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INTRODUCTION

HYUNDAI MOTOR INDIA LIMITED

Hyundai motors has been selling cars in use since 1986, it started its heavy trucks

stateside in 1988, South Korea¶s No.1 car maker. Hyundai produces various models of cars,SUVs and minivans, as well as trucks ,buses and other commercial vehicles .the company re-

established itself as Korea¶s leading car maker in 1988.The company is also manufacturing

machine tools for factory automation and material handling.

Hyundai Motor India Limited (HMIL) is wholly subsidiary of Hyundai motor

company, South Korea and is the 2nd largest, fastest growing cars manufacturer in India. HMIL

is situated in Irrungatukottai at Sri Perumbadur in Kanchipuram district in Tamil Nadu. It

presently manufacturers many variants of passengers¶ cars namely

Santro Getz

Accent Sonata embera

Tucson i10



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i20 Fluidic Verna

Santa Fe

ABOUT HYUNDAI:



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HMIL presently markets 54 variants of passenger cars across segments. These includes the

Santro in B segment, the i10,the Getz prime and the premium hatchback i20 in the B+ segment,

the Accent and the Verna in the C segment, the Sonata embera in the E segment and the Tucson

in SUV segment.

HMIL, continuing its tradition of being the fastest growing passenger car manufacturer,

registered total sales of 559,880 vehicles in the calendar year (CY) 2009, an increase of 14.4%

over CY 2008. In the domestic market it clocked a growth of 18.1% as compared to 2008 with

289,863 units, while overseas sales grew by 10.7%, with export of 270,017 units. HMIL

currently exports cars to more than 110 countries across EU, Africa, Middle East, Latin America



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and Asia. It has been the number one exporter of passenger car of the country for the 6th

year in

a row.

HMIL¶s fully integrated state-of-the-art manufacturing plant near Chennai boasts

of the most advanced production, quality and testing capabilities in the country. In continuation

of its commitment to provide the Indian customer with global technology, HMIL commissionedits 2

ndplant in Feb¶2008, which produces an additional 300,000 units per annum, raising HMIL¶s

total production capacity to 600,000 units per annum. HMIL has invested to expand capacity in

line with its positioning as HMC¶s global export hub for compact cars. Apart from the

expansion of production capacity, HMIL currently has 286 strong dealer network and 540 strong

service points across India, which will be further bolstered in 2011.

In December 2008, HMIL launched the much awaited premium compact the i20

after it had a global preview at the Paris Motor show in October, 2008. In 2009 HMIL also

launched the new facelift Sonata Transform and the new Verna which is vastly improved models

compared to outgoing models. In March, 2009 Hyundai i10 clocked the fastest 300,000 salessince its launch in October, 2007. HMIL also became the only car manufacturer to introduce

automatic transmission across the segments with the launch of i20 1.2L. Petrol automatic. The

i20 also simultaneously got a powerful 1.4L CRDI engine in July, 2009. The i20 achieved the

highest safety rating by the European NCAP. In September, 2009 HMIL introduced the new

refurbished Santro with luxurious interiors and improved exterior features. The Santro has been

the highest selling model for Hyundai with more than 15 lakh units sold since its launch in India

in 1998. Hyundai Motor India in December 2009 also crossed the 25 lakh car production

milestone.

The company¶s overall performance in automobile sector was recognized by themedia as it was awarded with the prestigious ³Manufacturer of the Year´ award by both UTV,

Auto car and NDTV Profit-Car and Bike in 2009.

ABOUT HMC:

Established in 1967, Hyundai Motor Co. has grown into the Hyundai-Kia

Automotive Group which was ranked as the world¶ 5th

largest automaker in 2007 and includes

over two dozen auto-related subsidiaries and affiliates. Employing over 75000 people

worldwide, Hyundai motor posted sales of USD74.9 billion in 2007 on a consolidated basis and

USD32.8 billion on a non-consolidated basis (using the average currency exchange of 929 won per US dollar). Hyundai vehicles are sold in 193 countries through some 6,000 dealerships and

showrooms.



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BEYOND GEOGRAPHICAL BOUNDARIES:

Around its factory in Tamil Nadu it has been working towards the social and

economic development of the villages, assisting them in the areas of primary healthcare,

education, basic amenities and employment opportunities .As a part of its community

development projects, the company has adopted 4 villages.

TOWARDS EMPOWERMENT:

HMI pays emphasis on the education and overall development of children and

socially vulnerable groups. Besides undertaking mentoring programs for children and

youngsters from the low-income backgrounds, Hyundai has offered private financing of

educational infrastructure in remote areas, and has set up night-schools in the villages. The

company has imparted job-oriented training to unemployed youth of the village around its plants

and has provided employment to the eligible people. As a company, it believes empowerment to

meet the needs is vital than donating necessities. Education thus forms the core pillar towardsempowerment.

SAFETY OF ALL:

Hyundai is committed to road-safety and undertakes myriad initiatives ranging

from creating awareness to help implement road discipline, besides producing cars that confirm

to highest safety standards to make the Indian roads safer. HMI, in association with the Institute

of Road Traffic Education and Delhi Traffic Police, launched an innovative road safety program

called ³Hyundai Traffic Squad´, a Student Traffic Volunteers Scholarship Scheme to create roadsafety awareness and support Delhi Traffic Police in improving Traffic Management System in

Delhi.

Under the scheme, young college and university students assist the police in

traffic management for three hours during the peak traffic hours besides educating the road users.

The scheme offers monthly stipend to 100 students, who are already selected for the purpose

under the banner ³Hyundai Traffic Squad´.

The Scheme comprises Physical training and Classroom training, Traffic drills,

hand signaling and practical control of traffic at intersections are taught in the physical training

to the volunteering students. In the classroom-training program, the students are imparted

knowledge about traffic control devices, road geometric and environmental features, laws of the

road, types of road users, administering the First Aid and post-accident management etc.

