A Report on Industrial training at

Mercedes-benz service centre

From 15th may – 26th May, 2018
Prepared by: Anand Panchal

L.D.COLLEGE OF ENGINEERING
DEPARTMENT OF MECHANICAL ENGINNERING

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 Abstract
As a Mechanical Engineering Student I am very interested in automobile Engineering. I always keen
to learn different mechanisms used in vehicles, I used to watch animated videos on YouTube about
automobile mechanisms like Differential, Automatic transmission gearbox etc, but I never watched
it in real. So, it was a great opportunity for me to do two weeks internship at Mercedes-benz Service
centre, Ambli, Ahmedabad. The internship was concentrated on the car services. At the beginning of
the internship I had several queries in my mind regarding the different technologies used in Mercedes-
benz and what skills are needed in organization. During my internship several queries are cleared by
doing some activities. The objective of this internship is to understand working of different
mechanisms, to get knowledge of regular services and the major-minor problem that can be observed
in day to day life. Apart from technical knowledge, I also learnt rules and safety instruction, Inventory
management, Quality Control. I realize the responsibility of technicians working on the car. So, this
internship was a great experience. I found out how much I am strong in automobile field. I gained
new knowledge and skills and met many new people. Working together with people having different
background and education was great experience. I also accompanied by other 2-3 students who were
also on industrial training, so it was nice knowledge sharing. I achieved many of my learning goals.
I got insight into the work of an organization. At last this internship has given me new insights and
motivation to pursue a career in mechanical engineering.

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 CONTENTS

Abstract……………………………………………………………………………………….……....2

Training certificate…………………………………………………………………………………...3

Content……………………………………………………………………………………………….4

CHAPTER 1: INTRODUCTION……………………………………………….……………….5-7

1.1 Company overview……………………………………………………………….……………....5

1.2 Mercedes-Benz models In India………………………………………………………………….6

CHAPTER 2: WORKING IN WORKSHOP ……………………………….……………8-15

2.1 Benchmark Cars – Mercedes-Benz Service centre ………………………………………….…...8

2.2 What Learned?..................................……………………………………………………………..9

2.2.1 How to read tyre size………………………………………………………………………..….9

2.2.2 Brake Booster…………………………………………………………………………………10

2.2.3 Types of Filters………………………………………………………………………………..11

2.2.4 Different types of Oils and its importance…………………………………………………….12

2.2.5 Wheel Alignment………………………………………………………………………...……13

2.2.6 Tire Balance…………………………………………………………………………..……….15

2.2.7 Brake…………………………………………………………………………………………..16

2.2.8 Bushing (isolator) – Mounting…………………………………..……………………………17

2.2.9 Engine Control Unit………………………………………………………..…………………18

2.2.10 Exhaust Gas Recirculation……………………………………………….………………….18

2.2.11 Anti-lock braking system……………………………………………………………………19

CONCLUSION……………………………………………………………………………….........20

REFRENCES……………………………………………………………….……………………...20
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Chapter 1: Introduction
1.1 Company overview:

Established in 1994, Mercedes-Benz India Pvt. Ltd. pioneered the luxury car market in
India and boasts of more than 130 years of cutting edge innovation in the luxury automobile industry
globally. Set up in 2009, Mercedes-Benz India’s world class production facility is spread over 100
acres in Chakan near Pune. The production facility now carries an investment of INR 1000+ crores
and has the largest installed production capacity for any luxury carmaker in India.

Mercedes-Benz India also has the largest network spread amongst any luxury carmaker,
with presence in 41 Indian cities through 89 outlets. Through the exclusive AMG Performance
Centres located in 5 metros including Delhi, Mumbai, Hyderabad, Bangalore and Pune; the AMG
performance sub-brand of Mercedes-Benz also boasts of a strong retail network presence in the
country.

