INTERNSHIP

MAY 25, 2017

HYUNDAI
23 St, Shuwaikh Industrial, Kuwait
 INDUSTRIAL TRAINING

A REPORT

Submitted by
SAAD SAYEED HALDE
[1516080074]

DIPLOMA
IN
MECHANICAL ENGINEERING

AI-ABDUL RAZZAK KALSEKAR POLYTECHNIC

 ACKNOWLEDGEMENT

I am truly thankful to all the guides who

imparted the lecture on various topics and took
me to the workshop in a guided study visit along
detailed explaining about the cars and their parts
and problems.
I would like to thank all the people also that
works in the organization. With their patience
and openness, they created an enjoyable
working environment. Furthermore, I want to
thank all the engineers with whom I did the
internship. I experienced great things together
and they taught me many more things regarding
automobile.
I am indebted to respected officers and
engineers:
1.Mr. Munir Musameh (General Manager)
2.Mr. Azim Kagadi (Service Manager)
 CONTENTS

CHAPTER NO.
1. COMPANY PROFILE
2. INTRODUCTION TO PROJECT
3. DEPARTMENTS
4. ENGINE
5. PROBLEM FACED BY AUTOMOBILE
6. CONCLUSIONS
 EXECUTIVE SUMMARY
Chung Ju-Yung founded the Hyundai
Engineering and Construction Company in
1947. Hyundai Motor Company was later
established in 1967. The company’s first model,
the Cortina, was released in cooperation with
Ford Motor Company in 1968. When Hyundai
wanted to develop their own car, they hired
George Turnbull, the former Managing Director
of Austin Morris at British Leyland. He in turn
hired five other top British car engineers. They
were Kenneth Barnett body design, engineer
John Simpson and Edward Chapman, John
Crosthwaite ex-BRM as chassis engineer and
Peter Slater as chief development engineer. In
1975, the pony, the first Korean car, was
released, with styling by Giorgio Giugiaro of
Ital Design and powertrain technology provided
by Japans Mitsubishi Motors.
CHAPTER-1
COMPANY PROFILE
 THE HYUNDAI GROUP: COMPANY OVERVIEW

Hyundai is a global company with local

understanding. Founded by Ju-Yung in
1947. It was later established in 1967.
The company was founded in 1967 and,
along with its 32.8% owned subsidiary
Kia Motors, together comprise the
Hyundai Motor Group, which is the
worlds fifth largest automaker based on
annual vehicle sales in 2012. In 2008,
Hyundai Motors (without Kia) was
ranked as the eight largest automakers.
As of 2012, the company sold over 4.4
million vehicles worldwide in that year
and together with Kia, total sales were
7.12 million.
Hyundai is currently the fourth largest
vehicle manufacturer in the world. Hyundai
operates the world’s largest integrated
automobile manufacturing facility in Ukan,
South Korea, which has an annual
production capacity of 1.6 million units. The
company employs about 75.000 people
worldwide. Hyundai vehicles are sold in 193
countries trough some 6,000 dealerships and
showrooms.

Hyundai is a private diversified company

which is very well distributed all over the
parts of the world.
 NORTHERN GULF TRADING COMPANY

Northern gulf Trading is a Group of Companies

made up of three independent entities:
1. Northern gulf Trading Co.
2. Trans World Company.
3. Arabian Eastern Group.
Northern gulf Trading is the largest and oldest entity
(Established 1976). It primarily focuses on the
automotive and transportation sectors and is the
exclusive agent of Hyundai Motor Company
(Passengers vehicles & commercial trucks and
Buses).
 HYUNDAI CAR MODELS: -

 Hyundai Santa Fe
 Hyundai Elantra
 Hyundai Azera
 Hyundai Tucson
 Hyundai Veloster
 Hyundai Sonata
 Hyundai Genesis G80
 Hyundai Genesis G90
 Hyundai Genesis Coupe
 Hyundai H1
 Hyundai Accent
 Hyundai Creta
 Hyundai Grand i10
(1) Santa Fe. (2) Elantra.

