Summer Internship Project

A STUDY ON
“GALLOPS HYUNDAI”
Prepared by
JAPAN M VYAS
Enrollment No.: 200240102511
B.E AUTOMOBILE ENGINEERING

Under the guidance of

Prof. Sujal Thakkar
ACADEMIC YEAR
2022

Hasmukh Goswami College of Engineering, Ahmedabad.

Gujarat Technological University, Ahmedabad
JUNE, 2022
 HASMUKH GOSWAMI COLLEGE OF ENGINEERING
Automobile Engineering

2022
CERTIFICATE
Date:
This is to certify that a study on entitled “Gallops Hyundai’’ has been carried out by
Japan Vyas (200240102511) under my guidance in fulfillment of the degree of
Bachelor of Engineering in Automobile Engineering (7th Semester) of Gujarat
Technological University, Ahmadabad during the academic year 2022-23.

Internal Guide: Prof. Prakash Patel Head of Dept.: Prof. Sujal Thakkar

Asst. Professor, ME Dept. Head, AE Dept.

HGCE, Vahelal HGCE, Vahelal

 Student’s Declaration

I undersigned JAPAN MARKANDBHAI VYAS a student of HGCE B.E Mechanical

Engineering 7th semester, declare that summer internship project titled “Gallops Hyundai”
is a result of my/our own work and my/our indebtedness to other work publications,
references, if any, have been duly acknowledged. If I/we are found guilty of copying any
other report or published information and showing as my/our original work, I understand
that I/we shall be liable and punishable by Institute or University, which may include ‘Fail’
in examination, ‘Repeat study & re-submission of the report’ or any other punishment that
Institute or University may decide.

Name of Student: Japan Vyas

Enrollment Number: 200240102511

Signature:J.M.VYAS
 ACKNOWLEDGEMENT

The internship opportunity I had with Gallops Hyundai at Ahmadabad, Gujarat was a great chance for
learning and professional development. Therefore, I consider myself lucky as a very lucky individual
as I was provided with an opportunity to be a part of it. I am grateful for having a chance to meet so
many knowledgeable, experienced professionals who guided me throughout the period of internship
and were ready to help me whenever I had any doubts or difficulties.

I want to thank my mentor Mr. Raviraj sinh who took time out of their schedule and guided me
and allowed me to work on a project with other employees of the organization. I am also thankful
to my HOD and other for providing guidelines related to internship.
The Final Year Project Has Been Carried Out at the Department of Automobile, Gujarat Technological
University. I would like to express my sincere thanks to my external guide Mr. Prof. Sujal Thakkar whose
guidence and encouragement is invaluable. It has been an honor and memorable experience working with
him.
I would also like to thank my internal guide Prof. Prakash Patel, Head of BE Department, Finally we would
like to thank everyone and the faculty member who directly or indirectly helped us in the project.
Our thanks go to all the staff members of Department of Automobile Engineering

With thanks to all.

JAPAN M VYAS
( 200240102
 ABSTRACT

Industrial Internship plays an important role in a student’s life. A well planned, properly executed
and evaluated industrial training helps a lot in developing a professional attitude. It develops an
awareness of industrial approach to problem solving based on a broad understanding of process
and mode of operation of organization. Aim of industrial internship is to receive practical and
communication skills and technical knowledge which will help me, as an automobile Engineering
student.

The period of 2 weeks at Mercedes-Benz, Central Star, I was authorized in service department and
body panel department [denting and painting].

In service centre, I was exposed to all the modern services processes of Mercedes-Benz. All the
modern instruments such as oil filler machine, wheel balancer, wheel alignment machine were all
required to service the vehicles in service department.

In service department, service all required part with check list mark it out. Than start repairing or
service as per given servicing steps and need to provide the daily reports about serviced vehicles
and replaced parts . After completion of servicing and replacing , run-off or testing of vehicles
takes place for a pre-determined time to examine any issues and trouble shoot them.

In body panel department, I explored the accidental jobs to be done on the vehicle and complete
the vehicle with a finishing work.
200240102511

LIST OF FIGURES

Sr. No. Figure Pg.No.

1.1 Workshop from inside 2

1.2 Workshop from outside 2

1.3 Different products 3

2.1 Organizational structure 5

2.2 GDS diagnosis 6

2.3 Tyre replacement machine 7

2.4 Hydraulic lift 8

2.5 Paint booth 9

2.6 Wheel alignment 10

2.7 Wheel balancing 11

2.8 Air pressure gun 11

200240102511

TABLE OF CONTENTS

Sr .No. Contents Pg.No.