Hyundai has also sponsored for the insurance cover of the students. The tasks of

the students include controlling traffic at intersections under the direct supervision of the traffic

police, organize proper parking of vehicles in crowded commercial areas, and educate



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pedestrians, cyclists and other road users about the rules of the road and safe driving measures.

They also control passengers and bus drivers at bus stops to prevent overcrowding and jostling

while boarding, monitor traffic outside educational institutions and conduct surveys for better

traffic management.

CAR MAKING PROCESS FLOW:

KNOCK DOWN

PARTS

PRESS SHOP

(MIP)

LOCAL PARTS

PAINT SHOP

ASSEMBLY SHOP

ROAD TEST

PDI

CUSTOMER

BODY SHOP

FOUNDRY

TRANSMISSION SHOP

ENGINE SHOP VENDOR



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PRODUCTION SHOPS

INTRODUCTION:

Hyundai motor India ltd. Indulges the world class technology as the input for their

process, which contributes the making of India¶s top quality cars which are carried in variousshops.

Aluminum cast shop

Engine shop

Assembly shop

Body shop

Paint shop

Plastic shop

Press shop

Transmission shop.

1. ALUMINUM CAST SHOP:

In aluminum cast shop a critical component of the engine i.e. cylinder head I is made by casting process is aluminum foundry. A basic requirement of hi-tech engine is to

manufacture defect free castings for cylinder heads. Then these components are sent to engine

shop.

2. ENGINE SHOP:



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One of the biggest engine shops in the country, this unit is equipped with the most

modern tooling and testing facilities to make a wide range of engines in-house. The engine

component like cylinder head, piston, cylinder block, crank shaft, cam shaft, etc., are made and

assembled in this shop. The engine components are either forged or cast and the raw materials

required for this shop are either from MIP or from vendor. The engines for all the cars are made

in this shop with different assembly line for engines.

3. ASSEMBLY SHOP:



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In Assembly Shop all the engine and suspension parts, the electrical parts, the

under body parts etc are fitted into the car. The cars go through complete testing in the

Assembly Shop. The Assembly Shop comprises the Trim Line, the Chassis Line, the

Final Line and the OK Line. The assembly shop is the largest shop and has been

expanded to create a separate assembly line for EFI Sonata. The car bodies, which come

from special PBS conveyor after painting are fitted with plastic, mechanical and electrical

parts from various shops. Here the assembled cars are checked and rechecked for major

assembly defects by the QC inspector. The inspection is divided into interior and exterior

inspection and the defects are being recorded in the inspection card. The defects, if any

are corrected simultaneously on the conveyor line itself. After inspection, the car goes to

the chassis line for wheel alignment and head lamp aiming. Roll and brake test, pit

inspection for defects in the chassis and the air conditioning and the emission test on

passing these tests, the car goes to the road test where they are smoothness of operation, pick up, rating and abnormal noises, shaking and steering and a host of other function is

also performed.

The car then goes to the assembly shop to undergo the shower test, to check the water

leakage. After the shower test, the vehicles enter the final line, where they are again re-inspected

for touch up defects like scratch and paint problems. The car is then signed off and parked

outside the assembly shop where the PDI delivers again check and drive away to yard for

customer delivery.

4. BODYSHOP



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It is a hi-tech line that builds full body shells from panels. Automated robotic arms are used for

intricate welding operations that ensure superior and consistent build quality. In the body shop

all the sheet metal parts and panels, which are supplied from press shop and vendors

respectively, are converted into final shape of the car body is into the floor, side build, moving

and complete. The major process of au automotive body is electric resistant welding. After

welding the complete body is sent to the paint shop through conveyor skid for painting.

5. PAINT SHOP:

It is one of the most modern paint shops in the country and uses the environmentfriendly water based process for superior and lasting exteriors.

A unique process management system followed here helps us deliver the most extensive color

range, independent of minimum batch requirements, helping customers get their preferred color

anytime. The car bodies which arrive here from the body shop are painted in conveyors and

controlled painting process. The purpose of the painting is to give corrosion resistance property

and appearance value to the car body. The cost of the paint must give to the surface the desired



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color gloss, the abrasion and the corrosion resistance. When the appearance is beautiful it raises

the car¶s value.

6. PLASTIC SHOP:

This shop consists of injection molding line and bumper painting line. In injection

molding line crash pad, front and rear bumpers, luggage room, side trim left and right, and all the

doors trims are produced in the injection molding machine and then supplied to the assembly

shop for assembling.

7. PRESS SHOP:

A computer controlled line that converts sheet metal to body panels with high dimensional

accuracy and consistency. In the press shop all the sheet metals panels like floors, doors, roofs,

fenders, hood and tail gate of a car are produced using equipment like blanking line, transfer

press line etc. These panels are stored in pallet and sent to the body shop for welding.

8. TRANSMISSION SHOP:



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modern tooling and testing facilities to make a wide range of engines in-house. Transmission

shop consist of transmission assembly, heat treatment, clutch housing, sleeve, speed gears, shaft

& differential gear line & gear fully computerized numerical controlled machines, fully

automated gear testing machines to check critical dimensions and defects like nick, burr and runout, etc.

2. BODY SHOP #2



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A hi-tech line that builds full body shells from panels. Automated robotic arms used for intricate

welding operations that ensure superior and consistent build quality. The panels made in the

press shop are brought here to be joined into a complete body (referred to as ³Body in White´

(BIW). Here all I.P.KD and MIP panels are used. Mostly panels for the interior of the parts are

LP and all the exterior panels are MIP. This is done to ensure quality in body, as interior panels

of the parts require less sophistication and error can be handled to a limit. Panels are joined to

make parts on their respective sub-lines and parts from different lines are joined on ³Body

Build´ line and after passing through ¶Body complete¶ lines we get BIW which is then sent to

³paint shop´ after inspection. This shop has an output capacity of 57 UPH.

FUNCTIONS OF BODY:

Giving dwelling space which is safe and pleasant.

Adhering the parts which is needed to drive such an engine, suspension etc.,

Function of body are not separate but interrelated and it is important that they should be

harmonized on the high level on the basis of the condition such as cost, weight etc.