Mercedes-Benz India product portfolio comprises the locally produced Mercedes

Maybach S 500, S-Class, E-Class, C-Class, CLA luxury sedans and the GLA, GLE and the GLS
luxury SUVs.

The CKD GLC was the 9th product added to Mercedes-Benz’s local production portfolio.
Completely Built imported cars portfolio includes the A-Class, B-Class, CLS, E-Class Cabriolet, S-
Class Coupé, C-Class Cabriolet, S-Class Cabriolet and the S 600 Guard a range of other Guard
vehicles etc. The product portfolio also comprises the iconic off-roader Mercedes-AMG G 63 as well
as a wide range of other Mercedes-AMG performance cars like the AMG CLA 45, AMG C 63 S,
AMG S 63 Coupe, AMG S 63 Sedan, AMG GLA 45, AMG GLE 43 Coupe, AMG GT S sports car,
AMG SLC 43 and AMG C 43.

The long wheel base new E-Class is Made in India, for India, the first new generation car to
be locally produced since market launch. India is the first country to get an RHD version of the LWB
E-Class in the world.

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1.2 Mercedes-benz models in India:

Figure 1.1 Mercedes-Benz Models in India

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AMG Models:

Figure 1.2 Mercedes-Benz Models in India

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 Chapter 2: Working in Workshop
2.1 Benchmark Cars – Mercedes-Benz Service centre
I have done my internship at Benchmark Cars, Mercedes-benz Service centre. The technicians
working there are very helpful and I learned So many things from them. However photo shoot is
strictly restricted for me inside the workshop.

Figure 2.1 Benchmark Cars service mercedes benz

Features of workshop:
• Equipped with hi-tech lift machined for lifting the car to repair top bottom parts.

• All the technicians have their own equipment’s and machinery.

• They have a very large floor, sufficient area for working.

• Time to time sweepers clean the workshop to maintain the good working environment.

• All the major & minor faults would be find by manually or through software.

• The workshop have well maintained illumination and air circulation.

• All working and inventory are controlled computerised.

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2.2What Learned

2.2.1 How to read tyre size

Figure 2.2 Tire Nomenclature

For Example:
Example: 215/60R15

 215 is the width of the tyre in millimetres.

 60 is the aspect ratio or tyre profile.
 R means it is radial construction.
 15 is the diameter of the wheel rim in inches.

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2.2.2 Brake Booster
A brake booster is an enhanced master cylinder setup used to reduce the amount of pedal pressure
needed for braking. It employs a booster set up to act with the master cylinder to give higher hydraulic
pressure to the brakes and/or lower force applied on the brake pedal through a brake booster push-
rod. The brake booster usually uses vacuum from the engine intake to boost the force applied by the
pedal onto the master cylinder or may employ an extra vacuum pump to enable it. Without the engine
running the brake pedal feels very hard and ineffective on the braking capability. An "active" booster
is a non "conventional" booster where a solenoid is used to open the booster air valve to automatically
push the master cylinder forward to perform some forms of dynamic stability control. Brake boosters
come in either a single diaphragm or tandem diaphragm (which is generally used for bigger vehicles
and trucks). They can be "cabin-breathers" (taking clean filtered air from inside the cabin thus may
be noisier) or "engine-breathers" (less noisy but more at risk for becoming clogged with mud/ice if
not protected properly).

Apart from this additional booster setup, the braking system is a normal hydraulic brake system.