Declaration IV
Acknowledgement V
Abstract VI
List of Figures 7
Table of Contents 8

Chapter 1. Introduction of Company

1.1 History of the company 1
1.2 Introduction of workshop 2
1.3 Different products 3

Chapter 2. Overview of Different Units & Production Layout of Company

2.1 Work in the service center 4
2.2 Organizational structure 5
2.3 Technical specified tools and equipment 6
2.3.1 GDS diagnosis 6
2.3.2 Tyre replacement machine 7
2.3.3 Hydraulic lifts 8
2.3.4 Paint booth 9
2.3.5 Wheel Alignment 10
2.3.6 Wheel balancing 11
2.3.7 Air pressure gun 11
Chapter 3. Work Responsibilities
3.1 Day 1 13
3.1.1 Information of tool 13
3.1.1.1 Ring/box Wrench 13
3.1.1.2 Hammer 13
3.1.1.3 Fix/Open wrench 13
200240102511
3.1.1.4 Combination wrench 13

3.1.1.5 Allen key 14

3.1.1.6 Socket 14
3.1.1.7 Ratchet 14
3.1.1.8 Pliers 14
3.1.1.9 Punch 14
3.1.1.10 Adjustable Wrench 14
3.1.1.11 Hydraulic jack 14
3.1.1.12 Wheel Wrench 14
3.1.1.13 Torque wrench 15

3.2 Day 2
3.2.1 vehicle inspection 15
3.2.2 Fluid check 15
3.3 Day 3 15
3.3.1 Change oil filter 15
3.3.2 Change Air filter 16
3.4 Day 4 16
3.4.1 Oil change 16
3.4.2 Oil filter change 16
3.5 Day 5 17
3.5.1 Throttle Body service 17
3.6 Day 6 17
3.6.1 Breakpad Change 17
3.7 Day 7 17
3.7.1 Clutch Overhauling 17
3.7.2 oil change 18
3.8 Day 8 18
3.8.1 Sparkplug Change 18
3.8.2 Air filter Change 18
3.9 Day 9 19
20024010251
1 3.9.1 EV coolent Change 19

3.10 Day 10 24
3.10.1 Power window change 19
3.10.2 Sparkplug Change 19
3.11 Day 11 20
3.11.1 Fuel Filter Change 20
3.11.2 vehicle inspection 20
3.12 Day 12 20
3.12.1 Head Light change 20
3.12.2 Oil change 20
3.13 Day 13 21
3.13.1 Air filter change 21
3.13.2 Sparkplug Change 21
3.14 Day 14 21
3.14.1 vehicle inspection 21
3.14.2 Throttle Body service 22
3.14.3 Oil change 22

3.14.4 Breakpad Change 22

Chapter 4. 23
Skills Learned and the Experiences
Chapter 5. 24
Conclusion
Reference 25
 CHAPTER 1
200240102511

CHAPTER:1

INTRODUCTION TO COMPANY

1.1 History of the Company

Chung Ju-Yung was born in November 25, 1915.He was a South Korean entrepreneur, businessman
and the founder of Hyundai groups of South Korea. Chung was integral part of rapid development
of korea's economy.Chung Ju-Yung founded the hyundai engineering and construction in 1947.
Hyundai Motor Company was later established in 1967.
The company was founded in 1967 December 29 and along with its 32.8% owned subsidiary Kia
motors.The Hyundai motor company is a South Korean multinational automotive manufacturer.
Hyundai motor company is headquartered in Seoul, South Korea.
In 1968, the Cortina was the very first vehicle successfully assembled by Hyundai at its Ulsan plant,
in cooperation with Ford Motor Company. Hyundai set a record for the quickest time between
ground-breaking and full-scale operations for any Ford assembly plant around the world – just
under six months.
When Hyundai wanted to develop their own car, they hired George Turnbull in February 1974, the
former managing director of Austin Morris at British Leyland. He in turn hires five other top British
car engineers. They were Kenneth Barnett for body design, John Simpson and Edward chapman for
engineering, John Crosthwaite ex-BRM as chassis engineer and peter slater as chief development
engineer.
In 1975, the pony, the first south Korean car was released, with styling by Giorgio of Italy and
powertrain technology provided by Japan's Mitsubishi motors. Exports began in the following year
to Ecuador and soon thereafter the Benelux country.
When Hyundai wanted to develop their own car, they hired George Turnbull in February 1974, the
former managing director of Austin Morris at British Leyland. He in turn hires five other top British
car engineers. They were Kenneth Barnett for body design, John Simpson and Edward chapman for
engineering, John Crosthwaite ex-BRM as chassis engineer and peter slater as chief development
engineer.
In 1975, the pony, the first south Korean car was released, with styling by Giorgio of Italy and
powertrain technology provided by Japan's Mitsubishi motors. Exports began in the following year
to Ecuador and soon thereafter the Benelux country.

