacks not designed for a specific vehicle requires more than the usual care
in selecting ground conditions, the jacking point on a vehicle, and to ensure
stability when the jack is extended.

 A hydraulic jack uses a liquid, which is incompressible, that is forced into a

cylinder by a pump plunger.

 A hydraulic jack uses a liquid, which is incompressible, that is forced into a

Fig: 6.8 Hydraulic Press

cylinder by a pump plunger.

27
 Oil is used since it is self lubricating and stable. When the plunger pulls back, it
draws oil out of the reservoir through a suction check valve into the pump
chamber.

 When the plunger moves forward, it pushes the oil through a discharge check
valve into the cylinder.

 The suction valve ball is within the chamber and opens with each draw of the
plunger. The discharge valve ball is outside the chamber and opens when the oil is
pushed into the cylinder.

 At this point the suction ball within the chamber is forced shut and oil pressure
builds in the cylinderHydraulic jacks are typically used for shop work, rather than
as an emergency jack to be carried with the vehicle.

Fig: 6.9 Hydraulic Jack

WASHING GUN

  washing gun is a one kind of nozzle which is used in car washing plants
 its develop the high presser and water Patten
 in washing gun about 250 to 300 psi presser is produce

28
 he basic pressure washer consists of a motor that drives a high-pressure water
pump, a high-pressure hose and a trigger gun-style switch.
 Just as a garden hose nozzle is used to increase the velocity of water, a pressure
washer creates high pressure and velocity.
 The pump cannot draw more water from the pipe to which the washer is
connected than that source can provide:
 the water supply must be adequate for the machine connected to it, as water
starvation leads to cavitation damage of the pump elements.
 Different types of nozzles are available for different applications. Some nozzles
create a water jet that is in a triangular plane,others emit a thin jet of water that
spirals around rapidly
 Nozzles that deliver a higher flow rate lower the output pressure. Most nozzles
attach directly to the trigger gun.

Fig: 6.10 Washing Gun

AIR GUN

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 A pneumatic bolt tightening gun is air powered tool or pneumatic powered tool is
one type of power tools, driven by compressed air, supplied by an air compressor
one type of gas compressors.
 It can be also driven by compressed carbon dioxide (CO2) stored in small
cylinders allowing for portability. Pneumatic tools are safer to run and maintain
than their electric power tool counterparts, as well as having a higher power-to-
weight ratio, allowing a smaller, lighter tool to accomplish the same task.
 This tool easy to use for bolt tightening by using any type of box-spanner.
 An air gun is any kind of small arms that propels projectiles by means
of compressing air or other gases which are pressurized via mechanical methods
that involve with no chemical reactions, in contrast to a firearm, which
uses combustible propellants that involves an exothermic chemical reaction.
 They have been used in hunting, sporting and warfare. Modern air guns use one of
three types of power source depending on the design: spring-piston, pneumatic
and bottled compressed gas (most commonly carbon dioxide).
 Disadvantages are the need for an air compressor, pneumatic tubing and
pneumatic couplings
 Air tools were formerly unpopular in the Do it yourself market, but are becoming
increasingly popular due to costs decreasing, and have always been ubiquitous in
industrial and manufacturing
 Most pneumatic tools are to be supplied with compressed air at 4 to 6 bar

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 Fig: 6.11 Air Gun

VACUME MACHINE

 A vacuum cleaner, also known as a sweeper or hoover, is a device that uses an air
pump, to create a partial vacuum to suck up dust and dirt, usually from floors, and
from other surfaces such as upholstery and draperies.

 The dirt is collected by either a dustbag or a cyclone for later disposal.

 Wet or dry vacuum cleaners are a specialized form of the drum models that can be
used to clean up wet or liquid spills.

 Wet or dry vacuum cleaners are a specialized form of the drum models that can be
used to clean up wet or liquid spills. They are generally designed to be used both
indoors and outdoors and to accommodate both wet and dry debris; some are also
equipped with an exhaust port or detachable blower for reversing the airflow, a
useful function for everything from clearing a clogged hose to blowing dust into a
corner for easy collection.

31
 They are generally designed to be used both indoors and outdoors and to
accommodate both wet and dry debris; some are also equipped with an exhaust
port or detachable blower for reversing the airflow, a useful function for
everything from clearing a clogged hose to blowing dust into a corner for easy
collection.

32
 Fig: 6.12 Vacume Machine

GAS WELDING

 The most common gas welding process is oxyfuel welding also known as
oxacetylene welding.

 It is one of the oldest and most versatile welding processes, but in recent years it
has become less popular in industrial applications.

 It is still widely used for welding pipes and tubes, as well as repair work.

 The flame, since it is less concentrated than an electric arc, causes slower weld
cooling, which can lead to greater residual stresses and weld distortion, though it
eases the welding of high alloy steels.

 A similar process, generally called oxyfuel cutting, is used to cut metals.

 Oxy-fuel is one of the oldest welding processes. Still used in industry, in recent
decades it has been less widely utilized in industrial applications as other
specifically devised technologies have been adopted.

 It is still widely used for welding pipes and tubes, as well as repair work.

 It is also frequently well-suited, and favoured, for fabricating some types of metal-
based artwork.

33
 As well, oxy-fuel has an advantage over electric welding and cutting processes in
situations where accessing electricity (e.g., via an extension cord or portable
generator) would present difficulties

 it is more self-contained, in this sense hence "more portable

TYRE INFLATORS

 Many techniques have been developed for the measurement of pressure and
vacuum.
 Instruments used to measure pressure are called pressure gauges or vacuum
gauges.
 A manometer is an instrument that uses a column of liquid to measure pressure,

alt

Fig: 6.13 Gas Welding

hough the term is often used nowadays to mean any pressure measuring
instrument.

34
 Also known as a floor or track pump. To operate, the user rests the base of the
pump on the floor, resting feet at the base, and pulls and pushes full strokes with
handles. An additional tube must connect the pump to the fill valve, which may
create dead volume.
 Since tires are rated for specific loads at certain pressure, it is important to keep
the pressure of the tire at the optimal amount.

Fig: 6.14 Tyre Inflatos

PLIER WRENCH

 Plier wrench used for turning soft iron pipes and fittings with a rounded surface.
 They are not intended for use on hard hex nuts because they would ruin the
head.The design of the adjustable jaw allows it to rock in the frame, such that any
forward pressure on the handle tends to pull the jaws tighter together.

35
 Pliers are a hand tool used to hold objects firmly, possibly developed from tongs
used to handle hot metal in Bronze Age Europe.
 They are also useful for bending and compressing a wide range of materials.
Generally, pliers consist of a pair of metal first-class levers joined at a fulcrum
positioned closer to one end of the levers, creating short jaws on one side of the
fulcrum, and longer handles on the other side.
 This arrangement creates a mechanical advantage, allowing the force of the hand's
grip to be amplified and focused on an object with precision.
 The jaws can also be used to manipulate objects too small or unwieldy to be
manipulated with the fingers.
 Pincers are a similar tool with a different type of head used for cutting and pulling,
rather than squeezing.
 Tools designed for safely handling hot objects are usually called tongs. Special
tools for making crimp connections in electrical and electronic applications are
often called "crimping pliers"; each type of connection uses its own dedicated
tool.

OPEN END WRENCH

 Wrench with a U-shaped opening that grips two opposite faces of the bolt or nut.

Fig: 6.15 Plier Wrench

 It’s often double-ended, with a different-sized opening at each end.

36
 The ends are generally oriented at an angle of around 15 degrees to the
longitudinal axis of the handle to allow greater range of movement in enclosed
spaces.
 I took an old 3/4" open-end wrench, and modified it to be a narrow wrench.
 A 1/2 inch open-end wrench or socket wrench for the battery negative terminal
 The patented ratcheting open-end design fits neatly into tight spots and allows
movement without ever taking the wrench off the fastener, giving the speed of a
ratchet with the access of an open-end wrench.

Fig: 6.16 Open End Wrench

RING SPANNER WRENCH

 One-piece wrench with an enclosed opening that grips the faces of the bolt or nut.

