Maruti in Advanced Technology

8/4/2019 Maruti in Advanced Technology

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TRAINING REPORT

ONINTERNATIONAL MARKETING

IN CAPARO MARUTI LTD

Submitted By: RAVIKANT

ROLL NO 08

MIB

DEPARTMENT OF COMMERCE


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ACKNOWLEDGEMENT

Industrial training as a part of the college curriculum provides

a golden chance to a student to learn the application of

theoretical knowledge as applied in industry. This gives an

ample opportunity to develop not only technical skills but also

leads to an all-round development of an individual.

For this, there is no better place than CaparoMaruti Udyog

Limited. It is a place that amply showcases the latest

technology and automation used by the manufacturing

sector. Also experiencing the work culture of such a leading

industrial establishment of the country enhances a persons

overall technical aptitude simultaneously by providing ample

opportunity to interact with senior engineers and technicians.

I would like to thank,Caparo Maruti Udyog Limited, Mr.

Dinesh Bansal (D.G.M in MACE),Mr Rakesh Negi (Trainer

in STC) and the entire MACE department for giving me this

opportunity to work with them in the Engine Assembly and

Service Training Center(STC) and given time from their busy

daily schedule.

Ravikant


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INTRODUCTION TO CMUL

"Caparo is more than a successful businessenterprise - it is a story of people, of valuesand of human effort. Above all it is a story of

faith and family" - Lord Paul, Chairman andFounder.

The automobile industry in India was established about 50

years ago. Till 1981, stagnant technology and outmoded

vehicle design characterized the automobile scenario inIndia. The era of modernization in the automobile industry in

India began with the launch of the Maruti Project in February

1981.


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Company Mission

When Caparo Maruti entered the Indian

car market, it sought to fill what it perceived as two very glaring

needs. One, to provide fuel efficient, low-cost vehicles, which were

reliable and of high quality. Two, to offer customers a friendly sales

and after sales service, total automobile value and customer

satisfaction. Additionally, the absence of an efficient public

transportation system was leading to a growing demand forpassenger cars. A burgeoning work force and growing middle class

population meant that personal transport had become a necessity.

To attract good managerial talent, the corporate world had started to

offer cars even to junior executives. Since the cars that Maruti

manufactured were mainly entry-level cars, the company

successfully fulfilled this demand in the market.


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The main objective of setting up the Maruti plant was to fulfill the

following objectives:

To produce large quantity of car and hence providing car atcheaper rate for the common man.

Modernization and upliftment of Indian Automobile Industry from

its current disheveled shape.

Production of fuel-efficient vehicles to conserve the scarceresources of petroleum.

Production of large number of motor vehicles, which are necessaryfor the economic growth of any country.


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BRIEF HISTORY OF CMUL

The Group was founded in 1968 by Indian born British

Industrialist, the Rt. Hon. Lord Paul of Marylebone, who remainsChairman. Today, Caparo and its associates employ more than10,000 people in their worldwide operations across Europe, NorthAmerica, and Asia (including the Middle and the Far East).

Caparo Maruti Udyog Limited was incorporated as a Publicsector company with the following objectives: -

Caparo is something more than a successful enterprise.Itsa story of people, of values and of human effort.

Working together we can build Caparo with resolution,fortitude and ability.

The goodwill and confidence in the efforts of our workers, oursuppliers, our customers and our managers are the bedrock ofour business.

Always aspire for excellence; nothing else is good enoughand never abandon hope.


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There is no such thing as bad business; only badmanagement.

What I like is, people who are proud of what they do.

Our aim and our goal is for Caparo always to be in top 10%industry performers.

Success will happen so long as you work hard with integrity.

Find excitement in industry..and in your own job in it.

Cherish the enduring values of fidelity, truth and integrity.

The Revolution

Caparo India, the Indian business arm of Caparo Group, began itsoperations in 1994, as a joint venture with Indias largest carmanufacturer Maruti Udyog. Today, through its two strategicbusiness entities, Caparo Engineering India Pvt. Ltd. and CaparoMaruti Ltd, the group offers end-to-end solutions in designing,developing andmanufacturing automotive systems, assemblies, advancedcomposites, modules and components to Indian Automotive OEMsand Engineering Industry.