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200240102511
1.2 Introduction of Workshop

GALLOPS HYUNDAI is a chain of Hyundai Brand dealerships of PUGALIA GROUP, The group
runs under the leadership of Shri Rajkumar Pugalia and Mr Tanuj Pugalia. The Pugalia Group is
now recognized as a major business group in Ahmedabad, Mumbai & Rajkot with for the state art
showrooms and workshops. Hyundai currently has ten car models across segments – SANTRO,
GRAND i10,GRAND I10 NIOS, ELITE i20, ACTIVE i20, XCENT, VERNA,CRETA, VENUE,
ELANTRA & TUCSON. We provide facilities like Finance, Exchange, Insurance, Accessories and
Car Detailing. We truly believe in Customer Satisfaction and we give all customer a delightful
experience and family like environment.We are a proud family of over 70,000 happy customers and
counting...

Fig. 1.1 Workshop from inside

+

Fig. 1.2 Workshop from outside

2
1.3 Different Products

Fig. 1.3 Different products(1)

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CHAPTER 2

OVERVIEW OF DIFFERENT UNITS & PRODUCTION

LAYOUT OF COMPANY

2.1 Work in Service Centre

Car is a complex machine and it runs on various fluids that should be kept in the best shape in order
to ensure that your car remains in good health. Be it engine oil, coolant or other fluids, all of them
need to be replaced from time to time. If you replace these fluids timely, you can be sure of the fact
that your car will last longer and you will have a good ownership experience throughout.

Various works like vehicle servicing, accidental repairs, painting and washing are done within
the service center.
For breakdown maintenance, a 24 hour service vehicle is available if any of the Mercedes- Benz car
is breakdown on the road. Automobile service vans fitted with tools, equipments, generator, chain
pulley, grease gun, etc for cars.

A garage is a one-stop shop for all automotive repairs. Mechanics have to be very knowledgeable
about the workings of different makes and models of cars and an in dept h understanding of how
they work. Garages are the go-to place if you have any questions about your car’s performance; if
you need advice about motoring matters; if you know that there is something wrong with your car
and you need it fixed or if your vehicle is due a servic or MOT.

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2.2 Organizational Structure

Tanuj Pogaliya
(Dealership Owner)

Deepak shahu
(General Manager)

Pritesh Patel
(Service Manager)

Service Advisor

Floor

Technician

Fig. 2.1 Organizational structure

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An organizational structure is a system that outlines how certain activities are directed in order to
achieve the goals of an organization. These activities can include rules, roles, and responsibilities.
The organizational structure also determines how information flows between levels within the
company. For example, in a centralized structure, decisions flow from the top down, while in a
decentralized structure, decision-making power is distributed among various levels of the
organization. Having an organizational structure in place allows companies to remain efficient and
focused.

Various departments were organized by the company in order to maintain proper cust om experience
and maintain the data and execute the work smoothly.

2.3 Technical specified Tools and Equipment

The specialized tools and equipments used in the Hyundai

2.3.1 GDS diagnosis

Fig. 2.2 GDS diagnosis(2)

Description. The Hyundai GDS is the most advanced diagnostic tool for all Hyundai
vehicles. The GDS provides complete functionality from diagnosis to reprogramming as
HGCE-AUTO 6
200240102511 CHAPTER 2
well as maintenance and service information
GDS VCI Diagnostic Tool is an advanced service system that provides comprehensive coverage for
all Hyundai vehicles including all Hybrid cars. GDS provides complete diagnostics, analysis and
reprogramming capabilities as well as a huge library of technical, service and repair information.
2.3.2 Tyre replacement machine

Fig. 2.3 Tyre replacement machine(3)

A tire changer is a machine used to help tire technicians dismount and mount tires with automobile
wheels. After the wheel and tire assembly are removed from the automobile, the tire changer has all
the components necessary to remove and replace the tire from the wheel.