37
 The recess is generally a six-point or twelve-point opening for use with nuts or
bolt heads with a hexagonal shape.
 The twelve-point fits onto the fastening at twice as many angles, an
 advantage where swing is limited.
 Eight-point wrenches are also made for square-shaped nuts and bolt heads
 Ring spanners are often double-ended and usually with offset handles to
 improve access to the nut or bolt.
 Tenders are invited for Ring Spanner Double End Type Cromium Plated Set Of 12
No of Sizes 6 Mm To 32 Mm Heavy Duty Model No.
 Tenders are invited for Double Ended Ring Spanner Set 11Pcs Size- 6 X 7Mm, 6
X 9 Mm, 10 X 11Mm, 12 X 13Mm, 14 X 15Mm, 16 X 17Mm, 18 X 19Mm, 20 X
22Mm, 24 X 27Mm, 30 X 32Mm, 36 X 41Mm.
 One Set Consist Of 1 Ring Spanner 30X32 Mm- 25 Nos 2 Double Ended Spanner
30X32 Mm- 25 Nos 3 Ring Spanner 24 X 27 Mm- 25 Nos 4 Double Ended
Spanner 24X27 Mm- 25 No. 5 Ring Spanner 18X19 Mm- 25 No Double Ended
Spanner 12 X13 Mm- 20 No

Fig: 6.17 Ring Spanner Wrench

38
 SANDER

 Random orbit sanders, also called Dual-Action sanders are hand-held power
sanders where the action is a random orbit.
 A sander is a power tool used to smooth surfaces by abrasion with sandpaper.
 Sanders have a means to attach the sandpaper and a mechanism to move it rapidly
contained within a housing with means to hand-hold it or fix it to a workbench.
 Woodworking sanders are usually powered electrically, and those used in auto-
body repair work by compressed air.
 There are many different types of sanders for different purposes. Multi-purpose
power tools and electric drills may have sander attachments.
 It can be work using Electric Power Supply or Pneumatic Power Supply.
 The random orbit sanding pattern is produced by simultaneously spinning the
sanding disk and moving it in an ellipse.
 This ensures that no single part of the abrasive material travels the same path
twice. Because of this unique random sanding action, the tool does not leave
 swirl marks, and is not sensitive to the direction of the wood grain.

39
 Fig: 6.17 Sander

7. PRACTICAL EXPERIENCE

40
41
7.1 Free Service Procedure & Chart

 FREE SERVICE CHART

1st 2nd 3rd 4th

SERVICE SERVICE SERVICE SERVICE
CAR KM OR TIME WHICE EVER IS EARLIER
MODEL KM TIME KM TIME KM TIME KM TIME
1000 3 10000 20000 2
1
NANO TO MONT TO To YEA
YEAR -
1500 H 10500 20500 R
INDICA 1000 1 5000 6 10000 1 2000 2
TO MONT TO MONT TO YEA 0 YEAR
1500 H 5500 H 10500 R TO
T 2050
B 0
INDIGO 1000 1 Y 5000 6 10000 1 2000 2
R O TO MONT TO MONT TO 1 s
YEA 0 t
YEAR
1500
B H P 5500 H
P 10500 R TO
U D Fig: 7.1 Types Of Maintenance
, 2 2050 n
R E A I 0
Y
NTIAGO 1000 2 7000 6 14500 d ,
1 3
TO
EMONT S TO MONT
D TO YEA - -
N 2000 H 8000 H 15000 r d
R ,
I
TIGOR 1000
TO
A 2
MONT
7000
TO
S E
6
MONT
14500
TO 4
1
YEA - t -

N BOLT 2000
4500
K H
3
8000
14,50
H
1
R 15000
30000
R
2
h
G TOD
5000
MONT
H
0
TO
V I
YEAR To YEA
R
- -
30500
O 15000 C E
ZEST 4500 3 14,50 1 30000 2
TOW MONT 0 YEAR To YEA - -
5000 H TO 30500 R
N 15000
4000
4500 3 10000 6 20000 1 0
2
ARIA TO MONT TO MONT TO YEA TO
YEAR
5000 H 10500 H 20500 R 4050
0
SUMO 4500 3 10000 6 20000 1 4000 2

42
 0
TO MONT TO MONT TO YEA TO
YEAR
5000 H 10500 H 20500 R 4050
0
4000
4500 3 10000 6 20000 1 0
2
SAFARI TO MONT TO MONT TO YEA TO
YEAR
5000 H 10500 H 20500 R 4050
0

Table: 7.1 Free Service Schedule

 1st FREE SERVICE PROCEDURE(NANO SERVICE)

 Clean air filter

 Clean AC filter
 Check all lights(head light, fog light, tail light,hazad light)
 Check all power window ,horn and central locking system
 Check wiper blade and wiper spray
 Clean condenser fins
 Check & top up fluids (Engineoil,Coolant,Brake fluid, Wind screen washer fluid)
 All standard checks as per job card
 Check drive (Alternator & AC) belts for tension, adjust tension if required, replace
if necessary
 Check & Adjust free play of Clutch release cable
 Check AC system for satisfactory performance
 Check for the DTC in the ‘Engine Control Unit 'using diagnostic tool. Take
corrective action if necessary Clear the DTCs
 Car washing and cleaning

 2st FREE SERVICE PROCEDURE(INDIGO)

 Clean air filter

 Clean AC filter
 Check all lights(head light, fog light, tail light,hazad light)
 Check all power window,horn and central locking system
 cleaning brake pad
 Check fuel lines for leakage

43
 Check hydraulic clutch circuit for leakage
 Check wiper blade and wiper spray
 Wash the vehicle & clean condenser fins
 Check & top up fluids (Engine oil,Coolant,Brake fluid, Wind screen washer fluid)
 All standard checks as per job card
 Check drive (Alternator & AC) belts for tension, adjust tension if required, replace
if necessary
 Check & Adjust free play of Clutch release cable
 Check AC / HVAC system for satisfactory performance
 Check for the DTC in the ‘Engine Control Unit 'using diagnostic tool. Take
corrective action if necessary Clear the DTCs
 Car washing and cleaning

 3rd FREE SERVICE PROCEDURE(ZEST ENGINE

REVOTRON 1.2T)

 Wash the vehicle and Clean Condenser Fins

 Check and Top up Fluids (Engine oil,Coolant, Brake Fluid, Battery Electrolyte)
 Check fuel lines for leakage
 Check clutch pedal height and cable
 All standard checks as per job card
 Check rubber boots and bushes for damages and replace
 Check rubber hanger (Muffler)
 Clean air filter element
 Change engine oil and oil filter
 Change fuel filter
 Check accessory drive belts for tension, wear or damage & replace if required
 Replace Spark Plugs
 Check front brake pads & rear brake linings. Replace, if required
 Check parking brake adjustment
 Rotate tyres
 Check and adjust Wheel Alignment and Balancing
 Check headlamp focusing and adjust, if required
 Check Air conditioning/AC System for satisfactory performance, Clean A/c Filter
 Car washing and cleaning

44
 4th FREE SERVICE PROCEDURE

 Wash the vehicle & clean the condenser with compressed air.
 Check & Top up Fluids if required
 Drain water accumulated in Fuel Pre filter cum sedimenter
 Check engine compartment for loose fasteners and for any leakages
 Check Under body for loose fasteners & for any damage or leakage
 Apply grease on door latches, locks, check straps, strikers, bonnet
 Check for proper tightening of Door latch
 Change Engine Oil and Oil filter
 Change Main Fuel filter
 Change Air filter element
 Check All accessory Drive belts
 Change Timing Belt & Timing Belt tensioner
 Change Engine Coolant
 Check Accessory drive for Power Steering Pump.
 Change Gear box Oil and Clean Breather
 Grease propeller shaft with grease gun
 Check for rubber cracks on Torsional Vibration Damper (TVD)
 Check wheel alignment/Steering wheel spoke alignment
 Check shock absorber, bushes replace if necessary
 Check condition of rubber bushes in Top & Lower wishbones, roll bars, Rear
links, Pan-hard rod, rubber boots/dust cover/ bellow in Rack & pinion, steering
ball joints & column. Replace if necessary.
 Replace Power steering Oil & filter element
 Change Power Steering Belt
 Check parking brakes, adjust if necessary
 Check front brake & rear brake pads, re-grease DIH liner resting
 Replace Brake & Clutch Fluid
 Check headlamp focusing & functioning of all electrical equipments
 Check for looseness of + Ve Terminals on Alternator and Starter
 Check AC System for satisfactory performance, attend if required.
 Tyre Rotation

45
7.2 Paid Service Procedure & Chart

 PAID SERVICE CHART

PAID
SERVICE
KM OR TIME WHICE EVER IS EARLIER
CAR MODEL
KM TIME

NANO 10000 1 year

INDICA 10000 1 year

INDIGO 10000 1 year

TIAGO 10000 1 year

TIGOR 10000 1 year

15000
To
BOLT 1 year
20500
15000
To
ZEST 1 year
20500

ARIA 20000 1 year

SUMO 20000 1 year

SAFARI 20000 1 year

Table: 7.2 Paid Service Schedule

46
 PAID SERVICE PROCEDURE

 Clean/Change air filter

 Clean/Change AC filter
 Change gear box oil
 Change differential oil
 Change Coolant
 Top up brake fluid
 Check all lights(head light, fog light, tail light,hazad light)
 Check all power window,horn and central locking system
 Check fuel lines for leakage
 Check hydraulic clutch circuit for leakage
 Wash the vehicle and Clean Condenser Fins
 Check and Top up Fluids (If required): Coolant, Brake Fluid, Battery Electrolyte
 Check fuel lines for leakage
 Check clutch pedal height and cable
 All standard checks as per job card
 Check rubber boots and bushes for damages and replace
 Check rubber hanger (Muffler)
 Change engine oil and oil filter
 Change fuel filter
 Check accessory drive belts for tension, wear or damage & replace
 Replace Spark Plugs
 Check front brake pads & rear brake linings. Replace, if required
 Check parking brake adjustment
 Rotate tyres
 Check and adjust Wheel Alignment and Balancing
 Check headlamp focusing and adjust, if required
 Check AC System for satisfactory performance
 Car washing and cleaning