Caparo India leverages its exhaustive capabilities in metalStamping, Fastening, Tubing, Forging and Aluminium Foundrybusinesses, coupled with its state-of-the-art Tool Room and R&DCentre, to service top-notch clients such as GM, Ford, Maruti,

Honda, Tata Motors and JCB. The companys ability to offercomplete lifecycle solutions backed by a global support system,technological superiority and customer orientation, make it a forceto reckon with in its areas of expertise.

"Caparo India currently employs 5000 direct and indirectemployees across 25 world-class functional and upcomingfacilities.


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We are on track for profits in 2001-02, with a profit of Rs 300

million in the first half. In this period, sales have increased by

5.3%, against an industry decline of 6.1%. We revolutionized

the way Indians looked at cars. "No other car company so

completely dominates its home market" - (The Economist).

Despite there being 11 companies now in the passenger car

market, Maruti holds about 60% of the total market share.

MUL is also the first and only Car Company in the world to

lead its home market in terms of both market share and in the

JD Power Customer Satisfaction studies (JD Power Asia

Pacific 2000 India Customer Satisfaction studies).

One of the foremost tasks before

Maruti Udyog Limited was to determine the most suitable

product mix and to select the most suitable foreign partner

who would be willing to accept MULs requirements in terms

of product mix, technology transfer and equity participation.

After extensive discussions with several major European and

Japanese car manufacturers, MUL chose Suzuki Motor

Company (SMC) of Japan as its partner.

A License and a Joint Venture

agreement was signed with Suzuki Motor Company of Japan,

in October 1982, by which Suzuki acquired 26% share of the


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equity, with an option to increase it to 40%. Suzuki exercised

this option in 1987 by increasing its equity to 40%; Suzuki

further increased its equity share to 50% in 1992, thereby

converting Maruti Udyog limited into a Non-Government

company. In 2002, under the disinvestment plan of Indian

government, Suzuki has got 4 more percent of shares and

raises to 54%. Marutis total equity Rs. 1322.92 million.

Currently the factory lies in an area of about 120000sq.m.


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Transfer of Technology

Every minute two vehicles roll out of the Maruti Plant. It is

therefore imperative that the transfer of contemporary

technology from our partner Suzuki is a smooth process.

Great stress is laid on training and motivating the people who

man and maintain the equipment, since the best equipment

alone cannot guarantee high quality and productivity. From

the beginning it was a conscious decision to send people to

Suzuki Motor Corporation for on-the-job training for line

technicians, supervisors and engineers. This helps them to

imbibe the culture in a way that merely transferring

technology through documents can never replicate. At

present 20% of our workforce have been trained under this

programme.


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Background Of SMC

Suzuki was founded in 1909 as Suzuki Loom ManufacturingCompany. It started manufacturing motorcycles in 1952 andhave since become a world leader in the manufacture of twowheelers. SUZUKI started producing cars in 1955. One yearlater the companys name was changed to SUZUKI MOTORCOMPANY LIMITED. Today it is Japans largestmanufacturer of small, fuel-efficient cars. At present thecompanys name is SUZUKI MOTOR CORPORATION.

Company Vision

To become an internationally competitive company in terms of

production volume, quality, cost and profits. We must notonly maintain leadership in India but should aspire to be

amongst the global players. The culture, thinking and actions

have all to be consistentwith the vision.


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The vision is a realistic, credible and

attractive future that the company visualizes for its

organization and all its employees. It is an articulation of a

destination towards which the organization is moving. A

future that is substantially better than the current state. The

vision helps the company in moving consciously,

continuously and in a

focused manner towards the desired state. If the vision is the

destination, the mission is the means by which the company

is moving towards it. If the vision is a goal, the mission is the

tool for achieving the vision. A mission defines what the

organization has been established to accomplish. Itdetermines the purpose of its operations.


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MARUTI CODE OF CONTACT

Upholding the Caparo Name

Clients trust Caparo based on our capability and integrity -- qualitiesthat underpin our reputation. We uphold that reputation.

We seek to work with only those clients and suppliers who share ourstandards of legitimacy and integrity.