(3) Azera. (4) Tucson.

(5) Veloster. (6) Sonata.

 (7) Genesis G80. (8) Genesis G90.

(9) Genesis Coupe. (10) H1.

(11) Accent. (12) Creta.

(13) Grand i10.

These are the current vehicles that are being
manufactured by the Hyundai Company. All
previous models are discontinued. The
specialty of this company is that it
manufactures cars for all types of economic
and the
models are in both petrol and diesel engine
which gives a choice to people to chose one
as per their comfort. These all car models
are available in both petrol and diesel
engine.
CHAPTER-2
INTRODUCTION
 OBJECTIVE

1. To understand the problems of the

problem faced by the four wheelers and
to solve its problems.

2. Understand the basic part of the car

and to know about everything in a very
precise manner.

3. Manage the problem that are

happening in the vehicle such as: Toe in /
Toe out problem, Knocking, Axle noise,
Gear problems, Clutch problems etc.

4. Resolving all the problems one by

one by knowing everything about the
material and product used.
CHAPTER-3
DEPARTMENT'S
The company where I did my Internship was
having two major departments: -

1. Maintenance Department
2. Repairing and Painting Workshop

Function of Departments:

Each department was equally important because at first what

used to happen is any car or automobile is first sent to the
maintenance department, there people used to check all the
problems that a car is being going through after that a list of
problems is to be make so that the person doesn’t have to look
again and waste the time in finding the problems. It is a time
saving process. After the maintenance department the vehicle is
sent to the repairing workshop where the vehicle is first washed
up properly and then the workers with their impeccable skills
and work experience solves the problem of the automobile.
These all repairing are all done in different workshop that is
Repairing Workshop. The cars who met with accidents and their
body parts were wrecked were also been repaired in that
Workshop some of the automotive need to be painted were also
done in that Workshop.
1. MAINTENANCE DEPARTMENT:

2. REPAIRING AND PAINTING WORKSHOP:

CHAPTER-4
ENGINE
PETROL ENGINE:
A petrol engine is also known as (Gasoline Engine)
is an internal combustion engine with spark ignition
designed to run on petrol (gasoline) and similar
volatile fuels. It was invented in 1876 in Germany
by German inventor Nikolaus August Otto. In most
engines, the fuels and air are usually premixed
before compression.

FOUR STROKE ENGINE:

A four-stroke engine is an internal combustion (IC)
engine in which the piston completes four separate
strokes while turning a crankshaft. A stroke refers to
the full travel of the piston along the cylinder, in
either direction. The four separates strokes are: -
1. SUCTION: The stroke of the piston begins at
the top dear center (T.D.C) and ends at bottom
dead center (B.D.C). In this stroke the intake
valve must be in the open position while the
piston pulls an air-fuel mixture into the cylinder
by producing vacuum pressure into the cylinder
through its downward motion.

2. COMPRESSION: This stroke begins at bottom

dead center (B.D.C), or just at the end of the
suction stroke, and ends at the top dear center
(T.D.C). in this stroke the piston compresses the
air-fuel mixture in preparation for ignition
during the power stroke. Both the intake and
exhaust valves are closed during this stage.

3. POWER: This is the start of the second

revolution of the four-stroke cycle. At this point
the crankshaft has completed a full
180°revolution. While the piston is at the top
 dear center (T.D.C). the compressed air-fuel
mixture is ignited by a spark plug or by heat
generated by high compression, forcefully
returning the piston to bottom dead center
(B.D.C). this stroke produces mechanical work
from the engine to turn the crankshaft.

4. EXHAUST: During the exhaust stroke, the

piston once again returns to top dear center
(T.D.C) from bottom dead center (B.D.C) while
the exhaust valve is open. This action expels the
spent air-fuel mixture through the exhaust valve.
DIESEL ENGINE:

The diesel engine (also known as CI engine) is an

internal combustion engine in which ignition of the
fuel that has been injected into the combustion
chamber is initiated by the high temperature which a
gas achieves when greatly compressed. This
contrasts with spark-ignition engine such as a petrol
engine (gasoline engine) or gas engine, which use
spark plug to ignite an air-fuel mixture.