MANUFACTURING PROCESS:

Door line (FR/RR-LH/RH).

Floor line

Side LH/RH.

Body Re-spot Line (BR).

Body Build Line (BB).

Body Complete line



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Main Operation in the Body Shop is Welding. Various types of Welding used are,

y Resistance spot welding.

y CO2 arc welding.

y Braze welding.

2.3 BODY SHOP GENERAL DETAILS

AREA 26,400Sq.m

CAPACITY 300,000/Yr

MODEL PA/RBI

NO OF ROBOTS 181

SPOT WELDING 123

HANGER 43



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SEALER 7

ACS 4

NO OF WELDING POINTS/CAR 1685

2.4 EQUIPMENTS IN BODY SHOP:

ROBOTS:

Robot is an automatically control, reprogrammable, multi-purpose manipulator,

programmable in 3 or more axis. The field of robotics may be defined as a study, design and use

of robot system for manufacturing, designed to move the material, parts, tools, or specialized

devices through variable programmed motion to perform a variety of task.

They are used to perform unsafe, hazardous, highly repetitive and unpleasant

tasks. There are two types of Robots used in the Body Shop. Such as

Six Degree of Freedom Robots ± Perform Arc welding, Resistance spot welding, Sealer

appliances etc. This type of robot is stationary.

Seven Degree of Freedom Robots ± Perform material handling, loading and unload functions,

painting etc. This type of robot is movable.

VARIOUS FUNCTIONS OF ROBOT:

Spot welding:

For the purpose of Spot Welding, Robot uses its end effectors to hold the Welding

Gun to spot weld the inner key assemblage in between the ends of the Gun.

Pick and Place (Hanger):



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The main function of this robot is to transfer the work or part from one place to another place.

Brazing:

Brazing Robot does the brazing operation at the hinge and latch side of the door.

SEALER APPLICATIONS:

Robots are used to apply sealers over the panels. This is done by attaching sealer gun to the

robot arm and a sealer pump setup. This sealer is applied to give reinforcement to the panels to

avoid water leakage and also to avoid panel to panel contact.

Various sealers used here such as,

SPOT SEALER:

This is used for avoiding rust during spot welding.

MASTIC SEALER:

It is applied on the roof rail to avoid vibrations at high speed.

HEMING SEALER:

Heming sealer is used in door panel to avoid vibrations.

BPR SEALER:

Body panel reinforcement sealer. It is used in doors and side outer doors for

strength.

AUTOMATIC CHECKING SYSTEM (ACS):

Automatic Checking System (ACS) is used to check the specification of the Body

in White (BIW).

No of check points : 81

Checking accuracy : 0.2mm.

No of Robot : 4

Type of sensor : laser.

VIN PUNCHING ROBOTS:

Vehicle Identification Number (VIN) is punched in the floor of the Body. For this purpose, VIN



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punching Robot is used. VIN is unique for every vehicle.

JIG:

It is plate or metal box, structure or a device usually made of metal over which

parts can be loaded and held in identical position for doing specific operation. It is mainly usedin mass production of single flow piece companies like automobile companies.

Various types of jigs are used in body shop such as:

welding assembly jig.

Installation assembly jig.

Sealant assembly jig.

Machining jig.

Swing type jig.

FIXTURE:

It is a structure which holds and locate work piece in a desired and definite position for a

specific purpose like inspection, marketing etc. Various types of Fixtures are used in body shop

such as,

Checking fixture.

Inspection fixture.

Aperture fixture.

In a body mainly two types welding are used such as spot welding and MIG welding.

VARIOUS LINES IN BODY SHOP:

DOOR LINE:

Here inner (LP) and outer (MIP) panels for doors are joined and sent in same



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manner but to the BCI line. Hood and trunk lids are joined to the main buck at BCI.

FLOORLINE:

Here three different panels (front, rear and center) are joined together to make the

complete floor. This process is done by robots after manual feeding of panels. After is complete

it is automatically sent to ³Body build line´. This is done according to production sequencespecified.

SIDE RH & LH:

These are two separate lines which make the same part for different sides of the

body. Outer panels from body shop and inner panels from local vendors are joined together by

robots after manual feeding and sent to BB line automatically through conveyors according to

production sequence.

CR (Cowl, Roof):

Here the panels for cowl and roofs are joined together and sent to BB line in same

manner as above sub-lines. All the parts are brought together by single carrier.

MAIN BUCK:

It is the place where Floor, Side LH & RH< Roof Rail, Cowl are joined together

to form a basic Car Body Structure.

BODYBUILDLINE(BB):

There are two such lines in the body shop BB and BR lines. In BB parts are

loaded automatically to chain conveyor and robots join them in body by spot welding.

BODYRESPOTLINE(BR):

After completing body build line, the body enters repost line where the remaining

spot welding operations are done. Roof panels are welded in this line only.



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BODY COMPLETE LINE (BCI)-SHUTTLE LINE:

The various moving parts like Doors, Hood, Tail gate, Door hinge, Fender are

assembled to the body manually using fasteners and jigs.

BODY COMPLETE LINE (BC2) ± SLAT LINE:

The final operations, touchup and inspection of the completed BIW are done here.

The bodies are discontinued from the line sent to rework area if any correction/repairs are

needed. The bodies passed from BC2 and rework area are then sent to the ³paint shop´.

CO2 WELDING:

This type of welding is done manually where the parts to be welded are not

accessible to the robots.

Special features:

y Good mechanical properties of Welding Metal

y No Porosity,

y Little tendency to over cut,

y Sound Weld deposition with consistency.

Application:

y Used for Carbon and Low Alloy Steel from 1.2mm to 8mm and above,

y Fabrication of Structural Steel,

y In semi automatic and automatic process to increase yield, productivity and quality,y Mining Industries, Automobile Industries, Chemical Plant commissioning and erection,

Ship building, Boilers and pressure vessels, etc.