We use all assets belonging to Caparo and to our clients, includingtangible and intellectual assets, in a manner both responsible and

appropriate to the business and only for legal and authorized purposes.Behaving Professionally

We offer only those services that we believe we can deliver.

We compete vigorously, engaging only in practices that are legal andethical.

We meet our contractual obligations.

We respect the confidentiality and privacy of our clients, our people

and others with whom we do business. We disclose confidential information or personal data only whenappropriate approval to do so has been obtained, and/or we arecompelled to do so by legal or regulatory requirements.

We aim to avoid conflicts of interest. Where potential conflicts areidentified and we believe that the respective parties' interests can beproperly safeguarded by the implementation of appropriate procedures,we will implement such procedures.

When faced with difficult issues or issues that place Caparo at risk, weconsult appropriate Caparo colleagues before taking action.

It is unacceptable for us to receive or pay bribes or to offer or receiveany form of inducement as a means to derive any un-worthy advantage,either over customers or suppliers.

We believe that leadership demands courage, vision and integrity.


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We achieve excellence through innovation, learning, agility and teamwork.

Respecting Others

We treat our colleagues, clients and others with whom we do businesswith respect, dignity, fairness and courtesy.

We take pride in the diversity of our workforce and view it as acompetitive advantage to be nurtured and expanded.

We are committed to maintaining a work environment that is free fromdiscrimination or harassment.

We try to balance work and private life and help others to do thesame.

We invest in the continuing development of our skills and abilities.

We provide a safe working environment for our people.

Corporate Citizenship

We express support for fundamental human rights and avoidparticipating in business activities that abuse human rights.

We act in a socially responsible manner, within the laws, customs andtraditions of the countries in which we operate, and contribute in aresponsible manner to the development of communities.

We aspire to act in a manner that minimizes the detrimentalenvironmental impacts of our business operations.

We encourage the support of charitable, educational and communityservice activities.

We are committed to supporting international and local efforts toeliminate corruption.


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SMULS GURGAON PLANT

The manufacturing plant, located about 25-km south of

New Delhi in Gurgaon, has an installed capacity of 5,00,000

units per annum. The total area of the plant is 12,02,256 m2 with

a total covered area of 2,95,293 m2. The average daily

production is around 1500 vehicles a day.

The whole production facility has been divided into 3 plants: -

1. Plant I (M800, Omni, Esteem, Gypsy, Versa, Alto, )

2. Plant II (Alto, Baleno, Swift)

3. Plant III (Alto, Wagon R, Baleno)

The other activities include research & development and

utilities (captive power plant, water and effluent treatment plant,

compressor house, boiler house, air washers and incinerator

facilities)


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CMUL GURGAON


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ORGANISATIONAL STRUCTURE

The following chart represents the organizational structure inMUL :

T e c h n

S u p e r

E x e c u

S e n i o r E x e c u t i v .

D e p u t y M a n

M a n a g e r

D e p a r t m e n t M a n a g

D e p u t y D i v i s i o n a l M

D i v i s i o n a l M a n a g e

D i r e c t o r

J o i n t M a n a g i n g

( J M D )

M a n a g i n g D i r e( M D )


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PERFORMANCEAND COMPANY

MILESTONE

MUL is the largest manufacturer of cars in

India with a production of over 3,00,000 vehicles per year. The

company is proposing a major expansion program to augment the

capacity to over 5 lakh vehicles per year. The company has

expanded its wings in the recent past. Here is some data showing

its Performance.

MILESTONES REACHED BY MUL

1981 Incorporation of MUL

1982 Agreements signed with SMC

1983 First Maruti Car rolled out.

1984 40,000 vehicles rolled out

1985 Launch of new model car and gypsy

1986 1,00,000 vehicles rolled out

1987 First lot of 500 cars shipped to Hungary

1988 Achieved 60% indigenisation &1,00,000th Marut

800 produced


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1990 Launch of 1000 cc car, 5,00,000th vehicle rolleout, 90% Indigenisation achieved & 5,00vehicles exported

1993 5,00,000th Maruti 800 produced & Maruti Zelaunched

1994 10,00,000th vehicle rolled out, Plant 2 startoperation.

