Analysis of Automobile Components: Maruti Suzuki Zen Project Report

This report details a project undertaken at the Automobile Training Academy, focusing on the analysis of components in a Maruti Suzuki Zen Lxi model car. The project involved dissecting, fixing, and reassembling the engine, with a focus on understanding the functionality of various systems such as steering, braking, and suspension. The student, acting as an Automobile Dissector/Fitter, identified and addressed mechanical issues, including engine vibration and water leakage, through innovative solutions and collaborative teamwork. The report outlines the engineering knowledge and skills applied, the tasks performed, and the identified issues along with their solutions. The project successfully enhanced the student's technical competencies, providing valuable experience in automotive engineering and problem-solving. The student's responsibilities included disassembly, reassembly, testing, and documentation of the entire process, demonstrating a strong understanding of automotive mechanics. The project also highlights the application of reverse engineering and collaborative work to achieve the project objectives within the given timeframe.

CAREER EPISODE 1
CE 1.1 Project Information
Name of the project: Analysis of the functions of Automobile Components: MARUTI
SUZUKI ZEN
Location of the project: 54, Udyog Kendra Extension Part-I, Ecotech-III, Greater
Noida, Uttar Pradesh-201306, India
Project Duration: June 15 of 2014 to July 18 of 2014
Organization: Automobile Training Academy
Role and Designation during the time: Automobile Dissector/Fitter
CE 1.2 Project Background
CE 1.2.1 Characteristics of the project
This project was undertaken for understanding the working mechanism of an automobile
and what is leading to the current event. This project was also about understanding the functions
of all the components of the automobile and implications in the absence of the parts or
components. This project considered Maruti Suzuki Zen Lxi model car that has four-stroke, four
cylinders inline and petrol engine along with manual transmission. I had focused on studying the
automobile components such as steering system, braking system and suspension system. I had to
study about the engine, its functions and mechanical breakdown possibilities of the components.
This project also focused on finding remedial solutions and measures for the mechanical
breakdowns.

CE 1.2.2 Aim and Objectives developed for the project
The main objectives of this project were:
 To dissect the engine of the automobile
 To fix the engine
 To reassemble the automobile engine and test it
CE 1.2.3 My area of work
My main area of work was to study and dissect the essential components of the Maruti
Suzuki Zen Lxi model car. I had to report to the project supervisor while working on this project.
I had to study the working of the steering system, its types, possible breakdown and its evolution.
I also had to analyse the suspension system, engine, transmission and braking system. I was
assigned the task to disassemble the automobile engine and identify the discrepancies. I had to
alleviate the problems by developing innovative solutions. I had to ensure the safety of the team
by making sure that everyone in the team was wearing the protective equipment. I also had to
clean the engine components and effectively carry out the dismantling process.

Academy Head
(Mr. Sworoop Nandi)
Project Supervisor
(Er. Akshay Ramachandran)
Project
Executor 3
Project
Executor 4
Project
Executor 2
Project Member
(Rudra Prasad Dahal)
CE 1.2.4 Project Group
Figure 1: People involved in the project
CE 1.2.5 My responsibilities throughout the project
I was assigned the role of an Automobile Dissector/Fitter under the Automobile Training
Academy. I was involved in this project from June 15 of 2014 to July 18 of 2014. It was my
responsibility to carry out the project objectives and ensure the success of the project. The
project supervisor had given me the responsibility to carry out the dismantling as well as the
reassembly process. I was responsible for identifying the mechanical inaccuracies of the
automobile engine and develop solutions for rectifying the faults. The entire testing process of

the reassembled parts was also under my responsibility. I was responsible for supervising the
activities of the project team members. I also had to accurately carry out the entire
documentation process.
CE 1.3 Distinctive Activity
CE 1.3.1 Comprehending the theory of the project
Automobile engine is considered to be a fuel-consuming device that can be used for
propelling automobiles. Chemical energy in the fuel can be transformed into mechanical energy
by automobile engines. The pistons are moved up and down at a high speed for transferring the
energy. The crankshaft as well as axle is used for converting the up-down motion into rotary
motion. Intake, combustion, exhaust and compression are the four engine strokes. With two
crankshaft rotations, a complete cycle occurs.
CE 1.3.2 Engineering knowledge and skills applied in the project
I have utilized the knowledge and skills of mechanical engineering for properly using the
tools and driving the shafts, bolts and nuts. I have used my engineering knowledge to
appropriately level the components and accurately handle placing management with discretion.
My strong knowledge of the working principle of camshaft, crankshaft, spark plugs, timing belt,
water pump and fuel pump has helped me to carry out the reassembly process effectively. The
reassembly process was completed before the expected time.
CE 1.3.3 Accomplishment and task performed
Effective panning helped me to achieve the project objectives. The initial step taken by
me during the dismantling process was removal of the three mounting on the engine. The gear
box was disconnected from the engine. I had put the engine on stand. I used a 12 mm ring