Technical specification

The wire rods used for making co2 wire are ER7086, WR3M, and WR3. The wires are made as

per IS6419 standard

Used for welding consumable wires in grades of high-strength steel structures like vehicles,

building, boat, bridge and etc, these can also be used for speed welding of sheet and pipes. These

are available at industry leading prices to our clients.



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ENGINE SHOP


modern tooling and testing facilities to make a wide range of engines in-house. In engine shop

the main components viz. Cylinder head, Crank shaft, Cam shaft and Connecting rod which need

precision dimensional accuracy, are machined using special purpose machines. Each componentis machined in a separate line. Thus there are 5 different lines in E1machining line and 4 in E2

machining line (As cam shaft is machined in E1 line only). Cylinder head is made by die casting

process in Aluminum foundry. Basic requirement of High-tech Engine is to manufacture defect

free casting for cylinder head. After this the machined parts of the cylinder head are sent to the

sub assembly, where they are assembled. Following this all the parts are sent to the main

assembly. The detail report of the machining of each component is shown.

Details of kappa engine of Hyundai

KAPPA ENGINE

The facts first: the new engine is an all-aluminum, DOHC, 16-valve unit that produces

80bhp@5200rpm, 11.4kgm@4000rpm, and is redlined at 6500rpm. It has a lubricated timing

chain, offset crank, and spark plugs that have been lengthened from 19mm to 26.5mm. The

valves incorporate hydraulic lash adjustors. Other innovations include the lack of a fuel return

line that helps save fuel by eliminating evaporation, and fuel injectors whose pulsing can be

varied, depending on the requirements of the moment ³warming up, power, or normal driving.

The i10 automatic will also be available with a four-speed transmission.

CYLINDER BLOCK



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The cylinder block forms the basis framework of the engine. It houses the engine

cylinders which serve as bearings and guides, for the pistons reciprocating in them. Around the

cylinders there are passages for the circulation of coolant. Cylinder block also carries lubrication

oil to various components through drill passages called µoil galleries¶. During manufacturing, the

oil holes are drilled and rarely cast. Here, cast iron is used to cast the cylinder block, in this

carbon is present as flakes of graphite, which makes it, more wear and corrosion resistant apart

from its better mach inability. Advantages of cast iron over Aluminum alloys are;

y It is good foundry material.

y It has high mach inability.

y It does not wrap, under high temperatures and pressures, developed in the cylinders.

y Due to its slightly porous nature, it remains better the lubricating oil film.

y It has good sound damping properties.

y It has low value for the coefficient of thermal expansion.

y It is relatively cheap

CYLINDER HEAD

The cylinder head accommodates the valve guides, camshaft and the valves. The cylinder

head is manufactured by the casting process in aluminum foundry plant of the company.

Aluminum being a light metal and easily cast able one. It is used for cylinder head casting. The

cylinder is of two types: Distributor less ignition type (DLI) and distribution ignition type (DI).

The distributor refers to the device used by ignition system to deliver spark to cylinders

according spark timing of each cylinder. In case of distributor less ignition type, it uses a cam

sensor (CPS) to detect the position of valves and accordingly induce spark in the cylinders. The

CPS is a new concept that uses electronic method of spark ignition and it is more reliable at all

speeds of the engine. There are provisions for two inlet valves and one exhaust valves for each

cylinder, which are 4 in number. There are also 10 bolt holes. 11 water jacket holes and 3 oil

drain holes in a cylinder block. The various stages of machining are shown:

CONNECTING ROD

The connecting rod so used to connect the crankshaft to the piston head of the cylinder. The

connecting rod transforms the reciprocating motion of the piston to the rotary motion of thecrank shaft. From the crank shaft it is transmitted to the transmission assembly from which it is

transferred to the wheels of the vehicle. The connecting rod is machined in two separate parts for

easy machining and assembly in crankshaft. Then they are fitted by nuts and bolts and are sent to

engine assembly line. The raw material is imported from KORIA.

CAM SHAFT



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The camshaft is used to maintain the valve timing of the inlet and exhaust valves. The

camshaft is a shaft with cams machined on the surface for each valve in the cylinder head. There

are two inlet and one exhaust valves for each cylinder and the engine assembled here has 4

cylinders. There are two camshafts: one for inlet valves and another for exhaust valves. These

cams are manufactured according to the engine valve-timing diagram; this diagram varies for

slow and speed engines. From the diagram the cam profile is drawn and then the cam profile is

machined on the cam shaft. In the MIP plant this cam shaft is brought for grinding, turning,

drilling bolt holes etc. before sending it to the cylinder assembly.

CRANK SHAFT

Crank shaft is the one of the main part in the engine. It is placed inside the cylinder block of

the engine. It converts the linear motion of a piston into rotary motion. One end of the crankshaft

is connected to the fly wheel. The main parts of the fly wheel are as follows:

y FLANGE END

:

it is the end where the fly wheel is mounted outside the engine. thisend comes outside the engine

y PULLEY END: it is the end where the pulley is fixed. This end also comes outside

the engine.

y PIN: the big end (crank end) is connected to the pin of the crank shaft and the small

end (piston end) is connected to the piston. Crank shaft consists of 5- pins.

y JOURNAL: it is used for placing crankshaft in crankshaft bore in cylinder block.

The material used for crank shaft is cast iron. Using cast iron crankshaft is manufactured by

means of ³casting process´. it is the process where the cast iron so melted and is casted into

the die.

ENGINE ASSEMBLY



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The engine assembly is the shop where the complete engine is assembled.

1. Cylinder block of the engine arrives. The various capacity of engine cylinder are:

y 1.0L (SANTRO)

y 1.1L (SANTRO)

y 1.5L (ACCENT)

y 1.6L (ACCENT VIVA)

y (SONATA and all other diesel engines are imported)

2. In the second stage the cylinder block, the cylinder block is checked for :

y Rust

y Matching with gasket

y Dummy plug check (if the engine get heated instead of original plug this

plug comes out )

y Piston code number



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y Check whether the cylinder block is gone through the water check

3. The cylinder block is washed in washing unit. Here in the 1st

case 31 part of glycerin is added

in 1001 part of water. In this second case 31 part of coolant is added in 1001 part of water. Here

in this case the steam temperature is 55 5ºC. In this case the engine number is printed (eg:

G4HC4) this number is based on as shown below.