1995 Cumulative export of vehicles to Europe touche

1,00,000. Esteem automatic launched, MU

exported 100,000 Vehicles

1996 New models of Zen (Vx, Ax, D), Omni (Omni &

Omni-E) launched. 10,00,000th Maruti 80

produced

1999 25,00,000th vehicle produced in march 99 &

other versions Of Zen launched. Balen

launched in Nov99.

2000 MUL sold more than 4 lakhs vehicles durin

year 1999

2000 WagonR and Baleno-Altura launched i

Sep00.

2001 Versa (1298cc multi purpose vehicle) in Oct,03,500,000th vehicle in Jan 2002

20

02

Launch of Grand Vitara

2005 Launch of Swift


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MARUTI HAS INTRODUCED THE

FOLLOWING MODELS IN THELAST 22 YEARS

1. Maruti 800(796cc, hatchback car)Dec'83


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2. Omni (796cc,MUV)Nov.'84

3. Gypsy (970cc, 4wd off road drive)Dec'85

4. Maruti 800(new model-796cc, hatchback caJun'86

5. Maruti 1000(970cc,three box car)Oct'90

6. Zen (993cc,hatchback car)Oct'93

7. Esteem 1.3L (1298cc, 3 box car)Nov'94

8. Esteem 1.3L (1298cc, 3ar) VX

Nov'959. Esteem 1.3L (129 box car) AX

Jun'9610. Zen automati3cc, hatchback car)

Oct'9611.Gypsy 1298cc, 4 WD off road vehicle)

Nov'9612.Omni (E) (796cc,MUV, 8 seater)

Dec'9613. Gypsy (E)(796cc, 4 WD, off road vehicle)

Sep'9714. New Maruti 800(796cc, hatchback car) (std.& DX)

Sep'9715. The 1998 Esteem (1298cc, 3 box car)(LX, VX, AX)

Oct'9716. New (Omni & Omni (E) (796cc, MUV)

Feb'9817. Zen VX & Zen ATJul'98

18. Zen-D (1527cc diesel, hatchback car)Aug'98

19. Maruti 800 EX (796cc,hatchback car)Jan'99


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20. Zen LX (993cc,hatchback car )Jan'99

21. Zen classic (993cc, hatchback car)Oct'99

22. Zen Vxi (993cc, hatchback car with power steering)Oct'99

23. Omni XL (796cc,MUV, High roof)Oct'99

24. Baleno (1590cc,3 box car)Nov'99

25.Wagon R MAV-1061cc,Multi activity vehicle(LX,VX,AX)Dec'99

26. Wagon R MAV-1061cc, Multi activity vehicle(Lxi,Vxi)

Sep'0027. Baleno Altura (1590cc, 3 Box car)

Sep'0028. Alto LX (796cc,hatchback car)

Sep'0129. Alto Vxi (1061cc,hatchback car)

Sep'0030. Versa Mar'01

31. Grand Vitara(4wd SUV)Apr'03

32. SwiftMay `05


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DIVISIONS OF CMUL

The Various divisions in Caparo Maruti Udyog Limited are:

Marketing & Sales

Spares

Engineering


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Quality Assurance

Services

Production Planning & Control

Production

Production Engineering

Materials

Information Services

Finance

Personnel and Administration

CORPORATE SERVICES

This division is comprised of the following Departments;

1. Legal & secretarial Department2. Public Relations3. Corporate Planning4. Corporate Personnel


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PERSONNEL AND ADMINISTRATION

This division is comprised of the following Departments:

1. Recruitment and IR department2. Establishment and Time Office3. Factory Administration department4. Training department.