The following list provides an explanation of an operator installing a tire onto a wheel using a tire
changer. The operator centers the wheel and securely fastens it onto the table top with the rim clamp
mechanism with the narrow bead-ledge up of the wheel. The operator pushes the bottom bead first in
the well of the wheel. The operator pushes the top bead down into the center well of the wheel under
HGCE-AUTO 7
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the duckhead and rotates the table top using the table top pedal. The operator installs a valve core.
The operator slowly inflates the tire until the beads "pop" on the bead ledge of the wheel. The
operator releases the rim clamps and inflates the tire to manufacturer specifications.

2.3.3 Hydraulic lifts

Fig. 2.4 Hydraulic lift(4)

Hydraulic lifts are able to move cars upward when a pump in their structure pushes a liquid from a
fluid container to a hollow cylinder. As the cylinder fills with the liquid, a piston component inside it
is forced to move upward, which generates the movement of the lift.

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2.3.4 Paint booth

Fig. 2.5 Paint booth(5)

A spray booth is a specially designed enclosure used to house spray equipment and isolate expelled
vapor that is generated during a spray application process. Spray processes are used to apply
corrosion preventative coatings to a metallic surface. Spray booths are typically intrinsically safe and
built to be fire and explosion proof.
A paint booth works by manipulating the principles of negative and positive air pressure. Spray
painting booth ventilation relies on the balance of the exhaust fan and the air replacement fan. If just
the exhaust fan is on, the booth takes on negative pressure, since more air is being removed than
pushed in. If the door opens, it will try to pull in as much air as it can from the outside, yanking in
dirt and debris along with it. If just the replenishing fan is on, you’ll get positive air pressure in the
booth, and it will try to push that air outward when the door is open.
Contaminants and debris will get swept away from it, keeping the inside cleaner.

A spray booth is typically used when it is impractical to conduct surface preparation or coating
activities outdoors or in an unprotected indoor area. This can be due to several factors such as
inadequate weather or atmospheric conditions, environmental hazards associated with the coating to
be applied, worker preference, temperature regulation and vapor confinement.
It is a large, contained environment equipped with exhaust fans and filters to make commercial spray
painting safer and cleaner. It improves results by altering air pressure to blow contaminants out of the

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container and clear out overspray from the paint sprayers. As it does this, fresh, clean air is
consistently pushed into the booth.

2.3.5 Wheel Alignment

Fig. 2.6 wheel alignment

Alignment refers to an adjustment of a vehicles suspension that connects a vehicle to its wheels.The
key to proper alignment is adjusting the angles of the tires which affects how they make contact with
the road. Alignment angles can also be altered beyond the maker's specifications to obtain a specific
handling characteristic.

2.3.6 Wheel balancing machine

Wheel balancing, also known as tire balancing, is the process of equalizing the weight of the
combined tire and wheel assembly so that it spins smoothly at high speed.

Balancing involves putting the wheel/tire assembly on a balancer, which centers the wheel and spins
it to determine where the weights should go. Every time a wheel is first mounted onto a vehicle with
a new tire, it has to be balanced.

HGCE-AUTO 10
200240102511 CHAPTER 2

Fig. 2.7 wheel balancing

2.3.7 Air Pressure gun

Fig. 2.8 air pressure gun

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200240102511 CHAPTER 2

An air gun, is a socket wrench power tool designed to deliver high torque output with minimal
exertion by the user, by storing energy in a rotating mass, then delivering it suddenly to the output
shaft.Air pressure gun speed up heavy duty processes a lot.
Majorly, air pressure gun is used for loosening or tightening bolts.

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CHAPTER 3.
WORK RESPONSIBILITIES

3.1 DAY 1

3.1.1 Information of Tool

Information about different Type of tool use in Service station

3.1.1.1 RING/BOX WRENCH

It is another type of wrench but with a box shape or closed circle shape.The benefit of a box
ended nut is that because they fit completely over the nut you get more powerful leverage,but
they are harder to use in tight spaces where you don't have enough clearance to slide the wrench
over the nut.

3.1.1.2 HAMMER
A hammer is a tool, consisting of a weighted "head" fixed to a long handle that is swung to
deliver an impact to a small area of an object. It is used for setting rivet.It is used to strike
blows on metal sheet up to a certain depth.

3.1.1.3 FIX/OPEN WRENCH

The job of a wrench is to tighten or loosen nut or bolt to fasten a joint.
the head of wrench fits over the nut providing leverage to tighten or loosen it.Many open ended
wrenches are double sided with different size of wrench on each end.

3.1.1.4 COMBINATION WRENCH

A combination of an open end wrench and a box end wrench.
This gives you the versatility of an open end wrench that can fit in tighter spaces and extra power
of box end wrench.
You can use the closed end wrench to loosen a difficult nut and then the fix end to remove the nut
more quickly.