47
7.3 Breakdown Service Procedure & Chart

 Breakdown service is one kind of facility which is given to the customer at home
or on the road
 there is two try of breakdown service
 1.only service at home
 2.running rapier at home or on road

 Indicative Response Time :

 Within City Limit 60 Minutes

 Ghat roads and other places 120 Minutes

Fig: 7.2 Brake Down Maintenance

48
  We have tied up with TVS Auto Assit (India) Limited to ensure that you get
immediate and hassle free service in the event of any car breakdown. Our network
for road-side assistance is spread across the length and breadth of the country and
covers cities, highways and hilly terrains across India.
 In the event of any mechanical or electrical breakdown and or traffic accident of a
vehicle, all you have to do is call our helpline number 1800 209 7979.
 We will track down your location and ensure that the nearest Authorized Service
Provider (ASP) reaches the spot immediately and rectifies the problem or tows it
to the nearest Tata Authorized workshop in case the vehicle is not repairable on
site.

t c c e a ti u fce r s h tc st nh oe e in mr c v i ci c i a ci a r e n i s g n o o t t o
a st n ht e a et ro r t ryc , ut h s te o c m a re ri s ' s
cm t oh o a no wi cn t m aeit n er ce g nt o a t ro n w ah r e d r se
tc sh e t a e th at h ea c t e ra w t r o i s r k n os h t o s tp a r t
w s o h r ok p
sh o p
49
7.4 Work done on Engine System

 CHANGE AIR FILTER IN INDICA

 Air filter is a component of engine which clean the intake air form the atmosphere
 Generally paper type filter is used in cars
 The air filter is placed before the turbocharger in intake manifold line

 Open the bonnet

 Check the air filter choke up level
 Remove the upper cover of the air filter body
 Remove the old air filter
 Fit the new air filler
 Fit the air filter body cover and close the bonnet
 generally air filters are change after 45000 km or 36 month

50

Fig: 7.3 Air Filter

 CHANGE ENGINE OIL

 Engine oil is a part of lubrication system which is lubricate the engine's all parts
 there are different grade and quantity oil is rub is in different cars
 engine oil is store in oil chamber

 open the chamber bolt

 empty all oil in to the oil
 clean the hemry on the bolt
 close the chamber bolt
 open the engine oil cap
 rub the oil
 check the oil level after 1 hour to check leakage

MODEL OIL GRADE QUANTITY

NANO 15W40 COMPACT 2.2 L

INDICA 15W40 5.5L

INDICA VISTA 15W40 3.2L

INDIGO 15W40 5.5L

Fig: 7.4 Engine Oil

INDIGO MANZA 10W40 5.5L

PETROL

51
INDIGO MANZA DIESEL 15W40 3.2L

ZEST/BOLT PETROL 5W30 4L

ZEST/BOLT DIESEL 5W30 3.2L

TIAGO/TIGOR PETROL 5W30 3.5L

TIAGO/TIGOR DIESEL 5W30 4L

SUMO 15W40 6.5L

SAFARI 15W40 7.5L

Table: 7.3 Oil Grade And Quantity

52
 CHANGE CNG PIPE(FOR LEAKAGE) IN NANO

 CNG pipes is a part of CNG kit which is flow the CNG gas one component to
another component
 Generally CNG pipes are made with the aluminium alloy
 CNG filer valve,CNG gauge,CNG cylinder,presser regulator and rail is conneted
to each other with CNG pipes

 Apply solution of soap on the all CNG joints

 soap bubbles are being on the leakage
 close the CNG cylinder valve
 remove the leakage pipe
 take new pipe and fit in the CNG line
 open the CNG cylinder valve

Fig: 7.5 CNG Pipe And Presser Gauge

PRESSER
GAUGE

53

PIPE
 CHANGE OIL FILTER IN ZEST(DIASEL)

 Oil filter is a part of lubrication system which is clean the oil

 il filter is placed on engine, before the oil pump
 generally paper type filter is use in cars
 oil filter is change after 10000 km or every paid service when change the engine
oil

 open the bonnet

 remove the oil filter
 take new filter and dab oil on o-ring 2 to 3 times
 fix the new oil filter

Fig: 7.6 Oil Filter

54
 CHANGE FUEL INJECTION PUMP IN INDICA VISTA(CAR
NOT START,FUEL PUMP NOT WORK)

 fuel injection pump is a part of fuel supply sytem,which is supply fuel with
presser of 200 MPa in injectors
 fuel pump is placed between injectors and filter
 fuel injection pump is work with the power of engine camshaft

 disconnect the injection line, filter supply line and return line pipe
 remove the vacuum pump
 remove the fuel injection pump
 take new injection pump and lock with the camshaft
 connect the all lines
 crank the engine 3 to 4 times

55
 Fig: 7.7 Injection Pump

 CHANGE FUEL FEED PUMP AND GAUGE(STARTING

PROBLEM) IN INDIGO

 Fuel pump and gauge is part of fuel supply system, fuel pump is supply fuel tank
to the injectors and gauge is show fuel level in the cluster panel
 generally electric type pump and gauge use in cars
 pump and gauge is common assembly which is placed in tank before the fuel filter

 Disconnect battery negative cable

 Disconnect electric socket and 3 pipe lines on fuel pump
 remove the fuel gauge from the tank
 take new pump and install in the tank
 connect socket and pipe lines
 connect battery cable
 Do 3 to 5 times ignition on and off

56
 CHANGE RADIATOR IN NANO (LEAKAGE PROBLEM)

 Radiator is a part of cooling system which is cool the engine coolant

 Aluminium fins type radiator is use in cars
 intake and outlet hose,coolent tank is connect with radiator

 remove all coolant of the radiator

 disconnect the overflow pipe, intake hose, outlet hose of the coolant
 remove the radiator mounting bolts
 remove the coolant tank mounting bolts
 remove the coolant tank
 disconnect the radiator fan socket
 remove the radiator on to the car
 remove the radiator fan from the radiator

Fig: 7.8 Fuel Pump And Gauge

  take new radiator and fix the fan and its socket
 fit the all mounting bolts
 fit the coolant tank in the car and hose pipes in radiator

57
 Rub 2.2 litre coolant in the coolant tank

Fig: 7.9 Radiator

 SERVICE FUEL INJECTION PUMP IN INDIGO (ENGINE

KNOKING PROBLEM)
58
 fuel injection pump is a part of fuel supply system, which is supply fuel with
presser of 250 MPa in injectors(TDI engine)
 fuel pump is placed between injectors and filter
 fuel injection pump is work with the power of engine camshaft

 disconnect the injector line,fule supply line,return line

 disconnect the accretion cable
 remove the suction pipe
 lock the timing
 remove the injection pump
 service the pump
 fix the injection pump
 fix the pipes and accretion cable

 Fig: 7.10 Injection Pump 

CHANGE SHUTTLE COMPENSATION VALVE (CAR NOT
CONVERT INTO CNG) IN NANO

59
 when we pressed the CNG convert button the SC valve is open and gas is flow in
to the CNG rail,SC valve is also control the flow of gas
 Shuttle compensation valve is fit in to the CNG kit in a presser regulator.

 Close the CNG cylinder valve

 Depressurize the gas into the CNG line
 Open the SC valve in to the presser regulator with the help of 16 no. land key
 fix the oaring into the presser regulator
 fit the SC valve into the presser regulator
 open the CNG cylinder valve

Fig: 7.11 Shuttle Compensation Valve

60
 CHANGE HLA(Hydraulic Lash Adjuster) IN ZEST(STRATING
PROBLEM)

 HLA is a part of engine, which is placed above valve and below the camshaft
 There is no tapped setting is needed in HLA

 lock the timing of crankshaft and camshaft

 remove the engine oil
 remove the oil chamber
 remove the water pump
 hold the engine with stand
 remove the A-mounting
 remove the oil pump
 remove the timing chain
 remove the rail and injectors
 remove the camshaft
 change the HLA

  fix the all above component

Fig: 7.12 HLA

61
 CHANGE SILENCER IN NANO(SILENCER BROKEN)

 Silencer is a part of exhaust system while is reduce noise and pollution of exhaust
gas
 silencer is placed before the catalytic converter in exhaust gas line
 If the silencer is broken. very loudly noise is occur due to the exhaust gas

 open the silencer's nuts

 remove the silencer
 fit new silencer
 must be fit the silencer gasket between silencer and catalytic converter