G - Fuel

4 ± Number of cylinders

H ± Development number

C ± Cubic capacity

4 ± Year of make

4. Now the engine is tilted and then the following operations are made :

y Cap is removed manually

y Bearing is fitted manually

y Then these places are oiled

5. Crank bore code in the engine and the crank shaft code are multiplied and the answer is

matched with color code of bearing as given in chart and the respective bearing is fitted with

crank board cap

BEARING SELECTION PROCEDURE (MXI)

6. Thrust bearing is fitted in center of the crank bolt. Then even tightening of the screws (to

avoid errors) is done by machine. Manually they check for free rotation of crank shaft.

7. The piston is fitted in the bore 4 pistons are fitted the size varies slightly foe free rotation of

the piston inside the cylinder bore the bore code is printed as (e.g: ABBC)

8. Bearing cap is fitted at the end of the piston. The bearing is fitted to avoid damage of piston

when in rotation with crankshaft instead of changing piston the bearing alone can be changed in

feature. It is fitted manually and is tightened using pneumatic tool.

9. Next the front case is fitted. It pumps the oil in the oil screen to head it has 3 holes one is for

measuring oil, second hole is for pumping oil and the third hole is to pump the oil into oil filter.

In this oil filter the oil is filtered and then it is pumped to the head



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10. Next the rear case is fitted where is has oil seal to avoid oil leaks and another function is for

packing.

11. Next the oil pan is fixed where the oil is stored.

1. MX ± 1.5L

2. LC ± 2.5L

12. Next they fix the gasket this gasket fills the gap in between the cylinder block and the

cylinder head, next they fix the fit bush knob in the cylinder block to fix the engine head and in

the next stage water pump is fitted the main function of the water pump is to suck the water from

the radiator and cools the engine by centrifugal force.

13. In this stage they fix the cylinder head, which comprises of inlet, exhaust valves, cam shaft

(it should rotate at half the speed of the engine speed).

14. Tension spring to keep in particular tension is fitted.

15. Tensioned (bearing) is fitted to keep the tension spring at particular position.

16. Crank position sensor is fixed in the engine and is connected to the ECU (electronic control

unit). The ECU controls the various sensors:-

Crank position sensor

Cam sensor

Throttle body sensor

O2 sensor

Water temperature sensor

Knock sensor

MAP (manifold absolute pressure) sensor

17. Next they fix the timing belt (timing gear is on the cam shaft) from timing gear to the

sprocket. This sprocket is fixed on the crank shaft. When the timing belt rotates it makes the

camshaft and the crank shaft to rotate. Wrong setting of the belt may lead to engine vibration.

18. Then they fix the exhaust manifold gasket.

19. Oil filter stud is fixed where the oil filter is mounted. Then they fix the exhaust manifold.

20. Next they do the valve clearance this is done because during heating process it expands the

valve is as follows:

i. Inlet ± 0.1mm

ii. Exhaust ± 0.75mm



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21. Rocker arm cover is fixed. This cover has opening through which the oil can be poured. Here

the camshaft sensor is fixed.

22. Next they fix the alternator brace where the alternator is mounted.

23. Then they fix the inlet manifold. A throttle body is fixed through which the air enters insidethe manifold. This inlet manifold has a throttle body sensor, which is connected to the ECU. The

manifold carries ISCA (Ideal Speed Control Accelerator), which controls the air fuel mixture at

ideal position. This ISCA and injector are called as actuators.

24. Next they fix the oil filter, spark plug (4 No¶s), and casing cover, it absorbs heat and directs

outside.

25. Then they fix water inlet pipe.

26. Spark plug cable is fixed which is connected to the ignition coil. This coil gets power from

the battery.

27. Vacuum nipple is also fitted which absorbs the extra air in the brake booster.

28. The manifold stay is fitted, which holds the engine head and block in order to avoid

vibration.

29. The alternator is fitted that converts the mechanical energy to electrical energy.

30. Crank sensor wheel is fixed. This shows the position of the stroke

31. Rear plate is fixed, this plate act as a washer for fitting the starter mortar.

32. Flywheel is fixed for engine balance power transmission.

33. Water temperature controller is fixed it has 2 functions:-

y It takes hot water from the engine and sends it to the radiator for cooling

y It sends 80ºC water into water inlet pipe.

34. Flywheel has holes to fit for level pin to fit clutch plate. Then they fix the timing cover.

35. Next they fix the ignition coil which carries 12V current from the battery and this current is

converted to 25KV-35KV.

36. Next they fix the crank pulley (the crank pulley is connected to the alternator by means of

belt) as the belt rotates the alternator also rotates and current is generated.

37. Next they fix the belt connecting the crank pulley. Alternator pulley, A/C, power steering and

water pump pulley are fixed.



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38. Next they fix the oil level gauge with earth cable.

39. Next they fit the air filter over the engine this air filter is fixed to the throttle body. Then they

fix the oxygen sensor which is fixed to the exhaust manifold. They also fix the side plank in the

air filter which controls the noise going inside.

40. Next they fix the heat protector on exhaust manifold.

41. Next they fill the oil in the engine this is done automatically.

y LC ± 3.3L

y MX ± 2.8L

42. Then they fix the clamp to separate O2 sensor and oil pressure sensor (to avoid shortage).

43. Then the following checking is done:

Oil or petrol leak

Engine sound

Checking whether the engine is in idle RPM

Silencer leak

Water leak

Oil check

Inlet manifold vacuum

Alternator lamp

Oil pressure switch lamp

Spark time settings

44. They also check the power balance. Here they cut on one cylinder supply and check the

RPM.

45. Then they will fix the clutch and transmission assembly.

TRANSMISSION



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Transmission is the mechanism that transmits power from the engine crankshaft

to the wheels. The whole transmission assembly sits behind the flywheel. The gearbox is really a

subset of the transmission. It contains gears which can either speed up or slow down the turning

speed of an axle attached to other parts of a machine. The transmission is connected to the engine

through the clutch.