3.1.1.5 ALLEN KEY

An Allen key or Allen wrench is also known as Hex key. This is a small handheld tool used for turning
bolts and screws which have hexagonal sockets.They are a lightweight addition to any toolbox that don't
take up much space, are inexpensive, and always come in handy.

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3.1.1.6 SOCKET
Sockets are a tool that attaches to a socket wrench, ratchet, torque wrench or other turning tools
to tighten or loosen a nut or bolt by turning it.Sockets are typically sold in sets with a drive tool.
Sockets are tools used to tighten mechanical fasteners.They fit over the head of the fastener to
provide torque.

3.1.1.7 RATCHET
A ratchet is a common wrench device with a fastener component.
A ratchet is a handle that snaps into one end of a socket by means of a square-drive connector.
The other end of the socket fits over a fastener.
A mechanism in the ratchet allows the handle to engage and tighten the fastener when you
swing it in a clockwise direction and turn freely when you swing it counterclockwise.

3.1.1.8 PLIERS
The primary use of pliers is for gripping.You can put them to work at loosening or tightening
bolts, holding objects for stabilization, or removing pins, nails or other fasteners.Pliers are
designed to be used for a combination of tasks including peeling/cutting wire.

3.1.1.9 Punch
Punches are used to drive fasteners such as nails and dowels, making a hole, or forming an
indentation/impression of the tip on a workpiece. The points in a line easily visible when cutting
or chipping the work piece.
In one stroke only the pointed end of punch gives sufficient impression on the work piece in the
form of the work.

3.1.1.10 ADJUSTABLE WRENCH

An adjustable wrench, also known as an adjustable spanner or crescent, is used to turn or loosen
a nut or bolt. This wrench has jagged jaws, one of which you can adjust to get the grip you
need.

3.1.1.11 Hydraulic Jack

A hydraulic jack is a device that is used to lift heavy loads by applying a force via a hydraulic
cylinder. Hydraulic jacks lift loads using the force created by the pressure in the cylinder
chamber.

3.1.1.12 WHEEL WRENCH

A wheel wrench is a tool used to manually loosen and tighten the nuts on automobile wheels. It
is also used with jack for lifting the car.

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3.1.1.13 TORQUE WRENCH

Used in car garages or in industry, a torque wrench is used to check and adjust the tightening
torque of bolts, screws and nuts. A torque wrench is a precision tool which guarantees reliable
and quality tightening.
Its use is essential to avoid any deterioration or breakage on the various clamping parts. It is
mostly used in engine overhauling.

3.2 DAY 2

3.2.1 Vehicle inspection

The inspection of tyre is taken first to measure the wear of all the four tyre along with the spare
wheel which is called “baby wheel”. The vehicle is inspected and remarked all the physical
damages along the job card. All the interior and exterior damages like scratches, dents, marks,
debris, etc are noted carefully. Then the vehicle is job card is prepared by the advicers.Then the
vehicle is taken for further process after this initial inspections.

3.2.2 Fluid check, Air filter check, Ac filter check

Check and inspect all fluid of car like engine oil, coolent, wind screen washer liquid. Check air
filter and ac filter

3.3 DAY 3

3.3.1 Change oil Filter

Place the car in correct position with respect to hydraulic lift and then lift up the car. Keep the oil
pan vertically below the oil filter. Now, loosen the oil filter using oil spanner. Now slowly
unscrew oil filter and remove.TAKE CAUTION WHILE REMOVING OIL FILTER, HOT
OIL MAY
BURN YOUR HANDS* Now lubricate the o-ring of the new oil filter and screw it using oil filter
spanner.*MAKE SURE THAT THE O-RING OF OLD OIL FILTER IS ALSO REMOVED, IT
CAN CAUSE LEAKAGE*

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3.3.2 Change Air Filter

Open the air filter box. WHILE OPENING AIR FILTER BOX, TAKE CAUTION BECAUSE
THE BOX MAY CONTAIN WIRING HARNESS AROUND IT* After opening the cover of the
air filter box, remove the old air filter.*INSPECT THE AIR FILTER AND MAKE SURE THAT
IT REALLY NEEDS TO BE CHANGED OR CAN BE USED AGAIN AFTER
CLEANING*Replace the old air filter with the new one.