Fig: 7.13 Silencer

62
 CHANGE WATER PUMP AND OIL PUMP IN
NANO(COOLANT LEAKAGE PROBLEM)

 water pump is a part of cooling system which is circulate the coolant in water
jackets
 water pump is placed between radiator lower hose and engine water jackets
 water pump is work with the power of engine
 generally belt drive is rotate the pump
 In nano,water and oil pump is a single unit

 open the tapped cover and lock the timing

 remove the all coolant and engine oil
 remove the timing cover
 remove the alternator,compressor and timing belt
 remove the camshaft and crankshaft pulley
 remove the oil sump
 remove the oil pump and water pump
 take new oil pump and water pump as single unit and fit it in engine
 fit all the above component

Fig: 7.14 Oil And Water Pump

63
 SERVICE ENGINE HEAD IN MANZA(COOLANT LEAKAGE
PROBLEM)

 engine head is placed above the engine block

 injecter,valve is placed in engine head

 remove all the coolant

 disconnect the battery cable
 open the air filter body
 open the injection rail
 open the injector
 lock the timing
 open the tapped cover
 open the cam box
 open the cylinder head
 service the head
 fix the all above component

 CHANGE 'C' MOUNTING IN NANO(MOUNTING BROKEN)

 mounting is a holding component which is hold the engine on the frame

Fig: 7.15 Engine Head

64
 mounting is also absorbs the jerk of the engine
 A.B AND C mounting is use in cars
 A mounting is placed engine timing side
 B ,mounting is placed gearbox side
 C mounting is placed in under body is hold the engine and gearbox both.
 hard rubber material is used in mounting

 open the two nut and bolt of C mounting

 remove the c mounting
 fix the C mounting
 fix the two nut and bolt of C mounting

Fig: 7.16 C Mounting

65
 CHANGE THERMOSTAT VALVE IN NANO(OVERHEATING
PROBLEM)

 A thermostatic radiator valve is a self-regulating valve fitted to hot water heating

system radiator, to control the temperature of a room by changing the flow of hot
water to the radiator.
 The thermostatic radiator valve contains a plug, typically made of wax, which
expands or contracts with the surrounding temperature.
 The valve gradually closes as the temperature of the surrounding area increases,
limiting the amount of hot water entering the radiator.
 As the valve works by sensing the temperature of the air surrounding it, it is
important to ensure that it is not covered by material

 remove the all coolant

 open the albo of thermostat valve
 remove the thermostat valve
 fix the new thermostat valve
 fix the albo with white bond
 rub the coolant

Fig: 7.17 Thermostat Valve

66
 CHANGE THE TIMING CHAIN IN INDICA

 timing chain is a part of engine, which is keep rotating timing of cam and crake
shaft
 timing chain is placed between cam and crank shaft

 lock the timing of crankshaft and camshaft

 remove the engine oil
 remove the oil chamber
 remove the water pump
 hold the engine with stand
 remove the A-mounting
 remove the oil pump
 remove the chain tensor
 remove the timing chain
 fix the new timing chain ad chain tensor
 fix the all above component

Fig: 7.18 Timing Chain

67
 CHANGE GLOW PLUG IN ZEST(TDS GLOW PLUD ERROR)

 Glow plug is a component of diesel engine, which is produce heat in cylinder

when the engine is start
 glow plug is placed in a cylinder

 disconnect the battery negative cable

 disconnect the glow plug socket
 remove the old glow plug
 fit the new glow plug
 connect the glow plug socket
 connect the battery cable

Fig: 7.19 Glow Plug

68
 SERVICE THE INJECTORS(PICK UP PROBLEM)

 injectors is a part of fuel supply system, which is inject the fuel in the cylinder
 injector is placed on the cylinder in cylinder head
 when the injector is not proper work, there is knoking,pick up problem occur

 disconnect the rail pipes

 disconnect the power sockets
 remove the injectors
 service the injectors
 fix the injectors in the cylinder head
 connect all socket and rail pipes

Fig: 7.20 Injector

69
 CHANGE FUEL FILTER IN INDICA

 fuel filter is a part of fuel supply system

 generally paper type filter is use in cars
 fuel filter is paced between fuel tank and fuel injection pump
 generally after 10000km or every service fuel filter is change

 disconnect the fuel tank, injection line and return line pipes
 remove the fuel filter
 fix o-ring in new fuel filer
 fix the new fuel filter
 connect all 3 fuel lines
 do 5 to 6 times fuel suction
 do 2 to 4 time ignition on/off before staring the car

Fig: 7.21 Fuel Filter

70
 CLEANING THE EGR VALVE IN ZEST(PICK UP PROBLEM)

 EGR valve is a component of EGR system which is recalculate the exhaust gas in
to the fresh in take air
 EGR valve is placed on intake manifold and connect with exhaust gas line

 disconnect the coolant line and exhaust gas line pipe

 remove the EGR valve
 valve clean with the petrol and carburettor spray
 fix the EGR valve

Fig: 7.22 EGR Valve

71
 REMOVE SEDIMETER LIGHT AND CHEKE ENGINE LIGHT
IN INDIAGO

 Sedimeter light is given in the cluster meter in diesel engine,which saws the water
in the fuel
 sedimeter sensor is placed in the pre filter in diesel fuel line.

 Open the sedimeter sensor in to the pre filter and drain the water of the filter
 change the sedimeter sensor
 heck the sedimerter wiring
 change the filter
 change the cluster meter
 change the ECU

Fig: 7.23 Sedimeter

72
7.5 Work Done On Transmission & Mechanism

 CHANGE BRAKE PAD IN INDOGO MANZA(NOT PROPER

BRAKE)
 Brake pad is a component of Dish brake system, when we push the brake pedal
brake pad is stick to brake disk so the motion resistance force is apply on the
wheel and vehicle stop or slow down
 brake pad is placed in the calliper
 ceramic material is use in brake pad

 fix car on to the lift and pull up

 Open the brake oil reservoir cap
 open the wheel
 Press the brake calliper piston
 open the caliper
 remove the old brake pad
 fix the new brake pad
 close the caliper
 fit the wheel and close the brake oil reservoir cap
 pull down the car and must be peddling brake pedal 10 to 15 times

 CHANGE WHEEL CYLINDER IN NANO(WHEEL CYLINDER

LEAKAGE)
 Wheel cylinder is a component of drum brake system
 Wheel cylinder is placed between two brake shoes in wheel brake support disk
 Wheel cylinder is a working on hydraulic fluid principle

 open the wheel

 open the brake drum

73

Fig: 7.24 Brake Pad

 
re

move the brake line pipe

 remove the wheel cylinder
 fix the new cylinder in brake support disc
 fix the brake line pipe
 fit the drum and wheel
 rub the brake oil
 must be do bleeding process

BLEEDING
NIPPLE

74

Fig: 7.25 Wheel Cylinder

  C
H
A
N
G

CLUTCH KIT IN NANO AMT

 A clutch is a mechanical device which engages and disengages power

transmission
 Clutch is placed between flywheel and gearbox
 Asbestos material is use in clutch

 Depressors the oil pressers of the AMT unit with the help of TDS software
 Disconnect battery negative cable, gear cable and clutch cable
 Remove the silencer
 Remove the throttle body
 Disconnect the starter motor. Sensors connections
 remove the starter motor mounting bolts
 remove the gear oil
 Loose the left axle
 fix the engine holding stand
 Remove the B and C mountings
 Remove the engine and transaxle mounting bolts
 Change the presser plate, clutch plate with the help of top shaft
 Change clutch bearing
 fix the engine and transaxle mounting bolts

75
 fit the B and C mountings
 remove the engine holding stand
 fix the left axle
 rub the gear oil
 connect the starter motor. Sensors connection
 fix the silencer and the throttle body
 connect battery negative cable, gear cable and clutch cable
 Make cutch bleeding and cultch kiss process with TDS software

76
 CLUTCH
PLATE

Fig: 7.26 Clutch Plate

  BRAKE BLEEDING


B

rake bleeding is the procedure performed on hydraulic brake systems whereby the
Fig: 7.27 Presser Plate

brake lines are purged of any air bubbles.

77
 This is necessary because, while the brake fluid is an incompressible liquid, air
bubbles are compressible gas and their presence in the brake system greatly
reduces the hydraulic pressure that can be developed within the system.
 The same methods used for bleeding are also used for purging, where the old fluid
is replaced with new fluid, which is necessary maintenance.
 The process is performed by forcing clean, bubble-free brake fluid through the
entire system, usually from the master cylinder to the calipers, but in certain cases
in the opposite direction
 . A brake bleed screw is normally t point on each cylinder or caliper.

 The pump and hold method, the brake pedal is pressed while one bleed screw at a
time is opened, allowing air to escape.
 The bleed screw must be closed before releasing the pedal

Fig: 7.28 Brake Bleeding

78
 TYRE PRESSURE

 Maintaining the correct tyre pressure will help to extend the life of your tyres,
improve vehicles

 We recommend doing this every two weeks to ensure optimum tyre pressure.