MAIN FUNCTIONS OF TRANSMISSION:

1. At low speeds the torque produced by an I.C>engine is very small, which increases with

increase of speed, peaks at some optimum speed and starts decreasing beyond that. This would

mean that:

y If the engine is directly connected to road wheels, it may not have enough tractate effortto start the vehicle from rest.

y The practical considerations for the running of automobile under different conditions

demands a large variation of torque at the road wheels, which would mean that it would

not be possible to run the engine eat optimum speed.

Thus, the main purpose of the transmission is to provide a means to vary the leverage or torque

ratio between engine and road wheel as required.

2. The transmission also provides a neutral position so that the engine and the road wheels are

disconnected even when the clutch is in engage position.

3. A means to back the car by reversing the direction of rotation of the drive is also provided by

the transmission.

SEQUENCEOFPOWERTRANSMISSION:

INPUT SHAFT-> I/P GEAR -> O/P GEAR-> OUTPUT SHAFT-> DD GEAR.



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TRANSMISSION DEPARTMENT:

The transmission department has well designed working environment with high

flexibility for future expansion and so meet international safety and quality norms.

TYPES OF TRANSMISSION:

All the four types of models are manufactured in the same plant by batch

production.

MAJOR SECTIONS OF TRANSMISSION DEPARTMENT:

1. Transmission machining

2. Heat treatment

3. Transmission assembly

4. Quality control

TRANSMISSION MACHINING:

At transmission machining section the raw material from the vendor is converted

into finished products by different sequence of operations and also finishing operations like

grinding and lapping processes are done after heat treatment. Different parts are machined by

specially designed layouts for respective components.

All machining processes are done by robot assisted by fully automated machines.

Conventional machines and special purpose machines are used to perform required operations.

Jigs and fixtures are designed for mass production and reducing the machining time to produce

components at low cost. The tools are also specially designed for required operations and used

only for recommended life time.

A centralized coolant system is maintained for temperature management for the entire plant.

Chain conveyers are used for intra-department material handling.

All layouts have an onsite inspection system to make sure of quality of all components.

Pneumatic and limit gauges are used to inspect machined components constantly.



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The following are the components made in transmission machining line.

y Transmission case

y Clutch housing

y Input speed gears 3/4/5

y Output speed gears 3/4/5

y Output shaft

y Input shaft

y Speed gear ½

y Speed gear 3/4/5

y Clutch gear

y Reverse idler gear

y Differential drive gear

y Synchronize sleeve 1&2,3&4,5

HEAT TREATMENT:

After all soft stage machining operations are finished the components are moved

to heat treatment to improve their material property like surface hardness and tempering.

Carburizing is followed in the heat treatment process, it is mainly done to improve its surface

hardness and wear resistance. The principle of this process is to convert the outer surface of the

job into high carbon steel by forming a solid solution of iron and carbon.

In heat treatment process the components¶ surfaces must be free from oil and dirtin order to get homogeneous property. So the components undergo washing operation initially to

clean all surfaces. After cleaning the metals move into the furnace, inside the furnace

carburizing operation is used in heat treatment process. The materials are heated up to 930°C

and RX gas is allowed to flow over the components at same temperature, in this process the

carbon particles get deposited over the component.

Heat treatment is done in two ways.

1. Batch carburizing

2. Continuous carburizing

TRASMISSION ASSEMBLY:



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In the assembly line all the parts are assembled together manually. All the four

types of models are assembled in the same line by batch production. After the components are

machined it is moved to the assembly section and is placed on specially designed jig over a chain

conveyor in assembly line at equal intervals. All different components are assembled in different

stages and at the end of the conveyor the full transmission gets assembled and sent to quality

section.



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In the assembly line initially input and output shaft sub assembly are made by

fixing the speed gears. Synchronize hub and bearings in a single press in hydraulic pressing

machine and all the gears and synchronize hub are locked with the shaft by a snap ring. The DD

drive gear is also assembled in the same way. All the sub assemblies are assembled one after

another. Every single transmission box in the given a serial number which is engraved over it.

QUALITYCONTROL:

After the transmission unit is assembled, the whole unit is sent to the quality

control section where the final inspection takes place. This is done by testing the transmission

unit by connecting it to an engine and testing it in a real time testing environment and extreme

conditions. The corresponding data collected during testing is fed to the computer and checked

and compared with standards, the transmission unit is given a ³transmission OK³pass. The units

that do not respond to the quality standards are rejected and sent to rework. All the transmission

OK units are given a specific bar code and sent to transmission storage unit.

MANUFACTURING OF GEARS:

Material for the gear is brought from the vendors and the gear is cut here. Gear

cutting is done by hobbing and shaping machines. Any burrs in the tooth are removed by gear

deburring machine. Gear shaving is done for exact lead & profile.

BEFOREHEATTREATMENT:

The raw material before heat treatment undergoes the following machining

operations.

1. HOBBING:

Hobbing is a special form of gear cutting operation. It is the major

industrial process for cutting gears. Hob is used as a cutter.

2. DEBURRING:

This operation is done to remove burr and chip from gear surface.



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3. SHAVING:

This operation is used to smoothen the surface.

4. BROACHING:

This operation is used to create internal splines in the sleeves.

5. ELECTRON BEAM WELDING:

electron beam welding (EBW) is a fusion welding process in which a

beam of high velocity electrons is applied to the materials being joined.

DURING HEAT TREATMENT:

The gears are heat treated to improve hardness. In heat treatment carburizing is

done in a BCF & CCF furnace to increase the hardness. Induction hardening is done when core is

to be soft and the outer surface is to be hard.

THE PROCESS FOLLOWS

1. DEGREASING:

It removes oil from the working substance by using degreasing furnace, which

heats the working substance by

LPG burner. The visual inspection is done to check that no oil or grease is

present.