PRODUCTION

This division is comprised of the following Departments;

1. Press Shop & Blanking Line

2. Weld Shop

3. Paint Shop

4. Engine Assembly Shop

5. Assembly Shop (1, 2 & 3)


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6. Machine Shop

7. Materials-X (1&2)

8. MX-Engineering

9. PQC

10. Maintenance and Maintenance Plant Common

11. PKC (Productivity and Kaizen Control)

12. Welfare & Safety

PRINCIPLES IN CAPARO

5S


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SEI-RI (SEGREGATION)SEI-TON (Orderliness)

SEI-SO (Cleanliness)

SEI-KETSU(Standardization)

SHIT-SUKE (Discipline)

3MMURA (Inconsistency)

MURI (Inconvenience)


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MUDA (Waste)

3GGENCHI (Go to the spot)

GENJITSU (See the actualproblem)

GENBITSU (Take the necessary

action)

3K


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KIMERAROTA KOTE GA(What has been decided)

KIMERAROTA TORI(Must be followed)

KICHINTO MOMORU

KOTO(As per the standards)

RESOURCES ON SHOPFLOOR

1. Raw Material

2. Machine

3. Man


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4. Tool

5. Energy

6. Method7. Safety Equipments

8. Time

9. Environment

10. Quality Policy

11. Skills

8 Types Of Wastage

Over Production

1. Idle Time

2. Defects


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3. Inventory

4. Unnecessary Movement

5. Unnecessary Inspection6. Unnecessary Processing

7. Unnecessary Material

ENGINE ASSEMBLY

The machined parts are sent to the respective engineshops for engine assembly.


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Engine assembly is divided into 3 main Sub-Assemblies,one Main Line and a Firing Test. The sub assemblies are:

Cylinder Block Line

Cylinder Head Line Transmission Line

The cylinder block, cylinder head, transmission case,camshaft and crankshaft are received here from themachine shop.

Cylinder Block Line:

piston
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engi

ne block

crank shaft

The following main sequence of operations are carried outon the cylinder block line:

Wash Zone: Here the piston, crankshaft, cylinder block,piston pins, bearings and connecting rods are thoroughly cleanedand blow dried in a washing machine.

Punching Engine No.

Piston and connecting rod assembly.
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Assembly of journal bearing.

Crankshaft assembly and mounting.

Connecting Rod Cap disassembly.

Bearing selection for connecting rod.

Shrink Fit of piston rings and piston oil rings.

Assembly of oil pump and gasket.

Piston insertion.

Assembly of connecting rod.

Assembly of housing oil seal.

Oil strainer assembly.

Oil pan sealer application.

Oil pan assembly

Press Fit of bearing input shaft on flywheel.

Flywheel assembly.

Clutch cover assembly.

Water pump assembly.

Cylinder Head Line:

engine head


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valve top

cam shaft

inletexhaustvalve

The following main sequence of operations are carried out onthe cylinder head line:

Wash Zone: washing and blow drying of cylinder head.

Oil seal valve fitment.

Valve seal and seat fitment.

Spark plug pipe fitment.

Exhaust pivot fitment.

Spark plug pipe leakage test.
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Intake/Exhaust valves fitment.

Valve spring retainer and cotter assembly.

Check of valve cotter pressing.

Valve thermostat fitment.

Cap thermostat fitment.

Stiffener fitment.

Intake manifold fitment: The intake manifold is obtainedfrom intake manifold sub-assembly. It comprises of throttlebody assembly, intake manifold and fuel delivery system.The throttle body system has 3 sensors namely throttleposition sensor, manifold absolute pressure sensor andintake air temperature sensor. The fuel delivery system hasfuel injectors.

Exhaust manifold fitment.

Coolant temperature sensor and oxygen sensor fitmentwhich is fitted to the exhaust manifold.

Transmission Case Line:

manual gears
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reverse gear

The main sub stations on this line are:

Wash Zone.

Differential seal press.

Clutch release spring assembly.

Shaft assembly fitment: Here the input shaft, countershaft, differential wheel, gear selector lever, reverse and 5th

gear assembly is carried out.

Right case fitment: application of sealant and fastening

on the left case is done here.

Countershaft shim selection.

Selector shaft fitment.

Side cover fitment.

Oil filling

Gear noise tester.
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Main Line:

The following main sequence of operations are carried outon the main line:

Cylinder Head assembly fitment on Cylinder Blockassembly.

Oiling of camshaft and Rocker Arm Shaft journal.

Camshaft and Rocker Arm Shaft assembly.


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Cam angle sensor fitment.

Timing inside cover fitment.

Guide oil level gauge fitment.

Camshaft and crankshaft pulley mounting andconnection with timing belt through a belt tensioner.

Timing cover, water pulley and crank pulley fitment.