 Under inflated tyres will have uneven contact with the road and will exhibit
excessive wear on the inside and outside edges of the tread if they are left
underinflated for some time.

 Not only does low tyre pressure wear your tyres out more quickly but you may
also experience increased rolling resistance with the road which means reduced
fuel efficiency and increased CO2 emissions.

 Putting too much air in your tyres can be just as damaging and costly.

 Over inflated tyres will have a smaller contact patch the part of the tyre that makes
contact with the road which can lead to a loss of traction and poorer braking
distances.

 Overly high tyre pressure will also cause heavy and uneven wear across the
central part of the tyre leading to shorter tyre lifespans than if it was correctly
inflated.

MODEL FRONT TYRE (PSI) REAR TYRE(PSI)

NANO 28 26
INDICA 32 28
INDICA VISTA 32 28
INDIGO 32 28
INDIGO MANZA 32 28
ZEST 33 30
BOLT 33 30
SAFARI 33 32
TIAGO 32 30
TIGOR 32 30

79
 HEXA 35 36
SUMO 35 35

 CHANGE BRAKE LINER IN NANO(BRAKE NOT PROPER)

 Brake liner is a component of drum brake system, when we push the brake pedal
brake liner is stick to brake drum so the motion resistance force is apply on the
wheel and vehicle stop or slow down
 brake drum is placed in the drum on brake liner holding dish
 ceramic material is use in brake liner

 open the wheel

 open the drum
 remove the liner holding spring
 remove old liner
 remove old springs from the lines
 fix springs in new liner
 fix new liner in the dish
 do brake liner setting
 fit the drum and wheel

Table: 7.4 Tyre Presser

80
 Fig: 7.29 Brake Liner

CHANGE RACK AND PINION ASSEMBLY WITH TIE

ROD(STEERING VIBRATION PROBLEM)

 rack and pinion is a part of steering system which is convert steering wheel
rotating motion to reciprocating motion
 pinion is connect with steering column and rack is connected with tie rod
 tie rod is connect to the wheel's nukkle

 disconnect the steering column's u-join to the pinion shaft

 disconnect the tie rod boll join to the nukkle
 remove rack and pinion assembly to the body
 fix new assembly to the the body
 connect column u-joint
 connect tie rod to nukkle
 must be do wheel alignment

81

Fig: 7.30 Rack And Pinion Assembly

  C
H
A
N
G
E

BRAKE DISH IN INDIAGO MANZA

 brake dish is a part of brake system

 when we apply the brake pedal the brake pad is stick to brake disk so the motion
resistance force is apply on the wheel and vehicle stop or slow down

 open the wheel

 open the one calliper pin
 push piston inside
 open the calliper hold 2 bolts
 remove the calliper
 open the disk holding bolt
 remove the brake disk
 fix new brake disk
 fix the above component

82
Fig: 7.31 Brake Dish

83
 WHEEL ALIGNMENT

 Wheel alignment, sometimes referred to as breaking or tracking, is part of

standard automobile maintenance that consists of adjusting the angles of wheels
so that they are parallel to each other and perpendicular to the ground.
 The purpose of these adjustments is to reduce tire wear, and to ensure that vehicle
travel is straight

 fix the 4 alignment sensor dick on the 4 wheel

 select the vehicle model in computer
 run vehicle ahead and behind as per the computer show
 rotate steering wheel right and left as the computer show
 Do steering lock with the steering holding stand
 adjust tie rod nut to set toe
 adjust nukkle bolt to set caster angle
 in nano we can only adjust toe
 in tiago,tigor,indica,indigo we can adjust only caster and toe
 in safari,sumo,hexa we can set caster, camber and toe

84

Fig: 7.32 Wheel Alingment

 CHANGE BRAKE CALIPER IN INDIAGO MANZA

 caliper is a part of brake system,which is placed above the brake dick

 there is piston assembly in the caliper
 when we apply the brake brake pedal piston pushing the brake pad

 open the wheel

 open the bleeding nipple
 open the one calliper pin
 push piston inside
 open the calliper hold 2 bolts
 disconnect the brake line pipe
 fix the new calliper
 connect the brake line pipe
 must be do bleeding process

Fig: 7.33 Brake Calliper

85
 CHANGE JUMPER IN TIAGO(NOISE PROBLEM)

 jumper is a part of suspension system which is reduce dapping effect of spring

 generally telescopic jumper is use in cars
 in front jumper, coil spring and jumper is a single unit
 jumper's one end is connected to the car's body and second end is connect with
nukkle

 open the wheel
 remove the castor adjustment bolt and another bolt
 disconnect the anti rod bar's link
 remove the jumper from the car's body

Fig: 7.34 Jumper

86
 WHEEL BALANCHING

 Since the tyre is the only patch of contact between an automobile and the road,
having the right tyre aside, it is critical to keep its ‘balance’ perfect to avoid
irregular wear and tear
 Counter weights are small weights that have a certain mass and help in counter-
acting the forces acting to imbalance the weight

 open the all tyres

 fix the tyre in the machine
 start the machine
 the tyre is rotate in the machine
 machine's monitor display the unbalance in the tyre
 fix balancing Weight in the rim as per machine show


Fig: 7.35 Wheel Balancing

87
 CHANGE 4TH GEAR IN INDIGO(GEAR SHIFTING
PROBLEM)

 gears is a component is transition unit, which is maintain speed and torque as per
the require
 gears are fitting in the gear box and gear box are placed between the clutch and
propeller shaft(FR vehicle) or differentiation(FF vehicle)
 the synchronizing ring,gear,sliv,fork,hub is a component of gear box

 Disconnect battery negative cable, gear cable and clutch cable

 Disconnect the starter motor and Sensors connections
 remove the starter motor mounting bolts
 remove the gear oil
 Loose the both axle
 fix the engine holding stand
 Remove the B and C mountings
 Remove the engine and transaxle mounting bolts
 remove the transaxle
 remove the 5th gear assembly
 open the gear box casing
 remove the gear shifter shafts and fork
 remove the main shafts 4th gear side bearing
 remove the 4th gear assembly
 remove the gear locking spring from the gear hub
 fix the locking spring in the new hub and sliv
 make synchronizing ring, gear and hub assembly and fix in the main shaft
 fix the bearing
 fix the gear changing shaft
 close the gearbox case
 fix the 5th gear assemly
 fix the engine and transaxle mounting bolts
 fit the B and C mountings
 remove the engine holding stand
 fix the both axle
 rub the gear oil
 connect the starter motor. Sensors connection
 connect battery negative cable, gear cable and clutch cable

88
Fig: 7.36 Gear Box Assembly

Fig: 7.37 Gear

89
Fig: 7.38 Syncronizing Ring

Fig: 7.39 Slive And Hub

90
 CHANGE ANRI BAR ROD LINKEGE

 anti bar rod lineage is a component of suspension system

 it's placed between jumper and anti bar rod
 it is made with steel material

 open the jumper side nut

 open the anti bar side nut
 remove the old linage
 fix the new lineage
 fit the 2 nuts

Fig: 7.40 Anri Bar Rod Linkege

91
 CHANGE THE SUSPENTION BUSHING IN INDICA(NOISE
PROBLEM)

 suspension bushing is a part of a suspension system, which is absorbs the jerk of

suspicion parts
 bushings are made with the high rubber material
 it is placed in lower arm and anti bar rod

 disconnect the ball joint of lower arm

 remove the cross rod
 remove the lower arm
 remove the all bushings in the lower arm
 Do gracing in lower arm where the bushes are placed
 change the anti bar rod bushing
 fix the lower arm and cross rod

Fig: 7.41 Bushing

92
 CHANGE THE BALANCING CROSS ROD IN INDICA(CROSS
ROD BEND)

 cross rod is a part of suspension system, which is hold the both lower arm
 cross rod is paced between booth lower arm
 when any under body damage is occur or the high impact on the cross rod, the rod
is bend

 open the 2 nuts of the lower arm

 remove the cross rod
 take new rod and placed in both lower arm with washer

Fig: 7.42 Cross Rod

93
 CLUTCH MASTER AND SLIV CYLINDER CHANGE IN
ZEST(CLUTCH NOT WORK)

 clutch master and slive cylinder is a part of clutch operating machinesme which is
engage and disengage the clutch
 master cylinder is connect to the clutch pedal and sliv cylinder is connected to the
cultch fork
 this component is hydraulically work

 disconnect the master cylinder to the clutch pedal

 disconnect the sliv cylinder to the fork
 fix new master and sliv cylinder
 connect hydraulic line pipe to the both cylinder
 rub brake oil
 do bleeding process

Fig: 7.43 Clutch Master And Slive Cylinder

94
7.6 Work Done On Electrical System

 CHNAG COOLANT TEMPRETURE SENSOR IN NANO

FOR RADATOR FAN NOT START PROBLEM

 Coolant tempreter sensor is measure the temperature of engine coolant and signle
to the ECU,than ECU control radiator fan on/off, radiator fan
series/parallel sercite,ignition timing.
 the coolant temperature sensor is also help to show engine
temperature on the cluster meter
 Coolant temperature sensor is placed in the engine block in water jackets
 Copper material is used in this sensor