3.4 DAY 4

3.4.1 Oil change

Place the car in correct position with respect to hydraulic lift and then lift up the car.*BEFORE
LIFTING THE CAR MAKE SURE THAT THE HOOD IS CLOSED*After lifting the car,
loosen the oil chamber bolt, and then hold the oil dripping pan closer to it. Now, slowly open the
chamber bolt, and let bad oil drain in pan.

After the oil is completely drained, lower the car, open hood, open engine oil cap and pour engine
oil. Close engine oil cap and hood.

3.4.2 Oil filter change

Place the car in correct position with respect to hydraulic lift and then lift up the car.*BEFORE
LIFTING THE CAR MAKE SURE THAT THE HOOD IS CLOSED*Keep the oil pan vertically
below the oil filter.Now, loosen the oil filter using oil spanner.

Now slowly unscrew oil filter and remove.*TAKE CAUTION WHILE REMOVING OIL
FILTER, HOT OIL MAY BURN YOUR HANDS* Now lubricate the o-ring of the new oil filter
and screw it using oil filter spanner. *MAKE SURE THAT THE O-RING OF OLD OIL FILTER
IS ALSO REMOVED, IT CAN CAUSE LEAKAGE*

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3.5 Day 5

3.5.1 Throttle body service

Open the hood and remove air filter body.Detach air filter body from throttle body.Ask helper to press
accelerator pedal.*THE ACCELERATOR PEDAL SHOULD BE KEPT PRESSED TILL COMPLETE
CLEANING IS NOT DONE*Spray the throttle body cleaner around the butterfly valve and wipe out all
the sludge formed after cleaning with a clean cloth.

3.6 DAY 6

3.6.1 Break pad change

Place the car in correct position with respect to hydraulic lift and then lift up the car. *DON'T
RAISE THE CAR TOO HIGH, IT MAY BECOME DIFFICULT TO REMOVE WHEELS AND
CHANGE BRAKE PADS**AND MAKE SURE TO OPEN THE BRAKE OIL CAP* Remove
the wheels. Loosen the lower and upper bolt of caliper. Open lower bolt and pivot caliper. Slide
out old brake pads and install retaining clips. Install new brake pads. Compress piston, reposition
caliper and tighten both bolts. Install wheels and tighten the wheel nuts. Lower the vehicle, check
brake oil level and top up if needed.

3.7 DAY 7

3.7.1 Clutch overhauling

Disconnect the Battery and remove it. Remove the battery stand, ECM and air filter
body.*DETACH THE ECM COUPLER CAREFULLY, IT MAY DAMAGE TERMINALS*

Disconnect the gear cables and remove the bolts (of the upper area) of rounding, and now raise
the vehicle. Remove the underbody cover if present and place tall jack stand to support engine
now drain the gear oil in a container and remove the lower mounting. Then remove live axle from
gearbox. Remove the lower rounding bolts. Remove the gearbox then the clutch would be
exposed.

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Remove the old clutch and reinstall the new. *MAKE SURE THAT THE CLUTCH CENTRE
COINCIDES WITH THE CENTRE OF FLYWHEEL* Now repeat the process in reverse.

3.7.2 Oil change

Place the car in correct position with respect to hydraulic lift and then lift up the car.*BEFORE
LIFTING THE CAR MAKE SURE THAT THE HOOD IS CLOSED*After lifting the car,
loosen the oil chamber bolt, and then hold the oil dripping pan closer to it. Now, slowly open the
chamber bolt, and let bad oil drain in pan.

After the oil is completely drained, lower the car, open hood, open engine oil cap and pour engine
oil. Close engine oil cap and hood.

3.8 DAY 8

3.8.1 Spark plug change

Open the hood and remove the air filter body. Below air filter body, HT cable is connected to
spark plugs. Detach HT cables from spark plugs. Attach connection rod to socket of correct size
and place over spark plug. Remove spark plugs one by one using ratchet. *TAKE CAUTION
WHILE HANDLING OLD SPARK PLUGS, THE MIGHT BE HOT* Install new spark plugs
carefully and attach HT cable according to number.

*DON'T DROP SPARK PLUGS IN SPARK PLUG SOCKET, THIS MAY AFFECT THE
ELECTRODE GAP* *MAKE SURE THAT THE SPARK PLUGS ARE TIGHTENED WELL
AND HT CABLE IS PROPERLY ATTACHED* Reinstall the air filter body.