The diesel engine has very good thermal efficiency

(engine efficiency) due to its very high compression
ratio and inherent lean burn which enables heat
dissipation by the excess air. A small efficiency loss
is also avoided compared to two-stroke non-direct-
ignition gasoline engines since unburnt fuel is not
present at valve overlap and therefore no fuel goes
directly from the intake/injection to the exhaust.
Diesel engine can have thermal efficiency the
exceeds 45%.
Diesel engine are manufactured in two-stroke and
four-stroke versions. They were originally used as a
more efficient replacement for stationary steam
engines.
 DIFFERENCE BETWEEN PETROL & DIESEL.

DIESEL ENGINE PETROL ENGINE

1) The air is compressed 1) Fuel is mixed with
first, and then the fuel air, compressed by
is injected. pistons and ignited
by sparks from spark
plugs.
2) Has no spark plug 2) Has spark plug
Combustion is due to the for ignition.
heat of compressed
air.
3) High compression ratio. 3) Low compression
ratio.
4) Produce more noise 4) Produce less noise
pollution. pollution.
5) Gives maximum 5) Gives maximum
35-40% efficiency 25% efficiency.
CHAPTER-5
PROBLEM FACED BY
AUTOMOBILE.
Problem faced by Automobile: -
There are certain problem which are faced by every
automobile when it is being used for a long period of
time.

Certain Problems are: -

1. Knocking
2. Caster and Toe
3. Engine Seizure
4. Over rigid suspension
5. Rough idling or Low idling
6. Brake seizure

These are the problems which are generally faced by

all type of automobile either it’s a petrol or diesel
engine. That’s why experts give advice of getting our
car for servicing after 5,000 km of ride and replace oil
for every 10,000 km of ride.
 ENGINE IDLE

Engine idle is a good measure of your engine’s health. If

anything is going wrong under the hood, there a good
chance it will be affecting your cars idle speed and quality.
Problems with idle speed, things like slow idle, low idle,
lumpy idle, fast idle. These are the symptoms that should
be investigated, troubleshooted, diagnosed and repaired.
The following symptoms and related problems should act
as a guide in helping you troubleshoot your idle issues.

SYMPTOMS: -
The engine will not cause smoothly, or it stalls during
idle when the engine is cold. When the engine is cold
and you take your foot off the gas pedal, the engine
runs very rough and may even stall. When you run the
engine at higher speed it seems to run fire. Or at least
it runs more smoothly.
POSSIBLE CAUSES: -

1. If you have carburetor you may have a bad accelerator

pump or power circuit
The fix: Replace accelerator pump or replace
carburetor

2. There may be a vacuum leak.

The fix: Check and replace the vacuum lines as
required.

3. There may some type of ignition problem.

The fix: Check and replace distributor cap, rotor,
ignition, wires and spark plug.

4. The ignition timing may be set wrong.

The fix: Adjust ignition timing.

5. The EGR valve may be bad.

The fix: Replace EGR valve.

6. The engine may have mechanical problems.

The fix: Check compression to determine engine
condition.
CHAPTER-6
CONCLUSION
It was a great internship in Hyundai full of
knowledge. I really enjoyed the training period.
I have learnt about different services and the
major minor defects generally seen in the car
and how to solve them.
Most of the time I used to do the free services
and some repair also like I have change the
brake pads, tiers, replacing the engine oil,
coolant and many other things, I also learned
how to check all the sensors are working or not.
I also seen that how an organization work under
extreme pressure and how to handle it like when
so many cars have to repair in the limited time it
is really a very big task.
Overall it was a good experience and it
increases my interest in the Automobile
engineering, now i am planning to enhance my
skills in this field.
REFERENCES:

1.Hyundai Santa Fe:

https://encryptedtbn2.gstatic.com/images?q=tbn:ANd9GcS4Xv8NdwGZ
1R4JrpWNBkOObPjpulJb6aUCSc1T74rRoEK4nTqyVOhdBbn4hw
2.Hyundai Elantra:
https://encryptedtbn0.gstatic.com/images?q=tbn:ANd9GcRh0P1J51_fZ
vvXwdFJHJ6qyjCuTURU102ygPbZ0VZQNiLvljCOEcQkoua0
3.Hyundai Azera:
https://encryptedtbn2.gstatic.com/images?q=tbn:ANd9GcTAuYFBULke
aSvRiXshxu3Tf6I2F4fy86-h8C7tGRJ_XifR2xp6n0zixda04A
4. Hyundai Tucson:
https://lh3.googleusercontent.com/proxy/MgdzT2MLpkw5V-n2XnHg-
o6PuAzUOD5UXaEKJZa3M7pHJ4_R8LTmxMsCCLLx1r8dLosBMf31rdfX2
mPqXKlQrihD6RndHpQElKusNJC8wUd7_GYG8Fd1FSE0ShVLZ0V-
rZtKnfH0dqlsJDRnUkmNFEtt2O_cVPuLi5h544Y-8oZhjpa_vWkg=w532-
h276-nc
5. Hyundai Veloster:
https://encryptedtbn1.gstatic.com/images?q=tbn:ANd9GcScTSItJ1cWw
UREUqIeLbITbIcf9LAzVV-VoPozmjEe3GruYq7MOugGBr7LQQ
6. Hyundai Sonata:
https://encryptedtbn0.gstatic.com/images?q=tbn:ANd9GcTuaZ2h30r3J
mZIDX121c_d48l0RJdO5qNaNArMmFgloIVjmOGW
7. Hyundai Genesis G80:
https://encryptedtbn0.gstatic.com/images?q=tbn:ANd9GcQZeQVRCoP-
PsWTecgk2UQWMzg8ZPUEsFQWxJkI_xsAUl14y1uHDj0yRJxC

8.Hyundai Genesis G90:

https://lh4.googleusercontent.com/proxy/y6WzzX6JipX5xqghwIiME8BH
G1PyArgcPXeEUEYi5RBzlpngPmVBTgkGOr4iS5brEjKIjSAQytKnEhlRXQ8T
7MgCI2bCeSRsMhv3ilqLZKxySkvXLyAd0JukienCmWHdypNUwRlFTXvUya
8Ovh8MNE8zS5v-UuexH_JKrH2uHHbdIsYsn-
D0tWnBvP0Uv5L0F_oiJUpNWqcqNelXgqbB95tvvqM3s=w443-h332-nc
9. Hyundai Genesis Coupe:
https://encryptedtbn2.gstatic.com/images?q=tbn:ANd9GcSv4M_lx5Pa8
ohWvtAkX0BR_Zq3EgnLUtSpCGvMUiH4gy76Rxldmvnl6K7iiA
10. Hyundai H1:
https://encryptedtbn0.gstatic.com/images?q=tbn:ANd9GcTBWhs9lWu
HPJnoGgnQgSySWi7LpQTHXm8qWkzeqwadnew_iN9ZGCLN6GgJRw
11. Hyundai Accent:
https://encryptedtbn1.gstatic.com/images?q=tbn:ANd9GcTJ7ysVqCtuB
KD5YebjSKiCDktv9Uhc1ztrmeROSF0HoBrgy4XkQw4fH3mP
12. Hyundai Creta:
https://encrypted-tbn1.gstatic.com/images?q=tbn:ANd9GcSCFO-
sv9eBSCjAmrdg8QJ2YG7f4CqOTj2q3NjguCOVWKU2sKUUbXBKukfYZQ
13. Hyundai Grand i10:
https://encryptedtbn0.gstatic.com/images?q=tbn:ANd9GcQWxsO0gJRr
cpyT1dNed_HWsrBA3O2Bjod67wdxvM0VR8Hevciqng