Fig: 7.44 coolant tempreture sensor

95
 NEW KEY PARING IN INDOGO MANZA

 Connect the TDS(Tata diagnose system) in the car

 go to the immo system
 go to the routing test
 go to ADD TRANSFER KEY
 than insert old key>new key>old key>new key and do ignition with in 10 second
 now the new key is paring with car's ignition system

 For centre lock pairing

 Insert new key 4 time and do ignition with in 10 second

 so it shows hazad light
 than push both button (lock and unlock button)on the key at same time
 now the new key is pairing with car's centre lock system

Fig: 7.45 Key

96
 IGNITION COIL CHANGE IN NANO(STARTING PROBLEM)

 Ignition coil is a part of a ignition system which is step up battery's 12.6V in to

20000 to 25000V
 Ignition coil placed between ECU and H.T. cables
 In modern vehicles multi ignition coil is given in one unit as per the number of
cylinder

 disconnect the battery's 12.6V socket

 disconnect the H.T. cable
 remove the ignition coil
 fix the ignition coil
 connect the socket and H.T. cables
 Must be take care H.T. cables are connect as per firing order in the coil

Fig: 7.46 Ignition Coil

97
 CHANGE HIGT TENTION CABLE IN NANO(MIDFIRING
PROBLEM)

 H.T. cable is a part of ignition system which is flow 20000V to 25000V current
ignition coil to spark plug
 H.T. cable is placed between ignition coil and spark plug
 High rubber insulating material is coated on the h.t. wire
 After 50000 to 55000 kms H.T. cable is change
 Must be take care H.T. cables are connect as per firing order in the coil

Fig: 7.47 H.T. Cable

98
 CHANGE CENTRAL LOCKING ACTUATOR

 this actuator is connect with the door lock

 when it takes signal from the centre locking control module it close the door lock
 it is placed between centre lock control module and door lock

 open the door trim

 disconnect the socket of the actuator
 disconnect the door lock from the actuator
 remove the actuator
 fix the new actuator
 connect the look and power socket

Fig: 7.48 Center Lock Actuater

99
 CHANGING FUSE

 The main function of the fuse is to protect the wiring

 The fuses are located in fuse box
 when electric load is very high the fuse is blown and Brocken the electric seircit
so its protect the electric parts
 generally semi conductor material is use in car fuse
 the fuse is use in battery, condenser fan, radiator fan,window,center lock,ignition
key,radio,realy etc.

Fig: 7.49 Fuse

100
 CHANGE WIPER BLADE IN SUMO(BLADE NOT PROPER
WORK)

 A wiper blade is a device used to remove rain, snow, ice and debris from a
windshield.
 Almost all motor vehicles, including cars, trucks, train locomotives, watercraft
with a cabin and some aircraft, are equipped with such wipers, which are usually a
legal requirement.
 A wiper generally consists of a metal arm, pivoting at one end and with a long
rubber blade attached to the other.
 The arm is powered by a motor, often an electric motor, although pneumatic
power is also used in some vehicles.
 The blade is swung back and forth over the glass, pushing water or other
precipitation from its surface.
 Most automobiles use two synchronized radial type arms, while many commercial
vehicles use one or more pantograph arms.

 unlock the wiper blade in to the arm and pull down

 remove the wiper down
 lock the blade in arm and pull up

Fig: 7.50 Wiper Blade

101
 CHANGE ROOF LIGHT IN TIAGO(ROOF LIGHT NOT
WORK)

 roof light is a component of light system, which is placed in the passenger

compartment in a roof
 roof light is multi function light, when we open the any door the roof light is
automatically on
 if the any door is open the roof light is continually on so we can care the car that
properly lock the all doors
 we can also manually on/off the roof light

 off the roof light

 open the upper cover of light
 remove the roof light with vej
 disconnect the socket
 take new roof light and connect the socket
 fit the roof light in the roof
 fix the upper cover of the roof light

Fig: 7.51 Roof Light

102
 BATTERY TESTING AND CHARGING

 with the help of hydrometer and multicenter we can test the battery

 with the multicenter we can check the battery voltege,if the batter's voltage is
12.60v and above its show battery is fully charge and one the vehicle is start the
battery voltage is goes about 14.35v it's show alternator is properly work

 with the help of hydrometer we can check the electrolyte's specific gravity

 if the electrolyte gravity is above the 1200 the battery is fully charge condition

 if the battery is not charge we can charge the battery with the help of battery
charge machine

Fig: 7.52 Battery Testing

  CHANGING REALY

 A relay is an electrically operated switch, which is placed in fuse box

 Relays are used where it is necessary to control a circuit by a separate low-power
signal, or where several circuits must be controlled by one signal.
103
 first the battery current is passed in fuse than the relay
 ground ,power input from the battery, power output to the actuater and operating
switch connection is given in the relay

Fig: 7.53 Relay

 CHANGE SPARK PULG IN ZEST(MISFIRING PROBLEM)

 Spark plug is a part of ignition system which is ignite to air and fuel mixer in a
petrol engine in the power stroke
 Spark plug is located on the cylinder in a cylinder head

104
 When the misfiring occurs first clean the spark plug, if the misfiring is not stop
than change the spark plug
 generally after 30000 km spark plug is change

 open the air filter body

 disconnect the 4 H.T. cable of the spark plug
 open the spark plug
 fix the new spark plug and connect the H.T. cable in firing order

 Must be take care the spark plug is not broken in the cylinder
head when open or close, if the plug is broken in the head than must be overhaul
the cylinder head to replace the plug

Fig: 7.54 Spark Plug

105
 CHANGE RADIATOR FAN IN NANO(FAN NOT WORK)

 Radiator fan is a part of cooling system which is cool the engine coolant
 plastic radiator fan is use in cars
 radiator fan is placed behind the radiator

 remove all coolant of the radiator

 disconnect the overflow pipe, intake hose, outlet hose of the coolant
 remove the radiator mounting bolts
 remove the coolant tank mounting bolts
 remove the coolant tank
 disconnect the radiator fan socket
 remove the radiator on to the car
 remove the radiator fan from the radiator
 fix the new fan and its socket
 fit the all mounting bolts
 fit the coolant tank in the car and hose pipes in radiator
 Rub 2.2 litre coolant in the coolant tank

Fig: 7.55 Radiator Fan

106
107
 CHANGE TAIL LIGT IN NANO

 tail light is a part of a lighting system

 the brake,revers light bulb are placed in a tail light
 tail light is placed back of the car

 open the back panel of the car in nano

 disconnect the tail light socket
 remove the tail light
 connect the electric socket in new tail light
 fix the new tail light
 fix the back panel

Fig: 7.56 Tail Light

108
 CHANGE OXYGEN SENSOR IN TIAGO(WIRING CUTTING)

 An oxygen sensor is an electronic device that measures the proportion of oxygen

in the gas or liquid being analyse.
 The most common application is to measure the exhaust gas concentration of
oxygen for internal combustion engines in cars
 The probe is typically screwed into a threaded hole in the exhaust system, located
after the branch manifold of the exhaust system combines, and before the catalytic
converter.
 New vehicles are required to have a sensor before and after the exhaust catalyst

 disconnect the battery negative cable

 disconnect he socket of oxygen sensor
 remove the oxygen sensor
 fit the new oxygen sensor
 connect the socket of oxygen sensor
 connect the battery negative cable

Fig: 7.57 Oxygen Sensor

109
 AUTOMOBILE BULBS

 Light bulbs for automobiles are made in several standardized series.

 Bulbs used for headlamps, turn signals and brake lamps may be required to
comply with international and national regulations governing the types of lamps
used.
 Other automotive lighting applications such as auxiliary lamps or interior lighting
may not be regulated, but common types are used by many automotive
manufacturers
 UN Regulation 37 covers motor vehicle filament lamps. These are categorized in
three groups
 those without general restriction that can be used in any application, those
acceptable only for signalling lights (not for road illumination lamps), and those
no longer allowable as light sources for new type approvals but still permitted for
production as replacement parts.