Figure 2.3 Brake Booster Working

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2.2.3 Types of Filters
ENGINE AIR FILTERS
There is an air filter in the engine that works to clean the air
that goes into the engine for combustion. Air filters are made
of different materials such as paper, foam, or sometimes even
cotton. The air filter cleans the air as it enters the engine to
remove any abrasive particles. This ensures that the
combustion occurs in the best possible conditions and it makes
sure the fuel efficiency of the vehicle remains where it should
according to the manufacturer.
Figure 2.4 Engine Air Filter

OIL FILTERS
As an engine runs, the metal wears down and tiny metal
particles release. These particles can block the flow and also
end up in the lubricant. The oil filter in your car catches these
particles that could potentially damage the engine. It is
important to change the oil filter according to the car
specifications to keep it working properly. This means about
every two years if you drive a new car and every year if you
have an older model.
Figure 2.5 Oil Filter

FUEL FILTERS
The purpose of a fuel filter is to remove impurities from the
fuel before they get to the engine. This filter picks up and
contains any dirt that might harm the engine or keep it from
working properly. It is important to change the fuel filter
periodically since the dirt, and small particles can build up
and get stuck in the filter. If it clogged or dirty, it will reduce
the amount of fuel flowing to the engine and affect the fuel
economy and performance.
Generally replaced after 30,000 km Figure 2.6 Fuel Filter

CABIN AIR FILTERS

The cabin air filter catches dust particles and also pollen
that can float around the air outside the vehicle and
prevents them from entering the car. These filters are
important for keeping the air inside the car clean and
breathable no matter what it is like outside. It is a good
idea to change the cabin filters about once a year to ensure
that they stay clean and keep filtering out the particles.
 Filters are generally replaced by checking its Figure 2.7 Cabin Air Filter
performance.
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2.2.4 Different types of Oils and its importance.

ENGINE OIL

Motor oil, engine oil, or engine lubricant is any of various well-developed lubricants (comprising oil
enhanced with additives, for example, in many cases, extreme pressure additives) that are used for
lubrication of internal combustion engines. The main function of these lubricants is to reduce wear
on moving parts; they also clean, inhibit corrosion, improve sealing, and cool the engine by carrying
heat away from moving parts.

 Generally replaced after 1 year.

TRANSMISSION OIL

Automatic transmission fluid (ATF), also known as transmission fluid or tranny fluid for short, is the
fluid used in vehicles with self-shifting or automatic transmissions. It is typically coloured red or
green to distinguish it from motor oil and other fluids in the vehicle.

The fluid is optimized for the special requirements of a transmission, such as valve operation, brake
band friction and the torque converter, as well as gear lubrication.

 Generally replaced after 45,000 km.

BRAKE FLUID

Brake fluid is a type of hydraulic fluid used in hydraulic brake and hydraulic clutch applications in
automobiles, motorcycles, light trucks, and some bicycles. It is used to transfer force into pressure,
and to amplify braking force. It works because liquids are not appreciably compressible.

Most brake fluids used today are glycol-ether based, but mineral oil and silicone-based fluids are also
available.

 Generally replaced after 1 year.

LUBRICATING OIL IN DIFFRENTIAL AND TRANSFER CASE

Gear oil is a lubricant made specifically for transmissions, transfer cases, and differentials in
automobiles, trucks, and other machinery. It is of a high viscosity and usually contains organosulfur
compounds.

 Differential and transfer case oil are long lasting and no need to change unless any issue found.

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2.2.5 Wheel Alignment

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

maintenance that consists of adjusting the angles of wheels to the car manufacturer specifications.
The purpose of these adjustments is to reduce tire wear, and to ensure that vehicle travel is straight
and true (without "pulling" to one side). Alignment angles can also be altered beyond the maker's
specifications to obtain a specific handling characteristic. Motorsport and off-road applications may
call for angles to be adjusted well beyond "normal", for a variety of reasons.

5 Benefits of Getting a Wheel Alignment.

 Increase Fuel Efficiency. When you automobile isn't aligned correctly, your wheels aren't
working together they way that they should.

 Reduce Expensive Auto Repairs.

 Experience Smoother Driving.

 Improve Vehicle Safety.

 Increase the Life of Your Tires.