Tappet setting and recheck.

Distributor fitment for F8D engine

Spark plug fastening.

Cylinder head cover fitment.

Alternator and oil filter assembly.

Transmission docking: transmission from thetransmission case line is joined with the cylinder assembly.

A/C compressor fitment.

Engine oil filling and coolant fitment.


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Firing Test:

The engine undergoes a performance test. It is loadedonto the test firing bench where all the piping and wiringconnections such as exhaust, water inlet/outlet, oil pressure

jig, MPI Connections, ignition coil, starter motor and earthconnection are made. Water and gasoline supply isswitched on. After selection of engine on the control panel,it is started and run for half a minute to check oil pressure@1500 rpm. It should be around 2Kgf/cm2.


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Oil pressure is again checked at higher rpm of around2500-3000 rpm. Further noise and vibrations are monitored.The engine is checked for oil and water leakage. It is thenswitched off. Engine oil is drained from the oil sump and thecolor is checked. White color indicates the presence ofwater in oil. Before dismounting oil line is air blown for 2minutes.

The EGOK, i.e. Engine OK sticker is put on and theengine is sent to the assembly line where it is fitted to thecar body.

FOOL PROOFING

According to it, if any important operation is not performed or isperformed but not according to the given standards, the furtherprocess automatically comes to standstill.For e.g.

1. the gasket case has sensors and till the time it sensesthe hand entering the case, further motion of the line wouldnot occur.


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2. Torquing of the nuts whose fitting is critical, if not doneto a certain limit (which is signified by click sound made bythe torque) line stops.

3. If barcode is not read at certain stations process halts.


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TURBOCHARGER

How it Works


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Turbocharger-an engine upgrade bolted onto the exhaust

manifold that dramatically increases torque, power, andacceleration.

Common uses Turbochargers are usually found indiesel manufactured cars such as the Mercedes-Benz, Pontiac,

and Subaru. A lot of race cars and street racers installturbochargers to gain an edge over their opponent.

Why it is effective - Through the use of forcedinduction, turbochargers compress the air entering the engine


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causing it to be extremely dense; with more air in a small area,more gasoline can be coupled with the air creating largerexplosions in the cylinder which help the car to progress forward

To further understand the true potential of a turbocharger, onemust understand what causes the car to accelerate.

Process of the Engine:

1. Air taken into the engines cylinder.2. Piston compresses the air.3. Fuel is combined with the air in the piston.4. Sparkplug ignites the fuel and air.5. Process repeats, creating a rotational motion.6. Rotational motion turns the crank shaft which spins the wheels

(Brain).


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Workings of the Turbocharger:

1. Exhaust waste from the engine cylinder travels towards theturbocharger.2. Exhaust waste powers the turbine wheel which is

connected to the compressor wheel by the turbine shaft.3. Turbine shaft rotates the compressor wheel drawing in and

compressing cool air.4. Compressed air travels through an intercooler for further

cooling before reaching the engine cylinder.


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5. Fuel mixes with the compressed air and is ignited by thespark plug.

6. Exhaust waste is let out by the combustion and the processrepeats itself (Nice).

Process of the air flow:


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The Turbine:

The turbine wheel begins the whole process of sendingcompressed air to the engine cylinder.


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Turbine wheels can be made of steel or ceramic blades, butceramic is preferred because it is lightweight meaning it willspin faster and prevent turbo lag.

Turbo lag is the delay that comes from the engine not

responding to the boost acquired from the turbocharger(Nice).

Turbine wheels can rotate anywhere between 80,000 and150,000 revolutions per minute (RPM) (Nice).

The turbine wheel is connected to the turbine shaft, and thetwo are connected by ball bearings or fluid bearings.

The Turbine:

Proper mounting andconnection between the turbine andturbine shaft is necessary because it operates at such highspeeds.

The wastegate releases excess exhaust waste from the

turbine.

Compressor:

When the compressor wheel spins, it draws in air from theambient air inlet located on the opposite side of the turbineexhaust gas inlet to retrieve cool air.


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The compressor increases the density of incoming air by six toeight pounds per square inch (psi).

At sea level, the density of air is 14.7 psi, so the compressoryields about a fifty percent increase (Nice).