3.8.2 Air Filter change

Open the air filter box. WHILE OPENING AIR FILTER BOX, TAKE CAUTION BECAUSE THE BOX
MAY CONTAIN WIRING HARNESS AROUND IT* After opening the cover of the air filter box,
remove the old air filter.*INSPECT THE AIR FILTER AND MAKE SURE THAT IT REALLY NEEDS

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TO BE CHANGED OR CAN BE USED AGAIN AFTER CLEANING*Replace the old air filter with the
new one.

3.9 DAY 9

3.9.1 EV coolent change

Your check engine light may turn on Coolant will frequently leak out when the engine is running.
Check the ground when you park. Your heater may stop working Steam will come from the
radiator or hood Sediment or rust will be interesting in the coolant. Your temperature gauge will
read well above ordinary with the engine on for a few minutes.
Sometimes, albeit improbable, you'll be productive to smell an odd burning odor coming from
under the hood. Unusual grinding noises can come from the engine

3.10 DAY 10

3.10.1 Power window change

Open the door which needs power window switch replacement. Remove cover of door latch and
plastic trim panel. *MAKE SURE THAT AFTER REMOVING PLASTIC TRIM PANEL, ALL
THE PUSH BUTTONS ARE ATTACHED TO TRIM PANEL* Remove coupler of switch and
then remove switch. Install new switch, attach coupler and check its operation. Attach trim panel
to door and then fix the door latch cover.

3.10.2 Spark plug Change

Open the hood and remove the air filter body. Below air filter body, HT cable is connected to
spark plugs. Detach HT cables from spark plugs. Attach connection rod to socket of correct size
and place over spark plug. Remove spark plugs one by one using ratchet. *TAKE CAUTION
WHILE HANDLING OLD SPARK PLUGS, THE MIGHT BE HOT* Install new spark plugs
carefully and attach HT cable according to number.
*DON'T DROP SPARK PLUGS IN SPARK PLUG SOCKET, THIS MAY AFFECT THE
ELECTRODE GAP* *MAKE SURE THAT THE SPARK PLUGS ARE TIGHTENED
WELL
AND HT CABLE IS PROPERLY ATTACHED* Reinstall the air filter body.

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3.11 DAY 11

3.11.1 Fuel filter change

Remove battery and ECM. Fuel filter is now exposed, now remove coupler of water sensor
and detach fuel pipes. Now remove fuel filter cover. Remove water sensor from bottom and
collect fuel in a container. Place fuel filter body on bench wise and remove filter Collect fuel in
container. Now install new fuel filter and attach water sensor then attach fuel filter to cover and
install it. Attach entry fuel pipe and water sensor coupler and then pump the filter until filter gets
filled with diesel.

3.11.2 Vehical inspection

The inspection of tyre is taken first to measure the wear of all the four tyre along with the spare
wheel which is called “baby wheel”. The vehicle is inspected and remarked all the physical
damages along the job card. All the interior and exterior damages like scratches, dents, marks,
debris, etc are noted carefully. Then the vehicle is job card is prepared by the advicers.Then the
vehicle is taken for further process after this initial inspections.

3.12 DAY 12

3.12.1 Head light change

Open the hood. Remove the bolts of head light with which it is attached to body. Remove
headlight so that adequate room is available for detaching coupler. Attach new headlight with
new coupler and install it. Check operation of new headlight.

3.12.2 Oil change

Place the car in correct position with respect to hydraulic lift and then lift up the car.*BEFORE
LIFTING THE CAR MAKE SURE THAT THE HOOD IS CLOSED*After lifting the car,
loosen the oil chamber bolt, and then hold the oil dripping pan closer to it. Now, slowly open the
chamber bolt, and let bad oil drain in pan.

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After the oil is completely drained, lower the car, open hood, open engine oil cap and pour engine
oil. Close engine oil cap and hood.

3.13 DAY 13

3.13.1 Air filter change

Open the air filter box. WHILE OPENING AIR FILTER BOX, TAKE CAUTION BECAUSE THE BOX
MAY CONTAIN WIRING HARNESS AROUND IT* After opening the cover of the air filter box,
remove the old air filter.*INSPECT THE AIR FILTER AND MAKE SURE THAT IT REALLY NEEDS
TO BE CHANGED OR CAN BE USED AGAIN AFTER CLEANING*Replace the old air filter with the
new one.