CAMBER ANGLE:

Camber angle is the angle made by the

wheels of a vehicle; specifically, it is the
angle between the vertical axis of the wheels
used for steering and the vertical axis of the
vehicle when viewed from the front or rear.
It is used in the design of steering and
suspension. If the top of the wheel is farther
out than the bottom (that is, away from the
axle), it is called positive camber; if the
bottom of the wheel is farther out than the
top, it is called negative camber.

Figure 2.8 Camber Angle

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CASTER ANGLE:

The caster angle is the angular

displacement of the steering axis from
the vertical axis of a steered wheel in a
car measured in the longitudinal
direction. It is the angle between the
pivot line (in a car an imaginary line that
runs through the center of the upper ball
joint to the center of the lower ball joint)
and vertical. In automobile racing, the
caster angle may be adjusted to optimize
handling characteristics for a particular
Figure 2.9 Caster Angle
venue.

TOE ANGLE

In automotive engineering, toe, also known

as tracking, is the symmetric angle that
each wheel makes with the longitudinal
axis of the vehicle, as a function of static
geometry, and kinematic and compliant
effects. This can be contrasted with steer,
which is the antisymmetric angle, i.e. both
wheels point to the left or right, in parallel
(roughly). Negative toe, or toe out, is the
front of the wheel pointing away from the
centerline of the vehicle. Positive toe, or
toe in, is the front of the wheel pointing
towards the centerline of the vehicle. Toe
can be measured in linear units, at the front
of the tire, or as an angular deflection. Figure 2.10 Toe Angle

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2.2.6 Tire Balance

Tire balance, also called tire unbalance or tire imbalance, describes the distribution of mass within an
automobile tire or the entire wheel (including the rim) on which it is mounted.

When the wheel rotates, asymmetries in its mass distribution may cause it to apply periodic forces
and torques to the axle, which can cause ride disturbances, usually as vertical and lateral vibrations,
and this may also cause the steering wheel to oscillate. The frequency and magnitude of this ride
disturbance usually increases with speed, and vehicle suspensions may become excited when the
rotating frequency of the wheel equals the resonant frequency of the suspension.

Tire balance is measured in factories and repair shops by two methods: with static balancers and with
dynamic balancers. Tires with large unbalances are downgraded or rejected. When tires are fitted to
wheels at the point of sale, they are measured again on a balancing machine, and correction weights
are applied to counteract their combined unbalance. Tires may be rebalanced if driver perceives
excessive vibration. Tire balancing is distinct from wheel alignment.

The uneven wear out of tire also cause tire unbalance and it leads to vibration in car and makes ride
uncomfortable.

Figure 2.11 Vibration Due to Imbalance Figure 2.12 Adding Extra weight to balance

Tire balancing is performed on the Tire Balancing machine, the measured weight is attached to the
defined location.

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2.2.7 Brake

A brake is a mechanical device which inhibits motion, slowing or stopping a moving object or
preventing its motion. Most brakes commonly use friction between two surfaces pressed together to
convert the kinetic energy of the moving object into heat, though other methods of energy conversion
may be employed. The brake disc (or rotor in American English) is usually made of cast iron, but
may in some cases be made of composites such as reinforced carbon–carbon or ceramic matrix
composites. This is connected to the wheel and/or the axle. To retard the wheel, friction material in
the form of brake pads, mounted on a device called a brake caliper, is forced mechanically,
hydraulically, pneumatically, or electromagnetically against both sides of the disc. Friction causes the
disc and attached wheel to slow or stop.

Figure 2.13 Brake Assembly

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Brake Disc is generally replaced when it wear out beyond the limit, the limit is mentioned at inner
part of the brake disc.

Figure 2.14 Brake Shoe

 Brake shoe is replaced when it wear out beyond 3 mm limit.