Fig: 7.58 Bulbs

110
 SERVICE THE ALTERNATOR

 An alternator is an electrical generator that converts mechanical energy to

electrical energy in the form of alternating current
 Alternators are used in modern automobiles to charge the battery and to power the
electrical system when its engine is running.
 automobiles used DC dynamo generators with commutators. With the availability
of affordable silicon diode rectifiers, alternators were used instead.
 car's alternator generates 14.3 to 14.5V

 disconnect battery negative cable

 remove the alienator cable
 disconnect alternators 2 sockets
 remove the alternator
 service the alternator(change bearing)
 fix the alternator
 connect the 2 sockets
 fix the alternator belt
 connect battery negative cable

Fig: 7.59 Alternator

111
 WIPER LINKEGE REPAIR IN SAFARI

 wiper linkage is a part of electric system, which is convert wiper motor's rotating
motion in to wiper oscillating motion
 wiper lineage is placed between motor and wiper blade

 remove the wiper blade

 remove the upper cove of wiper linkage
 disconnect the wiper linkage with the motor
 remove the linkage
 lubricate the linkage ends and slow blow of the hammer
 rouse the linkage eng
 fix the lineage
 connect with the motor
 fix the cover
 fix the wiper blade setting

Fig: 7.60 Wiper Linkage

112
 DESHBOARD REMOVE AND REFITTNG IN TIAGO FOR
NOISE

 remove the centre gearbox counsel

 remove the ac control penal counsel
 remove the control penal and Harman system
 remove the steering wheel
 remove the dashboard
 fit rubber shock absorbers in dashboard fitting knobs
 fix the dash board
 fix the steering wheel
 fix the Harman system, centre counsel

Fig: 7.61 Deshboard Remove

113
7.7 Work Done On Air Conditioner System
 AC GAS LEAKAGE CHACKING

 Connect gauge manifold's high presser scale to low presser AC pipe

 Connect nitrogen cylinder to gauge manifold
 Fill N2 gas in the AC pipe up to the 350 bar
 than close the manifold lobe
 leave it 7 to 8 hours
 if the presser is down to the above presser so it shows the leakage in the AC unit

GAS INJECT IN
LINES

GAS LEAKAGE SO
PRESSE IS DOWN
Fig: 7.62 Ac Gas Presser Manifold

 CHANGE AC CONTROL PENAL IN HEXA

 AC control unit is a part of ac system, which is control the cooling and heating
temperature AC air flow direction and the blower speed
 AC control penal is placed on the dashboard unit

114
 Remove the dashboard upper penal
 Open the ac control penal's 4 screw
 Loose the 2 wire of the control penal
 loose the electric socket
 Take new penal connect the 2 wire and socket
 Fit the penal in dashboard

Fig: 7.63 Ac Control Penal

115
 CHECK AC COOLING

 ac cooling is check with the thermometer

 fix the thermometer probe in the ac grill
 on the ac and set the full cooling mode
 set the blower speed at 2nd or 3rd point
 on the thermometer
 the thermometer shows the temperature of ac system

 the temperature goes down

 in one point the temperature is goes to the about 6 to 7C
 than ac is cut off and temperature is increases

 if the ac works above steps its shows ac work properly

Fig: 7.64 Ac Cooling Chaking

 CHANG AC FILTER IN TIAGO

 AC filter is a component of ac unit which is clean the blower's air

 AC filter is located in to the ac unit before the blower

116
 Cloth net type filter is generally use in AC unit

 open the 4 screw of AC filter

 remove the old filter
 take new filter and fit in unit

Fig: 7.65 Ac Filter

117
 RECHARGE AC GAS IN INDICA

 When ac gas is leakage from the ac's parts or ac's lines, change the ac's
component, cooling is not proper, it is needs to recharge ac gas
 CFC and HFC gas(R-134a) is use as ac gas
 There is different ac gas quantity in different cars

 connect the robiner's(ac machine) low and high presser nobe to the ac pipe
 recover the ac gas process
 vacuum the ac gas about 15 minutes
 inject the lubrication oil(about 25 to 40 ml)in ac pipe
 recharge the ac gas

Fig: 7.66 Ac Gas Charger

118
 SERVICE AC UNIT IN INDICA

 remove the dashboard

 remove old ac gas
 remove the ac unit
 remove the blower
 grassing the blower shaft
 remove the cooling coil
 cleaning the cooling coil with the air and water
 cleaning the pipes with the water
 cleaning the heating coil with the water and air
 fix the heating, cooling coil and blower in to the ac unit
 fix the ac unit in vehicle
 fix the dashboard
 charge the new gas in the unit

119
 Fig: 7.67 Ac Unit

 AC COMPRESEEOR TENSIONER BEARING

 tensioner bering is a part of ac system which is create the tension in the

compressor belt
 it is fix the under the compressor belt

 loose the tension of bearing

 open the bolt of bearing
 remove the old bearing
 fix the new bearing
 there is reverse thread in the Bering tensioner bolt

120

Fig: 7.68 AC Compreseeor Tensioner Bearing

 
C

HANGE AC CONDESER IN NANO(CONDERNR IS

LEAKAGE)

 Condenser is a part of AC system which is cool the compressor's high presser and
high temperature AC gas
 Condenser is made with aluminium material
 Generally condenser is placed behind the front bumper between the compressor
and dryer

 open the front bumper

 recover al l the AC gas with the help of robiner AC machine
 disconnect the compressor and dryer connection pipe
 remove the condenser
 fit the new condenser
 Do ac leakage test
 recharge the ac gas

121
Fig: 7.69 AC Condenser

122
7.8 Work done on Accident Shop

 CHANGE THE FRONT BUMPER IN TIAGO(BUMPER IS

DAMAGE)
 A bumper is a structure attached to or integrated with the front and rear ends of a
motor vehicle
 to absorb impact in a minor collision, ideally minimizing repair costs
 Regulatory measures have been enacted to reduce vehicle repair costs, and more
recently impact on pedestrians.

 remove the both headlights

 remove the upper bolts of bumper
 remove the button of bumper
 remove the bottom side bolts and nuts
 remove the side bolts
 disconnect the fog lamps sockets
 remove the old show grill and fog lamp
 take new bumper and paint it
 fit the show grill and fog lamp
 connect the fog lamp connection and fix the bumper in car
 fix the headlight

Fig: 7.70 Front Bumper

123
 CHANGE DOOR IN INDIGO(DOOR IS DAMAGE)
 A car door is a type of door, typically hinged, but sometimes attached by other
mechanisms such as tracks, in front of an opening which is used for entering and
exiting a vehicle.
 A vehicle door can be opened to provide access to the opening, or closed to secure
it.

 open the interior trim of door

 remove the rc lock
 remove the door lock
 remove the window glass
 remove the window winder
 remove the window motor
 take new door and fit in car
 set the door
 remove the door paint it
 fit the window motor,winder,galss,lock and interior trim

Fig: 7.71 Door

124
 CHANGE REAR BUMER IN NANO(BUPER IS DAMGE)

 A bumper is a structure attached to or integrated with the front and rear ends of a
motor vehicle
 to absorb impact in a minor collision, ideally minimizing repair costs
 Regulatory measures have been enacted to reduce vehicle repair costs, and more
recently impact on pedestrians.

 Open the boot

 remove the inner trim
 remove the both tail light
 remove the upper bolts
 remove the buttons
 remove the under body side buttons
 remove the side bolts
 disconnect the fog lamp sockets and remove the fog lamp in to the bumper
 take new bumper and paint it
 fit the fog lamp in the bumper
 connect the fog lamp sockets and fix the bumper in car
 connect the tail light sockets fit the tail light
 fir the inner trim

125
 Fig: 7.72 Rear Bumper

 CHANGE THE BONNET IN ZEST(BONNET IS DAMAGE)

 bonnet is the hinged cover over the engine of motor vehicles that allows access to
the engine compartment (or trunk on rear-engine and some mid-engine vehicles)
for maintenance and repair
 On passenger cars, a hood may be held down by a concealed latch. It is designed
to protect a car from thefts, damage and sudden hood opening on the road.
 The hood release system is common on the most of vehicles and usually consists
of interior hood latch handle, hood release cable and hood latch assembly.
 The hood latch handle is usually located below the steering wheel, beside the
driver's seat or set into the door frame.
 When a driver pulls a hood latch handle the hood panel pops up and allows access
to the engine compartment
 Hoods are typically made out of steel, but aluminum is rapidly gaining popularity
with auto companies.

 open the bonnet

 remove the bonnet holding bolts
 remove the bonnet
 take new bonnet and paint it
 fix the bonnet in car and set it

126
 Fig: 7.73 Bonnet

  RAIPER THE FENDER IN INDIGO WITH DENT PULLER

 the fender is called the wing (this usually refers only to the panels over the front
wheel arches, in modern cars, since the rear 'fenders' are more an integral part of
the car's body shape).
 The equivalent component of a bicycle or motorcycle, or the "cycle wing" style of
wing fitted to vintage cars, or over tires on lorries which is not integral with the
bodywork, is called a mudguard in Britain.

 mark the damage area

 remove the paint with the grinder
 draw the fender arc with the marker
 connect the dent puller earth connation to the body panel
 pulling the dent with the help of puller
 do fender heat with gas torch
 and rapidly blow with hammer
 grind the fender
 paint the fender

127
 PAINT THE RAPAIR FENDER IN TIAGO
 Abrasion the sander paper on the fender
 clean the fender
 apply the putty on the fender
 levelling the putty
 abrasion the Amery paper on the fender
 move the car in paint both
 attach masking paper where the paint is not neccecery
 on the vacuume in both
 first the paint metal pal coat
 then paint the polish or finish coat
 leave it in paint both for drying about 5 to 6 hours
 once the paint is dry then Amery polish make on the fender
 washing the car