2. CARBURIZING & QUENCHING:

This procedure is done to increase the hardness & wear resistance of the

substance by heating the working substance up to 930° in a batch carburizingfurnace and then quenching to salt bath. Several instruments such as Rockwell

hardness tester and Vickers hardness tester test hardness. Appropriate hardness is

58 HRC MIN.

3. WASHING MACHINE:

This machine is used to remove salt from the working substance. The substance is

dipped in hot water or given a hot water shower and then a cold water rinse. Visual

inspection is done to check for no salt deposit.

4. TEMPERING FURNACE:

Working substance is heated in a tempering furnace at 160° C and then air cooled

to remove the internal stresses. Destructive testing of a single piece inspects hardness and case

depth.

5. SHOT BLASTING:



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Shot blasting is done to remove the scales and burrs from the substance. Working

substance is blasted with steel balls and then air blown to remove the powder.

Visual inspection is one to check no burr, scales & dents.

Shot blasting details:

y Cycle time: blasting-18 minutes

DESCRIPTION OF THE CURRENT TRANSMISSION ASSEMBLY:

The plant currently manufactures four types of manual gearboxes for various

model cars-

y MX type (for Santro).

y LC type (FOR Accent & Verna).

y PA type (for i10)

The manual transmissions are produced regularly in batches along the same

assembly line as per orders. Automatic transmissions are directly imported from

South Korea. The gearbox or transmission consist of two shafts namely input

shaft and output shaft. These shafts on it have set of gear

SUB ASEMBLIES



37

INPUT SHAFT:



38

In the input shaft first, second, and reverse gears are fixed.

They are formed over input shaft in a single material. 3rd

, 4th

and 5th

speed gears are floating

gears, which are rolling over a needle bearing so that the power cannot be transferred from input

shaft to floating gears, but by synchronizer hub.

The input shaft is supported by two roller bearings inside the casting. The fiction

pad is connected at the front of the input shaft spine.

OUTPUT SHAFT:

In the output shaft 3rd

, 4th, 5

thare fixed gears. They are formed over output shaft

in a single material. 1st, 2

ndand reverse speed gears are floating gears, which are rolling over a

needle bearing so that power cannot be transferred from output shaft to floating gears but by

synchronizer hub.



39

The output shaft is supported by two taper roller bearings inside the casting. The

output shaft is connected with differential unit.

DIFFERENTIAL UNIT:

The differential unit consists of sun and planet gears. These gears are

perpendicular to each other. It has two sets of sun and planet gears. As the input pinion spins, it

meshes with the ring gear. The ring gear spins, spinning the cage and the two captive pinions.

When the vehicle is travelling in straight line, drive pinion doesn¶t try to spin differently from

others, so the captive pinions don¶t spin and the turning of the ring gear is translated directly to

both drive pinions. These are connected to the drive shaft, to the wheels. So effectively the ring

gear spins the wheels at the same speed that it is turning. When the vehicle starts to turn a corner,one of the wheels is going to spin more quickly than the other. At this point, the captive pinions

come into play, allowing the torque to them. One can tell if the differential is working properly

or not by jacking the driven axle up off the ground and spinning one wheel. When this is done,

because the gearbox is stationary, it holds the ring solid, captive pinions spin in opposite

direction and the other wheel on the axle spins the other way around. This also explains why a

two wheel drive vehicle can get into trouble when one wheel has less friction with the ground



40

than the other. The open differential cannot compensate for this. If one drive pinion is held solid

compared to other, then all the input gears redirected to drive pinion that has the least resistance.

This is why when you turn a two wheel drive car with one wheel on ice and the other on the

road, the wheel on the ice spins and the wheel on the road doesn¶t. You don¶t go anywhere

because all the engine power is directed to the wheel with least resistance the one on the ice.

Imagine the same scenario on a four wheel drive vehicle that has open differentials on the front

and rear. If you are off-riding in such a vehicle and get it into a situation where one front wheels

are off the ground, you are stuck. The differentials will spin the airborne wheels and send no

torque to the ones on the ground.

CLUTCH HOUSING:

The above picture shows transmission case other PA, MX & LC type. This is

made of aluminum. In the transmission case there are several provisions made for the assemblingthe parts like counter weight, clutch shaft, differential unit, input shaft and output shaft and fork

lift(tag) during the course of transmission assembly line,. The clutch housing ids bolted on the

pallet over the conveyor which runs at constant a speed.

CLUTCH RELEASE FORK ASSEMBLY:

It is used to operate the clutch engage and disengage. Clutch release fork

assembly consists of return spring to bring the clutch pedal back.

COUNTERWHEIGHT:

It is the part of the clutch housing assembly which is used as control for the

clutch. The purpose of the counter weight is similar to return spring.

FORK LIFT:

The manual gearbox is shown has a series of selector forks which are moved by

the physical position of the gear stick. In a sequential box, those selector forks are connected to a



41

single shaft that has corkscrew-type grooves in it. The collar that fits around this selection shaft

has a ball bearing in it which sits in a recess in the collar as well as in one of the corkscrew

grooves. When the gear stick is moved forward or backward, the selector shaft is mechanically

turned by some number of degrees. That twisting motion rotates the corkscrew groove which in

turn interacts with the ball bearings and the selector fork collars, forcing them to slide back and

forth. Each click of the gear stick rotates the shaft another number of degrees and all the selector

forks change position in one go.

REVERSE IDLER GEAR:

Reverse gear is normally with one extra gear involved. Typically, there will be

three gears that mesh together at one point in the gearbox instead there will be a gear each on the

lay shaft and output shaft, but there will be a small gear between them called the idler gear. The

inclusion of the extra mini gear causes the last helical gear on the output shaft to spin in the

opposite direction to all the others. The principle of engaging reverse is the same as for any other

gear.- a dog gear is slide into place with a selector fork. Because the reverse gear is spinning in

the opposite direction, when you let the clutch out , the gearbox output shaft spins the other way-

REVERSE.

SEALANT:

The sealant material acts as a gasket. The sealant material made of silicon resins

and synthetic materials. This sealant seals gap and does not allow air into it.