3.13.2 Sparkplug Change

Open the hood and remove the air filter body. Below air filter body, HT cable is connected to spark plugs.
Detach HT cables from spark plugs. Attach connection rod to socket of correct size and place over spark
plug. Remove spark plugs one by one using ratchet. *TAKE CAUTION WHILE HANDLING OLD
SPARK PLUGS, THE MIGHT BE HOT* Install new spark plugs carefully and attach HT cable according
to number.
*DON'T DROP SPARK PLUGS IN SPARK PLUG SOCKET, THIS MAY AFFECT THE ELECTRODE
GAP* *MAKE SURE THAT THE SPARK PLUGS ARE TIGHTENED WELL AND HT CABLE IS
PROPERLY ATTACHED* Reinstall the air filter body.

3.14 DAY 14

3.14.1 Vehicle inspection

The inspection of tyre is taken first to measure the wear of all the four tyre along with the spare
wheel which is called “baby wheel”. The vehicle is inspected and remarked all the physical
damages along the job card. All the interior and exterior damages like scratches, dents, marks,
debris, etc are noted carefully. Then the vehicle is job card is prepared by the advicers.Then the
vehicle is taken for further process after this initial inspections.

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3.14.2 Throttle body service

Open the hood and remove air filter body.Detach air filter body from throttle body.Ask helper to press
accelerator pedal.*THE ACCELERATOR PEDAL SHOULD BE KEPT PRESSED TILL COMPLETE
CLEANING IS NOT DONE*Spray the throttle body cleaner around the butterfly valve and wipe out all
the sludge formed after cleaning with a clean cloth.

3.14.3 oil change

Place the car in correct position with respect to hydraulic lift and then lift up the car.*BEFORE
LIFTING THE CAR MAKE SURE THAT THE HOOD IS CLOSED*After lifting the car,
loosen the oil chamber bolt, and then hold the oil dripping pan closer to it. Now, slowly open the
chamber bolt, and let bad oil drain in pan.

After the oil is completely drained, lower the car, open hood, open engine oil cap and pour engine
oil. Close engine oil cap and hood.

3.14.4 Breakpad change

Place the car in correct position with respect to hydraulic lift and then lift up the car. *DON'T
RAISE THE CAR TOO HIGH, IT MAY BECOME DIFFICULT TO REMOVE WHEELS AND
CHANGE BRAKE PADS**AND MAKE SURE TO OPEN THE BRAKE OIL CAP* Remove
the wheels. Loosen the lower and upper bolt of caliper. Open lower bolt and pivot caliper. Slide
out old brake pads and install retaining clips. Install new brake pads. Compress piston, reposition
caliper and tighten both bolts. Install wheels and tighten the wheel nuts. Lower the vehicle, check
brake oil level and top up if needed.

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CHAPTER 4.
SKILLS LEARNED AND EXPERIENCE
Build and assemble machines or mechanical components according to requirements. Inspect
machines, engines, transmissions etc. Conduct repairs aiming for maximum reliability.
Troubleshoot reported problems and resolve them in a timely manner. Perform thorough
maintenance on machinery, equipment and systems. The hands on shop experience puts an
engineer in a much better position to apply the classroom learning as an engineer. It shapes the
ability to design parts that are economic to make and gives you respect for the people anyone will
work with in the future. The skills learned is the detailed study and understanding the concept
behind each component of the vehicle. The experience was great full to learn about the German
parts components and the vehicle in detail along with the organizational structure and working.
I enjoy working in a team environment, and I get along well with people. In my past work
experience, I implemented a system to help organize the communication between my coworkers
to enhance our productivity as a team. It helped us delegate tasks more easily, which led to earlier
completion dates.

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CHAPTER 5.
CONCLUSION
In conclusion, the internship was a useful experience. I have find out what my strengths and
weaknesses are; I gained new knowledge and skills and met many new people. I achieved
many of my learning goals, however for some the conditions did not permit to achieve them
as I wanted. All disclosures were awaken myself in a boost of self-confidence to face life
more challenging now. There have been a lot I've learnt from my work at Gallops Hyundai.
Needless to say, the technical aspects of the work I've done are not flawless and could be
improved provided enough time. The whole experience related to the internship at Gallops
Hyundai has been very positive and exciting.

The main experience was to learn about the construction and working of Korian made cars
and its components. I have understood the organizational structure of the Gallops Hyundai.

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REFERENCES

1. https://autoportal.com/news/hyundai-cars-and-suvs-are-available-with-exciting-
offers-16212.html

2. https://diagnoex.com/products/hyundai-gds-dealer-diagnostic-tool

3. https://www.indiamart.com/proddetail/tyre-changing-machine-10766135373.html
4. https://www.indiamart.com/proddetail/hydraulic-car-lift-10963932488.html
5. https://www.indiamart.com/vinayak-hyundai/

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