2.2.8 Bushing (Isolator) – Mounting

A bushing or rubber bushing is a type of

vibration isolator. It provides an interface
between two parts, damping the energy
transmitted through the bushing. A
common application is in vehicle
suspension systems, where a bushing
made of rubber (or, more often, synthetic
rubber or polyurethane) separates the
faces of two metal objects while allowing
a certain amount of movement. This
movement allows the suspension parts to
move freely, for example, when traveling
over a large bump, while minimizing Figure 2.15 Engine Mounting

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 Figure 2.16 Rubber Mounting Figure 2.17 Transmission Coupler

transmission of noise and small vibrations through to the chassis of the vehicle. A rubber bushing
may also be described as a flexible mounting or antivibration mounting.

 This Bushing are replaced when it loses the capability to absorb vibration and get rigid and brittle.

2.2.9 Engine Control Unit

An engine control unit (ECU), also commonly called an engine control module (ECM), is a type of
electronic control unit that controls a series of actuators on an internal combustion engine to ensure
optimal engine performance. It does this by reading values from a multitude of sensors within the
engine bay, interpreting the data using multidimensional performance maps (called lookup tables),
and adjusting the engine actuators. Before ECUs, air-fuel mixture, ignition timing, and idle speed
were mechanically set and dynamically controlled by mechanical and pneumatic means.

If the ECU has control over the fuel lines, then it is referred to as an Electronic Engine Management
System (EEMS). The fuel injection system has the major role to control the engine's fuel supply. The
whole mechanism of the EEMS is controlled by a stack of sensors and actuators.

2.2.10 Exhaust Gas Recirculation

In internal combustion engines, exhaust gas recirculation (EGR) is a nitrogen oxide (NOx) emissions
reduction technique used in petrol/gasoline and diesel engines. EGR works by recirculating a portion
of an engine's exhaust gas back to the engine cylinders. This dilutes the O2 in the incoming air stream
and provides gases inert to combustion to act as absorbents of combustion heat to reduce peak in-
cylinder temperatures. NOx is produced in high temperature mixtures of atmospheric nitrogen and
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oxygen that occur in the combustion cylinder, and this usually occurs at cylinder peak pressure.
Another primary benefit of external EGR valves on a spark ignition engine is an increase in efficiency,
as charge dilution allows a larger throttle position and reduces associated pumping losses.

Figure 2.18 Exhaust Gas Recovery

2.2.11 Anti-lock braking system

An anti-lock braking system (ABS) is a safety anti-skid braking system used on land vehicles, such
as cars, motorcycles, trucks and buses. ABS operates by preventing the wheels from locking up during
braking, thereby maintaining tractive contact with the road surface.

ABS is an automated system that uses the principles of threshold braking and cadence braking which
were once practised by skilful drivers with earlier non-ABS braking systems. ABS operates at a very
much faster rate and more effectively than most drivers could manage. Although ABS generally offers
improved vehicle control and decreases stopping distances on dry and slippery surfaces, on loose
gravel or snow-covered surfaces, ABS may significantly increase braking distance, while still
improving steering control

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Conclusion:
It was great experience to work with highly trained technicians at Mercedes-Benz service centre. For
me this training is quite fruitful. I got exposure of how to implement theoretical knowledge in
practical use. Get idea about different mechanisms and electronics control used in modern Hi-tech
Mercedes car.

Reference:
 Wikipedia: Mercedes-benz India
 https://www.goodyearautoservice.com/en-US/tire-basics/tire-size
 Wikipedia Tire CODE
 Wikipedia: Anti-lock braking system
 Wikipedia: Engine control unit
 https://www.cars.com/articles/2013/06/when-do-you-need-a-wheel-alignment
 https://westautomotivegroup.com/5-benefits-getting-wheel-alignment
 https://www.depaula.com/4-types-of-car-filters-and-their-importance
 https://www.mlchryslerdodgejeepramlexington.com/blogs/1315/different-types-filters-
vehicle
 http://www.mgmnoida.org/img/notice/me/576957Industrial%20Training%20Sample%20Re
port.pdf
 https://www.scribd.com/doc/16607045/Format-for-Summer-Internship-Report
 Image Source: Google Images

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