TRANSMISSIONAXLECASING:

The transmission axle casing is bolted to the bottom casing which sealant is laid

to avoid air leak.



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ASSEMBLY PROCESS:

y Clutch housings are machined, finished and then fed to the star of the assembly line.

y Control shaft hole is greased and the shaft is fitted in the slot (MX and PA only). Bellowsare fitted for protection from dust (LC only).

y An identification number is engraved on the housing by a robot.

y Dowel pins are automatically fitted onto the outer edge of the housing to facilitate

joining.

y Differential sub-assembly.

y Input sub-assembly.

y Output sub-assembly.

y Rail shafts and shift forks are fitted into place- these provide the shifting mechanism.

Forks are fixed to the rail shaft by pins running through both.

y The reverse idler gear for PA type is fitted.

y The shafts are checked by machine for irregularities by rotating them against each other.

y Silicone sealant is applied along the edge of the clutch housing by a robot.

y The transmission assembly housing is fitted onto the clutch housing and is fixed using

nuts tightened by a nut-running machine.

y An elevated conveyor transports the gearbox to the second part of the line which runs

parallel to the first, but in the opposite direction.

y Reverse light is operated by a limit switch fixed to the appropriate rail shaft this switch is

fitted on the housing.

y The top of the gearbox is closed by a small housing, for PA another round of sealant is

added for this by a robot.

y Machines inspect the gearbox for air leaks.

y Oil is filled in two stages and the gearbox undergoes final inspection checks and tests.

y After inspection, it is coupled with the engine and the whole setup is sent to the main

assembly shop.

T/M ASSEMBLY PROCESS FLOW DIAGRAM:

In the T/M Assembly shop, the components are assembled one by one to form a

single unit called Gearbox and the assembly process flow diagram is as below.

WORKING OF PA, MX, & LC TRANSMISSION:

This type of transmission is synchronous type. The word asynchronous means

matching of speed with relation to other. This has input and output shaft. Both have asset of

gears, here the input shaft rotates at a constant speed is varied with the help of gears. The input

shaft has fixed 1st

and reverse gear on it and the other 2nd

, 3rd

, 4th, 5

thare floating gears =. The



43

output gears 2nd

, 3rd

, 4th

5th

are fixed and the 1st

, reverse gears and pinion are made in the shaft.

There are three rail shafts onto which fork selectors are fixed. The rail shaft A has fork shifter for

gears 1st

and 2nd

of output shaft. The rail shaft B has fork shifter for gears of 3rd

, 4th

gear on input

shaft. The rail shaft C has fork shifter for 5th gear on input shaft. The reverse gears are set of spur

gears. When engaged the input, output spur gear meshes with the idler gear. When fork shifter is

moved to reverse gear it changes the clockwise rotation of gear into anti clockwise. This propels

the wheel to move in anti clockwise direction.

1. The green shaft comes from the engine through the clutch. The green shaft and green gear

are connected as a single unit. (The clutch is a device that lets you connect and

disconnect the engine and the transmission. When you push in the clutch pedal, the

engine and the transmission are disconnected so the engine can run even if the car is

standing still. When you release the clutch pedal, the engine and the green shaft are

directly connected to one another. The green shaft and gear turn at the same rpm as the

engine.)

2. The red shaft and gears are called the lay shaft. These are also connected as a single

piece, so all of the gears on the lay shaft and the lay shaft itself spin as a one unit. The

green shaft and the red shaft are directly connected through their meshed gears so that if

the green shaft is spinning, so is the red shaft. In this way, the lay shaft receives its power

directly from the engine whenever the clutch is engaged.

3. The yellow shaft is a splinted shaft that connects to the drive shaft through the differential

to the drive wheels of the car. If the wheels are spinning, yellow shaft is spinning.

4. The blue gears ride on the bearings, so they spin on the yellow shaft. If the engine is off

but the car is coasting, the yellow shaft can turn inside the blue gears while the blue gears

and the lay shaft are motion less.5. The purpose of the collar is to connect one of the blue gears to the yellow drive shaft. The

collar is connected, through the spline directly to the yellow shaft and spins with the

yellow shaft. However, the collar can slide left or right along the yellow shaft to engage

either of the blue gears. Teeth on the collar, called dog teeth, fit into holes on the side of

the blue gears to engage them. There are three forks controlled by three rods that are

engaged by the shift lever. Looking at the shift rods from the top, they look like this in

reverse, first and second gear.

GEAR RATIOS OF i-10 TRANSMISSION SYSTEM

Final Drive Ratio 4.6



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Reverse Gear

Ratio 3.63

Gear Ratio Overall Ratio Kmph per

1000rpm

1st 3.54 16.28 6.56

2nd

1.89 8.69 12.28

3rd

1.19 5.47 19.52

4th

0.90 4.14 25.79

5th

0.77 3.54 30.16

ABBREVATIONS USED IN PROJECT

SL.NO LIST ABBREVATIONS

1 LH LEFT HAND

2 RH RIGHT HAND



45

3 FRT FRONT

4 RR REAR

5 ASSY ASSEMBLY

6 APR APERTURE

7 SPEC SPECIFICATION

8 CTR CENTER

9 PLR PILLAR

10 DR DOOR

11 T/G TAIL GATE

12 MES MANAGEMENT EXACUTION SYSTEM

13 WBT WEB BASED TERMINAL

14 SEQ NO SEQUENCE No.

15 VIN NO VEHICLE IDENTIFICATION NUMBER

16 FDR FENDER

17 ENG ENGINE18 MTG MOUNTING

19 DOM DOMESTIC

20 EXP EXPORT

21 LP LOCAL PART

22 KD KNOCK DOWN

23 LTR LITER

24 OD OUTER DIAMETER

25 T/M TRANSMISSION CASE

26 ECR ENGINEERING CHANGE REPORT

27 TEMP TEMPORARY28 DIA DIAMETER

29 OBJ BALL JOINT BOOT

30 C/M COUNTER MEASURE



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