spanner for removing the coolant pipe and compressor motor followed by the friction plate in an
order. I took the help of an L-bar with a 17mm socket for removing the flywheel. The ring
spanner was also used for removing the exhaust manifold. I had used a 14mm and 12mm socket
for loosening the side mountings. After relieving the oil filter, I had taken care of the oil spill. I
had disconnected the dip stick by using an 8mm T-bar. I used a 12mm key for detaching timing
cover and a 12mm ring spanner for drawing two bolts on the alternator. For separating the water
pump pulley, I had used a ring spanner of size 10mm. A 14m ring spanner was used for
removing the engine mounting. I used a 17mm socket along with an L-bar for disengaging the
camshaft pulley and a 10mm T-bar for removing the camshaft cap. I used a star-type special tool
of size 10mm while working on the cylinder head. This tool was used for removing the heads
inside nuts. I used a woodruff key for detaching the crankshaft gear. I had hammered the pistons
on the crankshaft side and had removed it. After removing the oil pump and water pump by
using a T-bar of 10mm, I had dismantled the crankshaft as well. The lifters were removed by me.
The lifters had control over the inlet valve and the head consisted of 16 valves. I pulled the
rocker shaft by using a 10mm bolt driver. After placing the whole setup in an order, I had
removed the valve spring and valves present on both the inlet and outlet. The cam shaft was
removed after removing the rocker shaft. I used a socket and L-bar for removing four spark
plugs. I had washed the several parts of the engine and concluded the dismantling process. The
reassemble process was carried out by me. The initial step was to assemble the cylinder head. I
had inserted the valve spring from below. The cotters were placed by using a valve spring
compressor. I along with my team members installed 16 valves with springs. After this, I had
placed the camshaft followed by the rocker shaft. My colleagues helped me to put the rocker arm
in the correct place. I was successful at placing the piston on the cylinder before mounting on the

engine block. I used a mallet to hammer the piston head and compress the piston for assembling
the piston on block. The crank shaft and cam shaft pulley were put on. I used a belt tensioner for
installing the timing belt. I was able to mount the water and oil pump on engine and put the
exhaust manifold along with the new gasket. I and my team members took the help of a crane to
lift the crane. I had tightened the bell housing nuts and bolts. I also fixed the starter motor, air
filter, AC condenser, radiator and all other electrical connections. This successfully concluded
the reassembly process. The educative and pragmatic nature of this project helped me to gain
extraordinary confidence and knowledge for solving bigger challenges in the future.
CE 1.3.4 Identified issues and their solutions
1.3.4.1 Issues
I carried out testing of the reassembled engine and found that there was no fault in the
engine. However, the spring number 3 and 15 were found to be faulty and was said to be
replaced. The high vibration of the engine during testing was considered to be one of the
technical anomalies. There was also water leakage from the water pump as well as the
lubrication system. The radiator had oil in it.
1.3.4.2 Solutions
I had bolted more engine mountings on the car for alleviating the vibration. I also
changed the gasket present on the water pump for solving the leakage problem. For detecting
whether one of the pressurized oil lines near the water jacket had leaked, I had opened the oil
cap. I found and replaced the damaged cap on cylinder head. I also changed the head gasket and
solved the problem.

CE 1.3.5 Plan to produce creative and innovative work
Innovative approach was undertaken to achieve the objectives of the project. I had used
the concept of reverse engineering while carrying out the reassembly process. I had developed
innovative solutions to solve the issue of high vibration of the engine and water pump leakage.
CE 1.3.6 Collaborative work
My colleagues and project team members were cooperative and respectful. I had
coordinated the activities of the team members. I ensured completion of project activities within
the given time by motivating the project team members and resolving any conflict among them.
CE 1.4 Project Review
CE 1.4.1 Project Overview
This project was undertaken during my summer internship training. It started on June 15
of 2014 and ended by July 18 of 2014. This project was about getting an insight into the
functions of the various components of an automobile. Maruti Suzuki Zen Lxi model car was
given to my team for carrying out this project.
CE 1.4.2 My contribution to work
The Automobile Training Academy had assigned me the role of an Automobile
Dissector/Fitter. I had successfully dissected and fixed the engine of Maruti Suzuki Zen Lxi
model car. I also identified the mechanical inaccuracies such as high vibration of the engine and
water pump leakage. I also developed innovative solutions for overcoming the inaccuracies. I
was able to effectively test the reassembled parts. The project document prepared by me had
impressed the project supervisor and the academy head. I was able to manage the project team

effectively for ensuring project success. This project enhanced my technical competencies and
motivated me to deal with bigger challenges in the future.