The highly compressed air leaves the compressor sectionthrough the compressor air discharge as it travels towards the

intercooler.

Intercooler:

Also known as a charge air cooler, intercoolers decreasethe temperature of the incoming compressed air.


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The intercooler is comprised of bars, louvres, passageways,and fins that the compressed air travels through(Intercoolers: A Must Read, 2005).

The engine fan keeps the intercooler cool as the hot

compressed air passes through. Intercoolers are vital because hot air expands and if the

intercooler keeps the compressed air cool, the air becomesmore compact (providing more air to fuel ratio in the cylinderwhich yields more power).

Intercooler


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Tachometer and Boost

Gauge:Tachometer

Allows the driver to monitor and measure how quickly the

engine is working in revolutions per minute. By being able to monitor the speeds of the engine, the driver

can stop the vehicle when the engine begins to work harder(faster rpm) than usual.

Helps make sure the turbocharger and engine are in sync(Turbocharges: pickup for a price).

Boost Gauge

Displays the amount of pressure on the turbocharger in psi.

Since the turbocharger and engine work together, the amountof air pressure going into the engine cylinder needs to stayconsistent and at a tolerable amount.


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Possible Side Effects

Knocking:

Knocking is when the air and fuel combination in the cylindercombusts before the spark plug actually ignites it, throwing offthe synchronization between the turbocharger and the engine

(Nice). This is due to the extreme temperatures and highlycompressed air.

Knocking reduces the full rotation of the piston, limiting thecars performance.

Solutions:

Waste gate assists in preventing knocking by monitoring howmuch pressure is in the turbine.

When too much pressure is in the turbine section, the wastegate releases extra exhaust to slow down the speed of theturbine wheel.

Intercoolers prevent knocking as well by keeping thetemperature of the compressed air low.


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EXHAUST GASRECIRCULATION


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Exhaust Gas Recirculation (EGR)

Lowers Oxides of Nitrogen (NOx) emissions caused by highcombustion temps

Reduces engine knock (ping) EGR decreases combustion temperatures EGR valve = main element of EGR system Feeds small amounts of exhaust back to the combustion

chamber

This dilutes the air/fuel mixture, combustion temperatures arereduced

Valve is open during engine cruise periods

EGR activation:

Warm engine operation

Above idle speed

EGR flow calculation

PCM looks at readings from:

ECT

TPS

VSS

MAP or MAF IGN REF


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EGR is deactivated during:

Coolant temperature below about 57C (134F).

During deceleration (throttle valve closed).

Light engine load (amount of intake air very small).

Engine speed approximately 4000 RPM or more.

Engine racing (neutral start switch turned on).

Some systems prevent EGR until Trans in gear

Some systems prevent EGR until VSS is present.

EGR VALVE

EGR opens and closes a passage between exhaust and intake.EGR valves are opened using:

Pintle

Spring

Passages


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Vacuum (usually ported, may use vacuum control solenoid)

Electronic (EGR valve uses solenoid)

Typically EGR is disabled when the following

condition exists Coolant temperature below 57C (134F).

During deceleration (throttle valve closed).

Light engine load (amount of intake air very small).

Engine speed approximately 4000 RPM or more.

Engine racing (neutral start switch turned on).


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VARIOUS EGR CONTROLS


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A


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NTILOCK BRAKING

SYSTEM


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Why Anti Lock Braking System?

Stopping a car in a hurry on a slippery road can be very challenging.

Anti-lock braking systems (ABS) take a lot of the challenge out ofthis sometimes nerve-wracking event.

In fact, on slippery surfaces, even professional drivers can't stop asquickly without ABS as an average driver can with ABS.

Getting the ABS Concept

A skidding wheel (where the tire contact patch is sliding relative to theroad) has less traction than a non-skidding wheel.

If stuck on ice, one can feel that, when the wheels are spinning there

will be no traction.

This is because the contact patch is sliding relative to the ice.

By keeping the wheels from skidding while you slow down,anti-lock brakes benefit you in two ways:

1.You'll stop faster, and

2.You'll be able to steer while you stop.