Fig: 7.74 Raiper Fender

128

Fig: 7.75 Paint Fender

 PAINT THE NEW BUMPER IN SAFARI

 fix the bumper on paint stand

 clean the bumper with water
 abrasion the Amery paper on the bumper
 dry the bumper
 move the bumper in paint both
 on the vacuume in both
 bumper clean with thinner
 first make plastic primer coat on bumper
 then make aster coat
 again clean the bumper with dry cloth
 make base paint coat on the bumper
 then paint the pal coat
 and finally paint the clear(finish) coat
 on heat in paint both
 leave it in paint both for drying about 5 to 6 hours
 once the paint is dry then Amery polish make on the bumper
 washing the car

129
Fig: 7.76 Paint Bumper

130
 RAPAIR ROOF WITH HAMMER,DOLLY AND SPOON IN
ZEST

 roof or car top is the portion of an automobile that sits above the passenger
compartment, protecting the vehicle occupants from sun, wind, rain, and other
external elements.
 Because the earliest automobiles were designed in an era of horse-drawn
carriages, early automobile roofs used similar materials and designs

 remove the interior roof trim

 remove the tar on the inside roof panel
 take dolly, and support inside
 do the hammer blow on the outer roof panel
 once the big dent is pulling then for finial shape use the spoon
 support the dolly and blow with the spoon
 paint the roof

Fig: 7.77 Roof

131
 CHANGE THE WINDSHIELD GLASS IN NANO(WINDSHILD
BROKEN)
 Windshields protect the vehicle's occupants from wind and flying debris such as
dust, insects, and rocks, and provide an aerodynamically formed window towards
the front.
 UV coating may be applied to screen out harmful ultraviolet radiation. However,
this is usually unnecessary since most auto windshields are made from laminated
safety glass.
 The majority of UV-B is absorbed by the glass itself, and any remaining UV-B
together with most of the UV-A is absorbed by the PVB bonding layer.
 remove the outer glass trim
 remove the inner pillar trim
 cut the glass with piano wire
 remove the glass
 remove the gasket Farsi
 apply the gasket maker adhesive on the penal where the glass is placed
 take glass with suction cup and fix the glass on the panel
 leave it 12 hours
 check leakage with solution of soap
7.9 Work done on Modern Technology
 CHANGE CRANK SHAFT POSITION SENSOR

 A crank sensor is an electronic device used in an internal combustion engine, both

Fig: 7.78 Windshild

petrol and diesel, to monitor the position or rotational speed of the crankshaft.

132
 This information is used by engine management systems to control the fuel
injection or the ignition system timing and other engine parameters.
 Before electronic crank sensors were available, the distributor would have to be
manually adjusted to a timing mark on petrol engines.
 The crank sensor can be used in combination with a similar camshaft position
sensor to monitor the relationship between the pistons and valves in the engine,
which is particularly important in engines with variable valve timing
 Common mounting locations include the main crank pulley, the flywheel, the
camshaft or on the crankshaft itself.
 This sensor is the 2nd most important sensor in modern-day engines after the
camshaft position sensor.
 When it fails, there is a probability the engine will not start, or cut out while
running
 The functional objective for the crankshaft position sensor is to determine the
position or rotational speed (RPM) of the crank.

Fig: 7.79 Crank Shaft Position Sensor

133
 CHANGE MASS AIR FLOW SENSOR

 A mass (air) flow sensor (MAF) is used to find out the mass flow rate of air
entering a fuel-injected internal combustion engine.
 The air mass information is necessary for the engine control unit (ECU) to balance
and deliver the correct fuel mass to the engine.
 Air changes its density as it expands and contracts with temperature and pressure.
In automotive applications, air density varies with the ambient temperature,
altitude and the use of forced induction, which means that mass flow sensors are
more appropriate than volumetric flow sensors for determining the quantity of
intake air in each cylinder.
 There are two common types of mass airflow sensors in use on automotive
engines.
 Neither design employs technology that measures air mass directly.
 However, with additional sensors and inputs, an engine's ECU can determine the
mass flowrate of intake air.

Fig: 7.80 Mass Air Flow Sensor

134
LT
IC
EH
V
R
A
7.10 Work done in Washing Area

Fig: 7.81 Car Washing Process

135
 car clean
with
cleanin com presser
g the d air
dashboa
rd
clean clean
the all the all
m ateing seats
s
clean clean the
the all intriar
engin clean trim s
e the
boot
Fig: 7.82 Car Cleaning With Compressed Air

136
 car cleaning with
solution of soap and
water

cleaning the
fander lining

clean the all clean

mateings boot

clean clean
the under
engine body

Fig: 7.83 Car

cleanCleaning With Solution Ofclean
SoapallAnd Water

the tyres
boot

137
 p c
p a p
o
o r o
l i
l i p l i
s
s o s
h
h l i h
t
a s d
h
l l h a
e
t i s
e
y n h
n
r g b
g i
e o
n
s a
e Fig: 7.84 Car Polishing
r
d

138
Fig: 7.85 Car Washing

139
7.11 Work Done In Front Office
 FRONT OFFICE

 The front office or reception is an area where visitors arrive and first encounter a
staff at a place of business.
 Front office staff will deal with whatever question the visitor has, and put them in
contact with a relevant person at the company.
 Broadly speaking, the front office includes roles that affect the revenues of the
business.
 The term front office is in contrast to the term back office which refers to a
company's operations, personnel, accounting, payroll and financial departments
which do not interact directly with customers.
 The front office receives information about the customers and will then pass this
on to the relevant department within the company.
 The front office can also contact the marketing or sales department should the
customers have questions.
 The company needs to give training to the front office manager as this position
will come in contact with customers the most.

Fig: 7.86 Front Office

140
  GENERAL STEPS OF CAR SERVICE

acc uud ssv tt a oo n mm c ee r b o o k i n g

scoc eaa n r c v ge i co c e at or ' s i s
orme rfm er c e a ter fit f or s r t s e r v i c e
atdr h do e vn a e c te h r a n
ttdsm ooe e ec ltt ieuhhv tr ee y r o n
wtwy e toaaa o rkm k i ns l hge oa pd e r
rrbs ee o ccr o vee k ipp c i ntitie goo n i s t o n
jfgs o ho br i t t co h a et r r d i a l o f
pntda dhia s e tvot e i nc ee r
scnc eaug rs vt oi c m e
er  JOB CARD MAKING
Fig: 7.87 General Step Of Car Service
141
 A job card can be described as a piece of paper that normally contains information
of a job that is to be done in a certain service facility. It contains the name of the
product, quantity,scheduling and any additional instruction.
 It is usually used to authorise service people in acertain authorised service
stations.

 A job card contains the following things:

 Customer Details

 Customer ID
 Contact No
 Customer Name
 Customer Address

 Vehicle Information

 Vehicle Model
 Vehicle Registration No.
 VIN No

 Service Information

 Job card no.

 Job type
 Odometer reading
 Vehicle Arrival Date & Time
 Promise Delivery Date & Time

 Vehicle Condition

 Vehicle Body Condition for Dent, Scratch, Peal, Cut, etc.

 Fuel Tank Level
 Accessories availability i.e. Warranty booklet, Tool kit, Jack & Handle, Spare
 Wheel, CD player, Mat, Steering wheel cover, Perfume bottle, Lighter, etc.

 Customer Request for Repairing work

 Estimated labour

142
 Work Performed
 Parts & Material used

143
Fig:7.88 Job Card
144
8. MY LIKING & DISLIKING OF WORK PLACES

145
146
9. LEARNING & CONCLUSION FROM TRAINING

In conclusion, I would like to say that by training at Cama Motors, I got

a reality check of the field which I am going to enter the knowledge which I got not
only about cars but the social level and economical level of the people with whom
which I am going to work with in future.

My 5 month industrial training at Cama Motors has been one of the most
interesting, productive and instructive experience in my life. Through this training, I
have gained new insight and more comprehensive understanding about the real
industrial working condition and practice; it has also improved my soft and functional
skills. All these valuable experiences and knowledge’s that I have gained were not
only acquired through the direct involvement in task but also through other aspects of
the training such as work observation, interaction with colognes, superior and other
people related to the field.

It also exposed me on some certain things about marine environment. In

addition, from what I have undergone, I am sure that industrial training program has
achieved its primary objective. Because of the program, I am now more confident to
build my future career, which I have already started with Cama Motors Limited.

I would like to thank all those people who made this happen, because the
experience of working at Cama Motors was remarkable.

It was a great honor that I got a chance to be a part of such a bright

company and such supportive college.

147
10. REFERENCES

 For Head Technician Terms Bhadreshbhai Vaghela

 For DET Terms Dhavalbhai Solanki

 Juned Sir As Team Leader

 https://en.wikipedia.org

 https://www.cardekho.com

 L J Polytechnic's All Faculty

148