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Location of anti-lock brake

components

Anti-lock brake pump and valves


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Components of Antilock Braking

System

ABS Controller

Wheel Speed sensors

Pump

Valves

1. ABS Controller

The controller is a computer in the car.It receives inputs from:

Wheel Speed Sensors (Each Wheels Speed)Brake Switch (Brake Pedal Operation)

Vehicle Speed Sensor (Vehicle Speed)

And Controls:

The solenoid valves (8 Nos)Pump Motor Assembly


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2. Wheel Speed Sensors

The speed sensors are located at each wheel, or in somecases in the differential

These sensors measure the speed of the respective wheelon which it is fitted

Which provides the information, when a wheel is about tolock up.

Solenoid Valves

There is a valve in the brake line of each brake controlled by the ABS.

The valve has three positions:

The valve is open; pressure from the master cylinder is passed rightthrough to the brake.

The valve blocks the line, isolating that brake from the master cylinder.This prevents the pressure from rising further should the driverpush the brake pedal harder.

The valve releases some of the pressure from the brake.


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4. Pump Motor

Outlet Solenoid valves release pressure from the brake lines.

When a valve reduces the pressure in a line, the pump operates to getthe pressure back up for the respective line.

Thus it help lock and brake of the wheel to effect Antilock brakefunctioning


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How ABS works???

The controller monitors the speed sensors at all times.

It is looking for any decelerations in the wheel that are out of theordinary.

Right before a wheel locks up, it will experience a rapiddeceleration.

If left unchecked, the wheel would stop much more quickly than anycar could.

It might take a car five seconds to stop from 60 mph (96.6 kph)under ideal conditions, but a wheel that locks up could stopspinning in less than a second.

The ABS controller knows that such a rapid deceleration isimpossible, so it reduces the pressure to that brake until it seesacceleration.

Then it increases the pressure until it sees the deceleration again. Itcan do this very quickly, before the tire can actually significantlychange speed.

The result is that the tire slows down at the same rate as the car,with the brakes keeping the tires very near the point at whichthey will start to lock up.

This gives the system maximum braking power.


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How

?????

When the ABS system is in operation you will feel a pulsing in thebrake pedal

This comes from the rapid opening and closing of the valves

Some ABS systems can cycle up to 15 times per second.


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Types of Anti-Lock Brakes

Four-channel, four-sensor

Three-channel, three-sensor

One-channel, one-sensor


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Frequently

Asked

Questions?


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What is ABS?

An antilock braking system works with the regular or foundationbrakes on your vehicle.

ABS simply keeps your base brakes from locking up.

In vehicles not equipped with ABS, the driver can manually pump thebrakes to prevent wheel lockup.

In vehicles equipped with ABS, the driver's foot remains firmly on thebrake pedal, allowing the system to automatically pump thebrakes.


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Why the brake pedal should not be pumped

when stopping in slippery conditions?

Pumping the brakes is a technique that is sometimes used inslippery conditions to allow the wheels to unlock so that the vehiclestays somewhat straight during a stop.

In a car with ABS the wheels should never lock in the first place, sopumping the brakes will just make you take longer to stop.

In an emergency stop in a car with ABS, apply the brake pedal firmlyand hold it while the ABS does all the work.

A pulsing feel will be there in the pedal that may be quite violent, butthis is normal so don't let off the brake.

Why is that important?

When your brakes lock up on wet and slippery roads or during a panicstop, you lose steering control and your vehicle can spin.

Rear wheel ABS prevents wheel lockup so that your car stays in astraight line.

If your car has ABS control on all four wheels, you also keep steeringcontrol.

If you have steering control, it is possible to avoid a crash by steeringaround hazards if a complete stop cannot be accomplished intime.


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Do cars with ABS stop more quickly than cars

without?

ABS is designed to help the driver maintain control of the vehicleduring emergency braking situations, not make the car stop morequickly.

ABS may shorten stopping distances on wet or slippery roads andmany systems will shorten stopping distances on dry roads.

On very soft surfaces, such as loose gravel or unpacked snow, anABS system may actually lengthen stopping distances.

In wet or slippery conditions, you should still make sure you drivecarefully, always keep a safe distance behind the vehicle in frontof you, and maintain a speed consistent with the road conditions.


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